AA_SBM-Quality Specification_main document_v3

SBM Quality Specification Main-Document (V3)1. General Information1.1. Aim of the SBM Quality Specification (SBM-QS)Generally, the purpose of an SBM Quality Specification is to describe the minimumtechnical requirements within a manufacturing process.1.2. Scope of validityThis SBM QS applies to all departments/divisions within the SBM Mineral Processingcompanyas well as to all of its suppliers and subcontractors.1.3. Areas of responsibilityThe Quality Management Dept. of SBM Mineral Processing is responsible forthis SBM QS. Requests for revisions and changes must be addressed to the QM(quality management) of SBM Mineral Processing.1.4. ValidityValidity must be checked with the author or purchasing department before use.It is the user's responsibility to check validity.Validity can be checked at the web page: http://www.sbm-mp.at, as well as atthe purchasing dept. or the QM of SBM Mineral Processing.2. Construction / Design2.1. Definition of construction tasks„Know How“ of design and construction should not be described in the SBMQS. There are special internal regulations for this such as. e.g. procedural/processinstructions and work instructions.Refer to: Work Instruction SBM_100_03_00_00 Preparation of Drawings3. WeldingFor this, refer to Annex 1 „SBM Quality Specification – Welding“4. PaintingFor this, refer to Annex 2 „SBM Quality Specification – Painting“5. GalvanizingFor this, refer to Annex 3 „SBM Quality Specification – Galvanizing“Print: 27.04.2010 Page 4 of 26

SBM Quality Specification Main-Document (V3)SBM Mineral Processing and its contractors are authorised to establish in anaudit whether the quality assurance measures of the supplier guarantee tomeet the customer requirements. The audit can be carried out as a system,process or product audit and its timing must be agreed upon before being car-Kommissions-NumberPart numberDrawingnumberpieceFigure 2 StücklisteProduct numberSignierposition7.4. Where is the marking to be made?On all existing assembly openings /boreholes.Interchangeable parts with the same Signierposition the same size, aregrouped together and labelled in one.8. Checking components8.1. Check of internal productionAccording to SBM test instructions.8.2. Check of external productionAll dimensions must be checked and documented according to SBM test protocols.The test protocols must be enclosed when delivering the accompanyingdocuments.If no test protocols are enclosed for an order then all dimensions that have tobe tested (marked on the drawings by a frame) must be checked and documented.The documentation must be handed over to SBM on request.8.3. AuditPrint: 27.04.2010 Page 6 of 26

SBM Quality Specification Main-Document (V3)ried out. Reasonable limitations of the supplier will be accepted to protect hisbusiness secrets.If quality problems arise caused by services or deliveries of a subcontractorthen the supplier is obliged to facilitate an audit at the subcontractor in question.8.4 Check of incoming goodsAccording to SBM procedural instruction VA 5.15.03 and the work instructions9. Transport and packaging9.1. Special instructionsThe contractor is responsible for selecting the right packaging and used materials.When delivering particle board, palettes, boxes, parts packaging, etc.,the packaging must be chosen based in weight and type of product delivered.This is the minimum requirement for packaging. If, in the experience of thecontractor, additional requirements are necessary to protect the goods thenthese should be made on agreement with SBM.The contractor must use economical and space-saving packaging.Generally, the packaging must be so designed that the goods packaged andthe packaging itself can be transported and stored without being damaged.Additionally, the packaging must be able to withstand handling during transport.Small parts (screws, nuts, washers, etc.) should be packaged in a plastic bag.Special care must be taken regarding corrosion protection and the selection ofthe right packaging due to the effects of the climate during sea transport (e.g.contact with seawater, condensate, salty air temperature fluctuations).The marking and description of the content of the package must be completeand must exactly match those in the packaging lists.A copy of this packaging list must be attached to the package in a waterprotectedbag.When securing goods with steel strapping, wood or plastic should be used foredge protection.When packaging, pay special attention (e.g. for steel structures) to make surethat components are gathered together in their respective groups.Print: 27.04.2010 Page 7 of 26

