Acdc - Ringlock Manual Latest 25-02-2012

TECHNOCRAFT INDUSTRIES (INDIA) LTD.
,
A 25, STREET NO. 3, MAROL M.I.D.C, ANDHERI (E), MUMBAI 400 093. ( INDIA)
Tel.: (91)-22-2839 3144 to 47, 2839 9970 Fax No. (91)-22-2835 6559, 2836 7037
E-mail : technocraft@technocraftgroup.com Website : www.technocraftgroup.com
Page 1 of 6
CONTENTS
NAME OF SR DOCUMENT PAGE
DESCRIPTION
PRODUCT NO CODE NO.
TECHRING 1. PROCESS FLOW CHART OF TECHRING
VERTICAL VERTICAL. CHART NO: 57 06
2. STEEL GRADES CHART NO – 1 07-17
3. PROCEDURE FOR INSPECTION AND
TESTING OF IN COMING HR COILS.
QW: 7.4.3 18-33
4. WORK INSTRUCTIONS FOR CHEMICAL
ANALYSIS OF INCOMING MATERIAL AND QW-10-1A 34-40
PHYSICAL TESTING.
5. PLAN FOR INCOMING MATERIAL
INSPECTION (HR COILS).
QN: 7.4.3-01 41
6. ANNEXURE – I FOR QN: 7.4.3-1 QN: 7.4.3-01 42
7. ANNEXURE – II FOR QN: 7.4.3-01 QN: 7.4.3-01 43
8. ANNEXURE – II FOR QN: 7.4.3-01 QN: 7.4.3-01 44
9. COIL MEASUREMENT REPORT QR: 10.1-01 45
10. CHEMICAL ANALYSIS / PHYSICAL TESTING
REPORT.
QR: 10.1-02 46
11. PLAN FOR INCOMING PRODUCT
ITEM: METAL SPOOL
QN: SCAFF:7.4.3-10 47
12. SPECIFICATION CUM INSPECTION REPORT OF
INCOMING MATERIAL QR: SCAFF: 7.4.3-10 48
ITEM: METAL SPOOL
13. INSPECTION INSTRUCTIONS AND
RESPONSIBILITY OF SLITTING OPERATOR QW: 7.5.1 – 01 49
PROCESS STAGE – SLITTING
14. WORK INSTRUCTIONS FOR
IDENTIFICATION, TRACEABILITY AND QW: 7.5.3 50
TEST STATUS (EXISTING SYSTEM)
15. PRODUCTION CUM INSPECTION REPORT OF
SLITTING DEPARTMENT.
QR: 10.2-03 51
16. NON CONFORMITY REPORT (NCR) QR: 8.3-01 53
17. PROCEDURE FOR INSPECTION AND
TESTING AT TUBE WELDING STAGE.
a) DIMENSIONAL INSPECTION.
b) FLATTENING TEST QW- 8.2.4-02 54-59
c) FLARING TEST
d) TENSILE TEST
e) VISUAL INSPECTION.
18. PLAN FOR IN-PROCESS INSPECTION AND
TESTING PROCESS STAGE: TUBE MILL
QN: 8.2.4-02 60
19. ANNEXURE: I FOR QN: 8.2.4-02
REQUIREMENTS OF DIMENSIONS
QN: 8.2.4-02 61
20. ANNEXURE: II FOR QN: 8.2.4-02
REQUIREMENTS OF WELDABILITY.
QN: 8.2.4-02 62
21. ANNEXURE: III FOR QN: 8.2.4-02
REQUIREMENTS OF TENSILE TEST ON QN: 8.2.4-02 63
TUBES.
22. TUBE MILL IN PROCESS INSPECTION
REPORT
QR: 10.2-04/1 64
Page 2 of 6
23. PROCEDURE FOR IDENTIFICATION AND
TRACEABILITY CODE. (TECHRING SYSTEM)
QD: SCAFF: 129 65
24. INSPECTION REPORT OF STAMPING OF
VERTICAL TUBE.
QR: SCAFF: 10.2-321 66
25. TENSILE TEST REPORT OF TUBE QR: 10.2-05 67
26. DAILY NON CONFORMITY REPORT OF
TUBE MILL
QR: 10.2-06 68
27. WORK INSTRUCTION FOR END FACING OF
PIPE.
QW: 8.2.4-03 69
END FACING
QR-10-2-07 70
29. WORK INSTRUCTION FOR STRAIGHTENING
OF PIPE
QW: 8.2.4-05 71
STRAIGHTENING
QR-10-2-09 72
31. PROCEDURE FOR COLD SAW MACHINE (1ST
PCS INSPECTION & IN-PROCESS CHECK QD: SCAFF: 83 73
RECORDS)
32. PRODUCTION INSPECTION REPORT OF CUT
LENGTH TUBES FOR VERTICAL.
QR: SCAFF:10.2-303 74
33. PROCEDURE FOR IN-PROCESS INSPECTION
OF HOLE PUNCHING ON TECHRING QD: SCAFF: 118 75
VERTICAL
34. PRODUCTION INSPECTION FOR TECHRING
VERTICAL HOLE PUNCHING.
QR: SCAFF: 10.2-304 76
35. SPECIFICATION CUM INSPECTION REPORT
OF ROSETTE FOR TECHRING VERTICAL
(8 SLOT). (For Incoming Material 3 % For
QR-SCAFF: 10.2-318 77
Dimensions And 10 % Of Visual Inspection)
36. INSPECTION REPORT OF STAMPING ON
VERTICAL ROSETTE (RING)
QR: SCAFF: 10.2-305 78
37. PROCEDURE FOR WELDING OF TECHRING
STANDARD (VERTICAL)
QD: SCAFF: 119 79
38. RING WELDING REPORT OF TECHRING
VERTICAL.
QR-SCAFF: 10.2-306 80
39. PROCEDURE FOR 100 % VISUAL
INSPECTION AFTER WELDING PROCESS QD: SCAFF: 120 81
PRODUCT: TECHRING VERTICAL.
40. INSPECTION REPORT OF TECHLOK
VERTICAL AFTER RING WELDING.
QR: SCAFF: 10.2-307 82
41. PROCEDURE FOR INSPECTION OF
GALVANIZING PRODUCT. QW: 8.2.4-07 83
PROCESS STAGE: GALVANIZING
42. PROCEDURE FOR DETERMINATION OF
MASS / THICKNESS OF ZINC COATING
QW-10-2 84-86
43. IN-PROCESS INSPECTION REPORT OF HOT-
DIP GALVANIZING OF TECHRING QR: SCAFF: 10.2-308 87
VERTICAL.
44. PROCEDURE FOR FINAL INSPECTION OF
TECHRING VERTICAL
QD: SCAFF: 121 88
45. FINAL INSPECTION REPORT OF TECHRING
VERTICAL.
QR: SCAFF: 10.2-309 89
LENGTH TUBES FOR COUPLING PIN OF QR: SCAFF: 10.2-310 90
TECHRING VERTICAL
47. PRODUCTION INSPECTION REPORT OF
REDUCING FOR COUPLING PIN OF QR: SCAFF: 10.2-310/1 91
TECHRING VERTICAL
Page 3 of 6
HOLE PUNCHING FOR COUPLING PIN OF QR: SCAFF: 10.2-310/2 92
TECHRING VERTICAL
STAMPING FOR COUPLING PIN OF QR: SCAFF: 10.2-310/3 93
VERTICAL
50. PRODUCTION CUM
IN-PROCESS INSPECTION REPORT OF
GALVANIZING FOR COUPLING PIN OF
QR: SCAFF: 10.2-310/4 94
TECHRING VERTICAL
51. FINAL INSPECTION REPORT OF COUPLING
PIN FOR TECHRING VERTICAL
QR: SCAFF: 10.2-310/5 95
HORIZONTAL.
CHART NO: 58 96
HORIZONTAL
LENGTH TUBES FOR TECHRING QR: SCAFF: 10.2-311 97
HORIZONTAL.
TECHRING HORIZONTAL TUBE.
QR: SCAFF: 10.2-312 98
OF LEDGER HEAD FOR TECHRING SYSTEM.
(For Incoming Material 3 % For Dimensions And
QR-SCAFF: 10.2-313 99
10 % Of Visual Inspection)
TECHRING HORIZONTAL HEAD.
QR: SCAFF: 10.2-314 100
57. PROCEDURE FOR WELDING OF TECHRING
LEDGER (HORIZONTAL)
QD: SCAFF: 122 101
58. PRODUCTION INSPECTION FOR TECHRING
HORIZONTAL (LEDGER) WELDING
QR: SCAFF: 10.2-315 102
59. LOAD TEST ON END LEDGER HEAD OF
HORIZONTAL (TECHRING SYSTEM)
QR: SCAFF: 10.2-316 103
PRODUCT: TECHRING HORIZONTAL.
61. WORK INSTRUCTION FOR LOAD TEST ON
END FITTINGS OF TECHRING HORIZONTAL QD: SCAFF: 124 106
(LEDGER)
HORIZONTAL
OF WEDGE FOR LEDGER & BRACE
TECHRING SYSTEM. QR-SCAFF: 10.2-318 108
(For Incoming Material 3 % For Dimensions And
10 % Of Visual Inspection)
64. INSPECTION REPORT OF WEDGE
ASSEMBLY FOR TECHRING HORIZONTAL & QR: SCAFF: 10.2-319 110
BRACE.
TECHRING HORIZONTAL (LEDGER).
QD: SCAFF: 125 111
66. FINAL INSPECTION FOR TECHRING
HORIZONTAL (LEDGER).
QR: SCAFF: 10.2-320 112
DIAGONAL BRACE
CHART NO: 59 113
DIAGONAL
BRACE 68. PRODUCTION INSPECTION REPORT OF CUT
LENGTH TUBES FOR TECHRING DIAGONAL QR: SCAFF: 10.2-322 114
BRACE.
OF END PRESSING ON DIAGONAL BRACE.
QD: SCAFF: 126 115
Page 4 of 6
TECHRING DIAGONAL BRACE END QR: SCAFF: 10.2-323 116
PRESSING.
OF HOLE PUNCHING ON DIAGONAL QD: SCAFF: 127 117
BRACE.
TECHRING DIAGONAL BRACE END HOLE
PUNCHING & ZINC DRAIN HOLE
QR: SCAFF: 10.2-324 118
PUNCHING.
DIAGONAL BRACE
OF BRACE HEAD (LH & RH) FOR TECHRING
SYSTEM. (For Incoming Material 3 % For
QR-SCAFF: 10.2-326 120
Dimensions And 10 % Of Visual Inspection)
INSPECTION AFTER RIVETING / BOLTING
TECHRING DIAGONAL BRACE.
QD: SCAFF: 128 121
(AFTER GALVANIZING)
76. DIAGONAL BRACE HEAD ASSEMBLY
INSPECTION REPORT
QR: SCAFF: 10.2-327 122
TECHRING DIAGONAL BRACE.
QD: SCAFF: 129 123
78. FINAL INSPECTION REPORT OF DIAGONAL
BRACE
QR: SCAFF: 10.2-328 124
79. WORK INSTRUCTION FOR FINAL AND
QW: 8.2.4-60 125-127
IN-PROCESS INSPECTIONS.
TECHRING 80. PROCESS FLOW FOR ADJUSTABL BASE
SCREW JACK [SCAFFOLDING]
CHART NO: 29 128
ADJUSTABLE
BASE SCREW 81. PRODUCTION INSPECTION REPORT OF
QR: SCAFF: 10.2-178 129
JACK BASE SCREW JACK
82. WELDING PROCEDURE / INSTRUCTIONS
FOR TECHRING ADJUSTABLE BASE JACK.
QD: SCAFF: 91 130
PRODUCT: SCREW JACK.
84. SCREW JACK WELDING INSPECTION QR: SCAFF: 10.2-185
REPORT. 132
85. WORK INSTRUCTION FOR LOAD TEST ON
ADJUSTABLE BASE SCREW JACK
QD: SCAFF: 98 133-134
86. LOAD TEST ON ADJUSTABLE BASE JACK QR: SCAFF: 8.2.4-59 135
DIP GALVANIZING OF TECHRING SCREW QR: SCAFF: 10.2-193 136
JACK.
88. SCREW JACK NUT ASSEMBLY AND
COMPRESSION NOTCHING INSPECTION QR: SCAFF: 10.2-186 137
REPORT.
ADJUSTABLE BASE JACK.
QD: SCAFF: 93 138
90. FINAL INSPECTION REPORT OF SCREW
QR: SCAFF: 10.2-189 139
JACK.
91. Amendment – 1
QP: 8.3
TO PROCEDURE FOR CONTROL OF 140
NONCONFORMING PRODUCT
92. NON CONFORMITY REPORT (NCR)
[INCOMING STAGE]
QR: 8.3-02 141
Page 5 of 6
CANADIAN 93. PROCESS FLOW CHART FOR CANADIAN
CHART NO- 4 142
STEE PLANK STEEL PLANK
94. DRAWINGS FOR CANADIAN STEEL PLANK TRL-US-6010 143-145
95. Q.C. FORMS FOR CANADIAN STEEL PLANK 01_QR-SCAFF TRL-US-
6010-5-S
02_QR-SCAFF TRL-US-
6014-1
146-149
03_QR-SCAFF TRL-US-
6010
04_QR-scaff-_TRL-US-
6010-2
96. LIST OF GAUGES FOR CANADIAN STEEL GTRL-US-01 TO
150
PLANK GTRL-US-10-01
97. GAUGE DRAWING FOR CANADIAN STEEL
151-160
PLANK
Page 6 of 6
PROCESS FLOW CHART NO: 57
SECTION: SCAFFOLDING
PRODUCT: TECHRING VERTICAL (STANDARD)
START
VERTICAL PIPE
ROSETTE (STEEL PLATE)
DIA: 48.3 MM
THK: 3.2 MM
(H.T.MATERIAL, GR St 52.3) INCOMING INSP
INCOMING INSP HR COILS
HR COILS INSPECTION
SLITTING PROCESS
INSPECTION
INSPECTION
SLITTING PROCESS BLANKING
INSPECTION
INSPECTION
LESGER SLOT PUNCHING
TUBE MANUFACTURING
(ERW) INSPECTION
BRACE SLOT PUNCHING

INSPECTION
INSPECTION
PIPE CUTTING CENTER HOLE PUNCHING
INSPECTION INSPECTION
STAMPING AS CUSTOMER
HOLE PUNCHING ONE AT
REUIREMENT
EACH END ∅ 11.2 MM.
INSPECTION
STRESS RELIVING
INSPECTION
FLATTENING
ROSETTE WITH PIPE TACK ASSEMBLY.
INSPECTION
FULL WELDING ASSEMBLY.
ACCEPTED ASSEMBLY.
REJECTED ASSEMBLY
INSPECTION
GALVANIZING
REPAIRING INSPECTION
PART NO PRINTING
INSPECTION
REJECTED
ACCEPTED PACKING
FINAL INSPECTION
SCRAP
DISPATCH
STOP
TECHNOCRAFT INDUSTRIES (I) LTD. DOC CODE: CHART NO-1.
(TUBE DIVISION) STEEL GRADES
MURBAD – 421 401.
STEEL GRADES REQUIRED EQUIVALENT GRADES TO BE USED BY TECHNOCRAFT.
NAME OF COMPONENT STEEL
PHYSICAL PROPERTIES PHYSICAL PROPERTIES ON COMPONENT
PRODUCT OF PRODUCT Y. S. (Re) STEEL GRADE Y. S. (Re)
GRADE / T. S. (Rm) T. S. (Rm)
PSI (MPA) HARDNESS / SPEC. PSI (MPA) REMARKS
SPEC. PSI (MPA) MIN PSI (MPA) MIN
MIN MIN
Tube ∅ 48.3 CSAG40.21 50,000

NOT SPECIFY Not mention.
St 52.3(DIN)/ 60,000 75,000
mm (GRADE 50W) (345) Q 345(China) (414) (517)
Vertical ASTM A36 (OR)

Rosette (Ring) 38,000 39150 62350
(Techring) CSA G40.21 Not Specify Q 235
Pressed (GADE 38W)
(262) (270) (430)
50,000 45,000 St 52.3(DIN)/ 60,000 75,000

Coupling pin. C1010 Not mention.
(345) (310) Q 345(China) (414) (517)
Tube ∅ 48.3 CSAG40.21 50,000

St 52.3(DIN)/ 60,000 75,000
mm (GRADE 50W) (345) Q 345 (China) (414) (517)
Cast steel
Horizontal ASTM A27 36000 70000 Q 235 A / (China) 38,000 54,400 – 71050
Ledger head Not mention.
(Ledger) Grade 70-36 (250) (485) / St 37.2 (DIN) (262) (375 - 490)
Class-2
C1018 Case
Wedge with 87-94 Rockwell Q 235 A / (China) 38,000 54,400 – 71050
harden at A Not specify Not Specify
Revit Scale B / St 37.2 (DIN) (262) (375 - 490)
0.005” depth
Tube ∅ 48.3 CSAG40.21 50,000

St 46 CL(DIN)/ 59,160 69,745
mm (GRADE 50W) (345) Q 345(China) (408) (481)
Swivel face
brace Ductile Iron ASTM
A 536, Grade 60-40-
Brace Head 60,000 Q 235 A / (China) 38,000 54,400 – 71050
18 (or) 40,000(276) 18% Elongation
(RH & LH) CSA D60-40-18 (414) / St 37.2 (DIN) (262) (375 - 490)
D:\Tech Ring Manual\02_chart no. 1 steel grades.doc Page 1 of 1

Chart No-1 Steel grade for Techring system Material specification
Mechanical properties
(Minimum) as per approved Chemical properties
Material grade as per drawing Equivalent grade Raw material used as
Sl.No. Item Description. Remarks
drawing Tensile Yield per TECHNOCRAFT supply
Elongation Manganese( Silicon(Si Phosphorous
strengt strengt Carbon © Sulphur(S)
percentage Mn) ) (P)
h (Mpa) h (Mpa)
1 Vertical
0.22 0.60(Max. MTC of this equivalent
a Tube ST52-3 490 355 20 1.7(Max.) 0.05(Max.) 0.05(Max.) ST52-3/S355JR/Fe510/Q345 grade attached
(max.) )
b. Coupling pin. ST52-3 490 355 20 1.7(Max.) 0.05(Max.) 0.05(Max.) ST52-3/S355JR/Fe510/Q345 grade attached
(max.) )
MTC of this equivalent
c. Rosette Ring Q-235B/S235 340 235 24 0.22(Max.) 0.65(max.) 0.30(max.) 0.05(max.) 0.045(Max.) Q235 / S235 / WT41AT grade attached
2 Horizontal
a. Tube ST52-3 490 355 20 1.7(Max.) 0.05(Max.) 0.05(Max.) ST52-3/S355JR/Fe510/Q345 grade attached
(max.) )
b. Ledger head(Steel casting) Q235A/S235 340 235 24 0.25(Max.) 1.20(max.) 0.50(max.) 0.04(max.) 0.04(Max.) Q235 / ZG275-485H grade attached
c. Wedge Q235/S235 340 235 24 0.22(Max.) 0.65(max.) 0.30(max.) 0.05(max.) 0.045(Max.) Q235 / S235 / WG34AM grade attached
3 Diagonal Brace
a. Tube ST 46 CL 450 345 21 0.21(max.) 1.35(Max.) 0.40(Max.) 0.05(Max.) 0.04(Max.) ST 46 CL

b. Brace head(Steel casting) Q235A/S235 340 235 24 0.25(Max.) 1.20(max.) 0.50(max.) 0.04(max.) 0.04(Max.) Q235 / ZG275-485H grade attached
c. Wedge Q235/S235 340 235 24 0.22(Max.) 0.65(max.) 0.30(max.) 0.05(max.) 0.045(Max.) Q235 / S235 / WG34AM grade attached
d. Rivet SAE1008
4 Base Collar
a. Spigot pipe ST52-3 490 355 20 1.7(Max.) 0.05(Max.) 0.05(Max.) ST52-3/S355JR/Fe510/Q345 grade attached
(max.) )
b. Base collar tube ST52-3 490 355 20 1.7(Max.) 0.05(Max.) 0.05(Max.) ST52-3/S355JR/Fe510/Q345 grade attached
(max.) )
c. Rosette Ring Q-235B/S235 340 235 24 0.22(Max.) 0.65(max.) 0.30(max.) 0.05(max.) 0.045(Max.) WT41AT(Ispat make) grade attached
5 Screw jack
a. Screw for base jack Q345/S355 490 355 18 0.20(Max.) 1.60(Max.) 0.55(max.) 0.035(Max.) 0.035(Max.) ST 52-3 / Q345 / S355 grade attached
b. Base plate Q235/S235 340 235 24 0.22(Max.) 0.65(max.) 0.30(max.) 0.05(max.) 0.045(Max.) Q235 / S 235 / WG34AM grade attached
c. Forged Jack Nut S235 340 235 24 0.22(Max.) 0.65(max.) 0.30(max.) 0.05(max.) 0.045(Max.) Q235 / S235 / AISI 1018 / AISI 1020
6 Stillage
a. Square tube(63.5x63.5x3) ASTM A500 Grade-B 400 317 23 ST 52-3 / WT 41 grade attached
b. Rectangular tube(76.2x50.8x3) ASTM A500 Grade-B 400 317 23 ST 52-3 / WT 41 grade attached
c. Rectangular tube(76.2x25.4x2.05) ASTM A500 Grade-B 400 317 23 ST46 CL / WT 41 grade attached
d. Top and Bottom cup Q235A/S235 340 235 24 0.22(Max.) 0.65(max.) 0.30(max.) 0.05(max.) 0.045(Max.) Q235 / S 235 / WG34AM(Ispat make) grade attached
e. Side Wire Fabric / Mesh Q235/S235 340 235 24 0.22(Max.) 0.65(max.) 0.30(max.) 0.05(max.) 0.045(Max.) Q235 / S235 / AISI 1018 / AISI 1020
f. Bottom Wire Fabric / Mesh Q235/S235 340 235 24 0.22(Max.) 0.65(max.) 0.30(max.) 0.05(max.) 0.045(Max.) Q235 / S235 / AISI 1018 / AISI 1020
g. Wire coil STEEL 340 235 24 0.22(Max.) 0.65(max.) 0.30(max.) 0.05(max.) 0.045(Max.) Q235 / S235 / AISI 1018 / AISI 1020
PDF created with pdfFactory Pro trial version www.pdffactory.com
TECHNOCRAFT PROCEDURE FOR
INDUSTRIES (I) LTD INSPECTION AND
(TUBE DIVISION) DOC.CODE
TESTING OF IN COMING
MURBAD QW: 7.4.3
HR COILS. (QM: 7.4.3)
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 1
QAM RMM APR. 19, 2010
of 16
1.0 PURPOSE :
To document work instruction for implementing the inspection or other
activities necessary for ensuring that purchased product meets specified
purchase requirements in accordance with respective plan.
2.0 RESPONSIBILITY :
Chemist, Q.A. Inspector, respective supervisor, respective plant operators and
respective Incharge will be responsible for compliance with this document.
Note: Refer clause 13 for documentation respect to responsibilities.
3.0 MATERIALS TO BE TESTED :

3.1 Following items are identified to be controlled at the incoming stage that
effects the organizations ability to provide product that meets customer and
applicable regulatory requirements.
Sr. No Name of the item Clause No. QN: NO.
1 STEEL 5.0 QN: 7.4.3 – 01
2 ZINC 6.0 QN: 7.4.3 – 02
3 PACKING PATTI 7.0 QN: 7.4.3 – 03
(for Bundling)
4 BOUGHT OUT 8.0
COMPONANTS
i) G.I. / BLACK SOCKETS 8.1 QN: 7.4.3 – 04
ii) PVC PROTECTOR 8.2 QN: 7.4.3 – 05
iii) ‘C’ clamp for Diagonal Brace 12.4 QN: SCAFF:
8.2.4 – 1
5 CHEMICALS 9.0 QN: 7.4.3 – 06
6 CUTTING TOOLS 10.0 QN: 7.4.3 – 07
7 PACKING MATERIALS 11.0
i) HDPE SHEET 11.1 QN: 7.4.3 – 08
ii) BOPP TAPE 11.2 QN: 7.4.3 – 09
iii) CORRUGATED 11.3 QN: 7.4.3 – 10
BOXES
iv) PALLETS: (WOODEN) 11.4 QN: 7.4.3 – 11
v) M.S.STRIP (BLACK) 11.5 QN: 7.4.3 – 12
vi) PVC STRAP 11.6 QN: 7.4.3 – 13
vii) GI CLIP/PAINTED MS CLIP 11.7 QN: 7.4.3 – 14
viii) WOOD (AS A PACKING) 11.8 QN: 7.4.3 – 15
8 OTHERS 12.0
i) FURNACE OIL 12.1 QN: 7.4.3 – 16
ii) PAINTS 12.2 QN: 7.4.3-17
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 2
of 16
iii) WIRE POOL 12.3 QN:SCAFF:

7.4.3-10
9 Rosette 12.4
10 Ledger head with wedge 12.5
11 Brace head (RH &LH) with 12.6
wedge
4.0 TEST PROCEDURE :

4.1 Characteristics of the product given in relevant plan will be Inspected
to ensure their conformity to the specification requirements
4.2 Work Instruction given in relevant clauses will be followed to inspect above
said characteristics.
4.3 a. Sample size will be selected as per described in relevant inspection form.
b. Acceptance criteria given in annexure – A will be followed during inspection
of all incoming materials.
4.4 Unless otherwise approved by a relevant authority Product released will not
proceed until the planed arrangements have been satisfactorily completed.
4.5 Persons given in column ‘Verify by’ of plan arrangement will be responsible
for product released.
4.6 Values observed during inspection & testing will be recorded in respective
form which is also a part of planned arrangement.
4.7 When Non-conformity occurred during inspection & testing of incoming
material, follow the procedure as per QP: 8.3 (Procedure for control of
nonconforming product) and record your observations in QR: 8.3-02.
4.8 Give test status by applying different colored labels like yellow, white and red
to identify the material to be tested, tested (conforming) and tested
(nonconforming) respectively.
5.0 STEEL :
This raw material will be used for manufacturing various kind of tubes as per
requirements applicable standards described in Annexure III & IV of QN: 7.4.3-01
intended to use for conveying water and gas as well as for scaffolding by end
users and for manufacturing scaffolding items by TTD.
5.1 Carry out inspection and testing on receiving coils for the characteristics
recommended in clause 5.2 & 5.3.
5.2 DIMENSIONAL AND VISUAL INSPECTION :

