Kirby Pre Qualifications - Rev 1311

Structural Steel Prequalification Document (R2)
KIRBY
Structural Steel
Prequalification Document
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INDEX
Introduction 4 6 7 8 16 17 19 22 23
Market Sectors & Products Vision & Mission Statement Legal Status Iso Certificate
Design and Engineering Piece Monitoring System The Project Structure
General Description of Work Flow Procedures Engineering Design Output Design Review Design Validation Design Changes Software RFIs Pre-Production Planning Example
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Material Preparation Identification Handling, Storage and Stacking Consumable Storage Fabrication Drawings Beam Processing Beam Preparation Equipment Plate Processing Plate Processing Equipment Assembly Welding Curving and Straightening Non-Destructive Testing Surface Preparation and Painting Delivery of Finished Product Page 2 of 82
I N D E X (continued)
Attachments 32
Process Flow Chart Change Procedure Flow Chart s Change Procedure Documentation Project Quality Plan (Sample) Inspection and Test Plan (Sample) PMS Sample Schedules and QC Reports Welding Procedure Specifications Organisation Chart Customer Base Typical Projects 75 76 78
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Introduction
Kirby Steel Engineering emerged as a natural extension to the ever expanding Kirby steel fabrication network, as well as in response to the continuous requests from the market and satisfied customers. Kirby Steel Engineering complements Kirby Building Systems by providing services and customized Hot Rolled steel structures to industrial market sectors such as Oil & Gas, Petrochemical Industry, Heavy Industries, Cement Plants, Aluminium smelters etc The company also offers its services, expertise and products in other sectors such as Commercial sectors where it contributes, alongside its sister company Kirby Building Systems, in providing a complementary and wider range of products to clients whose projects may include a combination of heavier structural steel requirements, as well as Pre-engineered buildings. Kirby Steel Engineering is managed by a team of professionals with an average experience of twenty to thirty years experience in the structural steel industry and known to have executed a number of prestigious and high-profile projects in the GCC and Middle East. The engineering department uses the latest versions of internationally renowned industry standard 3D and 2D software for designing as well as drafting. Kirby Steel Engineering is affiliated to Kirby Building Systems, which in turn is part of Al Ghanim Industries having the Head Office in Kuwait. Kirby Building Systems - Kuwait is the premier producer of steel buildings and structures in the Middle East. In operation since 1976, Kirby maintains a strong reputation for providing cost effective solutions for buildings manufactured to the highest standards. Kirbys network includes 24 offices in the GCC countries (Kuwait, Saudi Arabia, Qatar, Oman, Bahrain and the UAE), the Middle East, Africa, and the Far East to service customers locally. Kirby manufacturing facilities produce hundreds of custom made steel buildings each year. Kirby upholds its position at the cutting edge of the industry due to its commitment to quality and customer satisfaction. Skilled structural engineers using the very latest in computerized engineering design and drafting systems permit the selection of the most economical, accurate and efficient framing and cladding systems. Kirbys customer base covers thousands of satisfied clients including General Motors, AT&T, PepsiCo and Coca Cola , Ministries of Defense, Oil companies and Petrochemical projects and other key international organizations over the world.
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Alghanim Industries has consistently maintained its position as a leading private sector trading and industrial group both in Kuwait and the GCC during the past 60 years. It is a privately owned, professionally managed holding company. The executive management is composed of professionals with international education and experience in varying areas of expertise. Overall, with the companys wholly owned subsidiaries, joint ventures and associations, Alghanim Industries employs over 12000 men and women from over 40 different countries around the world. The groups major areas of activity are trading and distribution of consumer electronics, food and consumables, automotive vehicles and products, industrial manufacturing, engineering, technology, travel, shipping and transportation services, advertising, insurance and contracting. Furthermore each of Alghanims separate businesses employs operating autonomy with its own general manager, marketing managers and finance managers. Corporate policy matters remain centrally controlled and direction is provided through strategic business planning processes, quarterly operating review meetings and long term forecasting. Multinational in both outlook and operation, Alghanim Industries has offices in countries that span four continents. The diverse nationalities of the employees contribute to the companys strength and widen its perspective. Alghanim Industries has successfully fused progressive business procedures, local market place requirements and international resources.
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Market Sectors & Products