SBM Quality Specification Main-Document (V3)9.7. Packaging categoriesCategory Type of packagingPC 0 Not packagedPC 1 Shrunk in PE filmPC 2 Cardboard packagingPC 3 Still platePC 4 PalettesPC 5 Normal wood box without liningPC 6 Wood box prepared for sea transport with liningPC 7Wood box prepared for sea transport with lining andshrink-wrapPC 8 Shippers Own ContainerTable 2: Packaging categories9.8. Packaging matrixGeneral InformationThe packaging category is determined based on the packaging matrix (type oftransport for goods class).If several carriers are used to transport the goods then packing must be madeaccording to the highest packaging category/transport class.Methods of transportLorry Rail Sea Container AirGoods class(GC)Packaging category (PC)GC 1 0, 1, 3, 4, 8 0, 1, 3, 4, 8 1, 3, 6, 8 1, 3, 5 2, 4, 5GC 2 0, 2, 3, 4, 5, 8 2, 3, 4, 5, 8 3, 6, 8 2, 3, 4, 5 2, 3, 4, 5GC 3 2, 5, 8 2, 5, 8 6, 8 2, 5 2, 5GC 4 2, 4, 5, 8 2, 4, 5, 8 6, 8 5, 6 2, 4, 5GC 5 2, 4, 5, 6, 8 2, 4, 5, 6, 8 6, 7, 8 6, 7 2, 4, 5, 6GC 6 2, 4, 5, 6, 8 2, 4, 5, 6, 8 6, 7, 8 6, 7 4, 5GC 7 The legal requirements must always be observed!Table 3: Packaging matrix9.8.1. Packaging category PC 0: No packagingComponents are not packaged.During the loading, make sure that all parts are protected so that they can notdamage each other by the transport (wood, rubber, edge protection, etc.). Thecorresponding charging fuse may not lead to damage of the parts. Furthermore,the cargo must be able to be unloaded with a forklift, wood (minimum10 cm) has to be used.Print: 27.04.2010 Page 10 of 26

SBM Quality Specification Main-Document (V3)9.8.2. Packaging category PC 1: Shrunk in PE filmFigure3: Shrinking9.8.2.1. Instructions on shrink-wrappingA special PE shrink foil must be used to be able to shrink machine parts. This isplaced flat over the surface of the object to be packed and tacked at the bottomon wooden supports on the pallet, when applicable.The shrink foil is then evenly heated using a gas burner or electrical heater.When doing so, make sure that the heater is not held too long at the same lo-Print: 27.04.2010 Page 11 of 26

SBM Quality Specification Main-Document (V3)cation but instead is used with brushing strokes over the whole surface of thefilm.The plastic becomes soft when heated and then clings to the object to beshrunk. After cooling down, the film is tight around the packaged goods and ismuch harder than when raw. If holes are created when shrinking then theseshould be closed with tape.9.8.3. Packaging category PC 2: Cardboard packagingSmall parts and spare parts for transport within Europe or air shipments shouldbe packaged in stable cardboard boxes of conventional design, as long as theyare suitably dimensioned. The boxes must be wrapped with steel or polyesterstraps if the gross weight is 25 Kg or more. One-way pallets or europalletsmust be placed under the boxes when they are between 25 and 1000 kg gross.Figure4: PC 29.8.4. Packaging category PC 3: Still plateThis packaging category must be combined with Packaging Category PC 1.Usage:For cylindrical or similar goods.Each opening must be closed watertight, e.g. with plus, protective caps madeof metal or plastic, or larger openings using dummy flanges.Containers and apparatus with their own stands must be equipped with awooden base (at least 30 mm) for slip protection.Print: 27.04.2010 Page 12 of 26