5.2.1 Every coil will be inspected dimensionally & visually as per described in plan
QN: 7.4.3-01 (Plan for incoming material inspection)
A. WIDTH :
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 3
of 16
i.] Measure coil for outside and inside width and confirm that whether your
results meet the requirements given in annexure – I of plan QN:7.4.3 - 01
ii.] Use 2 meter steel tape to measure width of the coil.
B. THICKNESS :
i.] Measure thickness of the coil at two places top and bottom by leaving end
portion approximately 1.5 meter in length.
ii.] Use 0.25 mm micrometer to measure the thickness.
iii.] Thickness of the coil should remain within the tolerance as specified in
relevant annexure.
iv.] For specified thicknesses refer annexure – II of plan QN: 7.4.3-01(Plan for
incoming material)
C. WORKMANSHIP :
i.] Coil should free from surface lamination, loose winding, uneven winding,
notches, camber telescopicity, fish tail, dents, damages and holes.
D. Record your observations in inspection form QR:10.1-01
5.3 CHEMICAL AND MECHANICAL TESTING :
5.3.1 Select one coil sample from each heat lot and cut a test piece (Approx. 300 x
300 mm) to carry out chemical and mechanical tests for determining the
properties given in plan QN:7.4.3-01.
5.3.2 To follow the test procedures refer QW:10.1A (Work instruction for chemical
and mechanical testing ).
5.3.3 Results of chemical analysis and mechanical testing should be confirmed that
whether they meet with requirements of relevant standards & Customer
specification which are described in annexure – III & IV of plan QN:7.4.3
respectively.
5.3.4 Record your results of chemical properties and mechanical properties in
QR: 10.1-02. You may also use QR: 10.1-02/2 to record results of mechanical
properties.
6.0 ZINC :
6.1 Zinc having at least 98.5 % purity will be used for galvanizing the tubes.
6.2 Every consignment should be accompanied with test certificate.
6.3 To meet the requirements of QN: 7.4.3-02, test certificate will be
reviewed by the General Manager and verified by Factory Manager in the case
of consignment without test certificate F.M. will arrange to get it tested from
outside laboratory.
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 4
of 16
7.0 PACKING PATTI : (FOR BUNDLES)

7.1 Inspect packing patti for the characteristics as per given in plan QN:7.4.3-C.
A. WIDTH :
i.] Measure width of sample patti and ensure that whether your observation meet
the requirement 31.8± 0.2 mm.
ii.] Vernier caliper will be used to measure the width.
B. THICKNESS :
i.] Measure thickness of the sample patti and confirm that whether result meet
the specified requirements as per given in QR: 10.1-21.
ii.] Use 0.25 mm micrometer to measure the thickness.
C. TENSILE STRENGTH :
i.] Perform tensile test on sample patti as per test procedure described in work
instruction QW: 10.1A.
ii.] Minimum tensile strength will be 900 Mpa.
iii.] Use UTM to perform tensile test.
D. PERCENTAGE ELONGATION :
i.] Follow Same work instruction QW: 10.1A to detect % elongation in sample patti.
E. RECORD:
i.] QR: 10.1-21 will be used to record your results.
F. Cold -Weather impact testing (Tubes)
i] Perform the Tensile test base on ASTM E 23-07ae1 standard Test method for
Notched Bar Impact testing of metallic material.
ii ] Sample size shall be ¼ size (10 mm x 2.5 mm),and the number of sample
Shall be six for each heat of steel,of this six samples ,three shall be orientated
In the longitudinal direction and the remaining three shall be orientated in the
Transverse direction
iii ] Test Temperature will be -30 degree centigrade.
iv ] Minimum average result for all transverse samples shall be 7 J,
Minimum average result for all longitudinal samples shall be 18 J and
No single result shall be less than 6 J.
G. Reporting:
i] Specimen orientation with respect to the material axis

ii ] Specimen size.
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 5
of 16
iii ] Test temperature and individual test value for each specimen
H. Cold -Weather impact testing (Rosette Material)
i] Perform the Tensile test base on ASTM E 23-07ae1 standard Test method for
Notched Bar Impact testing of metallic material.
ii ] Sample size shall be ¾ size (10 mm x 7.5 mm),and the number of sample
Shall be six for each heat of steel,of this six samples ,three shall be orientated
In the longitudinal direction and the remaining three shall be orientated in the
Transverse direction
iii ] Test Temperature will be -30 degree centigrade.
iv ] Acceptance Criteria: Minimum acceptable individual result shall be 25J and
The Minimum average result of all six sample shall be 30J
H. Reporting:
i] Specimen orientation with respect to the material axis

ii ] Specimen size.
iii ] Test temperature and individual test value for each specimen
8.0 BOUGHT OUT COMPONANTS :
8.1 G.I./ M.S. SOCKETS :

Following tests are to be carried out on G.I./ M.S. sockets to meet the product
requirements as per specified in plan QN:7.4.3-04.
a. Outside Diameter
b. Length
c. Threads requirements.
d. Hydro – Static test.
e. Uniformity of coating
f. Chemical properties
A. OUTSIDE DIAMETER :
i.] Measure outside diameter of sample sockets at different places and confirm
that whether your lowest results meet the specified requirement as per given
in annexure – V of plan QN:7.4.3-04 for the respective size.
ii.] Use Vernier caliper to measure outside diameter of sample sockets.
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 6
of 16
B. LENGTH :
i.] Measure length of sample sockets at different places and confirm that whether
your lowest results meet the specified requirement as per given in annexure – V of
plan QN:7.4.3-04 for the respective size.
ii.] Use Vernier caliper to measure outside diameter of sample sockets.
C. THREADS REQUIREMENTS :
i.] Use taper plug gauge to observe performance of parallel threads of sockets.
ii.] Taper screw plug gauge should be screwed hand – tight.
iii.] The thread is within the permissible tolerance if the end of the thread lies
between the faces or flush with either face of the step on the gauge.
iv.] In visual inspection threads should free from roughness, broken and
washout.
D. HYDROSTATIC TEST :
i.] Use portable hydrostatic pressure testing machine to carry out this test directly or
use hydro pressure testing machine to carry out this test on jointed pipe.
ii.] Take two pieces of pipes having random length and make approximately 6 meters
long assembly by joining two pieces at both side of the sample socket.
iii.] Use sealing material like tephlone tape, fibre or any other material suitable to make
pressure tight.
iv.] Now carry out hydrostatic pressure test on above jointed pipe for compliance
with product requirement.
v.] There should no leakage in socket at 5 MPa test pressure.
vi.] Test pressure should be maintained for sufficient long for proof and inspection
vii.] Use pressure gauge to observe test pressure.
E. UNIFORMITY OF COATING (CUSO4 TEST) :

i.] To perform uniformity of zinc coating test follow the procedures described in
QW: 10.1A (Work instruction for chemical and mechanical testing.
F. CHEMICAL PROPERTIES :
i.] Select one socket sample from each size of every consignment and carry out
chemical analysis tests to meet the specified properties as per given in plan
QN:7.4.3-04 (annexure – VI)
ii.] To follow test procedures refer QW: 10.1A (Work instruction for chemical
and mechanical testing)
iii.] Record your result in QR: 10.1-27.
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 7
of 16
8.2 PVC PROTECTOR :

To comply with specified requirement given in accordance with QN: 7.4.3-05,
carry out inspection and testing for the following characteristics.
A. INSIDE DIAMETER (MAX) :

i.] Measure maximum inside diameter of sample protector and confirm that
whether your observations meet the requirements as per given in accordance
with annexure VII of plan QN:7.4.3-05.
B. LENGTH :
i.] Measure minimum length of sample protectors and ensure that whether your
results meet the requirements as described in annexure VII of plan QN:7.4.3-05.
ii.] Vernier caliper will be used to measure inside diameter and length of the
protectors.
C. FUNCTIONAL TEST :
i.] Strength of the PVC protectors will be checked by fitting on pipe threads
and ensure that whether this test meet the requirement as per given in QN: 7.4.3-05.
D. WORKMANSHIP :
i.] Visually protector should free from cracks, cuts, holes and roughness.
E. Observations will be recorded in QR: 10.1-16.
9.0 CHEMICALS :
A. Following chemicals are used in galvanizing and ETP plants.
Name of chemicals Grade Used for
i.] Hydrochloric acid Commercial Pickling

ii.] Zinc Chloride Flux Fluxing
iii.] Ammonium chloride Technical Fluxing
iv.] Sodium Dichromate Technical Chromating
v.] Calcium Hydroxide F.T.P Neutralizing
B. Carry out testing on chemical samples and ensure that whether your results meet
the specified requirement as per given in plan QN: 7.4.3-06.
C. Refer QW: 10.1A to follow the test procedures.
D. To maintain working efficiency of the processes, above chemicals will also be

tested as a part of inprocess inspection as per QW:7.5.1-06 (Monitoring and
measurement of processes in galvanizing plant.)
E. Record your observations in relevant inspection form as per given in plan

QN: 7.4.3-06.
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 8
of 16
10. CUTTING TOOLS:
A. To comply with product requirements, functional test will be carried out on

following cutting tools.
CUTTING TOOL APPLICABLE TO

i.] Trimming tool To remove upset bead in Tube Mill
ii.] White tool (HSS) End facing machine
iii.] Tool bits Used in tool room
iv.] Chasers Threading machine
B. Personnel of concerned department will carry out functional test on respective

cutting tool and give his observations to the stores in-charge.
C. In the case of tool shows wear out or breakage immediate after short working,
It will be taken where requirement is specified, for example chasers and
trimming tool should have hardness 60 to 65 HRC.
D. Refer plan QN: 7.4.3-07 to inspect characteristics mentioned therein and use
inspection form QR: 10.1-28 to record observations.
11. PACKING MATERIALS :
11.1 HDPE SHEET:
i.] Two types of HDPE sheets are used for covering the bundles of pipes and they will
be inspected for the following characteristics as per given in plan QN:7.4.3-08.
A. WIDTH:
i.] Measure width of HDPE sheet by using Measuring tape and confirm that whether
your results meet the specified requirements 1340±10mm and 1550±10mm.
B. THICKNESS :
i.] Measure thickness of HDPE sheet and confirm that whether your results meet
the specified requirement 0.10 to 0.18mm.
ii.] Use 0.25mm micrometer to measure thickness.
C. WORKMANSHIP :
i.] HDPE sheet should free from holes.
D. QR: 10.1-37 will be used to record your results.
11.2 BOPP TAPE:

To comply with requirement given in accordance with QN: 7.4.3-09, carry out
inspection and testing on sample Bopp tape for the following characteristics.
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 9
of 16
A. WIDTH :
i.] Measure width of sample Bopp tape and confirm that whether your result meet
the specified requirement 72.0 to 72.5mm.
ii.] Use vernier caliper to measure width of Bopp tape.
B. THICKNESS :
i.] Measure thickness of sample Bopp tape and ensure that whether your result is
matching with specified requirement 50um – 75um.
ii.] 0.25mm micrometer will be used to measure thickness.
C. GROSS WEIGHT :
i.] To comply with specified minimum gross weight weigh Bopp tape on digital
weighing machine and ensure that whether your result is matching with
specified requirement 285 gms.
ii.] Weight of cardboard reel is 47 gms maximum.
D. AIR BUBBLES (FISH EYES):

i.] Inspect visually for air bubbles and blisters and ensure that whether Bopp tape
is free from these defects.
E. UNIFORMITY OF ADHESIVE COATING:

i.] Adhesive coating should be uniform and it can be judged by observing Bopp
tape free from telescopicity and wrinkles.
F. ADHESIVE STRENGTH:
i.] Apply Bopp tape on corrugated box and pull out, box material should stick with
Bopp tape and should come out.
ii.] In this test visual inspection will be carried out.
G. TEARING TEST :
i.] Marked fold of Bopp tape from the adhesive sides and open it and confirm that
it should not teared off during opening.
ii.] Adhesive strength is also determined by this test as fold should not be opened
easily, meaning some considerable strength is required for offering the fold.
H. DIAMETER:
i.] Measure inside and outside diameter of Bopp tapes with the help of Vernier
caliper and confirm that whether your results are matching with the specified
requirements of inside diameter 81.0 mm Min (Excluding card board reel) and
outside diameter 106.0 mm Min.
ii.] Observations will be recorded in inspection form QR: 10.1-33.
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 10
of 16
11.3 CORRUGATED BOXES:

11.3.1 To comply with requirement as per QN: 7.4.3-10 conduct inspection and testing
on selected samples of corrugated boxes for the following characteristics:
A. DIMENSIONS :
i.] Measure size of sample corrugated boxes and confirm that whether your
observations meet the requirements given in accordance with inspection from
QR: 10.1-38.
ii.] Measuring tape will be used to measure the dimensions.
B. CLOSING PERFOMANCE :
i.] Close upper flaps of sample boxes and carry out visual observation for the
requirement.
ii.] There should no gap between upper flaps.
C. BULGING :
i.] Pack sample box with respective product and carry out visual inspection.
ii.] Box should be observed free from bulging.
D. BURSTING :
i.] Allow packed sample box to drop from 2’ height and carry out visual inspection.
ii.] Box should be observed free from bursting.
E. ADHESIVENESS :
i.] Fold, flaps of sample boxes and carry out visual inspection.
ii.] After folding of flaps, plies should be observed free from opening.
F. WETNESS :
i.] Press sample boxes with your thumb and carry out visual inspection.
ii.] Box should be observed free from feeling of wetness.
G. Results will be recorded in inspection form QR: 10.1-38.
11.4 PALLETS: (WOODEN)

11.4.1 To comply with specified requirements described in plan QN: 7.4.3-11 inspect
sample pallets for the following characteristics:
A. SIZE :
i.] Measure size of pallets with the help of measuring tape and confirm that
whether your observations meet the requirements specified in above said plan.
ii.] There are pallets in three different sizes.
B. CAPACITY :
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 11
of 16
i.] Carry out palletization process on sample pallet and allow it to lift with the help
of forklift. (Use approx. 2MT load for paletization to be lifted at 4’ height)
ii.] Visually pallet should be observed free from breaking and cracking.
C. BOTTOM GAP FOR FORKS :

i.] Bottom gap for forks should be maintained 4.5” (exclusive of 1” wooden top plank)
ii.] Measuring tape will be used to measure gap.
D. FINISH :
i.] Visually pallet should be free from nail, nail heads and screw projections.
E. FORKS ENTRY :
i.] Allow forks to enter in palletization from all the four sides.
ii.] In this trial forks should be found ease.
F. Observations will be recorded in QR: 10.1-39.
11.5 PACKING M.S. STRIP (BLACK) : (FOR PALLETS)

11.5.1 To comply with product requirements given as per plan QN: 7.4.3-12 carry out
inspection and testing on sample strips for the following characteristics.
A. WIDTH :
i.] Measure width of M.S. strips and confirm that whether product requirement is
matching with your observation.
ii.] Specified width of the M.S. strip is 16.0 ± 0.15 mm
iii.] Use Vernier caliper to measure width.
B. THICKNESS :
i.] Measure thickness of M.S. strips as a part of incoming material inspection and
confirm that whether your observations meet the specified requirements.
ii.] Specified thickness of M.S. strip is 0.5 ± 0.05 mm.
iii.] Use 0.25mm micrometer to measure the thickness of the strips.
C. TENSILE STRENGTH :
i.] Perform tensile strength on M.S. strap with the help of UTM.
ii.] Specified tensile strength is 600 Mpa Minimum.
iii.] Refer work instruction QW: 10.1A to follow test procedure.
D. Observations will be recorded in QR: 10.1-40.
11.6 PVC STRAP:

11.6.1 To comply with specified requirement given in accordance with QN: 7.4.3-13,
carry out inspection and testing on PVC straps for the following characteristics.
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 12
of 16
A. WIDTH :
i.] Measure width of sample strips and confirm that whether your observations are
matching with specified values 12.0±0.15 mm.
ii.] Use Vernier caliper to measure width of the sample strip.
B. THICKNESS :
i.] Measure thickness of strap and confirm that whether your result meet the
requirement specified as 0.60 ± 0.05mm.
ii.] 0.25 mm micrometer or Vernier will be used to measure the thickness.
C. BRITTLENESS :
i.] Brittleness of the PVC strap will be checked by folding it manually.
ii.] Visually strap should be observed free from cracking.
D. STRAPING PERFORMANCE:
i.] Pack one corrugated box by using sample strap and observe its performance
visually.
ii.] Strap should be observed free from cracking during strapping process.
E. STRENGTH TEST :
i.] Take a sample of PVC strip and allow it for strapping the corrugated box with
the help of strapping machine.
ii.] During strapping process PVC strap should not be observed broken.
G. Record your results in QR: 10.1-41.
11.7 G.I. CLIP / PAINTED M.S. CLIP:
11.7.1 To comply with product requirements given in accordance with plan QN: 7.4.3-14
inspect sample clips for the following characteristics:
A. STRENGTH TEST :
i.] Take sample clips and allow it to be clipped by clipper M/C.
ii.] After clipping process clip should not be observed broken.
B. INSIDE WIDTH :
i.] Measure inside width of sample clip and confirm that whether your result meet
the specified requirement given in accordance with QR: 10.1-42.
ii.] Vernier caliper will be used to measure inside width.
C. FINISHING :
i.] Visually product should free from rust and oil.
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 13
of 16
D. EDGES :
i.] Visually edges should free from burr and sharpness.
E. HARDNESS :
i.] Visually material should be observed ductile enough to withstand clipping
process while strapping is carried out.
F. SLIPPAGE TEST :
i.] After clipping process, strap should be observed free from slippage.
G. Observations will be recorded in inspection form QR: 10.1-42.
11.8 WOOD ( FOR PACKING ):

To comply with product requirements given in accordance with QN: 7.4.3-15,
inspect sample wood for the following characteristics:
A. SIZE OF WOOD:
1) Measure size of the sample wood and confirm that whether your result meet the
specified requirements as per given in QR:10.1-42/1.
2) Measuring tape will be used to measure the size of sample wood.
B. COMPRESSIVE STRENGTH:
1) Cut 5”(appro.) long piece from a sample wood.
2) Measure length, width and height of cut piece (test piece) and calculate cross
section area by computing length and width (in inches)
3) Further multiply cross section area with 170 kg/inch2 to find out applicable load
in kilograms
4) Now put this test piece between two parallel plates of universal testing machine
and allow it to compress till reaching the applicable load.
5) On reaching the applicable load stop the machine and observe test piece for
deformation and splitting .
6) Deformation will be detected by measuring the size of test piece after completing
compression test.
7) There should no deformation and splitting in tested piece.
C. TREATMENT:
1) To save from termite wood should be treated with effective pesticide.
2) Use colour indicator to determine whether wood is treated or not.
3) Allow colour indicator to drop on wood and observe that it will be turned in
green colour as a indication of positive treatment of wood .
D. WORKMAN SHIP:
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 14
of 16
Visually Wood should be free from wetness, nail, knots, splits, cross grains and
termite.
E. RECORD:
Use QR: 10.1.42 to record above observations.
12 OTHERS:
12.1 FURNACE OIL:
For meeting the requirements of following characteristics, respective tests are
carried out on sample furnace oil as per QN: 7.4.3-16
A. TEMPERATURE:
1) Measure temperature of sample furnace oil (at ambient temperature)
2) Use 0-100° centigrade thermometer to measure temperature of furnace oil.
B. SPECIFIC GRAVITY:
1) Measure specific gravity of sample furnace oil at ambient temperature and
compare your test result with specified values given in chart no.7.4.3-01
2) Use hydrometer to measure specific gravity.
3) Use glass cylinder have sufficient depth to immerse hydrometer in furnace oil.
C. WATER CONTENT:
To perform this test take above glass cylinder with furnace oil and observe
that there is no presence of water at the bottom.
D. RECORD:
Use QR: 10.1- 43 to record the results of above tests.
12.2 PAINTS:
12.2.1 To comply with requirements specified in QR: 10.2-30, carry out inspection for
characteristics which are described in same inspection form.
12.2.2 Also refer QN: 7.4.3-17 to follow test procedures.
12.3 WIRE POOL:

12.3.1 To comply with requirements specified in QN: SCAFF: 7.4.3-10, carry out tests on
selected sample for the characteristics given therein.
12.3.2 Use inspection form QR: SCAFF: 7.4.3-10 to record your observations.
12.4 BOUGHT OUT COMPONENTS

(C – CLAMP FOR DIAGONAL BRACE)
12.4.1 To comply with requirements specified in QR: SCAFF: 10.2-16, carry out
inspection for characteristics which are described in same inspection form.
MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 15
of 16
12.4.2 Also refer QN: SCAFF: 8.2.4-1 to follow test procedures.
12.5 Rosette (Ring) :
Measure the Critical dimension of the Ring as per the drawing and incoming check
sheet, also do the Rosette bending test as per the check list given. Check list
attached.
12.6 Ledger Head with Wedge:
Measure the critical dimension of the ledger head and the wedge as per the drawing
and incoming material check sheet .
12.7 Brace Head with Wedge and Revits:
Measure the critical dimension of the ledger head and the wedge as per the drawing
and incoming material check sheet .
13 As per plan arrangement people who are responsible for conducting inspection
and testing of respective incoming materials, corresponding documented
responsibilities are given below.
i.] Q.A. Inspector – QD – 01 – QAM (H – 7)
ii.] Chemist – QD – 01 – QAM (H – 6)
iii.] Supervisor (Threading and Packing) QD- 01 – RMM (J-2)
iv.] QAM – QD – 01 SNR (H)
v.] Factory Manager – QD – 01 SNR (G)
vi.] Raw Material Manager (Packing In-charge) – QD 01 – SNR (E)
vii.] General Manager – QD – 01 – SNR (D)
Concern Departments
i.] Tube Mill operators – QW: 7.5.1-2/2
ii.] Finishing Supervisor – QD: 01 – FM (G – 5)
iii.] Tool room Incharge – QD – 01 – FM (G – 22)

MURBAD QW: 7.4.3
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
1 Page 16
of 16
iv.] Threading Operator – QW: 7.5.1 – 10.