The following is an indication, but is not limited to, of the market sectors serviced and the types of structures undertaken by Kirby Steel Engineering. The flexibility, expertise and equipment allows the company to customize and provide the right products or mix of products as required by the clients projects.
Market Sectors
Heavy Industries Oil & Gas Petrochemical Aluminum Smelters Fertilizer Plants Cement Plants
Structures
Pipe Racks Rectangular Platforms Circular Platforms Pipe Supports Main Workshop Structures Raw Material Storage Buildings Floor Gratings Staircases Handrails Ladders Temporary Structures Steel Bridges Heavy Duty Building Structures Platforms Equipment Support Structures Passenger Terminals Cargo Terminals Aircraft Hangars
Infrastructure
Bridges Power & Desalination Airports & Seaports Railways
Buildings Segment
Residential / Commercial Hi-rise Towers Shopping Malls Tower Crowns Leisure Centres Atrium Structures Multi-storey Car Parks Roof Structures Sports Centres
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Vision & Mission Statement
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Trade License - Kuwait
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Commercial License - Kuwait
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Chamber of Commerce Kuwait
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Commercial Register Kuwait
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Import License Kuwait
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Trade License Ras Al Khaimah - UAE
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Chamber of Commerce Ras Al Khaimah - UAE
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Commercial Register Ras Al Khaimah UAE
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ISO Certificate
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Design and Engineering

Kirby Steel Engineering uses the latest computer software in both Engineering and Design allowing both activities to be as fully integrated as possible. All work undertaken in the Engineering / Design Department is closely monitored by the Engineering Manager who is responsible for ensuring that the design conforms to the clients requirements and is in accordance with the relevant Design Codes and Regulatory Authority requirements The Design / Engineering Department is fully computerized, utilising the latest software packages to enable them to produce the most economical structures in the shortest time possible. The software packages most frequently utilised are :
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Design and Engineering Cont

The Drafting office is also fully computerised and utilises the following main software packages : Package AutoCad Description Specifications / Code Preparation of GA Drawings & N/A Fabrication Drawings Miscellaneous Works 3D Modelling Detailing of N/A Connections Automatic Generation of Fabrication Drawings, Production & Material Listings 3D Modelling Detailing of N/A Connections Automatic Generation of Fabrication Drawings, Production & Material Listings
BoCad
Strucad
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Piece Monitoring System What does it do ?

Maintains a full bill of quantities for each main and sub-assembly Establish Production Priorities for each component Automatically program each item of steel through the workshop to suit client requirements and production capacities Issue production requirements for each stage of fabrication Automatically maintain the independent KIRBY Steel Engineering quality assurance programme Real Time monitoring of production status
Piece Monitoring SystemThe Advantages

Each individual piece of steel is dynamically monitored at the stages of production to assure the client receives all the items on time Monitors the effects of design changes etc to enable the client to incorporate in their production schedules A full set of reports is available under password control in the Web Server. Reports can be downloaded by the user into spreadsheets, databases etc for later use
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Piece Monitoring SystemHow does it work ?