SBM Quality Specification Main-Document (V3)Figure5: Design of still plate9.8.5. Packaging category PC 4: PalettesPallets or suitable wooden constructions must be prepared for goods that cannotbe packaged in boxes due to their size, to allow these to be moved withfork-lifts.Preferably, europallets acc. to Austrian Standard ÖNORM A 5300 or DIN15146-2 should be used.The woods used to produce the packaging must be treated compliant to IPPCStandard.Parts are fixed using a suitable steel strap, plastic strap or screws to ensurethat they cannot slip. The parts must be suitably protected from damagescaused by the fixing material.A suitable barrier, e.g. antislip mat or similar, must be placed between thegoods and the wood packing.Recommended number of wooden supports for pallets:Print: 27.04.2010 Page 13 of 26

SBM Quality Specification Main-Document (V3)Figure6: Recommended number of wooden supports for pallets9.8.6. Packaging category PC 5: Normal wood box without liningThe design of the box must always be made taking into account the total grossweight of the goods.9.8.6.1. Floor of boxLongside runner at least 80 mm thick, floor boarding at least 24 mm thick.For boxes > 5t and/ or width > 2000 mm: Front wall of timber beam boltedonto longside runner (screw through both parts with washer + nut)Transverse and base runners up to 5t 100 x 100 mm thick, from 5 t, 100 x 120mm thick, must be bolted on with longside or intermediate runners or must besecurely nailed on several times.Transverse, base runner securing wood: Width as longside runner, height 100mm, length 400 – 1000 mm, the width of one fork-lift fork must remain free.Print: 27.04.2010 Page 14 of 26

SBM Quality Specification Main-Document (V3)From 2 t: Longside runner, securing wood or bar: Height as longside runner,width 80 mm, length according to width of box.Special instructions for packaging heavy cargo > 5 t:The boxes must be equipped with special heavy cargo fittings or box bracketsfor heavy cargo packaging.9.8.6.2. Side walls, face walls and lidMust be designed according to the requirements.For boxes > 2 t and / or length > 3000 mm then timberlike reinforcement isrequired.9.8.6.3. Bearing pressure of packShackle frames, diagonals and wooden pressure lids must be designed for apack bearing pressure of at least 1 t/m². The wooden pressure lids incl. thewooden pressure lid supports must be included at distances of 600 - 700 mmand nailed onto side panels.Figure7: Boxes with lids9.8.7. Packaging category PC 6: Wood box prepared for sea transportwith liningThe design of the box must always be made taking into account the total grossweight of the goods.9.8.7.1. Floor of boxLongside runner at least 80 mm thick, floor boarding at least 24 mm thick.Print: 27.04.2010 Page 15 of 26

SBM Quality Specification Main-Document (V3)For boxes > 5t and/ or width > 2000 mm: Front wall of timber beam boltedonto longside runner (screw through both parts with washer + nut)Transverse and base runners up to 5t 100 x 100 mm thick, from 5 t, 100 x 120mm thick, must be bolted on with longside or intermediate runners or must besecurely nailed on several times.Transverse, base runner securing wood: Width as longside runner, height 100mm, length 400 – 1000 mm, the width of one fork-lift fork must remain free.From 2 t: Longside runner, securing wood or bar: Height as longside runner,width 80 mm, length according to width of box.Special instructions for packaging heavy cargo > 5 t:The boxes must be equipped with special heavy cargo fittings or box bracketsfor heavy cargo packaging.9.8.7.2. Side walls, face walls and lidMust be designed according to the requirements.For boxes > 2 t and / or length > 3000 mm then timberlike reinforcement isrequired.9.8.7.3. Bearing pressure of packShackle frames, diagonals and wooden pressure lids must be designed for apack bearing pressure of at least 1 t/m². The wooden pressure lids incl. thewooden pressure lid supports must be included at distances of 600 - 700 mmand nailed onto side panels.9.8.7.4. LiningThe inside of the box must be suitably lined with overlap at the side panels andthe lid with a watertight special paper or similar material. The lining must notbe breached or damages.Print: 27.04.2010 Page 16 of 26

