FCI

Fabrication & Controlling Instruction

Welded Steel Work

Document No. ST.00.776.FCI.000

Revision 0

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others without expressed authorization is prohibited. Offenders will be held liable for the payment of damages.
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Maerz Ofenbau AG, Richard Wagner-Strasse 28, CH-8027 Zürich, Switzerland

+41 44 287 27 27, fax +41 44 201 36 34, info@maerz.com
www.maerz.com
Revision Table
File Name ST.00.776.FCI.000_Welded Steel Work.docx Master version RCH1-WD-QM-610_06.10.2016

Created by Christoph Thoma

Checked by Bujar Cimili

Approved by Thomas Buechel

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Table of Contents
1 GENERAL 5
1.1 Definitions 5
1.2 Scope 5
1.3 Sub-Contracting 5
1.4 Standards / technical codes 6
1.5 First specimen 7
1.6 Inspection 7
1.7 Copyright 8

2 DIMENSIONS AND ACCURACY 8

2.1 Dimension Control 8
2.2 Applicable Execution class acc. EN-1090 8
2.2.1 Standard list of Maerz components considered as steel structures 9

3 SPECIFICATIONS FOR THE STEEL PRODUCTS USED 10

3.1 Materials 10
3.1.1 Applicable standards 10
3.1.2 From manufacturer to provide inspection certificates 10
3.2 Fasteners, applicable standards 10

4 PREPARATION OF INDIVIDUAL PARTS 11

4.1 Cutting process 11
4.2 Forming 11

5 WELDING 12
5.1 Standard quality requirements for fusion welding of metallic materials acc. to ISO 3834-3 12
5.2 Weld preparation 14
5.3 Joint preparation for site welds 14
5.4 Welding consumables 15
5.5 Works to be done after welding 16
5.5.1 Weld seam identification 16
5.5.2 Weld dressing 16
5.6 Weld inspection 17
5.6.1 Inspection methods for surface irregularities 17
5.6.2 Inspection methods for inner irregularities (non-destructive testing methods) 17
5.6.3 Scope of inspection 17
5.6.4 Acceptance criteria 18
5.6.5 Elimination of defects 18

6 FINAL FABRICATION STEPS: INSPECTION 19

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6.1 Pre-assembly 19
6.2 Test erection and inspection 19
6.3 Functional tests 19

7 PREPARATION FOR TRANSPORT 20

7.1 Cutting for transportation 20
7.2 Component identification and match marking 20
7.3 Lifting lugs 20
7.3.1 Inspection 20

8 PROTECTION AGAINST CORROSION 21

8.1 Applicable standards 21
8.2 Surface preparation 21
8.3 Coating systems 21
8.4 Execution of anti-corrosion protection 21
8.5 Inspection of anti-corrosion protection 22
8.5.1 Acceptance criteria 22
8.6 Documentation of the anti-corrosion protection system 22

9 FUEL GAS PIPING SYSTEM 23

9.1 Classification of piping system 23
9.2 Manufacturing, installation and inspections 23
9.3 Materials 23
9.3.1 Applicable Standards 23
9.3.2 Material inspection certificates 24
9.3.3 Welding – work preparation 24
9.4 Inspection and testing 24
9.4.1 Factory acceptance test 24
9.5 Marking and documentation of the installed gas piping system 25
9.5.1 Applicable Standards 25
9.5.2 Marking 25
9.5.3 Documentation 25
9.5.4 Conformity declaration 25

10 DOCUMENTATION 26
10.1 General requirements 26
10.2 Form and number 26
10.3 Conformity declarations 26
10.4 Scope of documentation 27

11 PACKING AND TRANSPORT 28

11.1 Preparation for transport 28

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1 General

1.1 Definitions
“BUYER” Maerz Ofenbau AG and its subsidiaries
“MANUFACTURER” Recipient of purchase order or contract from BUYER
“P.O.” Purchase order or contract
“FCI” Fabrication and controlling instruction
“FIG” Fabrication and inspection guideline
“IRE” Inspection report
“ITP” Inspection and test plan
“COP” Controlling procedures

1.2 Scope
This Fabrication & Controlling Instruction (FCI) applies to the workshop manufacturing
and field installation of welded and bolted steel designs of MAERZ Ofenbau AG and its
subsidiaries for the MAERZ AG projects.
These FCI have to be observed by the MANAUFACTURER, if this document is
referenced in the P.O., Maerz standard and/or contract drawings such as .345.FCI,
.346.FCI, .347.FCI, .349.FCI, ST.00.772.FCI.000, ST.00.773.FCI.000,
ST.00.774.FCI.000, respective parts lists, or other documents, such as inspection report
(IRE) , inspection & test plans (ITP), controlling procedures (COP), or fabrication and
inspection guidelines (FIG).
If in for the P.O. relevant drawings, any manufacturing or inspection requirements
are described, they will overrule the requirements of the present document
ST.00.776.FCI.000 “Welded Steel Work”.
Depending on the application, additional specifications may have to be met, as detailed in
the relevant P.O. Should the additional specifications deviate from the requirements
specified herein, an agreement must be reached between BUYER and
MANUFACTURER regarding the procedures to be adopted.
If the MANUFACTURER has any reservations or doubts as to whether the quality
requirements in these instructions can be met due to reasons of manufacturing
technique, such reservations or doubts must be clarified with the BUYER in writing before
the order confirmation.

1.3 Sub-Contracting
Permission to sub-contract to a specific person or company has to be received from the
BUYER in writing. The same applies to further contracts the MANUFACTURER may
enter into. The MANUFACTURER is obligated to name his chosen sub-suppliers prior to
sub-contracting. The MANUFACTURER is obligated to hand out these instructions to his
sub-suppliers. Besides, in terms of welding related to sub-contracting, the rules in ISO
3834-3 subsection 6 must be taken into account.