The project is broken down into units of build-ability or client requirements Project programmes are developed using Primavera Project Manager Specialised CAD systems used to produce working drawings, also produce their own bill of materials which is automatically fed into the Piece Monitoring System. Drawings produced from other sources are taken off and entered manually. The PMS automatically reviews the programme, type of fabrication and production capacities to produce an individual fabrication programme for each item of steel. Full manual modification control is maintained to allow further requirements to be incorporated Production lists are produced for each stage of fabrication and production data reentered into the system Quality assurance inspection requests are generated automatically by the system and records maintained Full status reports are produced, cross-checked between each function The Web Server is automatically updated
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Index to the General Description of Work Flow Procedures
The purpose of the following section is to describe in general each activity executed during a project.
Index Engineering Software RFIs Pre Production Planning Example Identification Handling Storage and Stacking Fabrication Drawing Beam Processing Plate Processing Assembly Welding Curving and Straightening Non Destructive Testing Surface Preparation Delivery of Finished Products
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Engineering
All Technical information received from the client such as drawings, project specifications, bills of quantity, agreed scope of work and any other pertinent information is forwarded to the Design Department who review all relevant documentation to establish the design parameters. Any clarifications and requests for information are communicated to the client in writing. Should circumstance arise were the requested information is not available then the Design Department clearly detail any and all assumptions they have made. This information is forwarded to the client. Design Output The design output is expressed in the following formats : Computer generated calculations prepared on propriety software Design sketches containing all the necessary information to allow drafting to generate general arrangement drawings The General Arrangement drawing package shall consist of but not be limited to: Anchor Bolt Layout Roof Framing Plan Elevations Connection Details (if requested)
Design Review During the Design Sketch and calculation stage, the activities of the individual designer are monitored by the Design Department Supervisor On completion of the calculations the designer details in writing all parameters used in the calculation, the Design Supervisor verifies that the design parameters are correct as per contract documentation. Should the contract require the formal submittal of the design calculations to the client then the Design Supervisor forwards the package to the Engineering Manager for Approval. All General Arrangement drawings developed from design sketches are reviewed by the drafting department for drawing accuracy and signed as checked then the package is forwarded to the Design Department for review by the Designer against his design sketches to determine if they have been correctly interpreted. The design package is then forwarded to the client for review and comment.
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Design Validation All design packages, as detailed in the contractual requirements are forwarded to the client for review comment and approval prior to the start of fabrication. Should any comments or status codes be applied to the submitted design package other than approved, these comments are addressed and another submittal is made to the client. This process is repeated until the design is acceptable to the client.
Design Changes When a change or modification to the design is required, the originator of the change documents the required modification and forwards written instructions to the relevant departments. Depending on the source of the change notice, the information is transmitted as follows : Internal Change notice Information to be forwarded to the Design Supervisor for review and action External (Client) notice Information to be forwarded to the Design Supervisor for review and action All change notices either in the form of commented drawings or written instructions are filed in the Project File for future reference.
Software KIRBY Steel Engineering has standardized the computer software used in order to ensure compatibility with clients and other third parties involved in the project: RFI s If during the review, engineering design, or drafting cycles, additional information or clarifications are required, a formal RFI is raised and issued to the client. The issue and return of the RFI is recorded. Microsoft Office Primavera / Microsoft Project Autocad Strucad Bocad Staad Pro Master Key ProKon PMS system General Office Planning 2D Drafting 3D modeling and drafting 3D modeling and drafting 2D & 3D Design Connections Design Connections Design Production Tracking & Monitorng
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Pre-Production Planning On award of the contract the Planning Department review the overall structure to establish the following : Overall production requirements per week and month Sequence of contract execution in order to support the clients program Priority for each sub structure Engineering and Drafting planning Procurement planning
The 3D modeling & drafting systems utilized by KIRBY Steel Engineering produce a full Bill of Quantities during the "3 D" modelling phase of the drafting cycle. This information is transferred to the piece monitoring system where the pre-determined priority ratings for each Sub-structure are automatically assigned to the individual item This allows the Piece Monitoring System to automatically generate a detailed (item by item) production program which is then grouped together to give the daily production requirements for all fabrication activities. Due to the modular format of the Piece Monitoring System the individual module and the relevant information required to control a specific activity can be downloaded onto the computer system of any associate company. This allows them to conduct their area of the operation in parallel with the overall project requirements.
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Example
Material Preparation The relevant material preparation modules of the Piece Monitoring System is forwarded to the relevant departments and all the production scheduling information downloaded. The engineering department also issues the plates and beam shafts drawings in the format required to program the CNC equipment used in the material preparation. As the material is processed in accordance with the production schedule, the Piece Monitoring System is regularly updated by the computer system controlling the CNC equipment or by manual entry periodically through the shift. This updated information allows monitoring the progress of the contract piece by piece. This example is applicable to each individual stage of the fabrication process.
Identification All material received either from the mill or merchants stock is inspected on receipt for: Completeness of order Compliance with Purchase Order requirements Transport Damage Identifiable to valid mill certificate
As the material is processed through the preparation stage of the fabrication process the heat number of the individual piece is logged onto the cutting schedule against its unique position / item number. This information is then transferred to the Piece Monitoring System providing material trace-ability for each individual piece back to the mill certification
Handling, Storage and Stacking Steel plates and sections are either delivered to the preparation facility on a JIT basis or stored and stacked in a KIRBY Steel Engineering designated area. All material is stored and stacked in such a manner as to prevent distortion twisting or bending.
Consumable Storage All welding rods painting and blasting material are stored in accordance with the anufacturer's recommendations.