SBM Quality Specification Main-Document (V3)Figure8: Boxes with lids9.8.8. Packaging category PC 7: Wood box prepared for sea transportwith lining and shrink-wrap9.8.8.1. Boxes with lidsCompliant to packaging category PC 69.8.8.2. Goods/cargoThe goods must be wrapped in aluminum foil. Edges or protruding parts mustbe sufficiently padded. Distance between foil and wall of box: 30 – 50 mm.Direct contact between the aluminum foil and the floor of the box should beavoided (pull in the bubble wrap, foam, etc.).9.8.8.3. After processingAfter processing the foil, the trapped air must be sucked off (vacuum, approx.6 m bar) and a leak test must be carried out. Sufficient desiccant (silica gel,etc.) should be added to absorb the humidity in the package or suitable measuresshould be taken to ensure that the environment in the package preventscorrosion. To prevent contact corrosion, add desiccant in such a way that nodirect contact to the packaged goods is possible. The desiccant packaging mustbe guaranteed dust-free and so stable that it does not open if the package isdropped.9.8.8.4. Packaged goodsThe packaged goods must be secured within the box against horizontal forces(tilting, shunting shock, bumps, etc.) in such a way that it remains undamagedby such forces. It can be secured by bolts at the runners and / or on the floor,fixing with frames to the ground, padding between the device and the wall ofthe box, etc.Print: 27.04.2010 Page 17 of 26

SBM Quality Specification Main-Document (V3)9.8.8.5. Oscillating goodsOscillating goods must be secured (by shock mounts, spring elements, etc.) insuch a way that no mutual vibration from forces of inertia and excitationarises, thereby preventing damages.Figure9: Inside packaging and bolts9.8.9. Packaging category PC 8: Shipper's Own ContainerIn contrast to the container of the shipping company, the shipper's own containermust be viewed as a means of packaging, because the goods can bekept in it until they are used.When possible, box containers should be used for sea transport.For the purpose of optimum packaging and handling, the goods should bepackaged on the ground and then pushed into the container with a fork-lift.Figure10: Shipper's Own ContainerPrint: 27.04.2010 Page 18 of 26

SBM Quality Specification Main-Document (V3)Figure11: Example for container floor9.8.9.1. Fixing to container floorRing eyelets are fixed on the outside to the longsides of the container floor. 36mm polyester straps can be pulled through these to lash down the parts.Print: 27.04.2010 Page 19 of 26

SBM Quality Specification Main-Document (V3)Figure12: Ring eyelets on container floorFigure13: Example for a container floorTo once more remove the floor from the container when it has reached its recipient,2 stable shackles or wire rope must be attached to the door opening ofthe contained facing the floor or face side. The shackles have been designed sothat standard shackles and rope can be attachedPrint: 27.04.2010 Page 20 of 26

SBM Quality Specification Main-Document (V3)Figure14: Example for shackles on container floorHeavy cargo fittings (trailer metal sheetings and edge brackets)Boxes and fittings with a gross weight more than 5 t are equipped with steelfittings at the top and bottom edges in the lap (sheet thickness depending onthe weight but at least 3 mm).Trailer metal sheetings must be designed and installed according to the totalweight of the loaded box. The edge brackets are used to protect the box fromdamage when shackling with ropes, chains, etc. onto a crane.Print: 27.04.2010 Page 21 of 26

SBM Quality Specification Main-Document (V3)Figure15: Attaching heavy cargo fittings10. Regulations on markings and designationsBefore marking/designating, the base (underground) must be smoothed orprepared with primer, or must be degreased if metallic.Tin/metal and/or plastic marking/designation shields can be used as long asthey are lightfast, watertight, and non-sensitive to sea water and UV radiation.The paint/ink used for marking/designating must be smudge-proof, lightfast,non-sensitive to sea water and UV radiation and must be clearly distinguishablefrom the underground.A template should be used for marking/designating. Latin capitals and arabicnumerals should be used; their size depends on the size of the packaging.Print: 27.04.2010 Page 22 of 26