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1.4 Standards / technical codes
The engineering standards and regulations stipulated in this document are of paramount
importance for the workshop manufacturing and field installation of all different kind of
Maerz kiln components.
The following table provides an overview of the different kind of kiln components and
respective technical codes to comply with:

Kiln component type Manufacturing Kiln destination / Technical codes to Implicated quality
country country of comply with in requirements for
operation terms of the factory and
manufacturing and quality assurance
testing principles

a) Steel strutures1 Outside Europe Within Europe EN 1090-2 ISO 3834-3

2

(Legally specified area) (minimum

Within Europe Outside Europe requirement acc. to
EXC 2 or if EN
Outside Europe Outside Europe In the absence of standards not
contractual applicable)
agreement to the
contrary:

EN 1090-2

b). Pressure vessels Outside Europe Within Europe PED 2014/68/EU ISO 3834-3
3
(Legally specified area) EN 13445-4 (minimum
Within Europe Outside Europe requirement if EN
EN 13445-53 standards not
applicable)
Outside Europe Outside Europe In the absence of
contractual
agreement to the
contrary:

PED 2014/68/EU

EN 13445-43

EN 13445-53

c). Piping Outside Europe Within Europe PED 2014/68/EU ISO 3834-3

(Legally specified area) EN 13480-4 (minimum

Within Europe Outside Europe requirement if EN
EN 13480-5 standards not
applicable)
Outside Europe Outside Europe In the absence of
contractual
agreement to the
contrary:

PED 2014/68/EU

EN 13480-4

EN 13480-5

d) Mechanical engineering Outside Europe Within Europe Maerz document: ISO 3834-3
components such as traps,
discharge, etc.
Within Europe Outside Europe
(Legally not specified area) .349.FCI
Outside Europe Outside Europe

Fig. 1 Requirements: legally specified and non-specified area

1 Overview of Maerz steel structures: see Fig. 3
2 Independently from manufacturing country and kiln destination, fulfilling of the requirements in ISO 3834-3 is
required. In the case of components with Execution Class EXC3 according to EN 1090-2 the more
restrictive part ISO 3834-2 applies. Further remarks to Execution classes according to EN 1090-2 see Fig. 3
3 Instead of EN 13445 the AD 2000 Code is also admissible.

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 If there is a conflict between the requirements contained in the text of this document and
the applicable standards, in principle the more stringent requirement shall apply.
However, the manufacturer has the right to consult the BUYER, to find a mutually
agreeable solution.
Should no date of issue be mentioned, then the latest issue at time of order of the
relevant engineering standards, regulations and guidelines applies.
Provided it has been authorized by the BUYER in writing, national or international
standards, equivalent to those specified in this document, may be used.
This shall be considered on a case by case basis.

1.5 First specimen

If the P.O. demands a first specimen test, than a first specimen is to be produced, which
shall be thoroughly inspected in the presence of the BUYER’s inspector.
The following inspections have to be performed:
- Checking and recording of all dimensions specified in the drawing.
- Visual inspection of welds.
- Non-destructive testing (NDT) of welds as specified in present document
ST.00.776.FCI.000 and .349.FCI.
- Functional test.
- The results of the first specimen inspection must be recorded.
Release for manufacturing is only given after the assessment and approval in writing by
the BUYER or his agent.

1.6 Inspection
The BUYER’s inspectors as well as any additional third party inspectors must be granted
access to the manufacture’s facilities at any time during normal working hours after prior
notification.
The BUYER reserves the right to witness manufacturing activities, trial assemblies and
final inspections. For welded joints, which are not accessible during final inspection,
interim inspections shall be scheduled. On this basis, the BUYER’s quality control
department must be notified in due time of the individual inspection stages.
Before start of production MANUFACTURER must submit to BUYER an inspection and
test plan (ITP) for all ordered Parts in accordance with PO, Into Inspection and testing
plan must be indicated Inspection steps such as:
- Steps before manufacturing of the steel parts
- Materials income control
- Steps during fabrication
- Steps during final inspection
- Documentation and record of the inspection according to chapter 10
- Pre-shipment inspection
The MANUFACTURER shall provide all the equipment, tools and qualified personnel
required for the inspections.
All inspection protocols shall include inspection reference drawings, relating the results of
the inspected items to a clearly marked position on the reference drawing.
Should the existence of defects be discovered during inspections, then all costs associate
with correcting the defects, shall be borne by the manufacturer.

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 The manufactured parts and components are only then to be considered as accepted,
once the final acceptance after assembly and commissioning has taken place on the
construction site. Acceptance by the BUYER or his agents is not a substitute for internal
production control, nor does it release the MANUFACTURER and his sub-contractor from
his guarantee and liability commitments.

1.7 Copyright
Any print-out of these instructions is an uncontrolled copy. Without the prior consent of
BUYER, any utilization of the texts, even in extract form, contravenes copyright law and
makes the offender liable to prosecution. This also applies to reproduction, translations of
all kinds, scanning, microfilming and processing in electronic systems.

2 Dimensions and Accuracy

The dimensions specified in the drawings shall be contractually binding.
Unless otherwise agreed to, the dimensional tolerances must be in accordance with
.346.FCI. Dimensions with additional data of tolerances, for example 100H7 or 1232 +/-
0.5, shall overrule the general tolerances given in .346.FCI.
Whatever is specified on the drawing, it is the MANUFACTURER’s responsibility to pre-
manufacture parts, which will be assembled at the construction site, to conform to the site
requirements. Closing of inadequate large gaps by welding, are not acceptable. All
rework of not-fitting parts is the responsibility of the MANUFACTURER.

2.1 Dimension Control

Dimensional checks must be performed to verify the compliance of the work-piece with
the dimensions. In particular, connecting dimensions, machining allowances and
important dimensions marked with 

Fig. 2 Example for check gauge

All results of the dimensional check (actual and specified data) must be entered by a
representative of the MANUFACTURER into a protocol.
The entries have to be confirmed by the stamp and signature of the representatives of
both the MANUFACTURER and the BUYER.