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Fabrication Drawings Material preparation drawings are issued to the Preparation Facility in electronic format and are identified by phase substructure and cutting schedule. The assembly drawings are issued either in electronic format or paper copy again they are identified by phase substructure and assembly schedule
Beam Processing During the cutting operation each beam is marked with it's item / position number to allow identification and trace-ability through the rest of the fabrication process. After the beam has been marked and cut, and depending on the requirements, the beam is either moved directly to the transit lay-down area or processed thorough the CNC drill station.
Beam Preparation Equipment Please refer to the list of equipment attached.
Plate Processing Plates are processed using various methods depending on thickness contract requirements and end usage If the thickness of the plate is 12 mm or less, the plates can be sheared to the required size, however the end usage and contract requirements are also considered before work is detailed to these machines. Once the plate has been cut to the correct size and shape the final operation is producing the holes. This can be done either by drilling or punching. Again thickness, hole dia, and contract requirements are considered before allocating the work to the various machines During the cutting operation, each plate is marked with it's item / position number to allow identification and trace-ability through the rest of the fabrication process. All cut edges can be dressed to remove burrs, dross and irregularities. Holes are dressed as required to provide a smooth contoured surface.
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Plate Processing Equipment Please refer to the list of equipment attached. Once the preparation of the material has been completed the material is then ready for assembly.
Assembly When the material has passed it's inspection, it is released to the assembly / welding yard were it is segregated in the lay down yard prior to release to assembly. The material is assembled in accordance with the fitting schedule issued by Piece Monitoring System. The material is assembled in accordance with the fabrication drawings in such a manner that they are not bent, twisted or otherwise damaged, and any deformation is within the stated tolerances. All items, after assembly, are fully dimensionally checked, any deviations are corrected immediately. The results of the dimensional check are logged onto the Piece Monitoring System.
Welding All welding operations are carried out in accordance with KIRBY Steel Engineerings approved welding procedures by independently qualified welders. All procedures and welder qualifications are in accordance with AWS D 1.1 During the welding operation all welders are continually monitored to ensure that the welding parameters, as detailed in the relevant procedure, are adhered to and that the level of workmanship is maintained. All items, after completion of welding are visually inspected against the requirements of AWS D 1.1 for compliance. Any visual discontinuity is marked and repaired immediately. Only when the item has been fully passed and accepted will it be released to blasting and painting All welding inspections are entered onto the piece monitoring system.
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Curving and Straightening When it is necessary to curve or straighten components one of the following methods may be used: Mechanical - taking care not to cause indentations or changes in cross section Local Application of Heat - ensuring that the temperature does not exceed 650C Non-Destructive Testing Non destructive testing is carried out in accordance with the contract requirements, all NDT inspections are conducted by an independent 3rd party specialist company with AWS D1.1 acceptance standards used for determining the acceptability of the weld. The results of all NDT examinations are entered on the Piece Monitoring System. Surface Preparation and Painting The surface preparation / blast cleaning produces the required anchor pattern and cleanliness level as detailed by the paint manufacturer to ensure paint adhesion to the surface. The Painting Inspector carries out profile checks at the start of each blasting run to ensure that the required profile and cleanliness levels are met. All material once blasted are primed within 4 hours to prevent rust bloom. The painting operation is conducted ony if the following conditions are met: (as specified by the paint manufacturer) The surface temperature shall be at least 3 degrees centigrade above the dew point and the Relative Humidity (RH%) 40% and 85%. Visual checks on the surface shall be carried out to ensure none of the following point exist oil, grease, dirt, loose paint, rust and other surface contamination. There is protection from adverse weather conditions, such as wind that may blow sand, or other foreign bodies on the painted surface or it may disrupt the paint pattern or cause dry spray. Paint Strip shall be applied to all welds and corners if required. Primers, intermediate coats and top coats shall be contrasting colours, if more than one application is required to achieve the required film thickness, then the same colour should be used. But reference to Client's specifications must be made before implementation. Finished coatings shall be free of runs, drips, dry spray etc. Areas that are cracked, damaged or below minimum thickness shall be repaired in prior to dispatch Page 30 of 82
All defective areas are to be cleaned with solvents, detergents or clean water as required All repair areas blast cleaned to the metal surface, with the edges being feathered back at least 50 mm beyond the clean metal surface. For areas less than 1000 mm2, brush coating may be acceptable, but with reference to Client's specifications , areas greater than 1000 mm2 the paint shall be applied as to the original specification. Painted items shall be handled with proper care so that damage to the paint is minimised. Structural steel items shall not be handled until paint has thoroughly dried. Care shall be taken to avoid abrasions and other damage. Nylon / Canvas slings shall be used for handling the coated steelwork or when steel slings are to be used, they shall not be choked with wood to avoid / limit contact with coated steelwork.
Delivery of Finished Product Each piece of steelwork shall be distinctly marked with Item No and bar code before dispatch in accordance with the fabrication drawing . Steelwork shall be stacked on timbers in order to provide easy handling All attachments and fittings shall be securely attached. Loose plates and smaller items shall be either boxed or wired together and then wired to larger parts. Floor plates shall be bundled for shipment Bolts, Nuts and Washers shall be packed in strong bags with the Nuts and Washers assembled on the Bolts. The client should be informed of the time of delivery and delivery notes shall accompany all deliveries. The sequence of shipment shall be such as to expedite erection and minimise field handling of material
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Attachments i. ii. iii. iv. v. vi. KIRBY STEEL ENGINEERING Process Flow Chart & Description KIRBY STEEL ENGINEERING Change Control Procedure & Description KIRBY STEEL ENGINEERING Steel Sample Project Quality Plan KIRBY STEEL ENGINEERING Steel Sample Inspection & Test Plan P M S Sample Schedules & Q C Reports KIRBY STEEL ENGINEERING Welding Procedures
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KIRBY STEEL ENGINEERING Change Procedure
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KIRBY STEEL ENGINEERING Change Procedure The attached logic chart details the standard method adopted by KIRBY STEEL ENGINEERING for processing changes. This procedure may be amended to reflect ndividual contract requirements. Note: P = Project Management Team FW = Fabrication Workshop
SAMPLE DOCUMENTATION ONLY
PROJECT QUALITY PLAN Document No CGP-PQP-204 Revision 0
15-9-01 0 Douglas Bevan Henry Nasr Henry Nasr Date Revision Author Review Approval Page 39 of 96 KIRBY STEEL ENGINEERING Prequalification
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PROJECT QUALITY PLAN