TECHNOCRAFT WORK INSTRUCTIONS FOR
INDUSTRIES (I) LTD CHEMICAL ANALYSIS OF DOC.CODE
(TUBE DIVISION) INCOMING MATERIAL AND QW-10-1A
MURBAD PHYSICAL TESTING.
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 1
QAM MR April 19, 2008 1
of 7
1. PURPOSE
The purpose of these work instruction is to detail the activities necessary to analysis
of incoming material. Simulate
2. RESPONSIBILITY
Chemist is responsible for all action necessary to analysis for chemical composition.
3. PROCEDURE
3.1 DETERMINATION OF CARBON
3.1.1 Sampling:
The sample of raw material must be cleaned with organic solvent like either or
acetone dried in an air oven at 100 ± 5° C before use for drilling sample.
3.1.2 Apparatus:
Determination of carbon & sulphur by direct combustion method known as “strohlein
apparatus”. The oxygen for combustion is supplied from a gas cylinder at a constant
pressure.
3.1.3 Outline Method:
This is very quick method of determining both Carbon and Sulphur in ferrous
materials in one operation.
In sample Carbon is oxidized at a high temperature in a stream of dry and pure
oxygen to yield Carbondioxide. The Carbondioxide is absorbed in Potassium
Hydroxide solution. The decrease in volume of gas after absorption is read directly on
a scale as % of carbon, after making due corrections in the volume for the change in
temperature and pressure.
The Sulpher present in the material is also oxidized to Sulpherdioxide, which is
absorbed in Hydrogen peroxide and titrated with a standard Sodium Hydroxide
solution.
3.1.4 Before use the apparatus should be tested for satisfactory working against a blank test
and standard steel of appropriate values of carbon.
3.1.5 Bring the combustion furnace to the proper temperature (1000 to 1150°C) for plain
carbon steels (Low carbon).
3.1.6 Take one gram of an accurately weighed and clean sample free from extraneous
carbon in the form of small drilling in a porcelain boat which can withstand a
temperature of 1150°C without breaking or cracking.
3.1.7 Introduce the boat into the hot combustion tube in the combustion furnace kept at
1000°C without breaking or cracking.
3.1.8 Close the furnace inlet with a rubber stopper, allow the sample to heat for one to one
and a half minute. Regulate the flow of pure oxygen to 300-400ml per minute in to
the furnace and establish connection with the burette, which has been previously filled
with acidulated distill water colored with methyl red. So that the liquid level in the
bulbed portion of the gas burette closed not fall rapidly after a minute or so the level
of water in the burette begins to fall rapidly, though the same rate of oxygen is
maintained, indicating completion of combustion.
3.1.9 Take readings, when the level reaches near the zero graduation mark after closing the
bend way stop cock (four-way stop cock) and equalizing the levels of the burette and
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 2
of 7
the connected leveling bottle pass the collected and measured gas twice in to the
absorbing bulb, till constant reading is obtained. Record the burette reading on the
basis of gram of sample taken for analysis, the burette is graduated to measure
directly the percentage of carbon.
3.1.10 Examine the combustion boat for complete fusion of the sample, if not thoroughly
fused repeat the same with fresh sample.
3.1.11 Calculation :
Carbon, Percentage = (A-B) x F Where,
A = Burette reading after absorption of Carbondioxide in caustic potash with
one gram of sample.
B = Burette reading for the blank experiment.
F = Correction factor given temperature and pressure.
Note: Correction factor given in temperature and pressure temperature.
3.2 DETERMINATION OF SULPHUR
3.2.1 Apparatus
Determination of sulphur in ferrous materials by strohelein apparatus. In this
apparatus with attached a sulphur cup with non-returnable value (100 ml capacity).
3.2.2 Outline Method
The principle behind the determination of sulphur by strohelein apparatus is the same
proceeds exactly as described for determination of carbon as above.
The advantage of this method is that the apparatus is very compact one and the
determination is made within 7 minutes.
The sulphur present in the material is also oxidized to sulphurdioxide, which is
absorbed in hydrogen per oxide and titrated with a standard sodium hydroxide
solution.
3.2.3 Reagents
a) Hydrogen peroxide – 6% (1:9) (v/v)
b) Sodium Hydroxide Solution – N/40
c) Methyl Red Solution (pH 4.2 to 6.3)
3.2.4 A proper adjustment likes temperature in combustion furnace i.e. 1150°C, then a fresh
hydrogen peroxide solution fill up in sulphur cup. Also taken 2-3 drops red methyl
indicator then pass through in it flow oxygen regulator with slowly. After titrate with
sodium hydroxide till colour change red to yellow.
Now in the solution sulphur cup is complete for test, firstly we find out the factor of
standard sodium hydroxide with the help of standard seal sample.
Then one gram of an accurately weighed sample taken in combustion tube. After
slowly regulate the regulator of oxygen cylinder for oxygen. Now close the cock in
combustion tube and sulphur cup.
After completing reaction remove the cock from sulphur cup. Colour change yellow
to red. Flowing rate of oxygen some increase. Now titrate with known factor standard
sodium hydroxide. During the titration, oxygen is continued supplied.
Sulphur - Percentage = B x R x F
Where:
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 3
of 7
B.R. = Burette reading of standard sodium hydroxide consumed

F. = Known factor by standard steel sample, titrated with
standard sodium hydroxide.
3.3 DETERMINATION OF MANGANESE

3.3.1 Apparatus
One burette and one conical flask. (250ml capacity).
3.3.2 Out line Method
Manganese is oxidized in presence of silver nitrate to permanganic acid by
ammonium persulphate and titrated with sodium arsenate solution.
3.3.3 Reagents
A) Dilute Nitric Acid 1 : 2 (v/v)
B) Phosphoric Acid – 85%.
C) Ammonium Persulphate Solution : Fresh prepared, 10% (m/v)
D) Silver Nitrate Solution – 1% (m/v)
E) Sodium Chloride Solution – 1% (m/v)
F) Standard Sodium Arsenate Solution – 1% (m/v)
Take one gram of and accurately weighed pure arsenous oxide and 2.5 grams of
solution bicarbonate dilute 1 liter in a volumetric flask. Shake well vigorously to
dissolve settle the solution for 24 hours. Shake well before use.
3.3.4 Procedure
A) Take 200 milligram of accurately weighed sample in a 250ml conical flask. Add 10ml
of dilute nitric acid and 3 to 4 ml of phosphoric acid, and heat to till complete dissolve
the sample, boil few minutes to expel oxides of nitrogen and dilute to 100ml.
B) Add 20ml of flesh ammonium persulphate solution, after a few minutes boiling, when
solution becomes clear, add 10ml of silver nitrate and allow the pink colour of
permaganic acid to develop. Boil to destroy the excess of persulphate. Cool quickly to
room temperature.
C) After cooling the solution at room temperature, add 10ml of sodium chloride solution
to precipitate of silver chloride. Titrate rapidly the permaganic acid with standard
sodium arsenate solution until the pink colour is discharged.
D) Calculation
Calculate the manganese content as follow:
Manganese percentage = A x B x 100
C
Where:
A =Volume of standard sodium arsenic solution for titration.
B =Manganese equivalent of standard sodium arsenic solution in gm/ml.
C =Mass in gram of sample.
OR
Where:
B.R. = Burette reading of standard sodium arsenate solution consumed in unknown titration.
F= Factor of standard sodium arsenate solution, we get from titration of known
manganese of standard steel sample.
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 4
of 7
3.4 DETERMINATION OF PHOSPHORUS

3.4.1 Apparatus
Two burette (50ml capacity)
One conical flask, (25ml capacity) two filter paper, one funnel.

Phosphorus is converted to orthophosphoric acid and precipitated as ammounium
phosphomolybdate. The precipitate is dissolved in known of standard sodium
hydroxide solution and titrated against hydrochloric acid solution.
3.4.3 Quality of Reagents :
Analytical grade reagents and distilled water shall be employed in the test.
3.4.4 Reagents
A) Dilute Nitric Acid - (1:2)(v/v)
B) Potassium Permanganate Solution - 2% (m/v)
C) Sodium Nitride Solution - 5% (m/v)
D) Ammonia Solution - 25%
E) Concentrated Nitric Acid - 69-72% (Sp.gr. 1.42)
F) Ammonium Molybdate Solution.
Solution – I
Take 100gm of ammonia molybdate powder add in 200 ml boiling distilled water,
cool it at the room temperature. Add in the solution 200ml ammonia with cover the
solution complete cool at the room temperature. (Approx. 4 to 6 hours).
Solution – II
Take another 2.5 lit. capacity of glass or PVC jar, in 500ml concentrated Nitric Acid
and 750ml distilled water, cool it at the room temperature (5 to 6 hours).
Then after cooling solution – I mix solution – II slowly drop wise, with the help of
glass rod mix the solution vigorously.
After mixing I + II = III solution known as fresh ammonium molybdate solution.
Keep the solution for settled after 6 hours. Filter withfilter paper and keep the solution
in reagent bottle.
G) N/10 standard sodium hydroxide solution.
H) N/10 Standard hydrochloric acid.
I) Indicator, Phenoiphthalein solution.
3.4.5 Procedure
Take 1 gram of an accurately weighed sample in a 250ml capacity conical flask. Add
30ml of dilute nitric acid (1:2) till the vigorous reaction subsides. Keep the flask at
low heat till it dissolves.
Add 3% of potassium permanganate solution 5 to 10ml drop wise till colour brown
and boil for few minutes. If manganese dioxide does not precipitate add further
permanganate solution till a precipitate of manganese dioxides appears and boil for
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 5
of 7
few minutes. Add 5% of sodium nitrate solution drop wise till the brown precipitate is
dissolved. Boil to expel oxides of nitrogen. Cool the solution at the room temperature.
After then add 5 to 8ml of (25%) ammonia solution till brown precipitate. Dissolve
the precipitate by adding of concentrated nitric acid drop wise till all precipitate
dissolve with clear solution.
Warm the solution to about 60-80°C and add 30 – 35ml fresh prepared ammonium
molybdate solutions. Shake the solution vigorously for a few minutes and allow to
stand for half an hour, to settle down the precipitate.
Filter the precipitate through a filter paper pulp by suction. Wash the flask precipitate
and filter pad twice with 5ml portion of dilute hydrochloric acid (2:98). And continue
washing of the precipitate and filter pad with 1% of potassium nitrate solution (until
the washings acid free 10ml portion of the washings in presence of phenolphthalein
should turn pink on adding one drop of 0.1N sodium hydroxide solution.).
Transfer the pulp along with the precipitate to the flask. Add about 25ml of distill
water and 20 ml a known volume of 0.1N sodium hydroxide solution and 3-4 drops,
of phenolphthalein indicator and shake to dissolve the precipitate. Dilute to about 50-
80ml and titrate with 0.1N hydrochloric acid solution to the disappearance of pink
colour. Not the burette reading.
3.4.6. Calculation :
Phosphorous percentage = (B – A) x 0.01354
Where:
B = Known volume of 0.1N sodium hydroxide solution in ml.
A =Volume of 0.1N hydrochloric acid which consumed to disappearance of pink colour.
And 0.01354 Standard factor.
Note : Do carefully a same procedure for known quality of standard steel sample before a
unknown quantity of any steel sample with any standard factor.
3.5 DETERMINATION OF SILICON

3.5.1 Apparatus
One beaker, hot plate, muffle furnace hot air oven, silica crucible, desiccator and one
funnel.
After dissolution of the sample, silica acid is dehydrated by fuming with sulphuric
acid. The solution is filtered and silica is ignited, weighed and then volatilized with
hydrofluoric acid; the residue is ignited and weighed; the loss weight represents silica.
3.5.3 Reagents
A) Mixed Acids: Add 450ml of concentrated nitric acid to 500ml distilled water and
cool at room temperature. To another 500ml of distilled water add 250ml
concentrated sulphuric acid and cool it in a room temperature. Then after cooling mix
both acid, that is called dilute mixed acids.
B) Dilute Hydrochloric Acid (1:1) (v/v)
C) Dilute Sulphuric Acid (1:1) (v/v)
D) Hydrofluoric Acid 40%
E) Dilute Hydrochloric Acid (1:20) (v/v)
F) Silver Nitrate 0.5%
3.5.4 Procedure (For plain low carbon low silicon steels)
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 6
of 7
Take 5.0gm of an accurately weighed sample in 250ml capacity beaker; add 30ml of
mixed acid to dissolve the sample; heat until nitrous fumes are expelled and continue
heating till SO3 fumes are evolved. Cool and add 50ml of dilute hydrochloric acid
(1:1) and heat again.
Cool, dilute to 100ml with warm distilled water and add filter paper pulp. Stir well
and filter immediately through medium textured filter paper. Wash the residue with
hot dilute hydrochloric acid (1:20) and then with hot distilled water till residue is free
chloride (check it by 0.5% silver nitrate solution, if not milky colour, then washing is
completed).
Transfer the residue and filter to a silica crucible and dry at in hot air oven at 110°C.
Then heat, char and ignite in muffle furnace at 1050-1100°C for 30 minutes. Then
cool it in a desiccator and weigh.
Add 1-2 drops of dilute sulphuric acid to moisten the residue and then add 3-5ml of
hydrochloric acid. Evaporate to dryness and ignite at same 1050°C to constant mass.
Note the constant mass.
3.5.5 Calculation
Silicon, % by constant mass.
(A – B) x 46.75
C
Where:
A = Constant mass in grams of silica obtained in sample.
B= Constant mass in grams of silica crucible
C= Mass in gram of sample taken
Note: Check the same procedure with known silicon percent standard steel sample
before unknown silicon %.
4. WORK INSTRUCTION FOR TENSILE TEST

4.1. RESPONSIBILITY
Q. A. Inspector or chemist shall be responsible for compliance with this document.
4.2. METHOD FOR PREPERATION OF SAMPLE
4.2.1. To make a test sample (strip) given a sample to tool room which is cut from the coil.
4.2.2. Size of the strip will be 300 X 20 mm.
4.2.3. Remove burrs from the both edges after shaping process.
4.2.4. Take it to testing lab and measure width and thickness of the strip.
4.2.5. Calculate the cross sectional area by computing width X thickness.
4.2.6. Mark 50.8 mm original gauge length on test sample.
4.2.7. Put a mark on the middle of strip by using a sharp punch.
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 7
of 7
4.2.8. From the middle mark, make other markings, half the gauge length apart for the entire
length (it means distance between one point to other is ½ x OGL ) by using a Vernier
caliper and with punch.
5. METHOD FOR TESTING THE SAMPLE
5.1. Open the top clamps on the UTM by operating the lever and put the strip between
the clamp jaws while bottom end of the strip is between bottom clamp jaws.
5.2. Leave the top lever to its original position and lower the lever of bottom clamp to grip
the strip.
5.3. With keeping the bottom lever in same position start the machine so that top clamp
will go downward along with strip so that it will get tight.
5.4. Lifting of pointer on the pressure gauge shows the clamping is completed.
5.5. Leave the bottom lever to its original position and adjust the speed of machine by
operating the regulator.
5.6. If yield stress is required set the micrometer at the middle of strip in such a way as
just to grip it before starting the machine.
5.7. Now observing the load indicator.
5.8. At the yield point micrometer will drop down and corresponding load shall be noted
as yield load.
5.9. The strip will be further elongated up to particular load and where the breaking is
occurred.
5.10. Note the maximum load.
5.11. Joint the broken pieces and measure the final gauge length (FGL.)
5.12.. Calculate the yield stress, tensile strength and % of elongation as per the formulae are
given below:
Yield stress in Mpa = Yield load in Newton (N)

Cross section area
Tensile strength in Mpa = Max. load in Newton (N)

Cross section area
Percentage of elongation = (FGL – OGL) 100

OGL
Note: Record your test result inspection form no QR: 10.2-05.
TECHNOCRAFT INDUSTRIES (I) LTD, DOC CODE: QN: 7.4.3- 01
(TUBE DIVISION) PLAN FOR INCOMING MATERIAL INSPECTION (QM: 7.4.3)
MURBAD - 421401
ISSUED BY APPROVED BY DATE REVISION STATUS PAGE

QAM RMM AUGUST 4, 2006 1 1 of 1
Item Characteristics Specified values Method of Sampling Record Work
inspection / instruction Responsibility Verified by
Instrument
STEEL I. Dimensional & visual
(HR Inspection:
COILS) A. Width of coil As per indent Measuring Each coil QW: 7.4.3 QA Inspector QAM / R.M.M
QR: 10.1-01
Tolerance + 30 / - 0 mm tape cl: 5.2.1(a)
B. Thickness of coil 3.25 mm 0 – 25 mm Each coil QW: 7.4.3 QA Inspector QAM / R.M.M
QR: 10.1-01 cl: 5.2.1 (b)
Tolerance ± 0.20 Micrometer
C. Workmanship Coil should be free from Visual Each coil QR: 10.1-01 QW:7.4.3 QA Inspector QAM / R.M.M
lamination, loose cl: 5.2.1 (c)
winding, uneven winding,
notches, camber,
telescopicity, fish tail,
dents, damages, pits,
protrusions and holes.
II Chemical and C&S

Mechanical testing: Determinator One QW:7.4.3 QAM / RMM/
As per Annexure – I QR: 10.1-02
A. Chemical & sample cl: 5.3 Lab I/C F.M
Properties Chemical per heat. QW: 10.1A
analysis
B. Mechanical Properties As per Annexure – II Universal One QR: 10.1-02 QW:7.4.3 Lab I/C / Q.A. QAM / RMM/
testing sample cl: 5.3 Inspector F.M
machine per heat. QW: 10.1A
III Cold Weather Impact As per the Annexure-III Impact Six MTC and RMM QAM/RMM/F
Testing (Charpy Testing) Testing sample Lab report M
machine per heat
TECHNOCRAFT
INDUSTRIES (I) LTD ANNEXURE – I
(TUBE DIVISION) FOR DOC.CODE
MURBAD – 421401 QN: 7.4.3-1 QN: 7.4.3-01
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 1
QAM RMM AUGUST. 4, 2010 1
of 1
CHEMICAL PROPERTIES IN PERCENTAGE.
STEEL C Mn Si S P
GRADE Max. Max. Max. Max. Max.
ST52-3 0.22 1.70 0.06 0.05 0.05
Q-235B / S235 0.22 0.65 0.30 0.05 0.045
ST46CL 0.21 1.35 0.40 0.05 0.04
Q345 / S355 0.20 1.60 0.55 0.035 0.035
TECHNOCRAFT ANNEXURE – II
INDUSTRIES (I) LTD FOR
(TUBE DIVISION) QN: 7.4.3-01 DOC.CODE
MURBAD – 421401 QN: 7.4.3-01
APPROVE REVISION
ISSUED BY DATE PAGE
D BY STATUS
Page 1
QAM RMM AUGUST, 04, 2010 1
of 1
MECHANICAL PROPERTIES OF STEEL

MIN TENSILE MIN YIELD MIN ELONGATION
STEEL GRADE
STRENGTH MPa STRENGTH MPa %
ST52-3 490 355 20
Q-235B / S235 340 235 24
ST46CL 450 345 21
Q345 / S355 490 355 18
ASTM A500
400 317 23
Grade -B
TECHNOCRAFT ANNEXURE – III
INDUSTRIES (I) LTD FOR
(TUBE DIVISION) QN: 7.4.3-01 DOC.CODE
MURBAD – 421401 QN: 7.4.3-01
APPROVE REVISION
ISSUED BY DATE PAGE
D BY STATUS
Page 1
QAM RMM APRIL,19, 2010 0
of 1
Cold Weather impact testing:
ASTM E23-07 ae1 Standard Test Methods for Notched

Bar Impact Testing of Metallic Material
1. Sample size: ¼ size (10mx2.5mm)

2. Number of samples shall be six in each each Heat of the
Steel (of this three samples will be in longitudinal
Direction and the remaining three in Transverse
Direction)
3. Test Temperature will be -30 degree centigrade
4. Acceptance Criteria:
a) Minimum acceptable individual result shall be 7J
b) The minimum average result of all six samples shall
Be 18 J
Reporting
1. Specimen orientation with respect to the material axis

2. Specimen size.
3. Test temperature and individual test value for each
specimen.
QR-10-1-01 (991001)
TOLERANCES ON
TECHNOCRAFT INDUSTRIES (I) LTD.,
-0 (TUBE DIVISION) Date :
Specified Width:
+30 mm MURBAD Shift :
-0.10 mm COIL MEASUREMENT REPORT
Specified Thickness:
+0.25 mm
Heat No. Coil No. Source of Specified Mass in OBSERVATIONS
Material Size in mm Tonnes Actual width in Actual Thickness in Defects (Method: Visual)
(T x W) mm Top/Bottom mm Top/Bottom (Surface Lamination, Loose Winding,
(Method: (Method: Uneven Winding, Notches, Camber, Remarks
Measure Tape) Micrometer) Telescopicity, Fish Tail, Damages, holes,
pits etc.)
Q. A. Inspector Q.A.M.
TECHNOCRAFT INDUSTRIES (I) LTD. CHEMICAL ANALYSIS / PHYSICAL TESTING REPORT QR-10-1-02 (99 07 26)
(TUBE DIVISION)
MURBAD (INCOMING H. R. COIL)
Works / Suppliers Chemical Analysis Works / Suppliers

Test Tensile Properties Remarks
Certificate Coil No. Yield Strength
Date Heat No. Tensile Strength Percentage
No. C% Mn % S% P% Si % In Mpa
In MPa Elongation
Chemist Q.A.M.
TECHNOCRAFT INDUSTRIES (I) LTD,. PLAN FOR INCOMING PRODUCT DOC. CODE
( TUBE DIVISION ) QN: SCAFF:7.4.3-10
MURBAD-421401
ITEM: METAL SPOOL
QAM RMM SEPTEMBER 15, 2002 0 1 of 1

Name Characteristics Specified values Method of Record Work Instruction RESPONSIBILITY
of Inspection/ Primary Secondary Final
item Instrument
WIRE Diameter of 0.8 ± 0.02 mm Micrometer QR: Measure diameter of wire by using 0 – 25 mm Shift Production RMM/ QAM
SPOOL wire 1.2 ± 0.02 mm SCAFF: flat ends micrometer and ensure that whether supervisor In-charge
7.4.3-10 your results are met with specified
requirements or not.
Height of one 25 mm Max. Scale / -do- Cut one helix of wire pool and keep its both -do- -do- -do-
end of the Measuring ends touched with each other then allow it to
helix from the Tape drop freely on the floor, now measure height
floor of the ends which is deviate from the floor
and conform that whether your result is met
with specified value 25 mm Max. or not.
Distance 800 mm Max. -do- -do- This characteristics is also measured on same -do- -do- -do-
between two dropped helix by measuring distance between
ends of the two ends now, verify that whether your
helix results are met with specified value 800 mm
Max.
Winding No over lapping Visual -do- Carry out visual inspection and observe that -do- -do- -do-
winding of wire pool is whether free from
over lapping or not.
Corrosion No rusting Visual -do- Visually welding wire should free from -do- -do- -do-
corrosion
Straightness No waviness Visual -do- Visually welding wire should free from -do- -do- -do-
waviness
Copper coating Should be Visual -do- Copper coating should visually be uniform -do- -do- -do-
uniform and and free from gaps
free from gaps
TECHNOCRAFT INDUSTRIES (I) LTD, SPECIFICATION CUM INSPECTION REPORT OF QR: SCAFF: 7.4.3-10(20020611)
(TUBE DIVISION)
INCOMING MATERIAL DATE:
MURBAD – 421401
ITEM: METAL SPOOL
NAME OF PARTY: ACCEPTED QUANTITY: SAMPLING: 1 SAMPLE PER 25
INVOICE NO. & DATE: METAL SPOOL
TOTAL QUANTITY RECEIVED: REJECTED QUANTITY:
Sr CHARACTERISTICS SPECIFIED VALUE METHOD OF OBSERVATIONS REMARKS

No. INSPECTION/ Sample - 1 Sample - 2 Sample - 3 Sample - 4 Sample – 5
INSTRUMENT
1 Diameter of wire 0.8 ± 0.02 mm Micrometer
1.2 ± 0.02 mm
2 Height of one end of 25 mm Max. Scale/ Measuring
the helix from the floor tape
3 Distance between two 800 mm Max. -do-
ends of the helix
4 Winding No Overlapping Visual
5 Corrosion No Rusting Visual
6 Straightness No Waviness Visual
7 Copper Coating Should be uniform and free Visual

from gaps
REMARKS:
SHIFT SUPERVISOR PRODUCTION IN-CHARGE Q.A.M.

TECHNOCRAFT INSPECTION INSTRUCTIONS
INDUSTRIES (I) LTD AND RESPONSIBILITY OF
(TUBE DIVISION) SLITTING OPERATOR DOC.CODE
MURBAD QW: 7.5.1-01
PROCESS STAGE – SLITTING
REVISION
ISSUED BY APPROVED BY DATE PAGE
STATUS
MR FM APRIL 7, 2006 0 Page 1 of 1
1. PURPOSE:
To document work instruction and responsibility of the slitting operator.
2. RESPONSIBILITY:
Primary : Slitting Operator.
Secondary : Slitting I/C
Final : QAM / Factory Manager.
3. INSPECTION INSTRUCTIONS AND RESPONSIBILITY FOR SLITTING PLANT:
3.1 It is your responsibility to perform monitoring and measurement of process as well as

product while running the plant. (Refer QN: 7.5.1-01 Plan for monitoring and
measurement of slitting process & product)
3.2 Monitor your processes as per procedures described in QR: 7.5.1-01/1 and record your
results in column given as working evidence. Take help of your assistants to do this
inspection.
3.3 Measure width and thickness of the slits as per QR: 10.2-03 as a part of inprocess
inspection.
3.4 To measure width and thickness use measuring tape and micrometer respectively.
3.5 During inprocess inspection every coil should be measured three times for width and
thickness. Locations of the measurement are front, middle and end portion of the coil.
3.6 Note all three results in inspection form for the material to be used for IS: 1239(PT-I)
standard and
3.7 Note only middle result in said form for the material to be used for overseas standards.
3.8 Also inspect visually for the defects, which are described in QR: 10.2-03.
3.9 Provided that prior to use each and every coil should be checked for thickness, width and
visual defects as described in QR: 10.2-03.
3.10. Following non-conformities should not occur during the production of C.R. Coils.
a) No any marking or scratch on the surface of the slits.
b) Width of the slits should be remained within the tolerance given in production
Programme.
c) Burr should within the acceptance criteria.
d) No bend edges of the slits.
3.11. If required, you may take assistance of Q.A. Inspector of Tube Mill for the purpose of
measurement of the coil.
3.12. Carry out checking of operation and process corresponding to evaluating performance
of the product and judge that whether your process and operation are okay or not.
3.13.Adter slitting of coil, each slit of this coil should have identification and test status as per
work instruction QW: 7.5.3.
TECHNOCRAFTINDUSTRIES (I) LTD TABLE – 1 DOC.CODE
(TUBE DIVISION) TO QW: 7.5.3
MURBAD – 431 401 WORK INSTRUCTIONS FOR IDENTIFICATION, (QM: 7.5.3)
TRACEABILITY AND TEST STATUS.
ISSUED BY APPROVED BY DATE STATUS PAGE
QAM FM May 27, 2006 0 Page 1 of 14
SR AREA/ PRODUCT/ PROCEDURE FOR TEST STATUS PROCEDURE RESPONSIBILITY DETAILS OF

NO PROCESS TOOL IDENTIFICATION AND FOR IDENTIFICATION
STAGE TRACEABILITY CONFORMING NON PRIMARY FINAL AND
PRODUCT CONFORMING TRACEABILITY
PRODUCT
(a) (b) (c) (d) (e) (f) (g) (h)
1 SLITTING SLITTED Every coil will be White label & Red label and Slitting Factory Code number, Slit
PLANT COIL identified by applying code Inspection report inspection reports Plant Manager. number, Dimensions,
number,dimensions,weight. QR: 10.2-03 QR: 10.2-03 Operator Weight of slit, Date
QR: 8.3-01 and Shift.
SIDE SCRAP Use identification label - - Slitting Factory Date & Shift, Weight
Plant Manager. of scrap.
Operator
MEASURING There should be White label, Red label, Slitting Factory Code number, date of
INSTRUMENT identification label Calibrations Calibrations Plant Manager. calibration, error (+)
report. report. Operator or (-) if any
TECHNOCRAFT INDUSTRIES (I) LTD., QR: 10.2-03(20031201)
Date : ________________ (TUBE DIVISION)
MURBAD
Shift : ________________ PRODUCTION CUM INSPECTION REPORT OF SLITTING DEPT.
(Monitoring and Measurement of Slitting Processes)
Operator Name :
Crane Operator Name :
Work Specified Slitting Lubrication (if Preventive Maint. Cutter
Sr. Setting Time Break Down Coil Slitting Time
Coil No. Order Norms Thick/ Rejection Cutter Up not done 15% (If not done 15% Cheap
No.
No. Width From To From To Reason From To to Date deduction) deduction Off
1
2
3
4
5
6
(Method: Measure Tape) (Method: Flat Micrometer) (Method: Slitting Programme
Pre-
Coil Actual Width Actual Thickness Weight Visual) Total Slit Size Total Scrap
inspe Slit Size & No. of No of
No. a (Kgs) Workr- Remarks
ction Min Max Avg. Min Max Avg. Tolerance Slits Part ing mm Wt (Kgs) mm Wt (Kgs)
manship
Note: ⇒ Lubrication should be done otherwise 15% deduction from allowance. Name of Staff/Worker Present
⇒ Removal of scrap should be done within the shift otherwise 15% deduction from
allowance.
1 5
⇒ Crane Operator should do Lubrication, Maintenance of Crane otherwise 15% deduction 2 6
from allowance. 3 7
⇒ Setting time is considered as a production.
4 8
Note: Refer Chart No.1 For Requirements of width and thickness of HR coils, Chart – 2 for requirements of width and thickness of CR coils, Chart – 3 for Slit width of HR coils, Chart – 4 for
Slit width of CR coils.
ignature of Operator Signature of Slitting In-charge Signature of QAM Signature of RMM
TECHNOCRAFT INDUSTRIES (I) LTD QR: 8.3-01 (2006 08 20)
(TUBE DIVISION)
MURBAD – 421401
NON CONFORMITY REPORT (NCR)
PROCESS STAGE / AREA: DOC. CODE- DATE:
QP:8.3, QP:8.5.2, SHIFT:
QM:8.3, QM:8.5.2
Descript C.U. No / Nature of Causes of Controlling Corrective Preventive Responsibility Procedure of Reviewing Concession
ion of Traceability Defect occurring defect Procedure Action Action who deal initially given by
with non- Methods Reviewed by
item. code. taken taken [M.D.(Mfg.)/
conformity (*) F.M.]
Disposition Reverification
Test Result
Result of actions taken: Satisfactory/ Unsatisfactory (*)Method of Reviewing: Rejection / Rework /

