74 Refractory QC duties and counting …

74 Do’s and Don’ts for a refractory installers QC.

In the list below some instances may seem more like an Inspectors job, perhaps even a material controller, quantity surveyor, the supervisor or a quality manager. Yet as an installers QC it is your duty to support these people. Collaboration typically extends to 3rd party QC-inspector for the client or the clients 3rd party QA or consultant. However for the sake of being fairly comprehensive – a fine sub-division is ignored. Point being that an installers QC duties include involvement, and consideration of certain important tasks + there is the fact that individual project requirements differ. Some of us may work at one place, or for one company and have no deviation from a set system – but for others the norm is the constant change from one client to the next, and being able to say one can identify with a certain requirement will help.

Note that I refer to casting activities as a general guideline. Bricking and other applications will naturally have their specific checks – but for the sake of maintaining a fairly generic approach, and indicating that a QC has a wide scope of work – then this should suffice for now.

1. Take instruction from … : Respect the organograms & subsequent hierarchy. See all organograms – internal and from the client. Point is know whom to take instruction from.
2. Understand the working strategy: Meaning – get work done as per pre-determined or agreed systems. Know how the client requires certain specifics carried out.
3. Request latest revision drawings, verified bill of materials, batch specific test certificates, latest revision data sheets,  approved schedule, suppliers installation guidelines & or technical instructions. 
4. Get permission to take photos – get a permit, a sticker, badge or sign some relevant paper if required. High fives and handshakes as permission don’t count.
5. Bill of material verification! Qualities & quantities. In the process also understand storage, transport arrangements form manufacturer to site warehouse, from site warehouse to working area… is this all, ok? + Who has responsibility for material form which point in the logistics chain? 
6. Is the material protected: From water and direct sunlight?
7. Material shelf life: Make sure not to work with expired materials! Concessions and approvals for using expired material is a whole different process to record.
8. Be present during equipment, material, and applicator pre-qualifications. Any relevant training or inductions. Scope identification sessions (inspections), demolition, anchor patterns and welding as well as refractory installation. The required meetings and all toolbox talks.
9. Specifically assist the supervisor and the material controller, the clients appointed QC – inspection authority + relevant managers.
10. Have all the required Information ready filed and in soft copy -before site work starts. You cannot focus on quality and execution if you are not prepared.
11. Read – more like study – and understand drawings, technical instructions, guidelines, specifications, Standard Operating procedures …
12. Method statement compilation – do the draft version with the supervisor. Base it on verified instructions, drawings, specification & guideline demands with “good refractory practices” noted. A comprehensive MS can be copied into the test or control plan.
13. Compile the QCP, (& or ITP – if implemented) Facilitate adequate witnessing, verifying, data recording & holding points, etc…  
14. If an ITP is in place issue RFI (request for inspection) or NOI (Notification of inspection) promptly.
15. Make sure referrals and reference structure in the control documents are ACCURATE – IT’S A LEGAL DOCUMENT.
16. Make sure the team has latest revision drawings available with the relevant detail – close by on site, in the vessel at the point of work.
17. Have the first revision of paperwork in place ASAP… you will have to spend more time on site than in the office – avoid doing preparation work that should have been done before hand.
18. Submit Quality documentation for approval! Make sure to submit it to the correct parties.
19. Who signs documents? Have the correct responsible persons identified on control documents, concessions, NCR’s etc.
20. Only start work with the first revision control documents approved.
21. Don’t deviate from approved QCP/ITP  and method statement without prior discussion with client and concession.
22. Revisions: Whether it is for a drawing, a method statement … make sure it is communicated to the installation team. 
23. Make the control documents available to all signatories – let them know to be available @ X time or there abouts.
24. Do QC checks before requesting inspection. 
25. Sign in sequence! If the supervisor has not signed yet and you are dangling around in confusion. Do not dare ask a QA or Inspector or the client to sign.
26. Start with a next step of work only when a previous step is signed off. Shell condition, anchor welding, stop-ends – shutter conformity etc. … as noted in signoff control document, Method statement or task specific checklist.