Document No. CGP-PQP-204
Revision 0
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INDEX 1.0 2.0 3.0 4.0 5.0 6.0 Purpose Scope References Definitions Responsibilities Procedure 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 7.0 Exhibits Contract / Tender Review Document Control and Quality Records Procurement Procedure Material Control Identification and Tractability Process Control Inspection and Testing Control of Inspection Measuring and Testing Equipment Non Conforming Product Control Corrective and Preventative Action Material Handling Storage and Delivery Audit Procedure Training
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1.0
Purpose The purpose of this Standard Project Quality Plan is to outline the applicable procedures to be used for the execution of a project in conformance with KIRBY STEEL ENGINEERING Quality system.
2.0
Scope This procedure is applicable to all contracts where the generation of a specific Project Quality Plan is not called for by the client.
3.0
References KIRBY STEEL ENGINEERING's Quality Management System.
4.0
Definitions KIRBY STEEL ENGINEERING ITP KIRBY STEEL ENGINEERING Inspection and Test Plan
5.0
Responsibilities As Detailed in the procedure
6.0 6.1
Procedure Contract / Tender Review
6.1.1 All Tender Enquiry's Shall Be: Logged as received and assigned a Tender Number Reviews shall be carried out by Senior Management The contract shall be priced by engineering
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6.2
Document Control and Quality Records
6.2.1 Project Filing System On the award of a contract, a contract specific identification number shall be allocated by the Engineering Manager, and a Project File shall be generated All the in-coming and out-going documents related to their project will be logged in the Project File. On completion of the project, the Project files shall be filed for a minimum of 1 year. After which they may be disposed of, at the discretion of Senior Management 6.2.2 Drawing Receipt Approval and Issue All drawings received by KIRBY STEEL ENGINEERING relating to a specific project shall be acknowledged and a copy of the acknowledgement shall be filed in the project file All drawings as detailed in the contract shall be issued to the client for approval After approval Fabrication drawings shall be generated and issued to the relevant personnel Their issue and return shall be recorded in the Issue register maintained by the Head of Drafting or his designated nominee.
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6.2.3 Quality Records The QC Engineer shall maintain the following records: Material Certification Goods Inwards Inspection Reports Plate / Beam Cutting Schedules Consumable Certification (Electrodes, Paint, Bolts etc) Fabrication Check Lists NDE Reports if applicable Welders Qualifications Welders Records Weld Procedure Specifications Procedure Qualification Records Painting Release Forms Painting Inspection Reports Dimensional Check Reports Final Inspection Reports Copies of Delivery Notes QC Fabrication Drawings
On completion of a Project the quality records relating to the project shall be correlated by the QC Engineer into a Project Data Book. The quality records shall consist of: Material Certification Data Book Plate / Beam Cutting Schedules Data Book Fabrication Check Lists Data Book NDE Reports if applicable Data Book Painting Release Forms Data Book Painting Inspection Reports Data Book Final Inspection Reports Data Book Copies of Delivery Notes Forwarded with each delivery QC Fabrication Drawings Data Book Bolt Certification Data Book Paint Certification Data Book
On completion of the project the quality records will be archived for the minimum of one year
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6.2
Procurement Procedure
6.3.1 BOQ The Engineering Manager through his designated nominee shall ensure that a BOQ is raised for each project. The Stores shall check the BOQ against the stock lists and raise the necessary requisition orders for the balance material The Commercial Director shall review the requisitions for cost quantity and technical accuracy; if the requisition is acceptable he shall approve it and forward it to Procurement who shall raise the order. 6.4 Material Control
6.4.1 Material Receipt All material ordered by and delivered to KIRBY STEEL ENGINEERING shall be inspected by the Goods Inwards Inspector in accordance with the relevant Work Instructions and Procedures. 6.4.2 Traceability Material trace-ability shall be maintained by heat number, which shall be logged on the material cutting schedule against the relevant piece number. 6.4.3 Electrodes All electrodes shall be inspected upon receipt, stored in accordance with KIRBY STEEL ENGINEERING procedures and their issue, return and baking (if required) shall be recorded by the Rod Storeman.