Reclassification / Rectification / Reprocess/
Reviewing Corrective actions taken: Adequate/ Inadequate. Concession
Total non – conforming product :

Sorted out non – conformities:
Sorted out conformities: Chemist/ QA.Inspector Production I/C QAM Verified by
TECHNOCRAFT PROCEDURE FOR INPROCESS
INDUSTRIES (I) LTD INSPECTION AND TESTING DOC.CODE
(TUBE DIVISION) QW: 8.2.4-02
MURBAD PROCESS STAGE: TUBE MILL (QM: 8.2.4)
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 1
QAM MR MAY 22, 2006 0
of 6
1. PURPOSE:
To document procedure / work instruction for inprocess inspection and testing at the
manufacturing stage of tube welding.
2. RESPONSIBILITY:
Primary : Q.A.Inspector.
3. PROCEDURE:
At starting of production, the first piece will be inspected for visual defects
like roll markings, bad trimming, over lapping as well as dimensional
characteristics like Out side diameter, Inside diameter and wall thickness. If
there will no any evidence of failure, Tube Mill Plant will be started for continue
production. In the case of any characteristic will failure to meet the specified
requirement, necessary corrective actions will be taken to remove that defect and
plant will be started for continue production.
After regular manufacturing of tubes, Q.A.Inspectors are responsible to carry out

In-process inspection and testing as follows;
i) Dimensional inspection.
ii) Flatting test.
iii) Flaring test.
iv) Tensile test
v) Visual inspection.
3.1. DIMENSIONAL INSPECTION:

3.1.1. OUTSIDE DIAMETER:
Measure out side diameter of sample tube once in an hour as a part of In-process
inspection. Use Micrometer / Vernier / Go – No Go gauge to measure outside
diameter, minimum at two places 900 to each other as to find out dimensional ovality.
Note your results min. and max. in inspection form No. QR: 10.2 – 04/1 and confirm
that whether your results match with specified requirements given in accordance
Annexure – I of plan QN: 8.2.4 – 02.
3.1.2 INSIDE DIAMETER:

Measure inside diameter of tube once in hour as a part of in-process inspection. Use
Go gauge have specified diameter of 1.625” (41.275 mm). This gauge must be passed
into both ends of the tube. Note your observations in inspection form QR: 10.2 – 04/1
where column of Inside diameter is given for whether results are found satisfactory
or not. Refer annexure – I of plan QN: 8.2.4 - 02
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 2
QAM MR MAY 22, 2006 0
of 6
3.1.3. WALL THICKNESS:

Measure wall thickness of tube once in an hour as a part of in-process inspection. Use
ball type micrometer 0 – 25 mm to measure thickness at least four places surrounding
tube. Record your results in inspection form QR: 10.2 – 04/1. Refer Annexure–I of
plan QN: 8.2.4– 02 and conform that whether your results meet the specified
requirements.
3.1.4. INTERNAL FIN HEIGHT:

Measure internal fin height at both ends of sample tube once in an hour to find out the
result, first measure fin height including wall thickness of tube then measure wall
thickness of tube with the help of ball type micrometer, now you will get actual
internal fin height by calculating difference between both these observations. Record
your results in QR: 10.2-04/1 and match with specified requirement given in
accordance with plan QN: 8.2.4-02.
3.1.5. LENGTH OF TUBE:

Measure length of tube once in an hour as a part of in-process inspection to
meet the customer requirement given in accordance with production programme.
Record your result in inspection form QR: 10.2 – 04/1.
3.1.6. STRAIGHTNESS OF THE TUBE:

Straightness of the tube should not deviate 0.76mm / 1 Mtr.
3.2. FLATTENING TEST:

3.2.1. TEST SPECIMEN MAKING:
A test specimen is cut from the discretionary of tube which appearance is checked as
up to grade. Normally the length of test specimen is by and large same as the outside
diameter of the specimen, and if outside diameter of the tubing less than 20 mm then
the length should be 20 mm. However the length should be no more than 100 mm. It
is free of scratches on surface and changing of the mechanical properties during
mechanical processing (May create heat when intercepting the specimen). The end
face of specimen should be perpendicular to the tube. Both ends need to be
chamfered.
3.2.2. CONDITION OF TEST:

Test carried out in house at room temperature. The test specimen laid between the
two parallel plates, with the weld located at 900 from the line direction of force. The
speed of flattening is about 20 – 50 mm / min. Universal Testing Machine to be used
to carry out this test.
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 3
QAM MR MAY 22, 2006 0
of 6
3.2.3. RESULT OF FLATTENING TEST:

It will be judge to up to grade if there is no cracks, breaks, weld craze on the inside or
outside surfaces occurring until the distance between the two plates is two thirds of
the original outside diameter of the tubing. Record your results in inspection form
QR: 10.2-04/1.
3.3. FLARING TEST:

Test specimen is cut from the discretionary of tube which appearance is checked as
up to grade. It is free of scratches on surface and changing of the mechanical
properties during machining (Intercepting the specimen). The sections of specimen
should be perpendicular to the axis of tube both ends should be chamfered. The
length of specimen is about 1.5 times of outside diameter of the tubing, but no less
than 50 mm.
3.3.2. RAM (MANDREL) MAKING:

The taper of the ram is 600, ensure the surface is furnished and hard enough and
lubricated in test process.
3.3.3. THE CONDITION OF TEST:

The test carried out in house at room temperature. Ensure the speed of the ram that
goes into the specimen is 20 – 50 mm / min. Universal Testing Machine to be used to
carry out this test.
3.3.4. RESULT OF FLARIING TEST:

Check the flared part after the OD of the specimen being flared to 1.06 times of its
original OD, if there is no cracks, breaks, welding craze on the inside or outside
occurring, it will be judged as up to grade. Record your results in inspection form
QR: 10.2-04/1.
3.4. TENSILE TEST:

A test specimen is cut from the sample tube having length of 450-mm. Test can be
carried out either on full section of the test specimen or on the strip cut longitudinally
from the test specimen by using shaping machine. Strip will have 20 mm width in
parallel length without including the weld i.e. the strip being located at approximately
900 from the weld. Remove burr from the both edges and ensure the edges are
paralled. Snug –fitting metal plugs should be inserted for enough in the end of this
tubular specimen to permit the testing machine jaws to grip the specimen properly
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 4
QAM MR MAY 22, 2006 0
of 6
without crushing. The plugs shall not extended into that part of the specimen on
which the elongation is measured.
3.4.1.1. Measure outside diameter and wall thickness of the full section specimen and
calculate cross sectional area by using following formula;
(D-t) t X Π Where;
D: Outside diameter of test specimen.
t : Wall thickness of test specimen.
3.4.1.2. When strip is used to perform this test, measure width and thickness of the strip and
calculate cross sectional area by using following formula;
b2
ab 1 +
6 X D (D-2a)
a = Thickness of the strip.

b = Width of the strip
D = Original outside diameter of the tube
3.4.2. MARKING OF ORIGINAL GAUGE LENGTH:

3.4.2.1. Mark overlapping gauge length of 50.8 mm on the test specimen, which you have
selected either full section or strip.
3.4.2.2. Put a mark on the middle of strip by using sharp punch.
3.4.2.3. From the middle mark, make other markings, half the gauge length apart for the
entire length (it means distance between one point to other is ½ X OGL ) by using a
vernier caliper and with punch.
3.4.3. METHOD OF TENSILE TESTING:
3.4.3.1. Use Universal Testing Machine ( 60 MT) to carry out this test.
3.4.3.2. Change the appropriate jaws required for the test specimen.
3.4.3.3. Open the top clamps on the UTM by operating the lever and put the test specimen
between the clamp jaws while bottom end of the test specimen is between bottom clamp
jaws.
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 5
QAM MR MAY 22, 2006 0
of 6
3.4.3.4. Leave the top lever to its original position and lower the lever of bottom clamp to grip the
test specimen.
3.4.3.5. With keeping the bottom lever in same position start the machine so that top clamp will go
downward along with test specimen so that it will get tight.
3.4.3.6. Lifting of pointer on the pressure gauge shows the clamping is completed.
3.4.3.6. Leave the bottom lever to its original position and adjust the speed of machine by
operating the regulator.
3.4.3.7. If yield stress is required set the micrometer at the middle of strip in such a way as just to
grip it before starting the machine.
3.4.3.8. Now observing the load indicator.
3.4.3.9. At the yield point micrometer will drop down and corresponding load shall be noted as
yield load.
3.4.3.10. The test specimen will be further elongated up to particular load and where the breaking
is occurred.
3.4.3.11. Note the maximum load.
3.4.3.12. Joint the broken pieces and measure the final gauge length (FGL).
3.4.3.13. Calculate the yield stress, tensile strength and % of elongation as per the formulae are
given below:
Yield load in Newton (N)

Yield stress in Mpa =
Cross section area
Max. load in Newton (N)

Tensile strength in Mpa =
Cross section area
(FGL – OGL) 100

Percentage of elongation =
OGL
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 6
QAM MR MAY 22, 2006 0
of 6
3.4.4. WORKMANSHIP (VISUAL INSPECTION).

3.4.4.1. Visually tubes should be free from defects such as roll marking, overlapping, tool marking
and material defects like surface lamination, pits, holes and flows.
3.4.4.2. Observe straightness of the tube and conform that it should reasonably straight.
3.4.5. Record your results in inspection form QR: 10.2-06.
TECHNOCRAFT INDUSTRIES (I) LTD PLAN FOR IN-PROCESS INSPECTION AND TESTING DOC. CODE
(TUBE DIVISION) PROCESS STAGE: TUBE MILL QN: 8.2.4-02
MURBAD

QAM MR 4th FEBRUARY 2006 1ST REVISION 1 OF 1
Sr. Characteristics to Requirements Method of Inspection/ Work Record Responsi- Verified Personnel Training Frequency Quality
No. be Inspected / Instrument Instruction bility By / Shift Record Objectives
Tested
1 Dimensional Once in QD:
inspection As per annexure 1 Micrometer/ Vernier QW8.2.4-02 QR: 10.2-04 Q.A. QAM Q.A. an hour 5.4.1-15b
1-1 Outside diameter of this plan -cl 3.1.1 inspector inspector
1.2 Inside diameter -do- Go gauge QW8.2.4-02 –2
-cl 3.1.2
1.3 Wall thickness -do- Ball type micrometer QW8.2.4-02 -do- -do- -do- -do-
-cl 3.1.3
2 Internal fin height 1.5mm max Flat end micrometer QW8.2.4-02 -do -do- -do- -do-
and ball type -cl 3.1.4
micrometer.
3 Length of pipe As per requirement Measuring tape QW8.2.4-02 -do- -do- -do- -do-
of customer -cl 3.1.5
4 Weld ability tests: As per annexure 2 UTM QW8.2.4-02 -do- -do- -do- -do-
4.1 flaring test of this plan -cl 3.3
4.2 flattening test -do- Compression testing QW8.2.4-02 -do- -do- -do- -do-
M/C -cl 3.2
5 Tensile test As per annexure 3 Universal testing M/C QW8.2.4-02 QR: 10.2-05 --do- -do- Once in
of this plan -cl 3.4 4 hours
6 Workmanship :- Pipe should be free Visual QW8.2.4-02 QR: 10.2-06 -do- -do- 100°
6.1 surface from Roll -cl 3.4.4
observation markings,
overlapping, tool
marking, and
material defect.
6.2 straightness of 0.76 mm / 1 Mtr. Srting, vernier QW8.2.4-02 QR: 10.2-04 -do- -do- 100°
tube -cl 3.4.4.2
TECHNOCRAFT INDUSTRIES (I) LTD ANNEXURE: I DOC. CODE
(TUBE DIVISION) FOR QN: 8.2.4-02
MURBAD- 421401 QN: 8.2.4-02
REQUIREMENTS OF DIMENSIONS
TH
QAM MR 30 APR 2006 0 1OF 1
SR TUBES ARE MANUFACTURED AS INSIDE Out side diameter Wall thickness
NO PER CUSTOMER DIAMETER
SPECIFICATIONS. BASIC MIN MAX BASIC MIN MAX
MIN
1. ASTM A500 1.625 Inch 1.90 In 1.890 In 1.910 In 0.128 In 0.120 In 1.45 In
41.275 mm 48.26 mm 48.006 mm 48.514 mm 3.25 mm 3.05 mm 3.68 mm
2. ASTM A512 N.A 1.3/8 In 1.38 In 0.188 In 0.169 In 0.207 In
-
34.925 mm 35.05 mm 4.78 mm 4.29 mm 5.26 mm
Technocraft Industries (I) Ltd ANNEXURE: II Doc Code
(Tube Division) FOR QN: 8.2.4-02
Murbad – 421401 QN: 8.2.4-02
REQUIREMENTS OF WELDABILITY.
TH
QAM MR 25 APR, 2006 0 1 OF 1
SR Tubes are manufactured as per Requirements
No. customer specification. Flaring test Flattening test
Distance between two plates
1 ASTM A500 1.06 X Original O.D. 2
X Original O.D.
3
2 ASTM A512 - 2
X Original O.D.
3
TECHNOCRAFT INDUSTRIES (I) LTD ANNEXURE: III DOC. CODE
(TUBE DIVISION) QN: 8.2.4-02
MURBAD- 421401
FOR
QN: 8.2.4-02
REQUIREMENTS OF TENSILE TEST ON TUBES.
QAM MR 30TH APR 2006 0 1OF 1
%
SR TUBES ARE MANUFACTURED AS PER YIELD STRESS TENSILE STRENGTH
NO
ELONGATION
CUSTOMER SPECIFICATION. MIN MIN
MIN
1. AISI 1513 60000 PSI 75000 PSI 17
AISI 1518 (422 Mpa) (527 Mpa)
2. ASTM A512, GR. AISI 1010 32000 PSI 45000 PSI 15
(221 Mpa) (310 Mpa)
TECHNOCRAFT INDUSTRIES (I) LTD QR-10-2-04/1 (2006 06 19)
Specification : (TUBE DIVISION) Control Unit No.:
Size : MURBAD Date :
Class : TUBE MILL IN PROCESS INSPECTION REPORT Shift :
Heat No: ______________________________________________________ Work Order No. : ___________________________

Outside Dia. in mm Thickness in, mm Flattening Test Tubes upto 50mm
Internal Fin Inside Length of Flaring Straightness
Intervals * Height in, mm
Workman ship NB Bend Test 180
1/1000
Remark
Min. Max. Min Max. diameter tube in, m Weld Material test **
First Off
1
2
3
4
5
6
7
8
9
10
11
12
Characteristics Method Specified Value Actual Value
* Each interval of one hour Outer diameter mm Vernier / Micro
** This columns is to be considered where applicable
Inside diameter meter
Gauge inspection
Thickness, mm Ball Micrometer Basic Min
Length, m Measuring tape /
Work order no.
Measuring stand
No.of pipes accepted Min % Weld Material
Flattening Test U.T.M, Vernier
No.of pipes rejected
Flaring test. Drift expansion test 1.06 times of original OD.
mandrel
Fin height, mm Micrometer Max 1.5 mm
Q. A. Inspector Q. A. M. Workmanship Visual Pipes have no major injury
INDUSTRIES (I) LTD IDENTIFICATION AND
(TUBE DIVISION) TRACEABILITY CODE. DOC.CODE
MURBAD (TECHRING SYSTEM) QD: SCAFF: 129
ISUED BY APPROVED BY REVISION STATUS DATE PAGE
QAM FM 0 23 APRIL, 2008 1 of 1
1. PURPOSE: -
To document procedure for Identification & Traceabolity code for Customer. (Techring
system)
2. RESPONSIBILITY: -
Primary : Operator.
Secondary : Shift supervisors / Q.A. Inspector.
Final : Factory Manager / QAM (Inspection & Testing).
3. PROCEDURE : -
3.1 Tube shall be embossed with nine digit number at 1mtr interval using stamping die in the tube mill stage
with following manner;
TI - MM - YY - XXX.
TI : Technocraft Industries
MM : Month
YY : Year
XXX : Heat number / Control unit number.
3.2 At the production stage, all Rosette are to be marked with a two - digit number referring to the factory
(WW). The marking will be placed on the face of the Ring.
3.3 At the production stage, all number referring to the marked with a two – digit number referring to the
factory. The marking will be placed on the ledger head/brace head visible from end horizontal.
3.4 Fill out a part identification sheet for each type part product from each heat number.
Example: Each batch of identification sheet. Perform four measurements of part identification sheet.
This shall be done prior to galvanizing that is at tube welding stage as well as at cold saw cutting stage.
Observation report shall be record in inspection report QR: SCAFF: 10.2-179.
D:\Tech Ring Manual\23_QD-SCAFF-88(TR).doc

TECHNOCRAFT QR: SCAFF: 10.2-321 (2008 04 23)
INSPECTION REPORT OF
INDUSTRIES (I) LTD
STAMPING OF VERTICAL
(TUBE DIVISION) TUBE.
MURBAD
W/O NO:
Techring Scaffold
Drawing No:
Product code:
Item description: Stamping of vertical 35.0 mm 35.0 mm
tube.
Tube heat No. / C. U. No:
Inspection characteristics: 1. Visual inspection or definition, accuracy and
position of ID mark.
Production Qty Inspection Qty / Production In Min. inspection
(1/Day) frequency Nos/ Pcs qty
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Results A=Acceptable R=Rejected
Sr. Sr. Sr.
No.
A R Date Time No.
A R Date Time No.
A R Date Time
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Fist inspection for first 20 Pcs taken place at commencement each new production setup.
Inspected by: Q.A.M.

TECHNOCRAFT INDUSTRIES (I) LTD., QR-10-2-05 (2006 06 18)
(TUBE DIVISION)
MURBAD Control Unit No:
Specification : TENSILE TEST REPORT OF TUBE
Frequency : Two Sample / Shift Date:
Shift Coil Nos / Size NB Class Outside dia. in Thickness in Mean width of Area (So) in mm2
Heat No. L/M/H mm, mm, longitudinal strip in For full section For Patti Strip from tube
mm, tube ab (1 + b2 )
D a b 3.1416 (D-a) a a X b 6D(D-2a)
A
Gauge Length Final Gauge Elongation in % Elongation Max. Load Tensile Strength Yield Load Yield Stress in
In mm Length in mm mm (Lu – Lo) x 100 in KN in Mpa in KN Mpa
√So Lo=5.65√So Lu Lu - Lo Lo Fm Rm = (Fm ÷ So) 1000 Fe Re = (Fe ÷ So) 1000
Q.A. Inspector
Q.A.M.
CHARACTERISTIC SPECIFIED VALUES METHOD

BS:1387 EN: 39 DIN:2440 AISI 1513 ASTM A512, GR. IS: 1239 (P-1)
AISI 1518 AISI 1010
Tensile Strength Min. 320 340 324 527 310 320 U.T.M
Max. 460 520 490 - - -
Yield Stress Min. 195 235 186 422 221 - U.T.M, Micro Meter
Elongation Percentage Min. 20 24 18 17 15 20 % for above 25 NB. Vernier
12 % for 15 to 25 NB
D:\Tech Ring Manual\25_QR-10-2-05 (2006 06 18)(TR).doc

TECHNOCRAFT INDUSTRIES (I) LTD DAILY NON CONFORMITY REPORT OF QR-10-2-06 (990714)
(TUBE DIVISION) TUBE MILL
MURBAD
Date & Shift

Control Unit No.
Work Order No. & Date
Reqd. Prod. In Tons / Pieces
Size NB & Class / Thickness mm
Length in M (Tolerance)
Total Prod. Pieces
Accepted Pieces
1. Open Pieces
Details of Non conformity
2. Joint Pieces
3. Over Lapping Pieces
4. Bad Trimming Pieces
5. Short Length Pieces
6. Long Length Pieces
7. Defective Material Pieces.
8. Roll Marking
9. Vice Marking
Total Non conforming Pieces
Remarks :
Signature of Q. A. Inspector
Signature of Q. A. M.
Signature of F. M.
Note:
1. If any corrective action is required write it in the column of remarks.
2. System of disposal is carried out as per QW-13.
INDUSTRIES (I) LTD IN – PROCESS INSPECTION
(TUBE DIVISION) AND TESTING DOC.CODE
MURBAD PROCESS STAGE: END FACING QW: 8.2.4-03
(QM: 8.2.4)
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 1
QAM MR APRIL 23, 2002 0
of 1
1. PURPOSE :
To document procedure / work instruction for in – process inspection and testing.
2. RESPONSIBILITY :
Shift supervisor is responsible for compliance with this document.
3. PROCEDURE :
3.1 The inspected and approved lots, which are received from tube mill are taken
up for facing (deburring) process in this production stage.
3.2 After the machine is set properly and regular production of tubes starts, carry
out inspection as per QN: 7.5.1-03.
3.3 Monitoring and measurement will be carried out on any five samples selected
from one-hour production.
3.4 BURR :
3.4.1 Inspect above five samples visually and ensure that there is no burr on faced ends.
3.5 END FACING:
3.5.1 In visual observation chamfering of the ends should be uniform, inside as well
as outside and chamfered face should square to the axis of the pipe.
3.6 FINISHING :
3.6.1 Visually finish ends should free from roughness.
3.7 Record your observation in production cum inspection report of end facing
QR: 10.2-07
QR-10-2-07 (20030705)
TECHNOCRAFT INDUSTRIES (I) LTD.

(Tube Division)
M.I.D.C., Murbad
Production cum Inspection Report of End Facing
Frequency: One Hour Date : ________________

Sample Size: 5 Nos. Shift : ________________
Heat No. : ___________
Control Unit No. : __________
Machine Unit No. : __________
Characteristic Specified Method Observation

Value First 1 2 3 4 5 6 7 8 9 10 11 12
Off
Burrs Pipe ends Visual

have no burr
Right
End facing End facing angle &
should be Filler
square to the gauge
axis of the
pipe
(Deviation
0.3 mm)
Finish Facing Visual
should not be
rough
Production :
Rejection :
Remarks :
Inspected By Sign of F. M. Sign of Q.A.M.

TECHNOCRAFT WORK INSTRUCTIONS
INDUSTRIES (I) LTD FOR IN – PROCESS
(TUBE DIVISION) INSPECTION AND TESTING DOC.CODE
MURBAD QW: 8.2.4-05
PROCESS STAGE: (QM: 8.2.4)
STRAIGHTENING
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 1 of
QAM MR APRIL 23, 2002 0
1
1. PURPOSE :
To document work instruction for In – process inspection and testing.
2. RESPONSIBILITY :
Shift supervisor is responsible for compliance with this document.
3. PROCEDURE :
3.1 The inspected and approved lots, which are received from hydro – testing are
taken up for straightening process.
3.2 After the machine is set properly and regular testing of tubes start, carry out in
process inspection as per QN: 7.5.1-04.
3.3 STRAIGHTNESS OF THE TUBE :
3.3.1 Straightness of the tube will be judged visually by allowing it to roll on skid.
Tube should be straight to the sight and should roll smoothly without jumping.
However, Straightness will be checked by tightly holding a string along the
length of the tube and measuring the gap at the center or at maximum point of
deviation. Tubes will not deviate from straightness as specified in QR: 10.2-09.
3.4 CONICAL ENDS :

3.4.1 Conical end occurred due to reduction in O.D. at front end should be limited
up to the lower limit of specified O.D.
3.4.2 Use vernier caliper to measure outside diameter.
3.5 ROLL MARKING :
3.5.1 Visually pipe should free from helical roll marking.
3.6 REDUCTION IN LENGTH :
3.6.1 To find out reduction in pipe length, measure the length of a pipe before
and after straightening it and calculate that difference between this
observation should not exceed 5 mm.
3.6.2 Use Measuring tape to measure the length.
3.7 Record your observations in production cum inspection form of

Straightening QR: 10.2-09
QR-10-2-09 (20030705)
No of Sample – 1 Pipe Heat No :

Size : TECHNOCRAFT INDUSTRIES (I) LTD., Control Unit No. :
Class : (TUBE MURBAD DIVISION) Date :
Length : MURBAD Shift :
PRODUCTION CUM INSPECTION REPORT OF STRAIGHTENING
Observation
Operation Characteristic Specific Value Method Frequency First 1 2 3 4 5 6 7 8 9 10 11 12 Remark
Off
Straightening Straightness 0.76 mm / 1 Mtr Vernier One Hour
deviation & String
Conical End * Conical end Vernier One Hour
occurred due to
reduction in OD at
both ends should
be limited up to the
lower limit of
specified OD
End Bend Straight to the Visual One Hour
eye
Roll Markings Pipes have no Visual Four Hour
marking
Length Before Four Hour
Straightening
Variation in Max. 5mm Measure Four Hour
Length after Tape
straightening
QUANTITY STRAIGHTENED :
QUANTITY REJE CTED :
* Specified values diameter of pipes 15mm NB to 80mm NB are given in Annexure – I of QN: 8.2.4-02.
Signature of Inspector Signature of F.M. Signature Of Q.A.M.