27. Make specific steps or points clear to the supervisor & team via toolbox or on-site work meetings. Ie: inspection points that require sign off that day, acceptance/rejection criteria task specific.
28. Temperature! Ambient, water, dry material, wet material … don’t use the back of your hand to take temperature! Record all temps on mixing sheet or checklist as your QC strategy requires.
29. Verify water quality. If using Litmus paper – is this accepted? Or must it be a lab test result? Lab result preferred by material supplier.
30. Verify alternative mixing liquid management: expiration and storage details.
31. Confirm mechanical handover. You don’t want to break out for a forgotten NDT inspection.
32. Verify shell condition is acceptable before starting works or that shell prep. by 3^rd party is released ie: sand/grit/ice-blasting, PWB team…
33. Check dimensions of equipment – verify drawing before starting work.
34. Verify protrusions and apertures are as per drawings.
35. Verify Anchors grade with relevant test certificates. Check diameter, length, shape-design & quality.   
36. Make sure when welding anchors to avoid cross welds. As pointed out in the pattern supplied and verified as drawn.
37. Dye Pen (Dpi) or other types testing of refractory anchors might be required as example with Hex or other erosion resistant anchor linings but be sure to execute specific requirements for conventional anchorage: Pattern, spacing, %Bend, %hammer, expansion allowance & in general visual. And let the other team sign on your QCP if they had to do some specific test.
38. Buckets and water is it enough and clean.
39. Check pre-installation that all equipment checklists are done, everything is in place and team is complete.
40. Complete check lists relative to the installation not equipment – that’s the operator responsibility, but check that its done
41. Progressively verify available material quantities with material controller or store person.
42. Do basic checks such as ball in hand for applicable material.
43. Ensure all mixing and placing of refractory is in accordance with manufacturers guidelines and approved control plan. Consider whether it is ramming thick or thin layer, gunning (dry), shotcrete (wet), pumping, casting via mixing & pumping …
44. Ensure test sampling is carried out and reflects– as installed – condition, curing included.
45. Sampling frequency, exact quantity requirements, exact size requirements. Ensure good quality samples are taken where they need to be taken and are tagged or marked accordingly. Use clean sample boxes.
46. Post installation curing for monoliths. Is it heat setting, chemical or hydraulic bonded. Make sure to cure as per suppliers guidelines. 
47. Close off and sign all mixing logs & checklists on site.
48. Check post installation conditions: mixers & buckets cleaned, samples in the process of being cured (binder dependent) housekeeping tended to.
49. Submit or store Samples as agreed beforehand.
50. Sign the sample register.
51. Accurately report back all deviations and/or progress up the organogram.
52. Deviations from method of installation, material type, drawings, approved documents or approved “as built” must be re-approved, signed and shared to all affected parties. NO VERBAL CHANGES OR INSTRUCTIONS ! If its not as per pre-agreed method it must have official approval.
53. Red-corrects: Any drawing deviations, changes, mistakes on the drawing … must be recorded and approval to go ahead given such change is required.
54. Initiate concessions and follow through. Ensure the agreed revised method is being carried out.
55. Follow through ie: NCR’s & getting concessions approved…
56. If schedule is going to be compromised – due to a Quality issue raise it as a concern to your manager.
57. Do repair maps based on scope of work.
58. Ensure all work carried out is in line with the approved QCP.
59. If punch lists apply – address them.
60. Keep records. All revisions, sketches, instructions, change orders etc… It will be needed at the next repair opportunity.
61. Be present during final inspections. (We noted it in point 6 as a general point)
62. Compile complete data pack hard and soft copies.
63. Hand over the data pack. 
64. Always have pens and a notebook.
65. Always have tape/ruler, chalk/marking pen and a flashlight available nearby.
66. Respect good refractory practice by knowing what it is.

NON – QC DUTIES.

1. Don’t say its not your job if it affects quality.
2. Don’t run the job or job site.
3. Don’t do any official inspection – alone and expect a signature.
4. Don’t commit to progress – there is a schedule, don’t commit to changes. If its compromised see point 56.
5. Don’t make decisions on design changes or material selection.
6. Don’t commit on someone’s behalf such as promising when a bricklayer will be done with “that course of bricks” or ask them to commit – it’s the supervisor’s call.
7. Don’t blame, whine, assume – always verify.
8. Don’t think its an office job! Get on site! Be present, be visible!