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6.4.4 Paint Paint shall be inspected upon receipt in accordance with KIRBY STEEL ENGINEERING's procedures; the paint shall be stored in the designated area, used within its shelf life and rotated through the stores on a first in first out basis. 6.5 Identification and Trace-ability All material shall be marked with its Project Number and position / piece number at the material preparation stage. The material heat numbers shall be logged on the Cutting schedule. 6.6 Process Control
6.6.1 Trace-ability of steel All steel material shall have a valid mill certificate and the material shall be identified to the mill certificate 6.6.2 Fabrication / Shop Drawings All in house drawings shall be checked for accuracy before issue The drawings shall contain all the necessary details for production to fabricate the item. Certain contracts may require specific information to be included on the drawing, the head of drafting shall be informed of these requirements 6.6.3 Marking All items shall be marked with their Project Number and their position / piece number as detailed on the cutting schedule, at the preparation stage. The Heat Number shall be transferred to the cutting schedule and logged against the items position piece number.
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6.6.4 Cutting Shaping Bending and Bolt Holes. Beams plates and sections shall be cut in accordance with their cutting schedules Cutting may be done by shearing, sawing, grinding and machine cutting. Hand flame cutting may be allowed if all other methods are impractical. Holes may be made by drilling or punching and slotted holes made by a combination of drilling punching and cutting. All tolerances shall be in accordance with the contract requirements as detailed on the ITP 6.6.5 Assembly All components shall be assembled in a manner such that they are not bent, twisted or otherwise damaged. 6.6.6 Curving and Straightening When it is necessary to curve or straighten components, this may be done by mechanical means or the local application of heat 6.6.7 Welding All welding shall be in accordance with the requirements of AWS D1.1 When required by contract all applicable welding procedures shall be submitted to the client for approval Pre Qualified welding procedures shall be used unless specifically stated in the contract documentation. The preparation and fit up of all parent metal shall be in accordance with the requirements of AWS D1.1 and the approved welding procedure. 6.6.8 Electrodes and Automatic Coils Electrodes and automatic coils shall be procured, stored, issued and controlled in accordance with KIRBY STEEL ENGINEERING's procedure
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6.6.9 Preheat and Interpass Temperature Minimum Preheat and Interpass Temperature shall be exercised as detailed in the approved WPS. 6.6.10 Inspection These activities shall be controlled in accordance with procedure KIRBY STEEL ENGINEERING Inspection and Testing procedures. And governed by the Test and Inspection Plan 6.6.11 Surface Preparation, and Painting All surface preparation, priming and top coating, will be in accordance with the KIRBY STEEL ENGINEERING' procedure of Paint Control 6.7 Inspection and Testing
6.7.1 Inspection and Test Plan KIRBY STEEL ENGINEERING standard Inspection and Test Plan shall be adhered to unless a project specific Inspection and Test Plan is required by the contract in which case the QA Manager shall draft, submit for approval and issue the relevant Project Specific Inspection and Test Plan. 6.7.2 Receipt Inspection All incoming material shall be checked by the Goods Inwards Inspector for conformance to KIRBY STEEL ENGINEERING's requirements. 6.7.3 In-process Inspection and Testing All stage inspections shall be carried out by the designated inspection personnel and the findings reported to the QC Engineer. 6.7.4 Non-destructive Examination The QC Engineer shall call up such NDT as required (10% MPI + Radiography of Splice Welds. KIRBY STEEL ENGINEERING normal in-house requirement) to ensure the quality of KIRBY STEEL ENGINEERING's fabrication.
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6.7.5 Records Records of all inspections shall be filed with the QC Engineer as objective evidence of the inspection. 6.8 Control of Inspection Measuring and Testing Equipment All inspection Measuring and testing equipment utilised by KIRBY STEEL ENGINEERING shall maintain a current calibration status that is traceable back to the national standards at all times 6.9 Non Conforming Product Control
6.9.1 Non-conformance of Procured material If purchased material is found not to conform to KIRBY STEEL ENGINEERING's requirements, then the material shall be returned to the supplier. The materials controller shall inform the supplier for the reason for rejection and the supplier may re-supply material that conforms to KIRBY STEEL ENGINEERING's requirements or the Materials Controller shall inform procurement who shall place the order with an alternate supplier. 6.9.2 Non-conformance during Production When a Non-conformance is noted during production the Inspector shall quarantine the material and an NCR shall be raised. The QC engineer shall evaluate the Non-conformance and decide on the relevant course of action to correct the non-conformance. Should corrective action be outside the specification requirements then a concession request shall be forwarded to the client for their recommendation and approval. Rejected material shall be removed from the production area and either down graded or scraped