TECHNOCRAFT PROCEDURE FOR COLD
INDUSTRIES (I) LTD SAW MACHINE (1ST PCS
(TUBE DIVISION) INSPECTION & IN-PROCESS DOC.CODE
MURBAD CHECK RECORDS) QD: SCAFF: 83

QAM FM 0 17 MAR 2006 1 of 1
1. Purpose: - To document procedure & work instruction for cutting cold saw M/C.
2. Responsibility : -
Primary : M/C Operator.
Secondary : Shift supervisors / Q.A.Inspector.
Final : Factory Manager / QAM.
3. Production Procedure: -
Initially after receiving production program from production planning dept. The production
program planning check sheet is filled with all details of pipes and cutting length, quantity, etc is
prepared by the production supervisor and this production program planning check sheet is given
to cold saw M/C operators.
The machine operators set the M/C according to the program with given tolerance and run the
machine. Check the first piece for dimensions. If any deviation observed it will be corrected and
then production will be started. Before starting the ok production approval will be taken from
Supervisor / Q.A. Inspector.
Now when the M/C puts in to production, the inspection to be done as per the inspection form at
a frequency of one hour. If there is any discrepancy in dimension or quality. The entire lot is put
for 100 % inspection, and those pcs not meeting the requirement will be rejected and recorded in
non conformity form QR: 8.3 – 01.
Relative records 1. Production program planning sheet.

2. Inspection form.
Cold saw machine setting procedure;
As per the given program operator can set the length by adjusting the stopper. During the shifting
of stopper display of panel board indicate the position of stopper from saw position and that will
be the length of the pipe. After cutting the first piece check the length of pipe by measuring tape
if any error is observed adjust if accordingly. After starting the production 5 consecutive samples
are to be checked for consistency. If all samples are ok then start the production.

PRODUCTION
INDUSTRIES (I) LTD INSPECTION REPORT OF
(TUBE DIVISION) CUT LENGTH TUBES FOR
MURBAD TECHRING VERTICAL.
W/O NO:
Techring Scaffold
Drawing No:
Product code:
Item description: Vertical tubes.
Tube heat No. /Coil no:
C. U. No:
Dimensions : A = 500.0 ±0.80,1000.0 ±0.80, 1500.0 ±0.80, 2000.0 ±0.80, ±0.80,
3000.0 ± 0.80. C = 48.4 ± 0.4. B = 3.25 + 0.40 / - 0.20.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Results: A = Acceptable R = Rejected
Sr. Sr. Sr.
A R Date Time A R Date Time A R Date Time
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: Q.A.M

TECHNOCRAFT
PROCEDURE FOR IN-
INDUSTRIES (I) LTD
PROCESS INSPECTION OF DOC.CODE
(TUBE DIVISION)
HOLE PUNCHING ON QD: SCAFF: 118
MURBAD
TECHRING VERTICAL
QAM FM 0 20 APR 2008 1 of 1
1. PURPOSE: -
To document procedure for in-process inspection of hole punching on Vertical.
Primary : Q.A. Inspector.
3. PROCEDURE : -
a. At the starting of the production check 10 pcs for hole punching. If each sample found ok
start the production other wise the die setting to be corrected accordingly.
b. The holes should through out at a distance 35.05 ± 0.4 mm from both ends of the tube.
c. Check the diameter of hole. It should be 11.2 ± 0.2 mm. The hole should not
have excessive burr.
d. The no of samples and frequency of inspection will be as per the sampling plan mentioned
QR: SCAFF:10.2-304.
e. Record your observation in QR: SCAFF:10.2-304..
D:\Tech Ring Manual\33_QD-SCAFF-118 (TR).doc

PRODUCTION
INDUSTRIES (I) LTD INSPECTION FOR
(TUBE DIVISION) TECHRING VERTICAL
MURBAD HOLE PUNCHING.
W/O NO:
Techring Scaffold
Drawing No:
Product code:
Item description:
Process: Hole punching for vertical.
Heat no / Control Unit No:
Dimension: 1. A = 35.05 ± 0.40 mm. 2. B = 11.2 ± 0.2 mm
3.Hole location must be at 900 to the bead of tube.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr No. A R Date Time Sr No. A R Date Time Sr No. A R Date Time
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
First inspection for first 10 Pcs taken place at commencement of each new production setup.
D:\Tech Ring Manual\34_QR-scaff- 10.2-304 (TR).doc

TECHNOCRAFT INDUSTRIES (I) LTD SPECIFICATION CUM INSPECTION REPORT OF ROSETTE FOR QR-SCAFF: 10.2-318 (2008 04 23)
(TUBE DIVISION) TECHRING VERTICAL (8 SLOT).
MURBAD. (For Incoming Material 3 % For Dimensions And 10 % Of Visual Inspection) Lot / Batch No:
Name of supplier : Vender code :
Challen No & Date : Sub vender code :
Received Qty.&Date: Month & Year of Manufacturing :
All dimensions are in mm: - mention minimum and maximum Date:
Drawing No: 213905
values Shift:
SPECIFIED METHOD OF 1 st OBSERVED VALUES
DESCRI
CHARACTERISTICS INSPECTION
PTION VALUES /INSTRUMENT off 1 2 3 4 5 6
Rosette Thickness 9.52 ± 0.3 Micrometer
ASTM /Vernier/ Gauge
A 36 Outside diameter 121.92 ± 0.5 Vernier / Gauge
Inside diameter 49.28 ± 0.5 Vernier / Gauge
Orientation of notch in R 6.35 (2 Nos) Radius gauge
periphery.
Notch location 22.50 TYP. From Bevel protractor /
centerline. Gauge
No. of slots 8 (Equal distance) Visual
Slot dimensions OD 101.85
ID 59.94 Vernier / Gauge
At 300 Angle
Concentricity of OD ∅ 49.28 & 121.92
& ID axis mm Deviation 0.78 Vernier / Gauge
mm
Bend test. Bending to 800 and Visual
observed: Plastic
deformed, No crack…
Cold weather impact test Acceptance Criteria Outside lab test report
shall be 25J to 30J. or supplier MTC.
Note: 1. Material: ASTM A36. Min. Yield Strength- 262 Mpa.
2. Weight of rosette: Average 445 Gms
3. After punching subject parts to stress relief treatment: 8500 Celsius for one hour, air cool to ambient temperature at 250 Celsius / minute.
4. For Detail dimensions please refer drawing No: 213905 (Rev 5.)
5. Please get the original MTC from supplier.
REMARKS:
INSPECTED BY.
NAME :
SIGNATURE : QAM
D:\Tech Ring Manual\35_QR-SCAFF- 10.2-318 (TR).doc

INDUSTRIES (I) LTD
STAMPING ON VERTICAL
(TUBE DIVISION) ROSETTE (RING)
MURBAD
W/O NO:
Techring Scaffold
Drawing No:
Product code:
Item description: Stamping on Rosette.
Lot No. / Batch No:
Inspection characteristics: 1. Visual inspection of stamping, accuracy and position
of ID mark. (TI 01 20), TI=Factory/Vendor Code, 01= Lot/batch no.20= Sub
Vendor Code. And also stamp Month & year of manufacture (09-98)
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Results: A=Acceptable R=Rejected
Sr. Sr. Sr.
No.
A R Date Time No.
A R Date Time No.
A R Date Time
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: QAM

INDUSTRIES (I) LTD WELDING OF TECHRING
(TUBE DIVISION) STANDARD (VERTICAL) DOC.CODE
MURBAD QD: SCAFF: 119

QAM FM 0 21 APRIL 2008 1 of 1
Purpose : - To document procedure & work instruction for welding of techring standard.
Responsibility : - For compliance with this document the responsibilities are assigned;
Primary : Operator / Welder.
PROCEDURE FOR WELDING OF TECHRING STANDARD: -

A. TACK WELDING.
1. Before welding ensure that parent material is free from rust, greases & dirt etc. Which will affect
the quality of welding process.
2. The Rings are located on standard pipe as per the drawing / quality form No.
QR: SCAFF: 10.2-306 by tack welding on fixture by manually.
3. First piece will be inspected for dimensions & alignment. If it is ok then start the production. The
inspection details are given in QR SCAFF: 10.2-306.
B. RINGS FULL WELDING: -

1. Machine: Auto welding machine.
2. Welding process: MAG (Co2)
3. Joint type: Fillet.
4. Welding position and type: Horizontal (welding torch remain stationery and work revolving).
5. Sequence: 1200 apart; Three welds.
6. Parent material: Pipe – St 52.3 / Ring – ASTM A36/Q235.
7. Welding details;
a. Run – single.
b. Process – MAG.
c. Size of filler material: ∅ 1.20 mm wire.
d. Current (A): 200-210
Voltage (V): 22-23.
These values may change if welding is not found ok and its approval to be taken from
concerning authority not below the supervisor level
e. Type of current: DC.
f. Shielding: Co2
8. Filler metal classification & trade name: 1.2 mm – GEE make as per AWS A5. 18: ER 70 S-6,
DIN 8559:SG 3.
9. After tack welding the techring standard to be located in auto welding machine by locating
clamps & pin on ∅ 11.2 hole and of the machine. After starting the machine the welding will be
done sequently as per the running program feeded in the machine.
10. At the starting of each shift one sample will be drawn and tested for welding quality by load
testing as per QR: SCAFF: 10.2-

TECHNOCRAFT INDUSTRIES (I) LTD QR-SCAFF: 10.2-306 (2008 04 22)
(TUBE DIVISION) RING WELDING REPORT OF TECHRING HEAT NO / CONTROL UNIT NO:
MURBAD VERTICAL.
Drawing No: Sample size: 5 pieces In-process Frequency: One hour. Date:
Shift:
All dimensions are in mm: - mention minimum and maximum values
OPERAT CHARACTE SPECIFIED METHOD OF OBSERVED VALUES
DESCRI
INSPECTION 1st off
PTION IONS RISTICS VALUES /INSTRUMENT 1 2 3 4 5 6 7 8 9 10 11 12
st
Techring Welding 1 Ring distance 104.76± 0.8 Vernier
Standard from pipe end.
Ring to Ring 500 ± 0.8 Measuring tape

distance (pitch) / pitch gauge.
No of Ring 1, 2, 3, 4,5, 6. Visual
Concentricity Ring should be Concentricity

of Ring with concentric with gauge.
pipe. Axis pipe axis & Deviation +/-
ring should be 0.5º
perpendicular
to pipe.
Welding Uniform weld, Visual

workmanship free from weld 100 %
defect & no
of ring with under cut at inspection
pipe sharp edges.
REMARKS:
INSPECTED BY. PRODUCTION INCHARGE QAM
D:\Tech Ring Manual\38_QR-SCAFF- 10.2-306 (TR).doc

TECHNOCRAFT PROCEDURE FOR 100 %
INDUSTRIES (I) LTD VISUAL INSPECTION
(TUBE DIVISION) AFTER WELDING PROCESS DOC.CODE
MURBAD PRODUCT: TECHRING QD: SCAFF: 120
VERTICAL.
1. PURPOSE: -
To document welding procedure for 100 % visual inspection after welding process of Techring
Verticals.
Primary : 100 % Inspector.
Secondary : Q.A.Inspector.
3. PROCEDURE : -
100 % Inspection is carried out on scaffold items, after welding process is completed.
During this inspection Q.A.Inspector comes and carries out periodic inspection on the
samples selected as per sampling plan. Frequency of the periodic inspection will be
hourly. They will follow method of the inspection described as below.
a. Weld should be observed for the defects like cracks, porosity, blow holed and under
cutting..
b. Also observe that whether weld is uniformed and full welded.
c. Observe that whether all components are assembled and in right way.
d. First Ring poison and ring pitch distance to be checked as per sampling plan given QC
form.
e. Sample fails to meet the any requirement described as above; it will be removed from the
production and sent for recovery to the corner department.
f. Check all the verticals have 9 digits stamping and also 2 Digit manufacturer’s mark on
all the Ring.
g. Record your observation, accepted and non-conforming quantity in QR:SCAFF:10.2-307

INDUSTRIES (I) LTD
TECHRING VERTICAL
(TUBE DIVISION)
AFTER RING WELDING.
MURBAD
Ø 1 1 .2 ± 0 .2
Ø 1 1 .2 ± 0 .2
Ø 4 8 .4 ± 0 .4
3 5 .0 5 3 5 .0 5
500 P IT C H
1 0 4 .7 6 ± 1 .0
9 .5 2 T H K .
STA N D A R D LE N G TH "A "
W/O NO: Drawing No:

Techring Scaffold Product code:
Item description: Process: Inspection for vertical.
Inspection characteristics: 1. Welding inspection visual: 100 % ; 2. Accumulative tolerance in 500
mm should not more than 1.0 mm; Checking the nine digit number stamping and its format should be
TI (Vender ID) – MM (Month) – YY (Year)- XXX (Three last digit number from the heat number /
Control unit number)
Inspection Qty / Production In
Production Qty (1/Day) Min. inspection qty
frequency Nos/ Pcs
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
ITEM SR
DIMENSION A R DATE TIME SR NO. A R DATE TIME
CODE NO.
3000.0 MM 1 16
2000.0 MM 2 17
1500.0 MM 3 18
1000.0 MM 4 19
500.0 MM 5 20
6 21
7 22
8 23
9 24
10 25
11 26
12 27
13 28
14 29
15 30
Inspected by: QAM

TECHNOCRAFT
PROCEDURE FOR INSPECTION OF
INDUSTRIES (I) LTD
GALVANIZING PRODUCT.
MURBAD PROCESS STAGE: GALVANIZING. QW: 8.2.4-07
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 1
QAM MR MAY 25, 2006 0
of 1
1. PURPOSE:
To document procedure for inspection at galvanizing stage.
2. RESPONSIBILITY:
Chemist cum Q.A.Inspector is responsible for compliance this procedure.
3. PROCEDURE:
3.1. After fabrication and inspection, products go to the galvanizing plant.

3.2. All scaffolds will be Hot –Dipped galvanized.
3.3. To obtain quality zinc coating galvanizing processes and galvanized product are
checked periodically as per plan arrangements.
3.4. Inspections are carried out on galvanized products as per following methods;
A. IN-PROCESS INSPECTION.
i). To control defects like black spots, bare spots excessive roughness and lumps visual
observation is carried out.
ii). To determine zinc coating thickness (75 µm Min) non-destructive method (magnetic
method) is implemented. Refer doc. Code QW: 10.2 to follow the test procedure.
iii). Destructive method can also be implemented. This method includes the determination
of mass per area by the gravimetric method converted to thickness (microns) by
dividing the grams per square meter. Refer doc. Code QW: 10.2 to follow the test
procedure.
B. 100 % VISUAL OBSERVATIONS AND REWORKING AFTER GALVANIZING

i). Excessive zinc accumulated in Ring,Ledger head, and at the rear ends of the pipes
is removed by filing and grinding methods. Excessive zinc deposit on other items like
horizontal (ledger), Clamp brace, Jackscrew etc will cleared so that it will not
interfere the functioning.
ii). Excess zinc inside the tube surface should be removed.
iii) Zinc rich paint is applied in the areas where the excessive zinc removed by filing and
grinding.
iv). Ensure that thickness of the base metal shall not be reduced than the minimum
specified limit, when filing and grinding process are applied for removing excessive
zinc.
v). Other than above defects like bend, damages during handling and galvanizing each
and every piece is also observed visually. In the case of finding any other defect that
piece is removed from the good production and sent for recovery to concerned
department.
vi). Stamping of 9 digit should be as per requirement and clearly visible on the tube.
2 Digit manufacturer’s mark should also be as per requirement and clearly visible.
INDUSTRIES (I) LTD DETERMINATION OF MASS / DOC.CODE
(TUBE DIVISION) THICKNESS OF ZINC QW-10-2
MURBAD COATING
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 1
QAM MR MARCH 10, 2006 0
of 3
1. SCOPE:
To document procedure for determining thickness of zinc coating.
2. PURPOSE:
Thickness of zinc coating is determined by following two methods.
a). Non-destructive method.
In this method thickness of zinc coating is detected as direct result by magnetic
method.
b). Destructive method.
This method includes the determination of mass per area by the gravimetric method.
This can be converted to thickness (micron) by the grams per square meter dividing
by the nominal density of the zinc.
3. RESPONSIBILITY:
Galvanizing chemist cum Q.A. inspector will be responsible for compliance with this
document
4. PROCEDURE FOR NON-DESTRUCTIVE METHOD:
4.1. At least three reference areas shall be taken on each article in the control sample. On
each article (taken separate) in the control sample the mean coating thickness within
the reference areas shall be equal to or greater than the specified coating thickness.
Three reference areas are located at the both ends and middle of the article. Thickness
measurements shall not be taken on cut surface or areas less than 10 mm from edges,
or corners.
4.2. TERM (S).
a). Hot dip galvanized coating: Coating obtained by hot dip galvanizing.
b). Coating mass: Total mass of zinc and / or zinc – iron alloys per area of surface
(expressed in grams per square meter. g/m2).
c). Coating thickness: Total thickness of zinc and / or zinc –iron alloys (expressed in
micrometer, µm ).
d). Control sample: The article or group of articles from a lot that is selected for testing.
MURBAD COATING
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 2
of 3
e). Reference area: The area within which a specific number of single measurements has
to be made.
5. PROCEDURE FOR DESTRUCTIVE METHOD:

a. For tubes with thickness up to 5mm cut 100mm long sample from opposite
ends of the selected galvanized tube sample. To determine mass of zinc coating,
follow the test procedure as mentioned below:
b. Clean the test pieces with solvent naphtha, trichloroethylene, carbon tetra
chloride or any other suitable organic solvent then with alcohol and finally
dried thoroughly.
6. Prepare stripping solution as follows:
6.1 Dissolve 20 grams of antimony trioxide or 32 grams of antimony tri-chloride in
1000ml of concentrated hydrochloric acid (Specific gravity 1.16).
6.2 Immediately before test, prepare the stripping solution by adding 5ml of the
solution prepared under 3.1 to 100ml of concentrated hydrochloric acid
(Sp.gravity 1.16). Mix well.
6.3 Weigh the prepared sample by using electronic balance.
6.4 Protect the coating on the inside surface of the tube with a substance resistant to
chemical attack by the stripping solution, e.g. rubber plugs for full tube section.
6.5 After weighing immerse test piece in test solution prepared in 3.2 and allow it to
remain there until the violent evolution of hydrogen ceases, and only a few
bubbles are being evolved. This requires about 15 to 30 seconds.
6.6 Take out the tube sample from solution, wash it thoroughly in water, clean and dry
it.
6.7 Measure the average thickness of the stripped tube samples and weigh it.
6.8 Calculate the mass of zinc coating using following formula.
M1 – M2
For out side coating M= X 106
MURBAD COATING
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 3
of 3
Π DL
Where M=Mass of zinc coating in g/m2 of surface

M1 = Original mass in grams of test sample,
M2 = Mass in grams of stripped test sample
D = Out side diameter of test sample
L = Length of the test sample.
6.9 The coating thickness of the zinc coating in µm, is determined by grams per
square meter dividing by the nominal density of the coating (7.20/cm3)
6.10 The minimum mean coating thickness 75 µm on the outside surface of the
article shall be obtained from the number of measurements for a magnetic test or
the single value from the gravimetric test.
6.11Record your result in in-process inspection form QR:SCAFF: 10.2-308. and conform whether your
result with the requirement there in.
TECHNOCRAFT IN-PROCESS INSPECTION QR: SCAFF: 10.2-308 (2008 04 22)
INDUSTRIES (I) LTD REPORT OF HOT-DIP
(TUBE DIVISION) GALVANIZING OF
MURBAD TECHRING VERTICAL.
Ø 1 1 .2 ± 0 .2
Ø 1 1 .2 ± 0 .2
Ø 4 8 .4 ± 0 .4
3 5 .0 5 3 5 .0 5
500 P IT C H
1 0 4 .7 6 ± 1 .0
9 .5 2 T H K .
STA N D A R D LEN G TH "A "
W/O NO: Techring Scaffold

Drawing No: Product code:
Item description: Process: In-process inspection of
Heat no / Control Unit No: galvanized vertical.
Inspection item: 1. Visual inspection of the galvanizing free of defects such as the zinc burs, color
deviation, black spot, excessive zinc deposit and roughness… 2. Verify the zinc layer not less than
75µm. 3. 9 digit stamping clearly visible. 4. ID ∅ 41.60 Min.
Production In
Production Qty (1/Day) Inspection Qty / frequency Min. inspection qty
Nos/ Pcs
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
ITEM DIMENSION SR
CODE NO.
A R DATE TIME SR NO. A R DATE TIME
L
3000.0 MM 1 16
2000.0 MM 2 17
1500.0 MM 3 18
1000.0 MM 4 19
500.0 MM 5 20
6 21
7 22
8 23
9 24
10 25
11 26
12 27
13 28
14 29
15 30
Inspect for first 10 Pcs at commencement of each new production setup.

TECHNOCRAFT
INDUSTRIES (I) LTD PROCEDURE FOR FINAL
(TUBE DIVISION) INSPECTION OF TECHRING DOC.CODE
MURBAD VERTICAL. QD: SCAFF: 121

1. PURPOSE: -
To document welding procedure for final inspection of Techring Vertical.
3. PROCEDURE : -
Select number of sample as per sampling plan, which is given in relevant inspection for,
and carry out visual inspection to ensure following checks.
a. There shall be no excessive zinc on the any part of the vertical.
b. There should be no excess zinc inside the tube surface.
c. All areas shall be painted with zinc rich paint where excessive zinc is found removed.
d. There shall be no any mechanical damages.
e. Straightness of the vertical shall be ensured.
f. No crack in weld and base metals. No porosity, blow holes and under cutting.
g. Weld shall be uniform.
h. Length of the articles shall be conformed as per customer requirement.
i. No any sample without full welding.
j. Ensure that bundle taken for inspection have correct quantity as per packing slip and
numbers of bundles are correct as per customer requirement.
k. QR: SCAFF: 10.2-309 will be used for recording your observations.