2.2 Applicable Execution class acc. EN-1090

Strictly refer to PO (Purchase Order) or Contract for applicable Execution Class.
If no execution class is defined, the following list provides an overview of Maerz steel
structures and the respective usual execution classes.
Steel structures of the P.O. that are not listed in Fig. 3 must be manufactured and
inspected according to execution class EXC2, in the absence of contractual agreement to
the contrary.

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2.2.1 Standard list of Maerz components considered as steel structures
2 2
# Component designation Component / drawing numbers EXC2 EXC3

1 Skip bridge 425 X

2 Skip hoist foundation 007 X

3 Anchor bolts 023 X

4 Platforms 118 | 146 | 358 | 359 | 360 | 361 | 362 | 363 | 364 | X
365 | 366 | 367 | 368 | 370 | 373 | 374 | 375

5 Stairs 382 | 384 | 385 | 387 | 389 | 391 X

6 Connecting gangways 381 | 388 | 390 X

7 Waste gas duct 401 | 402 X

8 Chimney after filter 403 X

9 Silo anchors, platforms and cladding 419 | 436 | 437 | 438 | 446 X

10 Skip winch building 434 X

11 Waste gas filter supporting structure 830 X

12 Supporting structure for skip hopper n.a. X

13 Ladders 393 | 441 X

14 Railings 392 | 394 X

15 Silo on kiln 424 X

16 Kiln supporting structure 021 X1

17 Shaft part I, II, III and IV 045 | 047 | 048 | 049 | 050 | 051 | 052 X1

18 Support of load bolts / longitudinal 063 | 371 | 372 X1

bracings

19 Longitudinal bracings 376 | 377 X1

20 Kiln housing 380 X1

21 Stair I on kiln 386 X1

22 Solid fuel silo and support 415 | 417 X1

23 Dust silo and supporting structure 458 | 459 X1

24 Crane beam and crane girder 191 | 214 | 432 X1

Fig. 3 Maerz steel structures according to EN 1090-2

1 As a general rule EXC2 applies, but in certain projects for the components 16 – 24 EXC3 may apply. The
manufacturer must clarify this eventuality with Maerz on time (e.g. during quotation phase).

2 The notion execution class (EXC) only applies for steel structures according to EN 1090-2. If other
national regulations apply, a different execution or weld quality classification system may apply.

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3 Specifications for the steel products used

3.1 Materials
Only materials of the quality specified in the drawings and parts lists may be used.
If a specified material is not available, then the MANUFACTURER shall propose to the
BUYER an equivalent alternative material. Such alternative material shall only be used
with the BUYER’s permission in writing. Plates and profiles must always be used in
maximum sizes and lengths.
If plates or profiles are not obtainable in the required dimensions or thicknesses, the
nearest adequate size is to be selected as an alternative. The BUYER shall be informed
in good time of any substitutions required in this way.

3.1.1 Applicable standards

- Maerz standard .345.FCI “Material comparison”
- Maerz standard .346.FCI “General tolerances“
- Maerz standard .347.FCI “Protection against corrosion“
- Maerz standard .349.FCI “Welding requirements”
- Maerz standard ST.00.772.FCI.000 “Tagging of material”
- Maerz standard ST.00.773.FCI.000 “Packing and Marking”
- Maerz standard ST.00.774.FCI.000 “Packing list”
- Materials used, must conform to DIN EN 1090-2
- The descriptions of the steel types used, DIN EN 10 027-1
must conform to DIN EN 10 027-2
- Inspection certificates must conform to DIN EN 10 204
- Marking transfer certificates for all materials with
material certificates 3.1 must conform to DIN EN 10 204
- Marking transfer certificate, for all materials with
material certificates 3.2 must conform to DIN EN 10 204
- Manufacturer certificate 2.2 for welded parts in workshop DIN EN10204
- On high operational demands in through thickness
direction, materials with improved deformation properties, perpendicular
to the load bearing surface, have to be used in accordance with DIN EN 10 164

3.1.2 From manufacturer to provide inspection certificates

Products made from unalloyed structural steel

- Material 1.0038 (S235JR), 1.0039 (S235JRH) or similar certificate 3.1
- Material 1.0577 (S355J2), 1.0576 (S355J2H) or similar certificate 3.1
- All stainless and heat-resistant steels certificate 3.1

3.2 Fasteners, applicable standards

- Inspection certificates for screws and bolts must conform to DIN EN 10 204
- Selected fasteners must conform to the policy outlined in DIN EN 1090-2
- Inspection certificates 3.1

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4 Preparation of individual parts

4.1 Cutting process

Performance, classification and quality tolerances for thermal cutting must be in
accordance with.346.FCI.
Plates and profiles can be cut by shearing, sawing or flame-cutting. The cut surfaces
must be free from cracks, notches, burrs, and must not show any sign of other damage.

4.2 Forming
Forming and aligning of the parts must be performed so that any constraints during
further processing are prevented. Structural members must be formed without twisting. All
formed or aligned parts must be completely free from cracks and surface damage after
the forming or aligning.
Any damage to the part surfaces by hammering etc. must be avoided. Any damage has
to be eliminated by grinding.
Cold forming is only permissible when the material is suitable for this procedure. All areas
concerned must be thoroughly visually examined for surface damage and cracks.
Aligning is not permissible in the temperature range between 200 and 300 °C (blue
brittleness).