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6.10
Corrective and Preventative Action
6.10.1 Customer Complaints The QA manager shall record investigate and respond to any formal complaint from the client. 6.10.2 Quality System Deficiencies When a deficiency is identified in the Quality System, then the deficiency shall be reviewed against the relevant procedure. Should it be found necessary to amend the procedure this shall be done in accordance with Procedure Preparation Style and Format procedure and the eview and issue procedure as detailed in the Quality Manual. 6.11 Material Handling Storage and Delivery
6.11.1 Before and After Fabrication All material shall be stacked in such a manner as to minimise damage and distortion. The material during fabrication shall be laid out clear of the ground and in such a manner as to acilitate inspection 6.11.2 After Painting All painted material shall be stacked in bundles, with wooden strips in between adjacent members these bundles shall then be metal strapped before loading. All lifting operations of painted steel shall be done with nylon / canvas slings so as to minimise damage. Paint touch-up is acceptable before dispatch. 6.11.3 Delivery of Finished Product All items shall be marked with their item number as detailed on the erection drawings All loose items shall be securely fastened, bundled or bagged before dispatch.
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6.12
Audit Procedure The QA Manager or his designated nominee shall carry out periodic audits of the quality system to access its effectiveness and the level of compliance to the Quality Management Procedure.
6.13
Training While it is not generally KIRBY STEEL ENGINEERING's policy to employ then train personnel but to employ already trained personnel. Should the need for training of personnel be identified then this training shall be accomplished in one of the following manners Verbal Instruction Tool Box Talks Work Instructions In House Training Training Agency (outside the Company)
7.0
Exhibits Inspection and Test Plan
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Organisation Chart
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Customer Base
Kuwait Snamprogetti/Equate Al Hamra / MOD Jahra Mega Warehouse PIC/Kuwait Fertilizer Plant Public Warehousing RECAFCO Kuwait Co.for Processing Plant C Ministry of Defence TOYO Kuwait Airways Corporation (KAC) Ahmadi Governorate Kuwait Free Trade Zone Coca Cola Kuwait Oil Co. National Guard Qatar Al Jaber Engg. J.G.C. Qapco/Snamprogetti Qatar Clay Bricks Co. Naseer Enterprise NBKS Qatar Steel Co. (QASCO) Al Madar Cont. Trdg. Oman Khimji Textile Mill Oman Ceramics Qurum Contractors Steel Service Centre Raysyt Cement Co. Yemen Canada Dry Yemen Co. For Ind. Invest. Ltd. H.S.A. - (YCFM)
United Arab Emirates National Food Co. System Construct Choithram & Sons System Construct Sharjah Airport System Construct Fawaz Al Khateeb Orion Engineering Sheikh Saleh Bin Ham. Abu Dhabi Municipality Gulf Erection / EMC System Construct Boskin Factory Dubai Municipality Bahrain Jawid Textile Mill Manama Textiles Daewoo Desalination Project Rolls Royce / Chrysler Bahrain Airport Service Saudi Arabia Ministry of Defence, S.A. Al Owaidah / Ministry of Awkahf NADA Al Othman Agri Products Al-Othaim Central Warehouse Pro. Ministry of Education Sahara Building Cont. Hussain Bakri Gazzaz & Partners Nesma & Al Fadel Cont. Co. Al Turki Trdg. Cont. Co. Saudi BinLaden Group TADCO Saudi National Guard
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Customer Base Ctd.
Syria Rubi Eco. Group Deiri Group Arab Agri. Mfg. Co. Granada Ceramic Ind. Lebanon Sukom Liban Lait Sal Sudan Sudan Railway Corporation Coldair Ethiopia H'rena Pvt. Ltd. Summit Partners Burayu Spring Vietnam Indochina Ceramics American Standard Triumph International Nestle Bangladesh Spinning Mill/Silver Line Composite Pakistan Adam Motor Co./Car Plan Guam S.H. Behbehani
Jordan Jordan Royal Airforce International Arabian Dev. Co. Egypt Arab Brothers Inglen Misr Al Amria Al Safadi Group Misr Al Amria Tanzania P.B. Power / Rolls Royce Libya F.L. Smidth Alimaz Sri Lanka Industrial & Commercial dev. Co. Factory Complex/Star Packaging Cotton Line Korea Toforby Corporation Romania Al Muhaidib & Sons Cambodia Manitel / Pochentong Airport
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Typical Structural Steel Projects
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Kirby Pre Qualifications - Rev 1311