FINAL INSPECTION
INDUSTRIES (I) LTD
REPORT OF TECHRING
(TUBE DIVISION)
MURBAD VERTICAL.
Ø 11.2 ± 0.2
Ø 11.2 ± 0.2
PART NO. Ø48.4 ± 0.4
ID STAMP ID STAMP
35.05 35.05
500 PITCH 104.76 ±1.0
9.52 THK.
STANDARD LENGTH "A"

Item description: Process: Final inspection for vertical.
Inspection characteristics: 1. Visual inspection Hot-Dip Galvanizing; 2. Clear the excess zinc
and zinc painting.; 3. Bundle count correct; 4. Dimension = L; 5. Checking the nine digit
number stamping and its format should be TI (Vender ID) – MM (Month) – YY (Year)- XXX
(Three last digit number from the heat number / Control unit number); 6. Check part No.
Production In
Production Qty (1/Day) Inspection Qty / frequency Min. inspection qty
Nos/ Pcs
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
ITEM DIMENSION SR
CODE L IN MM NO.
3000.0 MM 1 16
2000.0 MM 2 17
1500.0 MM 3 18
1000.0 MM 4 19
500.0 MM 5 20
6 21
7 22
8 23
9 24
10 25
11 26
12 27
13 28
14 29
15 30
Inspected by QAM

TECHNOCRAFT PRODUCTION QR: SCAFF: 10.2-310 (2008 04 23)
INDUSTRIES (I) LTD CUT LENGTH TUBES FOR
(TUBE DIVISION) COUPLING PIN OF
MURBAD TECHRING VERTICAL
"L" "D"
T"
W/O NO: Product code:
Techring Scaffold Item description: Coupling pin.
Drawing No:
C. U. No:
All dimension are in mm Method of dimensional inspection: Vernier / gauge
Dimensions : Cutting length L : 235.0 ± 0.8 mm , Thickness T: 2.41 , Diameter
(OUTSIDE) D: 40.9
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: Q.A.M

D:\Tech Ring Manual\46_QR-scaff- 10.2-310 (SPIGOT CUTTING)(TR).doc
TECHNOCRAFT PRODUCTION INSPECTION QR: SCAFF: 10.2-310/1 (2008 04 22)
REPORT OF
INDUSTRIES (I) LTD REDUCING FOR COUPLING
(TUBE DIVISION) PIN OF TECHRING
MURBAD VERTICAL

Drawing No:
C. U. No:
All dimension are in mm Method of dimensional inspection: Vernier / Gauge
Dimensions : L=235±0.8 mm , R = 6.35 (Both ends).
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No.
A R Date Time No.
A R Date Time No.
A R Date Time
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: Q.A.M
D:\Tech Ring Manual\47_QR-scaff- 10.2-310-1 (TR).doc

PRODUCTION QR: SCAFF: 10.2-310/2 (2008 04 22)
TECHNOCRAFT
INDUSTRIES (I) LTD
HOLE PUNCHING FOR
(TUBE DIVISION) COUPLING PIN OF
MURBAD TECHRING VERTICAL
± 0.2 ± 0.2

Drawing No:
C. U. No:
All dimension are in mm Method of dimensional inspection: Vernier / Gauge
Dimensions : L=235±0.8 mm , C= 70.10 mm+0.00, Hole dia D= 11.11 ± 0.2(Weld bead
should be 90 degree to the hole.),Hole position from one end of the pipe = 49.28mm.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: Q.A.M

D:\Tech Ring Manual\48_QR-scaff- 10.2-310-2(TR).doc
TECHNOCRAFT PRODUCTION QR: SCAFF: 10.2-310/3 (2008 04 22)
STAMPING FOR
(TUBE DIVISION)
COUPLING PIN OF
MURBAD VERTICAL
± 0.2 ± 0.2

Item description: Coupling pin.
C. U. No:
Inspection characteristics: 1. Visual inspection of stamping, accuracy and position of
ID mark, 2. 25 mm from both ends.
Inspection Qty / Production In Min. inspection
Production Qty (1/Day)
frequency Nos/ Pcs qty
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No.
A R Date Time No.
A R Date Time No.
A R Date Time
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: Q.A.M

D:\Tech Ring Manual\49_QR-scaff- 10.2-310-3 (TR).doc
TECHNOCRAFT PRODUCTION CUM QR: SCAFF: 10.2-310/4 (2008 04 22)
IN-PROCESS INSPECTION
INDUSTRIES (I) LTD REPORT OF GALVANIZING FOR
(TUBE DIVISION) COUPLING PIN OF TECHRING
MURBAD VERTICAL
± 0.2 ± 0.2

Product code: Drawing No:
C. U. No:
75µm. 3. 9 digit stamping clearly visible.
frequency Nos/ Pcs
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No.
A R Date Time No.
A R Date Time No.
A R Date Time
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: Q.A.M

TECHNOCRAFT FINAL INSPECTION QR: SCAFF: 10.2-310/5 (2008 04 22)
INDUSTRIES (I) LTD REPORT OF COUPLING
(TUBE DIVISION) PIN FOR TECHRING
MURBAD VERTICAL
± 0.2 ± 0.2
PART NO
C. U. No:
Inspection item: 1. Visual inspection of the galvanizing free of defects such as the zinc burs,
color deviation, black spot, excessive zinc deposit and roughness…; 2. Verify the zinc layer
not less than 75µm.; 3. OD: 40.90 ; 4. 9 digit stamping clearly visible. ; 5. Check part No.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Ti
A R Date Time A R Date Sr. No. A R Date Time
No. No. me
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: Q.A.M

PRODUCT: TECHRING HORIZONTAL (LEDGER)
START
INCOMING INSP
LEDGER PIPE (HORIZONTAL) LEDGER HEAD (STEEL CASTING) LEDGER WEDGE (STEEL PLATE)
DIA: 48.3 MM (BOUGHT OUT. COMPONENT) (BOUGHT OUT. COMPONENT)
THICKNESS: 3.2 MM.
(H.T.MATERIAL, GR St 52.3)
INSPECTION
HR COIL.
INSPECTION
SLITTING PROCESS
INSPECTION
TUBE MANUFACTURING
(ERW)
.
INSPECTION
PIPE CUTTING
INSPECTION
LEDGER HEAD WITH PIPE
FULL WELD ASSEMBLY.
INSPECTION
GALVANIZING
INSPECTION
WEDGE FIXING IN LEDGER
HEAD (RIVETING) (WEDGE
FIXING AFTER GALVANIZING)
INSPECTION
REJECTED ASSEMBLY
ACCEPTED ASSEMBLY.
INSPECTION
REPAIRING
PART NO. PRINT
INSPECTION
FINAL INSPECTION
PACKING
REJECTED ACCEPTED INSPECTION
DISPATCH
SCRAP
STOP
INDUSTRIES (I) LTD INSPECTION REPORT
(TUBE DIVISION) OF CUT LENGTH TUBES
MURBAD FOR TECHRING
HORIZONTAL.
W/O NO:
Techring Scaffold
Drawing No:
Product code:
Item description: Horizontal tubes.
C. U. No:
Dimensions: A = (11’2” = 3404.0, 10’ =3050.0, 9’= 2743.0, 8’ = 2438.0,7’ =2130.0,
6’ = 1829.0, 5’ 4” = 1626.0, 5’ 2” = 1572, 4’ = 1219.0, 3’ 10” =1150.0, 3’6” =
1065, 3’= 914.0, 2’ 10” = 864.0, 2’ 2” = 650.0, OD= 48.40 ± 0.4. B = 3.25 + 0.40/-
0.20
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: Q.A.M

INDUSTRIES (I) LTD
STAMPING OF TECHRING
(TUBE DIVISION)
HORIZONTAL TUBE.
MURBAD

Techring Scaffold Item description: Stamping of horizontal Tube.
Drawing No: Tube heat No. / C. U. No:
of ID mark.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45

TECHNOCRAFT INDUSTRIES (I) LTD SPECIFICATION CUM INSPECTION REPORT OF QR-SCAFF: 10.2-313 (2008 04 22)
(TUBE DIVISION) LEDGER HEAD FOR TECHRING SYSTEM.
Lot / Batch No:
MURBAD. (For Incoming Material 3 % For Dimensions And 10 %
Of Visual Inspection)
Received Qty.&Date : Month & Year of Manufacturing :
All dimensions are in mm: - mention minimum and maximum Date:
Drawing No: 213906 (Rev 0.)
values Shift:
SPECIFIED METHOD OF 1 st OBSERVED VALUES
DESCRI
Ledger Total length 73.03 ± 0.5 Vernier / gauge
Head Total width 52.32 ± 0.5 Vernier / gauge
Height outside the pipe 52.3 ± 0.5 (REF.) Vernier / gauge
Total height 58.65 ± 0.5 Vernier / gauge
Slot width (Ring 14.29 Vernier / gauge
sitting)
Pipe sitting diameter ∅ 41.40 ± 0.5 Vernier / gauge
Outside diameter 52.32 ± 0.5 Vernier / gauge
Note: 1. Material: Cast steel per ASTM A 27, Grade 70-36, Class 2, Or equivalent as per ASTM 148, Grade 70-36.
2. Weight of ledger head: Avg. 520 Gms
3. Casting to be fully normalized and tempered..
5. Please get the original MTC from supplier
REMARKS:
INSPECTED BY.
NAME :
SIGNATURE : QAM
D:\Tech Ring Manual\55_QR-SCAFF- 10.2-313 (TR) ledger head.doc

INDUSTRIES (I) LTD
STAMPING OF TECHRING
(TUBE DIVISION)
HORIZONTAL HEAD.
MURBAD
W/O NO:
Techring Scaffold
Drawing No
Product code:
Item description: Stamping of horizontal
End Fitting. (Ledger Head)
Heat No:
Lot/batch no:
of ID mark.(TI:31 01),TI=Vendor Code,31= Sub Vendor Code, 01= Batch No.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No.
A R Date Time No.
A R Date Time No.
A R Date Time
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspect 20 Pcs at commencement of each new production setup.

INDUSTRIES (I) LTD WELDING OF TECHRING
(TUBE DIVISION) LEDGER (HORIZONTAL) DOC.CODE
MURBAD QD: SCAFF: 122
ISSUED BY APPROVED BY REVISION STATUS DATE PAGE

1. Purpose : - To document the procedure & work instruction for welding of Techring
Horizontal (ledger).
2. Responsibility : -
Primary : Welder.
3. As per the production program given by the supervisor the operator will set and run the machine
as per procedure.
PROCEDURE FOR WELDING OF TECHRING LEDGER: -
1. The welding parent material will be free from rust, greases etc.
2. Put the Ledger head & pipe on respective locators of auto welding machine.
3. The machine shall be adjusted as per the length of ledger. The facility is provided on the machine
for some.
4. After starting the production the first piece will be inspected for visual defects and if it is found
ok then welding test will be carried out as per QR: SCAFF: 10.2-315.
5. At the starting of each shift one sample will be drawn and tested for end fitting of weld by testing
as per QR: SCAFF: 10.2 – 316.
6. Welding parameters & details as given below;
a. Welding process: MAG.
b. Joint type: Fillet weld.
c. Job rotation: 3600
d. Parent material: As per Q345 / Blade: Forged. St 37.20
e. Run: Single.
f. Size of filler metal: ∅ 1.2 mm wire.
g. Current (A) : These values may changed if welding is not found ok and its approval to be
taken from concerning authority not below the supervisor level.
Auto-welding m/c no.1 234-236Amp. Auto-welding m/c no.2 224-226Amp.
h. Voltage (V): 27-28V 26-28V
i. Type of current: DC.
j. Shielding: Co2
k. Filler metal classification & trade name: 1.2 mm – GEE make as per AWS A5. 18: ER 70
S-6, DIN 8559:SG 3.
l. Torch angle: 450

INDUSTRIES (I) LTD INSPECTION FOR
(TUBE DIVISION) TECHRING HORIZONTAL
MURBAD (LEDGER) WELDING.
L ± 0.8
GMAW
48.40 ± 0.4 X 3.25 + 0.4 / -0.20 TYP.
50.0 35.0 mm 35.0 mm 50.0
W/O.NO: Techring Scaffold

Product Description: Horizontal (ledger) Product no:
Drawing No: Process description: Welding horizontal.
Heat no/Coil No:
Control unit No:
Inspection characteristics: 1. Check – “L” Length, 2. Check the welding quality 100 %,
3. Both the ledger head should be parallel deviation 10.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Results A = Acceptable R = Rejected
Product Dimensions
L Sr No. A R Date Time Sr No. A R Date Time
Code
11’-2” 3404 1 15
10’ 3050 2 16
9’ 2743 3 17
8’ 2438 4 18
7’ 2130 5 19
6’ 1829 6 20
5’-4” 1626 7 21
5’-2” 1572 8 22
4’ 1219 9 23
3’-10” 1150 10 24
3’-6” 1065 11 25
3’ 914 12 26
2’-10” 864 13 27
2’-2” 650 14 28
Inspected by: Q.A.M

TECHNOCRAFT INDUSTRIES (I) LTD LOAD TEST ON END LEDGER HEAD QR: SCAFF: 10.2-316 (2008 04 22)
(TUBE DIVISION) DATE OF TESTING:
OF HORIZONTAL (TECHRING
MURBAD TIME:
SYSTEM)
WELDING PROCEDURE: MAG WELDING
REFERENCE DOCUMENTS:
PRODUCT CONTROL UNIT NO.: LOCATION OF TESTING: PHYSICAL AND
1. QD: SCAFF: 124
SAMPLING: ONE PER SHIFT CHEMICAL TESTING LABORATORY –
2. FIGURE:
PRODUCT CODE: TECHNOCRAFT TUBE DIVISION, MURBAD.
3. EN 39: 2001, BS EN 12811-1 : 2003.
HEAT NO:
METHOD OF
Sl. SPECIFIED
CHARACTERISTICS INSPECTION / TEST RESULTS REMARKS
No. REQUIREMENTS INSTRUMENT
1. Visual inspection of weld prior No cracks in weld metal,
to load test heat effected zone and
parent metal. Also no Visual
porosity, blow holes and
under cutting.
2. Load test on end fitting of Ledger head mounting
techring ledger fixture UTM,
a). Test load 908 Kg Visual, Dial
b). Load to be applied at a 127 MM gauge
distance from axis of the
standard.
(On either end one after another)
c). Tensile load. There should not be any crack UTM,
on weld,or bend in tube,or Visual, Dial
any kind of failure at this
gauge
above load
3. Macro examination Should show the weld

material penetration on Visual
mating parts.
CONCLUSION: WHETHER THE END LEDGER HEAD OF HORIZONTAL PASSED OR FAILED THE TEST AS PER BS EN 12811-1 : 2003.
TEST CARRIED OUT BY:
NAME :
QUALIFICATION : QAM
POSITION :
DATE :
SIGNATURE :
D:\Tech Ring Manual\59_QR-SCAFF - 10.2-316 (TR).doc
D:\Tech Ring Manual\59_QR-SCAFF - 10.2-316 (TR).doc
TECHNOCRAFT PROCEDURE FOR 100 %
INDUSTRIES (I) LTD VISUAL INSPECTION
(TUBE DIVISION) AFTER WELDING PROCESS DOC.CODE
MURBAD PRODUCT: TECHRING QD: SCAFF: 123
HORIZONTAL.
1. PURPOSE: -
To document welding procedure for 100 % visual inspection after welding process of techring
Horizontal.
Secondary : Q.A. Inspector.
3. PROCEDURE : -
100 % Inspection is carried out on scaffold items, after welding process is completed.
During this inspection Q.A.Inspector comes and carries out periodic inspection on the
samples selected as per sampling plan. Frequency of the periodic inspection will be
a. Weld should be observed for the defects like incomplete weld, cracks, porosity, blow
holed and under cutting..
b. Also observe that whether weld is uniformed and full welded.
c. Observe that whether all components are assembled and in right way.
d. Check bay length of the horizontal by using gauge.
e. Check ledger head are welded parallel to each other perpendicular axis of the horizontal
pipe.
f. Check all the horizontal have 9 digits stamping and also 2 Digit manufacturer’s mark on
both end ledger head.
g. Record your observation, accepted and non-conforming quantity in QR:SCAFF: 10.2-315.

TECHNOCRAFT WORK INSTRUCTION FOR DOC.CODE
INDUSTRIES (I) LTD LOAD TEST ON QD: SCAFF: 124
(TUBE DIVISION) END FITTINGS OF
MURBAD TECHRING HORIZONTAL
(LEDGER)
REVISION
STATUS
QAM MR 23 APRIL, 2008 0 Page 1 of 1
1. SCOPE:
This document sets out the method for determining the load carrying capacity of end
fittings of Techring horizontal (ledger).
2. APPARATUS: The following apparatus is required;

a. Universal Testing Machine for applying test force on end fittings of techring
horizontal (ledger).
b. Timer.
c. Wood or any other object for applying load to the end fittings of ledger.
d. One piece of 30 – 40 cm long, cut from the techring vertical (To be made simulate
assembly).
e. One full length of techring vertical. (To be made simulate assembly)
f. One Adjustable base jack. (To be made simulate assembly)
g. Base plate.
h. Bush.
i. Spanner of size22 mm and Allen key of size 10 mm.
j. Dial gauge.
k. Ledger head mounting fixture.
3. TEST PROCEDURE FOR LOAD TEST ON END FITTING:

a. After weld has been inspected, techring horizontal (ledger) shall be assembled with
the piece of vertical. This piece of vertical is inserted in holder, which is bolt fitted
with lower head of the Universal Testing Machine. This arrangement is provided to
prevent leaning of vertical piece when under the load. Other end of the horizontal
will be fitted with Ledger head mounting fixture, which is rested on adjustable base
jack dial gauge shall be fixed to the horizontal where point load will be applied
b. The test load (908 Kg) shall be applied vertically on the end of the ledger at a
distance of 127 mm from the axis of the vertical for the duration of two minutes, then
load shall be removed.
c. Observed is there any failure of welding or deformation in the pipe
d. If there is no such failure then the ledger is fit for the use.
4. RESPONSIBILITY OF THE LOAD TESTING.

Primary : Testing engineer.
Final :QAM.
D:\Tech Ring Manual\61_QD- SCAFF- 124 (TR).doc

MURBAD TECHRING HORIZONTAL
L ± 0.8
GMAW
48.40 ± 0.4 X 3.25 + 0.4 / -0.20 TYP.
50.0 35.0 mm 35.0 mm 50.0

Process: In-process inspection of galvanized
Item description:
horizontal.
75µm. 3. 9 digit stamping clearly visible.
frequency Nos/ Pcs
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
ITEM SR SR
DIMENSION A R DATE TIME A R DATE TIME
CODE NO. NO.
11’-2” 3404 1 19
10’ 3050 2 20
9’ 2743 3 21
8’ 2438 4 22
7’ 2130 5 23
6’ 1829 6 24
5’-4” 1626 7 25
5’-2” 1572 8 26
4’ 1219 9 27
3’-10” 1150 10 28
3’-6” 1065 11 29
3’ 914 12 30
2’-10” 864 13 31
2’-2” 650 14 32
15 33
16 34
17 35
18 36
Inspection for 10 Pcs at commencement of each new production setup.

TECHNOCRAFT INDUSTRIES (I) LTD SPECIFICATION CUM INSPECTION REPORT OF WEDGE QR-SCAFF: 10.2-318 (2008 04 23)
(TUBE DIVISION) FOR LEDGER & BRACE TECHRING SYSTEM.
(For Incoming Material 3 % For Dimensions And 10 % Of Lot / Batch No:
MURBAD.
Visual Inspection)
Date:
Drawing No: 213903 (Rev 3.) All dimensions are in mm: - mention minimum and maximum values Shift:
SPECIFIED METHOD OF 1st OBSERVED VALUES
DESCRI
Wedge Thickness 6.35 ± 0.2 Vernier / gauge
Total Length 139.70 ± 0.5 Vernier / gauge
Width: At Tail end 11.00 ± 0.5 Vernier / gauge
At Head end 28.57 ± 0.5
Hole on tail end ∅ 4.82 ± 0.2 Vernier / gauge
Location of hole 5.84 mm from Vernier / gauge
hole center to end
Radius at head end R 3.0 Radius gauge
corner & Tail end R 6.0
corner
Wedge taper 110 at one side. Bevel protractor
Workmanship No bur.. Visual
Rivet size Head ∅ 7.0 X 2.0 mm Vernier
Body ∅ 3.9 X 10 mm
Note: 1. Material: ¼” C1018 steel plate, case hardened at 0.127 mm depth Hardness 87-94 Rockwell Scale B.
2. Weight of Wedge: Avg. 130 Gms
4. Please get the original MTC from supplier
REMARKS:
INSPECTED BY.
NAME :
SIGNATURE : QAM
D:\Tech Ring Manual\63_QR-SCAFF- 10.2-318 (TR) wedge.doc

D:\Tech Ring Manual\63_QR-SCAFF- 10.2-318 (TR) wedge.doc
TECHNOCRAFT INSPECTION REPORT OF QR: SCAFF: 10.2-319 (2008 04 23)
INDUSTRIES (I) LTD WEDGE ASSEMBLY FOR
(TUBE DIVISION) TECHRING HORIZONTAL &
MURBAD BRACE.

Process: Inspection report wedge assembly
Item description:
(riveting)
Inspection item: 1. The wedge should not come out after riveting. 2. No sharp edge on rivet surface.
3. The taper portion of wedge should come on pipe side..
frequency Nos/ Pcs
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
ITEM SR SR
CODE
DIMENSION NO.
A R DATE TIME NO.
A R DATE TIME
3404 1 19
3050 2 20
2743 3 21
2438 4 22
2130 5 23
1829 6 24
1626 7 25
1572 8 26
1219 9 27
1150 10 28
1065 11 29
914 12 30
864 13 31
650 14 32
15 33
16 34
17 35
18 36
I
nspection for 10 Pcs at commencement of each new production setup.

TECHNOCRAFT
MURBAD HORIZONTAL (LEDGER). QD: SCAFF: 125

1. PURPOSE: -
To document welding procedure for final inspection of Techring Horizontal.
3. PROCEDURE : -
Select number of sample as per sampling plan, which is given in relevant inspection for,
b. All areas shall be painted with zinc rich paint where excessive zinc is found removed.
c. There shall be no any mechanical damages.
d. Straightness of the vertical shall be ensured.
e. No crack in weld and base metals. No porosity, blow holes and under cutting.
f. Weld shall be uniform.
g. Length of the articles shall be conformed as per customer requirement.
h. No any sample without full welding.
i. Ensure that bundle taken for inspection have correct quantity as per packing slip and
j. QR: SCAFF: 10.2-320 will be used for recording your observations.

TECHNOCRAFT FINAL INSPECTION QR: SCAFF: 10.2-320 (2008 04 23)
INDUSTRIES (I) LTD FOR TECHRING
(TUBE DIVISION) HORIZONTAL
MURBAD (LEDGER).

Techring Scaffold Item description:
Drawing No: Process: Final inspection for horizontal.
Inspection characteristics: 1. Visual inspection Hot-Dip Galvanizing; 2. Clear the excess zinc
on the pipe surface and blade then zinc paint; 3. Bundle count correct; 4. Dimension = L; 5.
Checking the nine digit number stamping and its format should be TI (Vender ID) – MM
(Month) – YY (Year)- XXX (Three last digit number from the heat number / Control unit
number); 6. Check part No.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
ITEM DIMENSION SR
CODE L IN MM NO.
1 16
2 17
3 18
4 19
5 20
6 21
7 22
8 23
9 24
10 25
11 26
12 27
13 28
14 29
15 30
Inspected by: QAM

PRODUCT: TECHRING DIAGONAL BRACE
START
INCOMING INSP INCOMING INSP INCOMING INSP INCOMING INSP

BRACE TUBE SHOULDER BOLT. BRACE HEAD
DIA: 42.16 MM BRACE WEDGE
BOUGHT OUT BOUGHT OUT
THICKNESS: 2.54 MM. BOUGHT OUT
COMPONENT. COMPONENT COMPONENT
INSPECTION
PIPE CUTTING
INSPECTION
PRESSING OF BOTH GALVANIZING GALVANIZING GALVANIZING

ENDS
INSPECTION
PIERCING OF AT BOTH
ENDS HOLE DIA: 17.46 MM
INSPECTION
GALVANIZING
INSPECTION
ASSEMBLY OF PIPE WITH BOLT

& BRACE HEAD
INSPECTION
WEDGE ASSEMBLY
WITH BRACE HEAD
INSPECTION
REJECTED ASSEMBLY ACCEPTED ASSEMBLY.
INSPECTION
INSPECTION
REPAIRING
PART NO PRINT
FINAL INSPECTION
PACKING
REJECTED ACCEPTED INSPECTION
DISPATCH
SCRAP
STOP
CUT LENGTH TUBES FOR
(TUBE DIVISION)
TECHRING DIAGONAL
MURBAD BRACE.
W/O NO:
Techring Scaffold
Drawing No
Product code:
Item description: Diagonal brace tube.
Dimensions : A = X ± 1.0. C = 42.16 ± 0.4.
B = 2.54± 0.25
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: QAM

TECHNOCRAFT PROCEDURE FOR IN-
INDUSTRIES (I) LTD PROCESS INSPECTION OF
(TUBE DIVISION) END PRESSING ON DOC.CODE
MURBAD DIAGONAL BRACE. QD: SCAFF: 126
1. PURPOSE: -
To document procedure for in-process inspection for end pressing of Diagonal Brace pipe.
3. PROCEDURE : -
a. At the starting of the production check 10 pcs for end pressing. If each sample found ok
b. Check the end-pressing dimension as per inspection form. .
c. Check forming of the end pressing with profile gauge.
d. Record your observations in QR: SCAFF: 10.2-323.

PRODUCTION
(TUBE DIVISION) TECHRING DIAGONAL
MURBAD BRACE END PRESSING.
W/O NO:
Techring Scaffold
Drawing No:.
Product code:
Item description: Diagonal brace end
pressing.
Dimensions :1.A = X ± 1.0,’ 2. C = 42.16 ± 0.4.’
3. B = 2.54 ± 0.25, 4. Thickness after flattening =6.25 ± 0.35 MM.’ 5. End
pressing form.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: QAM

TECHNOCRAFT
PROCEDURE FOR IN-
INDUSTRIES (I) LTD
PROCESS INSPECTION OF DOC.CODE
(TUBE DIVISION)
HOLE PUNCHING ON QD: SCAFF: 127
MURBAD
DIAGONAL BRACE.
1. PURPOSE: -
To document procedure for in-process inspection of hole punching on Diagonal Brace pipe.
3. PROCEDURE : -
a. At the starting of the production check 10 pcs for hole punching. If each sample found ok
b. Check the holes center distance and conform that whether it meet the requirement with
relevant inspection report.
c. Hole center from end is 23.88 mm.
d. Check the diameter of hole. It should be 17.46 ± 0.2 mm
e. Check visually there should not be any excessive burr.
f. Record your observations in QR: SCAFF: 10.2-324.
g. Zinc drain hole ∅ 9.52 at distance of 73.60 mm from end on one side only.

TECHRING DIAGONAL
(TUBE DIVISION)
BRACE END HOLE
MURBAD PUNCHING & ZINC DRAIN
HOLE PUNCHING.
W/O NO:
Techring Scaffold
Drawing No:.
Product code:
Item description: Diagonal brace end
hole punching.
Dimensions : Pressing of end hole punching ∅ : 17.45 ± 0.2.
Center distance of holes: X ± 0.7, Zinc drain hole : ∅ 9.52 both end one side.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: QAM

GALVANIZING OF
(TUBE DIVISION)
TECHRING DIAGONAL
MURBAD BRACE
W/O NO:
Techring Scaffold
Drawing No:
Product code:
Item description: In-process
inspection of galvanized clamp brace.
Inspection item: 1. Visual inspection of the galvanizing free of defects such as the
zinc burs, color deviation, black spot, excessive zinc deposit and roughness…
2. Verify the zinc layer not less than 75µm. 3. 9 digit stamping clearly visible.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: QAM

TECHNOCRAFT INDUSTRIES (I) LTD SPECIFICATION CUM INSPECTION REPORT OF QR-SCAFF: 10.2-326 (2008 04 23)
(TUBE DIVISION) BRACE HEAD (LH & RH) FOR TECHRING SYSTEM.
Lot / Batch No:
MURBAD. (For Incoming Material 3 % For Dimensions And 10 % Of
Visual Inspection)
Date:
Drawing No: All dimensions are in mm: - mention minimum and maximum values
Shift:
SPECIFIED METHOD OF 1st OBSERVED VALUES
DESCRI
Brace Rib width 52.0 ± 0.2 Vernier / gauge
Head Rib Length 49.0 ± 0.5 Vernier / gauge
Rib thickness 13.0 Vernier / gauge
∅ 17.0 hole on locate 26.0 X 19.3 ± 0.2 Vernier / gauge
centrally on rib / from
one end.
Min thickness at top. 8.0 ± 0.5 Vernier / gauge
Slot width (Ring 12.00 ± 0.5 Vernier / gauge
sitting)
Width of brace head. 58.0 ± 0.5 Vernier / gauge
Height of brace head 48.60 ± 0.3 Vernier / gauge
Note: 1. Material: Ductile iron ASTM A 536, Grade 60-40-18 Or CSA D60-40-18.
2. Weight of ledger head: Avg. 613 Gms
3. For Detail dimensions please refer drawing No: 213919RH & 213920LH (Rev 4.)
4. Please get the original MTC from supplier.
REMARKS:
INSPECTED BY.
NAME :
SIGNATURE : QAM
D:\Tech Ring Manual\74_QR-SCAFF- 10.2-326 (TR) diagonal head.doc

TECHNOCRAFT PROCEDURE FOR 100 % VISUAL
INDUSTRIES (I) LTD INSPECTION AFTER RIVETING /
BOLTING TECHRING DOC.CODE
(TUBE DIVISION)
DIAGONAL BRACE. QD: SCAFF: 128
MURBAD (AFTER GALVANIZING)
1. PURPOSE: -
To document welding procedure for 100 % visual inspection after Brace head riveting/bolting
process of Techring diagonal Brace.
3. PROCEDURE : -
100 % Inspection is carried out on scaffold items, after riveting/bolting of diagonal brace
with flattened pipe. During this inspection Q.A.Inspector comes and carries out periodic
inspection on the samples selected as per sampling plan. Frequency of the periodic inspection
will be hourly. They will follow method of the inspection described as below.
A. Check the riveting/bolting performance. After riveting/bolting Brace head (RH &LH)
Should free to rotate on the rivet/bolt.
b. Check the center distance between the brace heads riveted on the brace pipe.
c. Check all the brace pipe have 9 digits stamping and also 2 Digit manufacturer’s mark on
both end brace head.
g. Record your observation, accepted and non-conforming quantity in QR: SCAFF:10.2-327.