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5 Welding

5.1 Standard quality requirements for fusion welding of metallic

materials acc. to ISO 3834-3
Welding of all product types listed in Fig. 1 must generally be executed in accordance
with ISO 3834-3.
Exception: Steel structures with execution class EXC2 require ISO 3834-2 (see Fig. 4).
Depending on the execution class EXC (according to DIN EN 1090-2) defined in the P.O.
(overview: see Fig. 3), the following parts of EN ISO 3834 apply:

Execution Classes acc. to EN 1090-2 Applicable parts of EN ISO 3834

EXC 2 Part 3 – Standard quality requirements

EXC 3 Part 2 – Comprehensive quality requirements

Fig. 4 Applicable parts of EN ISO 3834 dependent on the execution class

The MANUFACTURER shall develop a welding plan prior to execution of the work and
make it available to the BUYER upon request.
The arc may only be struck at points which are later fused again by welding.
For the welding of multiple layers, the surface of the preceding layers must be cleaned
from slag. Cracks, holes and areas with lack of fusion must not be welded over. Run-off
strips are preferably used at the weld ends. Open end craters must be avoided.
To ensure faultless weld joints, root passes should be gouged out and a cap pass should
be counter-welded. If welding is performed from one side only, the welding parameters
must be selected so that full penetration welding is ensured.
The welding parameters must be selected so that flush weld interfaces are obtained
avoiding detrimental undercuts.
If the lengths of intermittent fillet welds are not clearly dimensioned in the manufacturing
drawings, the following dimensions shall be applicable:
Length of fillet weld L ≥ 6 x a; L min = 30 mm; L max = 150 mm
If the welding instruction on the drawing refers to a bigger scope of inspection for
instance, than given in the document .349.FCI, then the welding instruction given in
the drawing is binding.
As shown in Fig. 1, ISO 3834-3 defines for all Maerz kiln components the quality
requirements for welding. Manufacturers including those who are not certified according
to ISO 3834-3 must be conscious about the following sections of this standard permitting
him to deliver the expected welding quality and the respective complete welding
documentation (see chapter 10).

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 Subsection To review contents of ISO 3834-3 Extracts from ISO 3834-3
of ISO 3834-3before manufacturing
5.2 + 5.3 Review of requirements and technical Sections 5.2 and 5.3 of ISO 3834-3 to review!
review
6 Sub-contracting Section 6 of ISO 3834-3 to review!
7 Welding personal For all welders: Appropriate qualification according to ISO 9606-1 required.
Appropriate welding coordination personnel according to ISO 14731 at manufacturer’s disposal. Such persons having responsibility for quality
activities shall have sufficient authority to enable any necessary action to be taken. The tasks and responsibilities of such persons shall be
clearly defined.
(source: section 7 of ISO 3834-3)
8 Inspection and testing personnel Section 8 of ISO 3834-3 to review!
9 Equipment Section 9 of ISO 3834-3 to review!
10 Welding and related activities The manufacturer shall carry out adequate production planning
Welding-procedure specification (ISO 3834-3 | 10.2)
Imperative preparation and correct use in production of welding procedure specifications (WPS)
Qualification of the welding procedures (ISO 3834-3 | 10.3)
Prior to production, qualification of welding procedures according to ISO 15610, ISO 15611, ISO 15612, ISO 15613, or ISO 15614-1. If not
specified in the relevant technical code (e.g. EN 1090-2) or in our manufacturing order explicitly, procedure qualification can be achieved by
meeting any of these standards.
(source: section 10 of ISO 3834-3)
11 Storage and handling of welding Section 11 of ISO 3834-3 to review!
consumables
12 Storage of parent materials Section 12 of ISO 3834-3 to review!
13 Post-weld heat treatment Section 13 of ISO 3834-3 to review!
14 Inspection and testing Section 14 of ISO 3834-3 to review!
To check after welding whether compliant with relevant acceptance criteria
By visual inspection (VT) according to ISO 17637
By non-destructive testing according to ISO 17635 (general rules):
MT according to ISO 17638
PT according to ISO 3452-1
RT according to ISO 17636-1
UT according to ISO 17640 and ISO 22825
15 Non-conformance and corrective Section 15 of ISO 3834-3 to review!
actions
16 Calibration and validation of Section 16 of ISO 3834-3 to review!
measuring, inspection and testing
equipment
17 Identification and traceability Section 17 of ISO 3834-3 to review!
18 Quality records Section 18 of ISO 3834-3 to review!
Fig. 5 Quality requirements for fusion welding of metallic materials
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5.2 Weld preparation
The parts to be joined must be stored and held so that residual stress is minimized during
welding and the parts obtain the shape foreseen. If necessary, the parts to be welded
shall be positioned and aligned on the ground, on a layout pattern, to ensure that
dimensional deviations resulting from shrinkage do not accumulate.
The joint preparation must be in accordance with ISO 9692-1 (extract of standard: see
.349.FCI).
Cross joints are undesirable.
In concave fillets of rolled profiles manufactured from unskilled cast steels, weld seams in
longitudinal direction are not permissible.
If welding is to be performed in cold-formed areas including neighbouring areas up to a
width of 5 t, the limit values min. r/t according to the following table must be observed.

Fig. 6 Welding in cold-formed areas

The values of the degree of deformation in above table don’t need to be observed if cold-
formed parts are subjected to normalising prior to welding.
The weld zones of the parts to be welded must be dry and free from scale, rust, oil and
other contaminations. A uniformly thin and firmly adhering rolling skin may be left.
Except in the case of over-weldable coatings (welding primer), all coatings on plates or
profiles in the heat-affected zone have to be removed. This includes areas which are
opposite the welding side of the sheet.
On galvanized structural members, the zinc layer in the heat-affected zone must also be
removed.

5.3 Joint preparation for site welds

If the welded constructions are supplied in segments to be assembled and welded on the
construction site, the required joint preparation must be produced in the workshop.
The joint preparation to be carried out here is for the manual metal-arc welding process
111 (according to ISO 4063).
A joint preparation is not required for plate thicknesses < 6 mm.
Joints for site welds need to receive a corrosion protection treatment according to
.347.FCI.

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5.4 Welding consumables
The type of welding consumables shall be appropriate to the welding process, as well as
the material(s) to be welded and must be documented in the welding procedure
specification (WPS). The following table (Fig. 7) provides an overview of the welding
consumables and respective product standards to be used (inspired by EN 1090-2 | 5.5).
The welding consumables must be free from damage, contamination and moisture. If
required, they must be dried according to the supplier’s instructions.
If no such instructions are given, basic electrodes shall be dried in an electrode quiver for
2-4 hours at a temperature between 300 and 400°C, and submerged-arc welding flux
shall be dried for 4 hours at a temperature between 350 and 400 °C.