SBM Quality Specification Main-Document (V3)The marking/designation must be clear, defined, uncovered, parallel to thefloor edge and must remain legible for the duration of the storage time.Specifications on the text, form and attachment of the marking at the locationare contained in the conditions of the contract and/or figure.The handling marking must be filled out in accordance to this regulation andattached to the package.The driver's side and the driving side must be marked unambiguously andclearly on the packaging of machine components.Figure16: Example for labelling and handling markingThe size and number of symbols must be adapted to the shape and dimensionsof the packages. Preferable sizes are 50, 80, 100, 150 and 200 mm. All symbolsmust be attached without borders. Text specifications should be avoided.In exceptional cases, handling markings can be supplemented by text.The „centre of gravity“ symbol must be attached to packages of more than 500kg on at least two adjacent sides of the package.Print: 27.04.2010 Page 23 of 26

SBM Quality Specification Main-Document (V3)Figure 17: Symbol for handling markingPrint: 27.04.2010 Page 24 of 26

SBM Quality Specification Main-Document (V3)Figure 18: Symbol for handling markingThe symbol for the appropriate storage regulation must be attached to thepackage in agreement with the packing list.Details of the symbols are made known for the order in question.Print: 27.04.2010 Page 25 of 26

SBM Quality Specification Main-Document (V3)11. Tables11.1. Table of figuresFigure 1 requestion to order ..................................................................... 5Figure 2 Stückliste .................................................................................. 6Figure3: Shrinking ................................................................................. 11Figure4: PC 2 ........................................................................................ 12Figure5: Design of still plate .................................................................... 13Figure6: Recommended number of wooden supports for pallets ................... 14Figure7: Boxes with lids .......................................................................... 15Figure8: Boxes with lids .......................................................................... 17Figure9: Inside packaging and bolts ......................................................... 18Figure10: Shipper's Own Container .......................................................... 18Figure11: Example for container floor ....................................................... 19Figure12: Ring eyelets on container floor .................................................. 20Figure13: Example for a container floor .................................................... 20Figure14: Example for shackles on container floor ...................................... 21Figure15: Attaching heavy cargo fittings ................................................... 22Figure16: Example for labelling and handling marking ................................ 23Figure17: Symbol for handling marking .................................................... 24Figure 18: Symbol for handling marking ................................................... 2511.2. Table of tablesTable 1: Marking of components ............................................................................................. 5Table 2: Packaging categories ............................................................................................... 10Table 3: Packaging matrix ....................................................................................................... 1011.3. Table of standardsStandard Topic Document / Chapter PageISO 3834-4 Welding SBM QS - Welding 2DIN EN 287 T1/T2 Welding test SBM QS - Welding 2DIN EN 1418 Welding test and operator certificate SBM QS - Welding 2DIN EN 25817 Weld quality SBM QS - Welding 2ISO 15609-1 Power values MAG welding SBM QS - Welding 2EN 970 Visual inspection of weld SBM QS - Welding 2DIN/EN 571-1 PT checks SBM QS - Welding 3DIN EN 1289 Assessment of PT check SBM QS - Welding 3EN10204-3.1 Inspection document SBM QS - Welding 3DIN 55928 Painting - spraying SBM QS - Painting 2DIN 67530 Painting - degree of gloss SBM QS - Painting 4ISO 2409/DIN Painting - adhesiveness SBM QS - Painting 453151GT 0DIN EN ISO 1461 Galvanizing SBM QS - Galvanizing 2DIN EN ISO 2063 Thermal spraying with zinc SBM QS - Galvanizing 2ÖNORM A 5300 Packaging – europallets9.8.5 Packaging category 10(Austrian Standard)PC 4: PalettesDIN 15146-2 Packaging – europallets 9.8.5 Packaging categoryPC 4: Palettes10Print: 27.04.2010 Page 26 of 26