DIAGONAL BRACE HEAD
INDUSTRIES (I) LTD
ASSEMBLY INSPECTION
(TUBE DIVISION) REPORT
MURBAD
W/O NO:
Techring Scaffold
Drawing No:.
Product code:
Item description: Diagonal brace
assembly.
Inspection characteristics: Riveting/Bolting of brace head with brace pipe check
RH & LH brace head fixed correctly, For bolting apply thread lock solution on
bolt thread.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: QAM

TECHNOCRAFT
MURBAD DIAGONAL BRACE. QD: SCAFF: 129

1. PURPOSE: -
To document welding procedure for final inspection of Techring Diagonal Brace.
3. PROCEDURE : -
Select number of sample as per sampling plan, which is given in relevant inspection form,
b. Check the brace head (RH &LH) which should capable to rotate and fit for it’s function.
c. Check the center distance of the hole as per QR: SCAFF: 10.2-328.
d. All areas shall be painted with zinc rich paint where the excessive zinc is removed.
e. There shall be no any mechanical damages.
f. Length of the articles shall be conformed as per customer requirement.
j. Ensure that bundle taken for inspection have correct quantity as per packing slip and
h. QR: SCAFF: 10.2-328 will be used for recording your observations.

FINAL INSPECTION
INDUSTRIES (I) LTD
REPORT OF DIAGONAL
(TUBE DIVISION) BRACE
MURBAD
W/O NO:
Techring Scaffold
Drawing No:.
Product code:
Item description: Final inspection
diagonal brace.
Inspection characteristics: 1. Visual inspection Hot-Dip Galvanizing; 2. Clearing of excess
zinc and at it’s zinc painting; 3. Bundle count correct; 4. Free moment of Brace head (RH & LH) and
it’s function; 5. Center distance of holes: X ± 0.7; 6. Checking the nine digit number stamping and
its format should be TI (Vender ID) – MM (Month) – YY (Year)- XXX (Three last digit number from
the heat number / Control unit number) 7. Check part No.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by: QAM

TECHNOCRAFT
INDUSTRIES (I) LTD WORK INSTRUCTION FOR
(TUBE DIVISION) FINAL AND IN-PROCESS DOC.CODE
MURBAD INSPECTIONS. QW: 8.2.4-60
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 1
QAM MR MARCH, 12,2006 0
of 3
1. PURPOSE:
This instruction establishes the general sampling method for inspection by attributes
(“good” or “bad”) and also provides guidelines for inspection during production (“in-
process” inspection).
2. METHOD:
2.1. FINAL INSPECTION BY ATTRIBUTES (“GOOD” OR “BAD”).
2.1.1. SAMPLING:
A sample is drawn from a lot and a decision is made for the entire lot. The sample
size is chosen using table1.
2.1.2. TIME OF SAMPLING:
Samples may be drawn after all the units comprising the lot have been produced or
samples may be drawn during production of the lot. However the samples should
fairly represent all product produced, and the decision shall be taken after the entire l
ot has been produced.
2.1.3. ACCEPTABLE QUALITY LEVEL. (AQL):

The maximum number of nonconformities per hundred units that can be considered
satisfactory for the process average. For table 1, TTD specified AQL is:
AQL = 0.4 (0.4 % bad pieces)
The supplier’s process shall produce a number of maximum 0.4 nonconformities per
hundred units produced – the process average shall be less than or equal to AQL.
TABLE – 1
LOT OR
SHIPMENT SIZE REDUCED NORMAL TIGHTENED DEFECTIVE
PCS. ALLOWED.
1 – 500 3% 10 % 15 % 0
501 – 3200 1% 6% 9% 0
3201 – 10000 0.25 % 5% 7.5 % 0
10001 – 150000 0.2 % 4% 6% 0
Unless otherwise instructed, normal inspection will be utilized. If one or more defective
pieces are found in the sample, the entire lot must be rejected and inspected 100 %.
TECHNOCRAFT
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 2
of 3
2.2.4. TABLE – 2 SHOWS SAMPLING PLAN FOR PHYSICAL AND LOAD

TESTING.
Sr. Stage of the Sample Acceptance Rejection

Test description
No. sample size * number number.
Flat test, flaring test, First 2 0 1
1.
and tensile test. Second 2 0 1
Load test on scaffold First 1 0 1
2.
items. Second 2 0 1
* Number of samples shall be taken from product of each heat.
2.2. IN-PROCESS INSPECTION:

2.2.1. First off two samples shall be checked at commencement of each new setup of every
process (operation) if both samples found satisfactory production shall be continue. In
the case of failing any sample, investigation shall be carried out for the cause of
descripancy and appropriate corrective actions shall be taken. Again same inspection
procedure shall be implemented until get passed samples.
2.2.2. After starting of production, periodic inspection will be carried out on every hour
production at the each and every process stage. In each frequency five samples shall
be taken to inspect characteristics, which are determined in relevant inspection
form. If all five samples shall pass each and every test, whole lot of one hour
production shall be sent for further process with white tag. White tag includes proper
identification and traceability and also indicates test status as conforming material.
2.2.3. If any sample fails to meet the any specified requirement, more five samples shall be
taken and tested. All these five samples must pass every test to enter further process
or in the case of failing any sample such repeated sampling shall be carried out at the
lower and lower levels of this lot until received five samples pass all the tests.
Remove all upper leveled quantity from the lot which is found non-conforming and
kept separate with red tag, with furnishing NC report QR:8.3–1. Red tag also
indicates test status of non-conforming material. Further this non – conforming
quantity shall be taken for 100 % inspection. Rest material of the lot, which is found
OK, shall be allowed for the further process with appropriate identification and
traceability.
TECHNOCRAFT
APPROVED REVISION
ISSUED BY DATE PAGE
BY STATUS
Page 3
of 3
2.2.4. Material found non-conforming shall be taken for 100 % inspection and sorted out in
good and bad categories. Good quantity shall be sent for further process and bad
quantity if possible shall be sent for recovery otherwise not so shall be sent to scrap
yard with appropriate identification i.e. red tag with write up of “SCRAP”.
2.2.5. If any lot shall be missed to inspect during periodic inspection that lot will be kept
separate with yellow tag and appropriate identification and traceability. But during
his working hours responsible person will carry out inspection as per routine
procedure which are described in above clauses.
2.2.6. Following personnel’s are responsible to maintain procedure of in – process

inspection.
Primary : M/C operators.
Secondary : Q.A. Inspector / Shift Supervisors.
PRODUCT: ADJUSTABL BASE SCREW JACK [SCAFFOLDING]
START
INSPECTION. INSPECTION. INSPECTION.
PIPE ∅ 35 BASE PLATE NUT

WALL THICKNESS 4.8 MM (8.0 MM THICKNESS). BROUGHT –OUT
COMPONENT)
INSPECTION.
INSPECTION.
CUTTING OF PIPE IN SLITING OF COIL IN SLITS
PIECES OF OF 152 MM WIDTH.
INSPECTION. INSPECTION.
THREAD ROLLING. SHEARING AND HOLE

PUNCHING, CORNER CUTTING
AND SHEARING IN DIE.
INSPECTION.
INSPECTION.
SCREW AND BASE PLATE

FULL WELD ASSEMBLY.
INSPECTION.
GALVANIZING
SCREW AND NUT

ASSEMBLY.
INSPECTION.
END
TECHNOCRAFT QR: SCAFF: 10.2-178
PRODUCTION
INDUSTRIES (I) LTD
(TUBE DIVISION) BASE SCREW JACK
MURBAD
W/O NO:
System: Techring Scaffolding.
Product No:
Drawing No: PD – 029-A005.
Description: Thread rolling
inspection.
Inspection characteristics:
(1). Wall thickness prior to the rolling: 4.80 + 0.20 / - 0.50.
(2). Out side Dia: 36.50 + 0.20 / - 0.50. (3) TPI: 3.50. (4) Length after rolling: 602 ± 5.
(5) Straightness should not be deviate more than 0.5 mm. (6) Visual appearance.
1 – 500 15 % 25 every 20 Min
501 – 3000 8 % 40 every 45 Min
3001 – 10000 5 % 50 every 50 Min
10001 – 15000 4 % 60 every 60 Min
Results A = Acceptable R = Rejected
SR SR SR
A R DATE TIME A R DATE TIME A R DATE TIME
NO. NO NO.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by:
TECHNOCRAFT WELDING PROCEDURE /
INDUSTRIES (I) LTD INSTRUCTIONS FOR
(TUBE DIVISION) TECHRING ADJUSTABLE DOC.CODE
MURBAD BASE JACK. QD: SCAFF: 91

QAM FM 0 22 MAR 2006 1 of 1
1. PURPOSE: -
To document welding procedure / instruction for Techring Adjustable Base Jack.
Primary : Welder.
3. PROCEDURE FOR WELDING: -

1. The parent material will free from rust grease etc.
2. Place the thread rolled pipe & base plate on rotating fixture and carried out welding with
required current & voltage. After welding inspect it for any welding defect like porosity,
excessive burr etc as per QR: SCAFF: 10.2 – 185. Testing of base jack will be as per QR:
SCAFF: 8.2.4 – 59.
3. WELDING DETAILS ARE AS GIVEN BELOW;
a. Machine: Auto welding.
b. Welding process: MAG.
c. Joint type: Fillet weld.
d. Welding torch angle: 450 (Work revolving and torch stationary)
e. Run: Single.
f. Size of filler metal: ∅ 1.2 mm wire.
g. Current (A) : 200 Amp.
h. Voltage (V): 22 Volt.
i. Type of current: DC.
j. Shielding: Co2
k. Filler metal classification & trade name: 1.2 mm – ESAB make as per AWS A5. 18: ER
70 S-6, DIN 8559:SG 3.

TECHNOCRAFT
PROCEDURE FOR 100 %
INDUSTRIES (I) LTD
VISUAL INSPECTION DOC.CODE
(TUBE DIVISION)
AFTER WELDING PROCESS QD: SCAFF: 101
MURBAD
PRODUCT: SCREW JACK.
QAM FM 0 27 MAR 2006 1 of 1
1. PURPOSE: -
To document welding procedure for 100 % visual inspection after welding process of Techring
Screw jack.
3. PROCEDURE : -
100 % Inspection is carried out on scaffold items after welding of base plate with jack
screw. During this inspection Q.A.Inspector comes and carries out periodic inspection on
the samples selected as per sampling plan. Frequency of the periodic inspection will be
a. Check the welding performance. And the weld defect such as crack, porosity, blowholes,
under cut and incomplete weld etc.
b. Base plate not be bend after the welding.
c. Check the nuts have 2 Digit manufacturer’s marking.
d. Jack screw should be right angle with the base plate.
e. Record your observation, accepted and non-conforming quantity in QR: SCAFF:10.2-185.

INDUSTRIES (I) LTD SCREW JACK WELDING
(TUBE DIVISION) INSPECTION REPORT.
MURBAD
W/O NO:
Techring Scaffold
Drawing No: PD–029-A005.
Product code:
Item description: Welding of screw
jack.
Inspection characteristics: 100 % welding inspection, Base plate observation,.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by:
TECHNOCRAFT WORK INSTRUCTION FOR
INDUSTRIES (I) LTD LOAD TEST ON DOC.CODE
(TUBE DIVISION) ADJUSTABLE BASE SCREW QD: SCAFF: 98
MURBAD JACK
REVISION
STATUS
Page
QAM MR 15 APR, 2006 0
1 of 2
APPENDIX - G
TEST FOR ADJUSTABLE BASE SCREW JACK
G1. Scope: This appendix sets out the method of determining the strength of an adjustable leg.
An adjustable leg for testing purposes to gauge the effect of an eccentric load on the leg.
G2. Principle: The adjustable leg has one end fitted inside a scaffold tube with the maximum
extension of thread shank projecting. A predetermined force is applied to the assembly. The
strength of the adjustable leg is measured as a function of the movability of the adjusting nut
and straightness of the shank after the load is removed.
G3. Apparatus: The following apparatus is required:

(a) A device capable of applying a compressive load between two platens as shown in figure 15.
(b) A 300 mm minimum length of scaffold tube with ends square to tube axis.
(c) A steel plate tapered to a slope of 1 in 10.
G4. Procedure: The procedure is as follows;

(a) Set the adjusting nut of the adjustable leg to the maximum working extension of the shank.
Check the straightness of the shank in three positions 450 apart and record any deviation.
(b) Fit the tube over the adjustable leg and place the assembly on the tapered plate between the
testing machine platens.
(c) Measure and record distance between the underside of the adjusting nut and lower machine
platen.
(d) Apply a force of 60 KN for a period of 15 min.
(e) Remove the force, measure and record the distance between the underside of the adjusting
nut and lower machine platen.
(f) Measure and record the straightness of the shank in the same positions as before the test.
(g) Determine and record the ease with which the adjusting nut can be turned by the full depth
of the nut upwards and downwards from the test position.
G5. Report: The report shall include the following information;

(a) Manufacturers identification of adjustable leg.
(b) Detailed and numbered drawing of the adjustable leg or base plate.
(c) A detailed description, drawing or photograph of the force transmitting apparatus.
(d) Location of testing facility.
(e) Date and time of the test.
(f) Names, positions and qualifications of personnel carrying out or supervising the test.
(g) Names, positions and qualifications of witnesses, if any, to the test.
(h) Each page of report shall be singed and dated by the person responsible for the test.
(i) The test force applied to the adjustable leg assembly.
TECHNOCRAFT WORK INSTRUCTION FOR
INDUSTRIES (I) LTD LOAD TEST ON DOC.CODE
(TUBE DIVISION) ADJUSTABLE BASE SCREW QD: SCAFF: 98
MURBAD JACK
REVISION
STATUS
Page
QAM MR 15 APR, 2006 0
2 of 2
(j) The vertical deflection of the adjusting nut, the change in straightness of the shank, and the
ease with which the adjusting nut can be turned by hand for the full depth of the nut upwards
and downwards from the position.
(k) A statement whether the adjustable leg or base plate has failed or not failed. Failure is
determined by
(i) the change in straightness of the shank if it exceeds 2 mm; or
(ii) the inability to turn by hand the adjusting nut for the full depth of the nut upwards and
downwards from the test position.
(l) A reference to this test method, i.e. AS 1576.2, Appendix G.
CONNECTED RECORD:
i). QR: SCAFF: 8.2.4 - 59

TECHNOCRAFT INDUSTRIES (I) LTD QR: SCAFF: 8.2.4-59 (2006 04 20)
(TUBE DIVISION) LOAD TEST ON ADJUSTABLE
DATE OF TESTING:
MURBAD. BASE JACK
TIME:
WELDING PROCEDURE: REFERENCE DOCUMENTS: LOCATION OF TESTING: PHYSICAL AND
SAMPLING: ONE PER SHIFT 1. QD: SCAFF: 98. CHEMICAL TESTING LABORATORY –
2. APPENDIX G TO AS/NZS 1576.2-1991. TECHNOCRAFT TUBE DIVISION, MURBAD.
Sl. METHOD OF
No. CHARACTERISTICS SPECIFIED REQUIREMENTS INSPECTION / TEST RESULTS REMARKS
INSTRUMENT
1 VISUAL INSPECTION OF NO CRACK IN WELD METAL, HEAT
WELD PRIOR LOAD TEST. EFFECTED ZONE AND PARENT VISUAL
METAL. NO POROSITY, BLOW
SATISFACTORY
HOLES AND UNDER CUTTING.
2. LOAD TEST ON ADJUSTABLE
BASE JACK. UTM, DEFLECTION UNDER LOAD
a. AXIAL FORCE 60 KN VISUAL, DIAL 1 MM. RECOVERY 100 %
i). LOCATION OF NUT 150 MM BELOW THE TOP END OF GAUGES AFTER RELEASING LOAD.
THE ADJUSTABLE BASE JACK.
NUT ROTATES FREELY
ii). HOLDING TIME OF 15 MINUTES ALONG THE LENGTH OF THE
LOAD. SCREW.
iii). DEFLECTION UNDER THERE SHOULD BE NO
LOAD. PERMANENT DEFLECTION
b. TEST LOAD UNTIL FAILURE TEST LOAD AND NATURE OF PERMANENT DEFLECTION IS
OCCURS. FAILURE SHOULD BE OBSERVED UTM, 2.3 MM. ULTIMATE LOAD IS
AND RECORDED. VISUAL, DIAL 125 KN. NUT DOES NOT
i). LOCATION OF NUT AT THE MIDDLE OF THE GAUGES ROTATE FREELY ALONG THE
ADJUSTABLE BASE JACK. LENGTH OF THE SCREW. NO
ii). DEFLECTION DEFLECTION SHOULD BE SIGN OF CRACK IN WELD &
MEASURED AND RECORDED. MATERIAL.
CONCLUSION: WHETHER THE ADJUSTABLE BASE JACK PASSED OR FAILED THE TESTS AS PER APPENDIX – G TO AS/NZS 1576.2-1991:
TEST CARRIED OUT BY:
SIGNATURE: NAME: QUALIFICATION: POSITION: DATE: QAM
86_QR SCAFF 8.2.4-59(TR).DOC

TECHNOCRAFT IN-PROCESS INSPECTION QR: SCAFF: 10.2-193
MURBAD TECHRING SCREW JACK.
W/O NO:
Techring Scaffold
Product code:
Item description:
Process: In-process inspection of
galvanized screw jack.
Inspection characteristics: 1. Visual inspection of the galvanizing free of defects
such as the zinc burs, color deviation, black spot, excessive zinc deposit and
roughness…; 2. Verify the zinc layer not less than 75µm; 3. Nut should br rotate
freely; 4. Manufacturer’s 2 digit marking on nuts.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by:
TECHNOCRAFT SCREW JACK NUT QR: SCAFF: 10.2-186
INDUSTRIES (I) LTD ASSEMBLY AND
(TUBE DIVISION) COMPRESSION
MURBAD NOTCHING INSPECTION
REPORT.
W/O NO:
Techring Scaffold
Product code:
Item description: Screw jack of
notching inspection.
Inspection characteristics: Free movement of nut assembly inspection, Notching
distance 150 MM.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No. No. No.
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by:
TECHNOCRAFT
(TUBE DIVISION) INSPECTION OF DOC.CODE
MURBAD ADJUSTABLE BASE JACK. QD: SCAFF: 93

QAM FM 0 25 MAR 2006 1 of 1
1. PURPOSE: -
To document welding procedure for final inspection of Adjustable Base Jack.
3. PROCEDURE : -
Select number of sample as per sampling plan and carry out visual inspection described as
below. Following the sampling plan given in accordance QR: SCAFF: 10.2-189.
a. There shall be no any type of mechanical damages in thread, nut and plate.
b. Nut should be rotate freely up and down on entire length of the screw.
c. Straightness should not deviate 0.02” (0.508 mm) on the length of adjustable base jack.
d. Observation of weld;
- No cracks in weld metal and parent metal
- No porosity, blow holes and excess under cutting in the weld.
- Weld should be uniform.
e. No excessive zinc deposited on the any part and the areas where the excessive zinc is
cleared should be zinc painted.
f. Ensure that bundle taken for inspection, have correct quantity as stated in the packing slip.
Also ensure numbers of the bundles as per customer requirement.
g. Length of the articles shall be conformed as per customer requirement.
h. Stamping of the manufacturers name on the nut, shall be ensured. It should be in two
digits.
i. QR: SCAFF: 10.2-189 will be used for recording your observations.

INDUSTRIES (I) LTD FINAL INSPECTION
(TUBE DIVISION) REPORT OF SCREW JACK.
MURBAD
W/O NO:
Techring Scaffold
Product code:
Item description: 100 % inspection
Inspection characteristics: 1. Visual inspection Hot-Dip Galvanizing; 2. Bundle
count correct; 3. Excess zinc removal and it’s zinc painting: 4. Length = 610.0;
5. Base plate; 6. Welding; 7. Lock notching; 8. Manufacturer’s 2 digit marking on
nuts.
1 – 500 15 % Every 60 Min
501 – 3000 8 % Every 60 Min
3001 – 10000 5 % Every 60 Min
10001 – 15000 4 % Every 60 Min
Sr. Sr. Sr.
No.
A R Date Time No.
A R Date Time No.
A R Date Time
1 16 31
2 17 32
3 18 33
4 19 34
5 20 35
6 21 36
7 22 37
8 23 38
9 24 39
10 25 40
11 26 41
12 27 42
13 28 43
14 29 44
15 30 45
Inspected by:
TECHNOCRAFT INDUSTRIES (I) LTD Amendment – 1 DOC.CODE
(TUBE DIIVSION) To QP: 8.3
MURBAD. PROCEDURE FOR CONTROL OF NONCONFORMING
PRODUCT
MR FM SEPTEMBER 23, 2002 0 Page 1 of 1
TABLE – 1
Sr Process Nature of defect Controlling Procedure Related Rework / Reviewed by
No. stage / area responsibility reclassification /
rectification /
(Primary) reprocess/ concession/ Reverification
Re-testing Test Result
a. b. c. d. e. f. g. h.
1. INCOMING Characteristics Lot failed in any relevant test will be Refer Retest (Refer F.M. Relevant Yes - Allow
MATERIAL those are kept separate with proper identification Annexure – 1 QW: 7.4.3A for Retest for subsequent
STAGE described in and with red label and furnished NC of QD-01- Acceptance and processing.
relevant plan of report QR: 8.3-02. QAM (H1) Rejection criteria
the incoming of the incoming No - Reject
product product)
TECHNOCRAFT INDUSTRIES (I) LTD QR: 8.3-02 (2002 07 15)
(TUBE DIVISION) NON CONFORMITY REPORT (NCR)
MURBAD – 421401 DATE: -
[INCOMING STAGE]
NAME OF THE SUPPLIER: NAME OF ITEM: DOC. CODE- SHIFT: -
QP: 8.3, QP: 8.5.2, Traceability Code: -
INVOICE NO. & DATE: TOTAL QTY. RECEIVED: QM: 8.3, QM: 8.5.2
Name of Tracea Nature of Cause of Controlling Corrective Responsibility who Procedure of Reviewing Concession
Item bility defect occurring defect procedure for action taken deal initially with given by
Methods (*) Reviewed by
non-conformity [M.D.(Mfg.)/
Code Non –conformity
No. F.M.]
Disposition Reverification
Test Result
Result of actions taken: Satisfactory/ Unsatisfactory (*)Method of Reviewing: Rejection / Rework /

Reclassification / Rectification / Reprocess/
Reviewing Corrective actions taken: Adequate/ Inadequate. Concession
Total non – conforming product :

Sorted out non – conformities:
Sorted out conformities: Chemist/ QA.Inspector Production I/C QAM Verified by
ANHUI RELIABLE STEEL TECHNOLOGY CO. LTD.
PROCESS FLOW CHART NO- 4
( FOR SAFEWAY CANADIAN PLANK )
START
END HOOK ALUMINIUM

PLANK SECTION
4.5 MM THK. RETAINER LOCK
1.7 MM THK.
INSPECTION INSPECTION INSPECTION
FREE GALVANIZING SHEARIGN OF SHEAT TO BROUGHTOUT ITEM

COIL TO ROLL FORMING SLITS WIDTH: 217 MM
BLANKING
SECTION CUTTING
INSPECTION
INSPECTION
INSPECTION 1ST FORMING INSPECTION
GRIPP HOLE PIERCING INSPECTION

INSPECTION
INSPECTION 2ND FORMING
INSPECTION
SIDE HOLE PIERCING INSPECTION
ELECTRO PLATING INSPECTION

INSPECTION
INSPECTION
RESTRICKING INSPECTION
RETAINER LOCK SIDE INSPECTION
(STRAIGHTNESS) HOLE TAPPING
INSPECTION
STAMPING INSPECTION
INSPECTION
INSPECTION
ASSEMBLY WITH PLANK, HOOK,

INSPECTION
RETAINER LOCK AND BOTH SIDE
BUTON HEAD WITH SELF JAMNUT.
INSPECTION
CUSTOMER
LABELING
INSPECTION
FINAL INSPECTION
INSPECTION
INSPECTION
DISPATCH
END
Page 1 of 1
TORQUE ITEM 6 IN TAPPED
34.9 38.1 HOLE TO 15-17 FT LBS PRIOR
Ø8.0 A
22.2 TO INSTALLATION OF NUT
AND WASHER
1.5 'OR 1.0
Typ.
34.9
Typ.
34.9
Typ.
28.6
241.3
Typ.
28.6
1.59
Typ.
34.9
TYP
1.5 'OR' 1.0
Typ.
34.9
22.2 25.4
76.2 76.2 PLAN A
304.8 (Typ.)
A
B
WIND LATCHES ITEM 3 MUST
SLIDE FREELY FROM OPEN
TO CLOSED POSITION
S TI 06 08 XXX
47.6 31.8 47.6

ELEVATION
127.0 247.65
NOTES:
10 DIGIT IDENTIFICATION CODE TO BE STAMPED
241.3 IN LOCATIONS SHOWN (MIN 6mmTEXT HEIGHT).
S- CUSTOMER CODE.
TI-FIRST TWO DIGITS: VENDOR ID.
06-NEXT TWO DIGITS: MONTH OF MANUFACTURE
69.8
66.6
08-NEXT TWO DIGITS: YEAR OF MANUFACTURE
XXX-LAST THREE DIGITS: STEEL COIL NO./HEAT NO.
30.6 MUST BE LEGIBLE AFTER HOT DIP GALVANIZING.
Section: "A-A"
Changed drawing-from pan head 6-lobe screw to button head cap screw
& change lg from 1" to 1.25" & washer added
Changed the drawing to suit latest revised drawing of Item:2 [Rev.5]i.e.Plank Hook.
5/16"-18TPI-UNC x 1.25" LG.
5/16"-18TPI-UNC x 0.75" LG.