Welding consumables Product standards

Shielding gases for arc welding and cutting EN ISO 14175
Wire electrodes and deposits for gas-shielded EN ISO 14341
metal arc welding of non-alloy and fine grain
steels
Tubular cored electrodes for metal arc welding EN ISO 17632
with and without gas shield of non-alloy and
fine grain steels
Welding consumables – Tubular cored EN ISO 17634
electrodes for gas shielded metal arc welding of
creep-resisting steels - Classification
Welding consumables - Covered electrodes for ISO 3581
manual arc welding of stainless and heat-
resisting steels - Classification
Welding consumables - Rods, wires and EN ISO 636
deposits for tungsten inert gas welding of non-
alloy and fine grain steels - Classification
Welding consumables - Covered electrodes for EN ISO 2560
manual arc welding of non-alloy and fine grain
steels - Classification
Welding consumables - Wire electrodes, wires EN ISO 14343
and rods for arc welding of stainless and heat-
resisting steels - Classification
Welding consumables - Tubular cored EN ISO 17633
electrodes for metal arc welding with or without
a gas shield of stainless and heat-resisting
steels - Classification
Welding consumables – Wire electrodes, wires, EN ISO 21952
rods and deposits for gas-shielded arc welding
of creep-resisting steels - Classification
Welding consumables – Covered electrodes for EN ISO 3580-A
manual metal arc welding of creep-resisting
steels - Classification
Welding consumables – Covered electrodes for EN ISO 3581-A
manual metal arc welding of stainless and heat-
resisting steels - Classification
Fig. 7 Welding consumable standards to be used

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5.5 Works to be done after welding

5.5.1 Weld seam identification

For each component the manufacturer shall
- generate a “Component Welder List” with the names and identification sign (ID) of
each welder, who has worked on the component, and
- a copy of the respective drawing as part of the inspection report showing welder’s ID
and all the seams which were executed by said welder.
For traceability the welders shall stamp the component at a predetermined location.
These stamp location shall be marked on the drawing showing the welder’s IDs.

Example:

Fig. 8 Example of welder list and corresponding drawing including welder ID

5.5.2 Weld dressing

Weld spatter and slag must be removed after the weld zone has cooled. Any further
cleaning of the weld zone shall be in accordance with the requirements for surface
treatment as anti-corrosion protection.
If this is necessary for the assembly of the components or specified in the respective
drawings, the welds have to be appropriately finished.
Any aids or temporary attachments welded to the component must be removed without
causing damage to the base metal. It is not permissible to strike off such aids or
attachments. The area in question must be carefully ground.

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5.6 Weld inspection
Inspection rules for all different kind of products are defined in the respective technical
codes (see Fig. 1) and summarised in .349.FCI.

5.6.1 Inspection methods for surface irregularities

In order to detect surface irregularities the following methods are usually applied:
100% visual testing (VT) according to ISO 17637, either magnetic testing (MT) according
to ISO 17638 or penetrant testing (PT) according to ISO 3452-1. The welding
coordination must consider the following general rules, especially before deciding
between MT and PT.

Materials Inspection method

Ferritic steels VT
VT and MT
VT and PT

Austenitic steels, aluminium, nickel VT

VT and PT
Fig. 9 Generally recognised inspection methods for surface irregularities for all kind of welds
including fillet welds (in line with ISO 17635)

5.6.2 Inspection methods for inner irregularities (non-destructive testing

methods)
Sometimes, supplementary non-destructive testing (NDT) may be done by either
radiographic testing (RT) according to ISO 17636-1 or ultrasonic testing (UT) according to
ISO 17640. The following table provides the welding coordination personnel an aid to
decision making for the appropriate NDT method.

Nominal thickness (t) of the base material to be welded

Material / Type of joint
t ≤ 8 mm 8 < t ≤ 40 mm t > 40 mm

Austenitic / butt joint RT RT or (UT) RT or (UT)

Austenitic / T-Joints (RT) or (UT) (RT) or (UT) (RT) or (UT)

Ferritic / butt joint RT or (UT) RT or UT UT or (RT)

Ferritic / T-Joints (RT) or (UT) UT or (RT) UT or (RT)

Note: “()” means the method has only limited applicability.

Fig. 10 Generally recognised inspection methods for inner irregularities for butt- and T-joints with full
penetration (in line with ISO 17635)

5.6.3 Scope of inspection

The scope of inspection comprising the extent of visual testing (VT) and supplementary
NDT is defined in the respective technical codes and standards (see Fig. 1) and
summarised in .349.FCI.

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5.6.4 Acceptance criteria
The acceptance criteria for weld inspection are defined in the respective technical codes
and standards (see Fig. 1) and cited in .349.FCI.
The following table provides a summary of the respective quality levels / limits for
imperfections according to ISO 5817 for weld irregularities, valid for VT and NDT.
Kiln component Technical codes to comply Quality levels / limits for
type with in terms of imperfections according to ISO
1
manufacturing and testing 5817
a) Steel structures EN 1090-2 EXC 2 C
(Legally specified EXC 3 B
area)
b) Pressure vessels PED 2014/68/EU
(Legally specified EN 13445-4
area) EN 13445-5 C
(instead of EN 13445 the AD
2000 Code is also admissible)
c) Piping PED 2014/68/EU Maerz gas pipes: B
(Legally specified EN 13480-4 branch welds < DN100
area) EN 13480-5 All other welds of C
process air and gas
pipes
d) Mechanical Maerz document:
engineering .349.FCI C
components such
as traps, discharge,
etc.
(Legally not
specified area)
Fig. 11 ISO 5817: Quality levels for imperfections