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Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Design and Engineering Piece Monitoring System The Project Structure

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Market Sectors & Products

Bridges Power & Desalination Airports & Seaports Railways

Structural Steel Prequalification Document (R2)

Vision & Mission Statement

Structural Steel Prequalification Document (R2)

Trade License - Kuwait

Structural Steel Prequalification Document (R2)

Commercial License - Kuwait

Structural Steel Prequalification Document (R2)

Chamber of Commerce Kuwait

Structural Steel Prequalification Document (R2)

Commercial Register Kuwait

Structural Steel Prequalification Document (R2)

Import License Kuwait

Structural Steel Prequalification Document (R2)

Trade License Ras Al Khaimah - UAE

Structural Steel Prequalification Document (R2)

Chamber of Commerce Ras Al Khaimah - UAE

Structural Steel Prequalification Document (R2)

Commercial Register Ras Al Khaimah UAE

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Design and Engineering

Structural Steel Prequalification Document (R2)

Design and Engineering Cont

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Piece Monitoring System What does it do ?

Piece Monitoring SystemThe Advantages

Structural Steel Prequalification Document (R2)

Piece Monitoring SystemHow does it work ?

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Index to the General Description of Work Flow Procedures

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Beam Preparation Equipment Please refer to the list of equipment attached.

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

Structural Steel Prequalification Document (R2)

KIRBY STEEL ENGINEERING Change Procedure

Structural Steel Prequalification Document (R2)

SAMPLE DOCUMENTATION ONLY

PROJECT QUALITY PLAN Document No CGP-PQP-204 Revision 0

Structural Steel Prequalification Document (R2)

SAMPLE DOCUMENTATION ONLY