CANADIAN STYLE
Z:\TSD\TECHRING\TSI\TRL-US-6000 DRG.
241.3 ±0.6
135.6 [I.P.]
"D"
99.6 15.9
-0.8
92.6 [I.P.]
6.3 +0.0
1.6 ±0.1
P.
26.0
TY
18.9[I.P.]
33.3 ±0.4
241.3 +0.8
-0.0
+0.8
50.9[I.P.]
69.8
18.0
66.6 -0.0
6.3 +0.0
-0.8
INNER SIDE
17.9
2.38
TYP.
Ø9.53
19.2
Ø8.8 ±0.2
30.6 Ø19.05
Detail: "D" I.P. - Intersection Point
1.6 ±0.1
SLIT WIDTH (SIZE-482x1.6x"B")
1) ALL DIMENSION ARE IN MM.
Z:\TSD\TECHRING\TRL-US-6000-5 DRG.
38.1
216.2
R9.5 27.2 3.2
193.8 16.0
182.5
12° REF.
119.6
51.6 48.2
3.2
33.1
R6.4
12.7 REF.
29.9
9.2
21.3 (WHILE IN FLAT)

1.59 REF. R3.2 TYP. Ø15.9 DISTORTION OK TYP . (Scale: 4:1)
(Scale: 2:1)
132.1 (Ref.)
+1.3
71.8-0.3
47.63 0.38
R1.6 TYP. Ø49.5
12.7 42.4
96.8
101.2 REF.
47.6
TAPPED HOLE
71.0
65.1
THIS SIDE ONLY 1.59(Ref.)
60.3 REF.
25.4
19.1
STAMP ID
20.6
12.2 TYP.
23.2
33.4 (Typ.)
22.2
41.2
184.1 Ø6.65/Ø6.48
5°(Ref.)
Tap the Holes after
203.2 Galvanising to 5 /16-18UNC
29°(In Flat)
237.5
225.4
(Scale: 2:1)
R3.2 (Typ.) 6.0 6
Ø8.73 HOLE
10.4 TYP. 46.3
R4.8 12.7 ONE SIDE ONLY
TYP.
6.4
46.7 TYP.
TAPPED HOLE
66.6 TYP.
10.9 15.9
THIS SIDE ONLY TYP.
19° 104.7
4.5 0.22 MM
THK. REF.
42.4 (Typ.)
+0.4
40.83-0.8 (Typ.)
1.59 (Ref.)
1.54 (Typ.)
6
6
23.2 (Typ.)
(Scale: 1.5:1)
Ø49.5 (Typ.)
Z:\TSD\TECHRING\TRL-6000-2
01-QR-SCAFF: TRL-US-6010-5-S (2011 09 20 ) Rev. 0
ANHUI RELIABLE STEEL SPECIFICATION CUM INSPECTION REPORT OF FORMING OF STEEL CYCLE TIME:
TECHNOLOGY CO. LTD. PLANK OF TECHRING SYSTEM Production as per cycle time on 100 % efficiency:
Production as per cycle time on 85 % efficiency:
Production Production In Min. inspection
CUSTOMER: W.O.NO: ORDER QTY: Qty / Lot
Inspection Qty. Nos/ Pcs qty
PLEASE REFER THE MASTER SAMPLE AT COMMENCEMENTS OF PRODUCTION AND FILL UP THE FIRST
OFF INSPECTION COLUMN.
1 – 500 10 % Traceability code/Heat No.
NOTE: THE FIRST OFF INSPECTION SHOULD BE DONE AND SIGNED BY TWO PERSON i.e. Q.C. INSPECTOR & Date:
501 – 3000 6% Shift:
SUPERVISOR AND THEN STARTS THE PRODUCTION IF IT FOUND OK.
Drawing No: TRL-US-6010-5-S (Rev. 0) 3001 – 10000 5%
New Drawing No: 10001 – 150000 4%
DESCRI OPERA SR. CHARACTERIST METHOD OF FRE 1st Observed values (Min. –Max.)
NO. SPECIFIED VALUES INSPECTION QUE
OFF Remarks
PTION TIONS ICS /INSTRUMENT NCY 1 2 3 4 5 6 7 8
Steel Pre 1 Slit width 465.0 ±1,0 Measuring tape
Each lot
plank inspectio Sheet thickness 1.7 ± 1.0 Micrometer
n Surface finish Surface should be free from such
Bending imperfections like surface lamination, pits, Visual
operation black spot and chamber, etc.
Steel 2 Height of legs 19.20 ± 0.8 Vernier
board 3 Width of bending 30.60 ± 0.8
Material Vernier
Roll (inside)
grade: forming 4 Height of steel plank 69.80 ± 0.8 Vernier
Q235 5 Inside height of steel 66.40 + 0.8 / - 0.0
plank
Vernier
TS- 340- 6 Width of steel board to 241.3 ± 0.6 Vernier / right
and bottom side both end
470 Mpa. face must to be parallel. angel / visual
YS- Min. 7 Width of plank center 15.90 ± 0.8 Vernier / snap
235 Mpa. grove. gauge
Elong. 8 Groove depth 6.3 + 0.0 / - 0.8 Vernier
Min. 24 9 Center distance of 33.2 ± 0.4
groove from inside
Vernier
%
10 One side Distance form 135. 6 ± 0.8
grove opposite end to Vernier
Hourly
plank end.
11 Center width of side grove 18.0 ± 0.8 Vernier
12 Distance from plank top 18.9 ± 0.8
end to grove first curve
Vernier
end to grove second curve
Vernier
end to grove fourth curve
Vernier
0
15 Workmanship of plank Section should come in 90 ± 0.8 of all Right angle /
section four side. Visual
16 Length of steel plank Bay Size Length
Part No.
TRL-US-6011-1 0.65 Mtr 565.20 + 2.0 / -0.0
TRL-US-6012-1 1.15 Mtr 1065.20 + 2.0 / -0.0 Measuring tape
TRL-US-6013-1 1.57 Mtr 1487.20 + 2.0 / -0.0
TRL-US-6014-1 2.13 Mtr 2045.20 + 2.0 / -0.0
17 Surface finish No material crack and No rough
Visual
surface on forming area.
18 Max. Twist / bend / diagonal dimension should be controlled with Plan surface +
1.0 mm. / MTR. Length of plank. Filler gauge
INSPECTED BY:
NAME :
SIGNATURE : PRODUCTION INCHARGE : QAM
02-QR-SCAFF:TRL-US-6014-1 (2011 09 20) Rev. 0
ANHUI RELIABLE STEEL SPECIFICATION CUM INSPECTION REPORT OF GRIP HOLE PIERCING CYCLE TIME:
TECHNOLOGY CO. LTD. OF STEEL PLANK OF TECHRING SYSTEM Production as per cycle time on 100 % efficiency:
Production Production In Min. inspection
CUSTOMER: W.O.NO: ORDER QTY: Qty / Lot
Inspection Qty.
Nos/ Pcs qty
PLEASE REFER THE MASTER SAMPLE AT COMMENCEMENTS OF PRODUCTION AND FILL UP THE FIRST OFF
INSPECTION COLUMN.
501 – 3000 6%
SUPERVISOR AND THEN STARTS THE PRODUCTION IF IT FOUND OK. Shift:
Drawing No: TRL-US-6014-1 (Rev. 0) 3001 – 10000 5%
New Drawing No: 10001 – 150000 4%
DESCRI OPERA SR. METHOD OF FRE 1st Observed values (Min. –Max.)
NO. CHARACTERISTICS SPECIFIED VALUES INSPECTION QUE Remarks
PTION TIONS NCY OFF
/INSTRUMENT 1 2 3 4 5 6 7 8
Steel Pre 1. Length of steel plank Part Bay Size Length
plank inspectio No.
grip hole n TRL-US-6011-1 0.65 Mtr 565.20 + 2.0 / -0.0
Measuring tape
Each lot
TRL-US-6012-1 1.15 Mtr 1065.20 + 2.0 / -0.0
piercing
TRL-US-6013-1 1.57 Mtr 1487.20 + 2.0 / -0.0
TRL-US-6014-1 2.13 Mtr 2045.20 + 2.0 / -0.0
Sheet thickness 1.70 ± 0.1 Micrometer
Material Surface Surface should be free from such imperfections
grade: like surface lamination, pits, and chamber, etc. Visual
finish
Q235 Steel 2. Hole dia Ø 9.53 ± 0.2 Vernier
board 3. Dia of projected hole Ø 19.05 ± 0.2 Vernier
grip hole 4. Height of projection from 2.38 ± 0.2
Vernier
piercing steel plank
5. Pitch of hole le longitudinal 38.10 ± 0.2
Vernier
direction
6. Pitch of hole transverse 35.0 ± 0.2
direction
Vernier
7. First center hole distance 34.90 ± 0.2
from plank end.
Vernier
8. Last center hole distance 29.0 ± 0.2 (Ref.)
from plank end.
Vernier
9. Plank height side hole size Ø 8.7 ± 0.2 (4 Nos.) Vernier
10. Plank height side hole 47.6 (Typ.) plank end to hole
position
Vernier
center distance
Hourly
11. Width wise distance from 1st Hole – 22.20
hole center to plank end both 2nd Hole – 57.20 Vernier
sides. 3rd Hole – 92.10
12. Center hole in grove distance 25.4 ± 0.2
from plank end to hole Ǿ 8.0 Vernier
center and hole dia
13. Pitch of center hole and 4th 76.20
Vernier /
hole center from 1st hole 304.8 (typ)
center distance . measuring tape
14. ∅ 9.53 mm hole distance from
Should not be extreme end Visual / Measuring
end width wise should be
(Maintain pitch distance) tape
equal length.
15. After hole punching width. 241.3 ± 0.8 Vernier
16. Surface finish No burr, No material crack and No
rough surface on punched area.
Visual
17. Max. Twist / bend / diagonal dimension should be controlled with Plan surface +
1.0 mm. / MTR. Length of plank. Filler gauge
18. Stamping on 9 digit identification code to be stamped in
steel plank location shown in drg. At 2 places (Min. text Visual
height 6 mm) TI 10 11 XXX (Heat No.)
INSPECTED BY:
NAME :
03-QR-SCAFF: TRL-US-6010 (2011 09 20) Rev. 0
ANHUI RELIABLE STEEL SPECIFICATION CUM SUB ASSEMBLY AND FINAL INSPECTION REPORT CYCLE TIME:
TECHNOLOGY CO. LTD. OF STEEL PLANK OF TECHRING SYSTEM Production as per cycle time on 100 % efficiency:
Min. inspection
CUSTOMER: W.O.NO: ORDER QTY: Production Qty / Lot Inspection Qty. Production In Nos/ Pcs
qty
PLEASE REFER THE MASTER SAMPLE AT COMMENCEMENTS OF PRODUCTION AND FILL UP THE FIRST
OFF INSPECTION COLUMN.
501 – 3000 6% Shift:
SUPERVISOR AND THEN STARTS THE PRODUCTION IF IT FOUND OK.
Drawing No: TRL-US-6010 (Rev.0) 3001 – 10000 5%
New Drawing No: 10001 – 150000 4%
DESCRI OPERA SR. CHARACTERISTI METHOD OF FRE 1st Observed values (Min. –Max.)
NO. SPECIFIED VALUES INSPECTION QUE
OFF Remarks
PTION TIONS CS /INSTRUMENT NCY 1 2 3 4 5 6 7 8
Final Final 1 Hook assembly Hook should be fit in properly in the plank.
inspectio inspectio Assembly of hook with plank with socket button head
n cap screw should be assembled right side. Opposite
n steel side of hook socket button head, hook, retainer lock
plank. with washer and self locking jam nut with washer
Visual
should have little gap max 1 mm for free moment of
retainer lock.
Steel Check there should not any twist in the hook.
plank Check the hooks pipe setting end (bend one and other
Material small straight end is as per the drawing)
grade: 2 Center distance of plank
Part no. Bay size C/C Distance + 2.0/-0.0
Q235 TRL-US-6011-1 0.65 Mtr 650.0 mm
TRL-US-6012-1 1.15 Mtr 1150.0 mm Measuring tape
TRL-US-6013-1 1.57 Mtr 1572.0 mm
Hook TRL-US-6014-1 2.13 Mtr 2130.0 mm
material: TRL-US-6015-1 3.05 Mtr 3051.0 mm
Hourly
grade: 3 Width of steel board 241.3 ± 0.8 Vernier
Q235 4 Height of plank 69.80 ± 0.8 vernier
5 Workmanship of plank Section should come in 900 ± 0.8 of all four Right angle /
section sides. Visual
6 Hook thickness 4.5 ± 0.22 Visual
7 Stamping on hook J11TI Visual
J=Month, 11=Year and TI=Manufacturer
8 Stamping on steel plank (9
Digit identification code to
be stamp in locations shown TI XX XX XXX Visual
in Drawing (Min. 6.0 text
height)
9 Customer requirement
Label
CUSTOMER LABEL NO. 7112A0105 Visual
10 Max. Twist / bend / Should be controlled with 1.0 mm. / MTR. Plan surface +
diagonal dimension Length of plank. Filler gauge
11 Pre galvanizing Zinc coating should be free from such imperfections like zinc
flanking rough coating, black spots. No deposition of excess
performance zinc in any part or cavity. The areas cleaned by filing should Visual
get touch up with zinc rich paint.
12 Pre galvanizing 05.0 micron minimum Coating
coating thickness gauge
13 Fitment test (Refer Assembly 4 – 8 plank (as shown in figure) on assembly bay &
measure the followings
Every
the drawing)
shift
1. C/C Distance length wise. Visual /

2. C/C Width wise Measuring tape
3. Diagonal should be equal on both side.
4. Check for proper fitment.
INSPECTED BY:
NAME :
Singhania, QR scaff:TAPL-6014 rev.3 cut length QC form

ANHUI RELIABLE STEEL SPECIFICATION CUM INSPECTION REPORT 04_QR: SCAFF: TRL-US-6010-2 (2011 09 03)
OF HOOK FOR TECHRING STEEL PLANK Traceability code:
TECHNOLOGY CO. LTD.
CUSTOMER: W.O.NO: ORDER QTY:
PLEASE REFER THE MASTER SAMPLE AT COMMENCEMENTS OF PRODUCTION AND FILL UP THE FIRST OFF INSPECTION COLUMN
Drawing No: TRL-US-6010-2 (Rev. 0) PART NO: SIZE: Sample size: 5 pieces In-process Date:
All dimensions are in mm: - mention minimum and maximum values Shift:
SR. METHOD OF FRE ST
OBSERVED VALUES
1
NO. CHARACTERISTICS SPECIFIED VALUES INSPECTION QUE
OFF /INSTRUMENT NCY 1 2 3 4 5 6 7 8
1. Length of hook bottom side 237.50 ± 0.5 Vernier
Length of hook top side 225.40 ± 0.5 Vernier
2. Width of hook 132.1 (Ref) Vernier
3. Thickness of hook 4.5 ± 0.22 Micrometer
Ǿ 6.65 / 6.48 (Tapped hole a/f platting) Ǿ
8.73 only onside, position .from hole
4. Side hole dia and position center to top side 33.40 mm and from hole
Vernier
center to plank end 12.70 mm
5. Plank stopper to hook formed end 71.80 + 1.3 / - 0.3 Vernier
Plank stopper to back side end to hole
Hourly
6. center.
47.63 ± 0.36 Vernier
7. Height of grove 3.2 Vernier
8. Distance between both grove end to end 51.60 Vernier
9. Height bending end to inside plan end. 20.60 Vernier
10. Hook inside plan surface to pipe center 23.20 Vernier
Hole diameter of forming end Ǿ 15.90 Vernier
11. Hole distance from formed end 12.70 Vernier
Length X Width of ear and taper 10.6 X 16.00 Vernier
12. Height of ear 3.2 Vernier
13. Burr No burr excessive. Visual
Free from burr, die-punch marks,
14. Workmanship Visual
bending and twisting.
15. Check the hook profile matching with gauge. Hook profile should be match with gauge. Gauge.
Check by pressing with finger after over
16. There should not twist in the hook. machined bed.
Manually
17. Check the fitment with steel plank. It should be free movement. Manually
REMARKS: Total Production :
Accepted Quantity :
Rejected Quantity :
INSPECTED BY.
NAME :
SIGNATURE : PRODUCTION INCHARGE QAM
Note: Please took some photo and send India.
D:\Tech Ring Manual\95_04_QR-scaff-_TRL-US-6010-2 (steel_plank_hook).doc
LIST OF CANADIAN PLANK GAUGEES
SR DRG. NO. /
GAUGE DESCRIPTION
NO. GAUGE NO.
Snap gauge drawing of ﬂat hook & steel
1. GTRL-US-01
plank
Plank hook width checking gauge for TRL- GTRL-US-02-
2.
US-6000-2 00
Plank hook height checking gauge for TRL- GTRL-US-02-
3.
US-6000-2 A
Taper & Ǿ 6.7, 8.73 drill gauge (hook) for FTRL-US-02-
4.
TRL-US-6000-2 B-00
Plank sec on gauge a er sec on r oll i ng&
5. GTRL-US-03
before punching for TRL-US-6000-1-S
6. GTRL-US-03A
7. GTRL-US-03B
8. GTRL-US-03C
Plank sec on hei ght gauge for TRL - US - GTRL-US-03-
9.
6000-1-S D
Steel plank length checking gauge for TRL- GTRL-US-04-
10.
US-6000 00
Steel plank Ǿ8.80 hole checking gauge for GTRL-US-04-
11.
TRL-US-6000-5 A-00
Proﬁle checki ng for ret ai ner lock for TRL - GTRL-US-05-
12.
US-6000-3) 00
Steel plank bay size length checking gauge GTRL-US-06-
13.
for TRL-US-6000 00
GTRL-US-03-
14. Plank small hook height checking gauge
01
GTRL-US-10-
15. Plank small hook R 24.75 checking gauge
01
70.0 STEEL PLANK
SECTION
31.3 0.1
6.3 0.1
R3.2
R1.6 PLANK
25.0
18.5 0.1
0.1
56.4
31.2
HOOK
R3.2 6.3 0.1
R7.7
0.1
PLANK HOOK
18.5
GAUGE
100.0
3mm 'OR' 4mm thk
spring steel sheet metal
Z:\TSD\TECHRING\TSIGAUGES\GTRL-US-01
"GO" "NO GO"
226.17
224.57
67.11
"GO" "NO GO"
Z:\TSD\TECHRING\TSIGAUGES\GTRL-US-02-A
67.11
"GO" "NO GO"
67.11
66.14
100.00
"GO" "NO GO"

230.00
69.05
"NO GO"
" NO-GO"
170.00
"NO GO"
"NO GO"
145.00
70.55 69.05
"GO" "NO GO"
70.55
69.05
"GO" "NO GO"
235.00
70.55
"GO"
"GO"
170.00
70.55
"GO"
"GO"
145.00
Z:\TSD\TECHRING\TSIGAUGES\GTRL-US-02-B-00
Ø5.73
Ø7.73
200.00
67.11
32.00
33.40
Ø4
8 .4
0
32.00
PLANK BENT HOOK EDGE
SHOULD NOT MORE THAN
GAUGE EDGE. GAUGE EDGE
50.0
.5
49
Ø
6.0
125.0
MAT-SPRING STEEL
SCALE-1:1
SUR. FINISH-:
TOTAL QTY-02 NOS
01 FLAT 01 50 X 6 X 130 LG 00.30 KG
P.NO. DESCRIPTION MAT QTY. RAW MAT. SIZE WEIGHT
BILL OF MATERIAL
REV.
1OF1 0

-0.20
-0.20
-0.20
-0.20
-0.20
NOGOGAUGE
TRL-US-6001-1
+0.20
+0.20
GOGAUGE
+0.20
+0.20
+0.20
+0.20
TRL-US-6001-1
12.0
560.0
465.0
Z:\TSD\TECHRING\TSIGAUGES\GTRL-US-04-00
130.0
21.0
24.0
55.0
55.0
75.0
34.0
102.5
MAT-SPRING STEEL
150.0
A 01 02 A B
16.0 10.0
Ø14.0 Ø8.0
MAT-EN-8
150.0
A DOWEL PIN-Ø8X25 LG-02 NOS.

B ALLEN BOLT-M6X15 LG -04 NOS
TOTAL QTY-02 NOS
(TUBE DIVISION) MURBAD - 421 401

DRAWN SBS PROJECTION
PROFILE CHECKING GAUGE
DATE 10/02/12 FOR RETAINER LOCK.
SCALE 1:1.25 (TRL-US-6000-3)
APPD. N.MODI TOTAL WT.IN KGS. SHEET DRG. NO. / FILE NAME REV.
4.60KG 1OF1 0

-
13.0
465.0
591.0
Z:\TSD\TECHRING\TSIGAUGES\GTRL-US-09-00
70.0
28.0
15.5
15.5
Ø8.0
Ø8.6 47.6
66.6
= =
Ø8.0
125.0
47.6
70.0
66.6
4.6
5
4 .7
R2
50.0
75
25.4
.0
°
133.0
MAT-SPRING STEEL
SCALE-1:1
SUR. FINISH-:
TOTAL QTY-02 NOS
01 FLAT 01 50 X 6 X 130 LG 00.30 KG
P.NO. DESCRIPTION MAT QTY. RAW MAT. SIZE WEIGHT
BILL OF MATERIAL
REV.
1OF1 0

Acdc - Ringlock Manual Latest 25-02-2012

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Acdc - Ringlock Manual Latest 25-02-2012

Hochgeladen von

Copyright:

Verfügbare Formate

TECHNOCRAFT INDUSTRIES (INDIA) LTD.

INCOMING INSP HR COILS

SLITTING PROCESS BLANKING

BRACE SLOT PUNCHING

Tube ∅ 48.3 CSAG40.21 50,000

Vertical ASTM A36 (OR)

50,000 45,000 St 52.3(DIN)/ 60,000 75,000

Tube ∅ 48.3 CSAG40.21 50,000

Tube ∅ 48.3 CSAG40.21 50,000

D:\Tech Ring Manual\02_chart no. 1 steel grades.doc Page 1 of 1

a. Tube ST 46 CL 450 345 21 0.21(max.) 1.35(Max.) 0.40(Max.) 0.05(Max.) 0.04(Max.) ST 46 CL

3.0 MATERIALS TO BE TESTED :

iii) WIRE POOL 12.3 QN:SCAFF:

4.0 TEST PROCEDURE :

5.2 DIMENSIONAL AND VISUAL INSPECTION :

D. Record your observations in inspection form QR:10.1-01

5.3 CHEMICAL AND MECHANICAL TESTING :

7.0 PACKING PATTI : (FOR BUNDLES)

F. Cold -Weather impact testing (Tubes)

i] Specimen orientation with respect to the material axis

H. Cold -Weather impact testing (Rosette Material)

i] Specimen orientation with respect to the material axis

8.0 BOUGHT OUT COMPONANTS :

8.1 G.I./ M.S. SOCKETS :

E. UNIFORMITY OF COATING (CUSO4 TEST) :

8.2 PVC PROTECTOR :

A. INSIDE DIAMETER (MAX) :

i.] Hydrochloric acid Commercial Pickling

C. Refer QW: 10.1A to follow the test procedures.

D. To maintain working efficiency of the processes, above chemicals will also be

E. Record your observations in relevant inspection form as per given in plan

10. CUTTING TOOLS:

A. To comply with product requirements, functional test will be carried out on

CUTTING TOOL APPLICABLE TO

B. Personnel of concerned department will carry out functional test on respective

11.2 BOPP TAPE:

D. AIR BUBBLES (FISH EYES):

E. UNIFORMITY OF ADHESIVE COATING:

11.3 CORRUGATED BOXES:

G. Results will be recorded in inspection form QR: 10.1-38.

11.4 PALLETS: (WOODEN)

C. BOTTOM GAP FOR FORKS :

F. Observations will be recorded in QR: 10.1-39.

11.5 PACKING M.S. STRIP (BLACK) : (FOR PALLETS)

D. Observations will be recorded in QR: 10.1-40.

11.6 PVC STRAP:

G. Record your results in QR: 10.1-41.

11.7 G.I. CLIP / PAINTED M.S. CLIP:

G. Observations will be recorded in inspection form QR: 10.1-42.

11.8 WOOD ( FOR PACKING ):

12.3 WIRE POOL:

12.4 BOUGHT OUT COMPONENTS

12.4.2 Also refer QN: SCAFF: 8.2.4-1 to follow test procedures.

12.5 Rosette (Ring) :

i.] Q.A. Inspector – QD – 01 – QAM (H – 7)

ii.] Chemist – QD – 01 – QAM (H – 6)

iii.] Supervisor (Threading and Packing) QD- 01 – RMM (J-2)

iv.] QAM – QD – 01 SNR (H)

v.] Factory Manager – QD – 01 SNR (G)

vi.] Raw Material Manager (Packing In-charge) – QD 01 – SNR (E)

vii.] General Manager – QD – 01 – SNR (D)

i.] Tube Mill operators – QW: 7.5.1-2/2

ii.] Finishing Supervisor – QD: 01 – FM (G – 5)

Heat No: ____________________________ Work Order No. : _