5.6.5 Elimination of defects

If VT and/or NDT detect non-acceptable indications, the following guidance according to
ISO 17635 Annex C shall be followed:
a) Two additional samples or areas of the same weld should be given the same type of
testing; and
b) if the samples or areas of the same weld examined as required under item a) are
acceptable, the defective item should be repaired or replaced and re-examined and
all items represented by these two additional samples or areas of the same weld
should be accepted, but
c) if any of the samples or areas of the same welds examined as required under item a)
reveals a non-acceptable indication, two further samples or areas of the same weld
per defective one should be examined and
d) if the samples or areas of the same weld examined as required under item c) are
acceptable, the defective item(s) should be repaired, replaced and retested and all
items represented by the additional samples or areas of the same weld should be
accepted, but
e) if any of the samples or areas of the same weld examined as required under item c)
reveals a non-acceptable indication, all items represented by the progressive
sampling should be either:
1) Repaired or replaced and retested as required, or
2) Fully examined and repaired or replaced as necessary, and retested.

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6 Final fabrication steps: Inspection

6.1 Pre-assembly
Time needed for the assembly and erection at the construction site, should be kept as
short as possible. It is therefore advantageous, to fabricate all the parts needed, in the
largest possible format which can be transported, and handled at the construction site.
To ensure smooth and trouble-free assembly of the components on site, components
consisting of individual segments shall be completely pre-assembled for inspection at the
manufacturer’s workshop location.
The following conditions must be fulfilled:
- The pre-fabricated parts must have a coat of paint.
- All the assembly welding joints must be prepared in the workshop in order to permit
proper site welds.

6.2 Test erection and inspection

For the inspection of dimensions and proper fit, the supporting structure and kiln shaft
parts shall be temporarily erected at the workshop location.
They then have to be separated again and packed with reinforcements in order to ensure
that they keep their shape during transportation.
The manufacturer is responsible for acquiring official authorization, should special
transportation be necessary.

6.3 Functional tests

All hydraulically operated parts, namely the flap valves, need to be fully assembled,
including the silicone rings, mechanically examined and functionally tested. As the
hydraulic cylinders usually aren’t available before commissioning on site, the
MANUFACTURER needs to manufacture workshop jigs representing the cylinders in
order to simulate the flap end-positions
After the assembling of the parts is completed, the proper fit-up must be checked.
Spread chalk on the silicon gasket and move the flap blade by means of the installed jig
in the upper and lower end positions.
Move the flap blade into the middle position and check if the chalk imprint on the silicon
seal is complete on the entire circumference. Take pictures for documentation. If the
chalk imprint is imperfect, adjust the position of the flap by turning the adjustment screws,
or, if necessary, by other corrective actions.
Check the stroke length in both end positions and record it.
After successful completion of the functional test, the component must be given a coat of
paint as anti-corrosion protection
An inspection report of the functional test shall be prepared, including
- Photos of the chalk imprints
- Stroke lengths

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7 Preparation for Transport

7.1 Cutting for transportation

Should certain parts need to be cut for transportation, then the manufacturer must make
a proposal to the BUYER defining the intended cutting approach. The proposal must be
agreed upon in writing by the BUYER, before the cutting of the parts can take place.

7.2 Component identification and match marking

Completed components shall be clearly marked for erection at the construction site,
according to the BUYER’s tagging instructions given in Maerz standard document
ST.00.772.FCI.000 “Tagging of material”. The marking must include the project number,
the component number, the drawing number, and, if applicable, the item number on the
drawing.
Small parts can be marked by attaching labels made from laminated plastic, or, if
exposed to the environment, from stainless steel, according to the BUYER’s tagging
instructions given in ST.00.772.FCI.000.
Individual segments of components shall be marked additionally with the segment
number and matching markings next to the assembly joints.
For every component, which is to be assembled on site from individual segments, the
MANUFACTURER shall generate additional drawings (sketches), on which the segment
numbers and the assembly joints are shown and provide them to the BUYER at the time
of delivery of the components.

7.3 Lifting lugs

All parts have to be suitably equipped with lifting lugs. Even if it is not shown on the
drawings, lifting lugs according to DIN 28086 have to be welded onto the components for
safe handling.

7.3.1 Inspection
All weld seams of the lifting lugs must be inspected by
- 100% VT and
- 50% by either PT or MT.

Acceptance criteria for above inspections:

ISO 5817 quality level C

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8 Protection against corrosion
Anti-corrosion coatings must not be applied before the work piece has been released by
the BUYER’s inspector respectively not before final inspection.
The BUYER reserves the right to inspect the coating material and the execution of the
protection measures against corrosion at any time either by sending one of his
representatives, a representative of the coating material manufacturer, or a respective
expert.

8.1 Applicable standards

- Maerz standard .347.FCI “Protection against corrosion“
- Surface preparation according to ISO 8501-1, -2
- Protective anti-corrosion coating shall conform to DIN EN ISO 12944-1, 4, -5, -7
- Method and procedure for measuring dry film thickness according ISO 2808 or ISO 19840
Additionally, the following instructions must be followed
- The rest of the paint, which can still be used, for repairing of transport and assembly
damages, shall be supplied together with the delivery of the steel components.

8.2 Surface preparation

Prior to the application of anti-corrosion coating systems, the surfaces to be coated shall
be prepared by sand blasting according to .347.FCI and ISO 8501-1 and -2.

8.3 Coating systems

Different anti-corrosion protection requirements are taken into account by adapted
coating systems compiled in the BUYER’s “Protection against corrosion“.347.FCI.
If the coating systems, as prescribed in .347.FCI, are not available, then the
MANUFACTURER shall propose to the BUYER an equivalent alternative system. Such
alternative coating systems shall only be used with the BUYER’s permission in writing.
The entire surface coating must be ordered only from one paint manufacturer. Paint
manufacturer and coating system must be duly coordinated between the BUYER and
MANUFACTURER.

8.4 Execution of anti-corrosion protection

The coating nominal thickness of the coating has to be according to .347.FCI.
The coating materials have to be applied in accordance with the instructions provided by
the manufacturer of the coating materials.
All areas where anti-corrosion coating was removed due to welding activities, it must be
re-applied after welding is completed.
All run areas in coating films on vertical surfaces have to be eliminated.
Parts and/or part sections which have been temporarily protected must be adequately
packed for transport to prevent damage through abrasion.

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8.5 Inspection of anti-corrosion protection
Verify the paint film is free of defects.
Verify that all masking tapes have been removed.
Verify that coating is cured as specified in the paint manufacturer’s application data. Cure
of catalysed materials may be determined by exposure to a suitable solvent as
recommended by the paint manufacturer.
Inspection and the reporting of the inspection results of the anti–corrosion coating shall
be in accordance with DIN EN ISO 12944-5 and -7.
The thickness of the individual layers, such as priming, intermediate and final coat, shall
be inspected by spot checking.
The nominal thickness of the entire paint system, as specified in Maerz standard
document .347.FCI, shall be inspected after the application and drying of all the individual
layers by measuring the dry film thickness (DFT) of the entire paint system.
The number of DFT measurements of the entire paint system shall be at least 5
2 2
measurements per 10 m or per individual piece of equipment of less than 10m surface
area and 2 for each piece of equipment at random location selected by BUYER’s
inspector.

8.5.1 Acceptance criteria

Visual Inspection
- The paint surface must be free from unevenness.
- The paint surface shall be free of blisters, bubbles, craters, sags, runs, dry spray and
unnecessary brush marks.

DFT Measurements
- The arithmetic mean of all the individual DFTs shall be equal to or greater than the
nominal dry film thickness (NDFT)
- Individual DFTs shall be equal to or above the NDFT.
- Individual DFTs between 80% of the NDFT and the NDFT are acceptable provided
that the number of these measurements is less than 20% of all the individual
measurements taken.
- All individual DFTs shall be less than or equal to 130% of the NDFT.

8.6 Documentation of the anti-corrosion protection system

At a minimum the inspection reports for each inspected component shall contain:
- Drawing and item number
- Identification of the coating system applied.
- Ambient conditions at the time of application of the coating
- Inspection drawing and results of dry film thickness (DFT) measurements
- Reference list of all the coating systems used and the name of the paint manufacturer
- Paint manufacturer’s technical information for each coating system used

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9 Fuel gas piping system

9.1 Classification of piping system

According to the Pressure Equipment Directive 2014/68/EU (PED) fluids are divided into
two groups.
For the purpose of this section, the following applies:
- “Gas” shall be considered as fluid group 1
- Pipes shall be considered category I, II, or III, according to the criteria given in the
PED. The pipe categories are a function of the highest allowable operating pressure
(PS) and the nominal diameter (DN) as shown in the table below.

Fluid Pipe
Criteria
Group categories
PS > 0.5 bar and DN > 350 or
III
PS > 0.5 bar and DN > 100 and PS * DN > 3500
PS > 0.5 bar and 100 < DN ≤ 350 and PS * DN ≤ 3500 or
1
25 < DN ≤ 100 and PS * DN >1000 or II
25 < DN ≤ 350 and 1000 < PS * DN < 3500
PS > 0.5 bar and 25 < DN ≤ 100 and PS * DN ≤ 1000 I
Fig. 12 Pipe categories according to PED 2014/68/EU

9.2 Manufacturing, installation and inspections

The manufacturing, field installation and inspections must be in compliance with
- PED 2014/68/EU,
- DIN EN 13480 parts 4 and 5
- All standards cited below.

9.3 Materials
The piping system must be made from seamless steel tubes for pressure purposes (tubes
acc. to EN 10216-2 made from P235GH – TC1/TC2). Pipes, elbows, T-pieces and fittings
with a DN < 500 must be seamless.

9.3.1 Applicable Standards

Flanges must be according to DIN EN 1092-1
Pipe fittings must be according to DIN EN 10253-2
Pipes must be according to: EN 10216-1, or
EN 10217-1, if applicable
DIN EN 10220
ISO 228-1 (if applicable)
Welding consumables must be according to DIN EN ISO 14341
DIN EN ISO 2560
Required material inspection certificates according to DIN EN 764-5
Material inspection certificates must be according to DIN EN 10204

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9.3.2 Material inspection certificates
The MANUFACTURER shall provide material inspection certificates for each single part
of the gas piping system (item no. on BUYER’s drawings/parts lists) as specified in DIN
EN 764-5.
The drawing and item numbers shown on BUYER’s drawings must be handwritten on
each sheet of the certificates, to enable back tracking. Sheets without item numbers will
be rejected.

Required inspection certificates

- for pressure baring materials of pipe categories II and III
- certificate 3.1 or 3.2 according to EN 764-5
- for all other materials
- certificate 2.2 according to EN 764-5
- for welding consumables
certificate 2.2

9.3.3 Welding – work preparation

Weld seam edges of main roots must be machined or flame cut and not ground.
The shape of the weld edges are NOT shown in the BUYER’s drawings. They have to be
defined by the MANUFACTURER’s welding coordination personnel according to ISO
9692-1 (extract of ISO 9692-1: see in .349.FCI).
For secondary welds the edges can by chamfered by grinding.
Except in the case of coatings that can be welded over (welding primer), all coatings on
pipes and pipe fittings in the heat-affected zone shall be removed prior to welding. This
includes areas which are opposite the sheet side from which the weld is performed.
For each gas pipe > DN 250 a weld map must be prepared, showing joint preparation,
welding position, number and size of layers, weld sequence, scope of NDT etc.
Material and ambient temperature at the welding location must be above the critical limits
according to the material specifications.

9.4 Inspection and testing

Inspection rules for all different kind of kiln components are defined in the respective
technical codes (see Fig. 1) and summarised in .349.FCI.
Weld inspection and pressure test must be in accordance with DIN EN 13480-5 (relevant
extracts: see in .349.FCI).
The essential data of the pressure test must be confirmed in an inspection certificate of
the pressure test, issued by the MANUFACTURER

9.4.1 Factory acceptance test

Prior to issuing the required conformity declaration, the Manufacturer shall perform a
factory acceptance test (FAT) according to DIN EN 13480-5: section 9.

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9.5 Marking and documentation of the installed gas piping
system

9.5.1 Applicable Standards

The piping system shall be marked according to
DIN EN 13480-4: section 11.
Documentation of the installed piping system shall be according to
DIN EN 13480-5: section 9.4

9.5.2 Marking
In order to clearly identify the pre-fabricated piping elements, they must be marked.
The marking can be by painting, stamping or by attaching a label.
The marking must remain visible for the duration of the installation of the piping system.
For clear identification of an installed pipeline or parts thereof it must be clearly marked,
by either painting, stamping or by attaching a permanent label. Based on the marking it
must be possible to identify to which piping system the pipeline belongs.
Pipelines belonging to categories I to III (according to PED) must have an unmistakable
marking directly on the pipeline or by an attached label. The marking must reference a
document containing information for operation, maintenance and required regular
inspections. The required information is specified in DIN EN 13480-4: section 11.2.

9.5.3 Documentation
At the end of manufacturing and installation of the piping system the MANUFACTURER
shall provide documentation for his scope of delivery, as required by
DIN EN 13480-5: 2012, section 9.5.

9.5.4 Conformity declaration

For manufacturing, installation and pressure test instructions of the piping system, the
MANUFACTURER shall confirm compliance with the PED and the standards DIN EN
13480 part 1 to 5, as well as all other applicable standards.
For the conformity assessment procedures of the different piping categories the following
“Conformity Assessment Modules” shall be used, according to PED 2014/68/EU Annex
III.

Conformity assessment / Admissible conformity assessment module combinations

piping category
III B + D, B + E, H

II E1
I A

After successful completion of the factory acceptance test and compilation of the
documentation and issuing all required material inspection certificates, the
MANUFACTURER shall issue a manufacturer’s declaration of conformity with the PED
and all applicable standards.

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10 Documentation

10.1 General requirements

- If nothing to the contrary is mentioned in the P.O., the MANUFACTURER shall provide
a complete manufacturing & inspection documentation for the scope of delivery as
defined in the P.O.
- The documentation must be in compliance with the standards cited in the individual
sections of this document.
- The documentation shall be compiled according to the following requirements.

10.2 Form and number

- If nothing to the contrary is mentioned in the P.O, the documentation shall be compiled
in English.
- The manufacturing & inspection documentation has to be provided electronically or on
BUYER’s demand in hard copy, paper form.
- The electronic documents are to be provided on a CD-ROM in pdf- format.
- Drawings are to be saved as AutoCAD compatible CAD-files (dwg or dxf format) and
delivered on a CD-ROM.

10.3 Conformity declarations

- Manufacturer’s declaration of compliance with the order
- Manufacturer’s CE-conformity declaration for the scope of delivery of manufacturing
structural steel work.
- Manufacturer’s CE-conformity declaration for the scope of delivery of installation of
mechanical engineering components.
- Manufacturer’s CE-conformity declaration for the scope of delivery of manufacturing
and installation of gas pipes.
- Manufacturer’s CE-conformity declaration for the scope of delivery of manufacturing
and installation of pressure vessels.

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10.4 Scope of documentation
The following QA/QC documents shall be issued for all manufactured components in
accordance with the stated standards, the requirements given in the individual sections of
this document, as well as with in 3.1.1 listed Maerz standards.
Material inspection certificates as required by EN 10204 shall be submitted to the
BUYER’s inspector prior to final inspection.
The inspection documents must be clearly marked, permitting the allocation of the
materials to the respective drawings and items on the drawing.
Item QA / QC document
No.
1 Record of requirement / technical review
2 Material inspection documents
Documents to provide acc. to

3 Welding consumable inspection documents

4 Welding-procedure specification (WPS)
subsections 17 and 18

5 Welding-procedure qualification records (WPQR)

6 Welder qualification certificates
7 Welding coordination personnel qualification
ISO 3834-3,

8 Heat-treatment procedure specification and records

9 Non-destructive testing procedures and reports
10 Dimensional reports
11 Records of repairs and non-conformance reports
12 Manufacturer’s declaration according to 10.3
13 Welder list according to 5.5.1
14 Anti-corrosion protection documentation according to 8.6
15 Documentation for the scope of delivery of the installed piping
system according to 9.5.3
Additionally

16 Functional test for all movement parts

required

17 Item markings and tagging of main points

18 Inspection and test report (ITP)
19 Photo documentation
Fig. 13 QA / QC documents

If the applicable standards require any additional documentation, the MANUFACTURER

shall be able to provide such documents to the BUYER.
The minimum period for retention of these documents is defined as follows.

Steel structures Pressure vessels Piping acc. to Mechanical

acc. to EN 1090-2 acc. to EN 13445 EN 13480 engineering
components
5 years 10 years 10 years 5 years
Fig. 14 Minimum period of retention

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11 Packing and transport
The BUYER’s packing instructions shall be observed.
Welded steel components must be secured with suitable means that deformation and
other damage during storage, loading and transport is excluded.
Tagging and packing of the products to be shipped must be in accordance with the
following Maerz documents:
ST.00.772.FCI.000 “Tagging of material”
ST.00.773.FCI.000 “Packing and Marking”
ST.00.774.FCI.000 “Packing list”

11.1 Preparation for transport

Items, especially cut items as the shafts, which may distort during handling and transport
must be braced. Even if it is not shown on the drawings, the manufacturer has to install
the bracings according to the MANUFACTUTRER’s experience.
The weight for bracings, transport supports etc. is not included in the weight lists.
Small, loose items as bolts, welding rods, sealing materials, etc. must be well marked for
the site erection and be packed into one or more steel containers.
These containers remain on the erection site until the end of the construction and
commissioning. The container must be lockable.

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