Abu Dhabi Conformity Assessment Scheme for Precast Concrete-Insulated Sandwich Panels

Transcription

1 Abu Dhabi Conformity Assessment Scheme for Precast Concrete-Insulated Sandwich Panels Assessment and Surveillance Plan

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3 TABLE OF CONTENTS 1 ABOUT THE ABU DHABI QUALITY AND CONFORMITY COUNCIL FOREWORD THE ENVIRONMENTAL TRUSTMARK REFERENCES CERTIFICATION REQUIREMENTS General Requirements Specific Requirements Mandatory Performance Requirements Constituent Materials Specifications Thermal Insulation Core Reinforced Steel Wythe Connectors Physical Properties Optional Sustainability Attributes Quality Management System Requirements ASSESSMENT OF THE APPLICATION IDENTIFICATION AND LABELLING SURVEILLANCE / AUDIT PROCEDURES General Quality Management System Testing and Inspection SCHEDULE OF FEES... 8 APPENDIX A APPLICATION, TERMS AND CONDITIONS, AND LICENSE FOR CERTIFICATION... 9 Page ii

4 1 ABOUT THE ABU DHABI QUALITY AND CONFORMITY COUNCIL The Abu Dhabi Quality and Conformity Council (QCC) was established by law No. 3 of 2009, issued by His Highness Sheikh Khalifa Bin Zayed Al Nahyan, President of the UAE and ruler of Abu Dhabi. QCC consists of a council of regulators that facilitate the provision of quality infrastructure in line with global standards. This quality infrastructure enables industry and regulators to ensure that products, systems and personnel can be tested and certified to UAE and International Standards. In addition to supporting regulators and government organizations through offering quality and conformity assessment facilities, expertise and resources, the Council is also engaged in promoting a culture of quality towards consumers. Additionally, the QCC is responsible for raising the quality of local products and ensuring exports meet international standards to improve interactions with global trade and integration into the global economy, as envisioned by Abu Dhabi Economic Vision Products certified by the QCC receive the Abu Dhabi Trustmark. The Trustmark is designed to communicate that products, personnel or systems conform to various safety, quality and performance standards that are set by Abu Dhabi regulators. 2 FOREWORD The Abu Dhabi Conformity Assessment Scheme for Precast Concrete-Insulated Sandwich Panels developed through consultation with regulators and industry, enables manufacturers and suppliers of these products to obtain voluntary certification when demonstrating compliance to the following UAE and Abu Dhabi regulations: Abu Dhabi International Building Code (ADIBC), 2013 The Pearl Rating System for Estidama: Building Rating System Design and Construction V 1.0, April 2010 The Pearl Rating System for Estidama: Villa Rating System Design and Construction V 1.0, April 2010 UAE Fire and Life Safety Code of Practice 2011, including Annexure A Rev.2 Fire stopping, exterior wall, cladding/curtain wall and roofing systems. The scope of certification includes precast concrete panels composed of two concrete wythes (layers) separated by a layer of rigid foam insulation. The panels are typically fabricated at a precast concrete manufacturing plant, shipped to the project site, and erected by cranes as exterior and interior walls for many types of structures. Concrete layers (wythes) Rigid foam insulation Page 1

5 It is anticipated that implementation of this product conformity assessment scheme will significantly benefit the Emirate of Abu Dhabi by ensuring compliance with quality and fire safety requirements, while reducing energy consumption and related costs in villas and buildings, particularly new construction. 3 THE ENVIRONMENTAL TRUSTMARK Products that achieve certification, through formal testing against the QCC certification scheme criteria defined in this document, will be granted a Certificate of Conformity and are licensed to bear the Abu Dhabi Trustmark for Environmental Performance in product promotion and merchandising. The Certificate of Conformity enables manufacturers and suppliers of Precast Concrete-Insulated Sandwich Panels to present evidence of meeting appropriate standards for Abu Dhabi's built environment. The Certificate of Conformity can be used to support the submission requirements of the Abu Dhabi Urban Planning Council (UPC) Estidama Pearl Rating System: PBRS and PVRS credits RE-R1, RE-1 and RE-2: to demonstrate the Precast Concrete- Insulated Sandwich Panels thermal performance used within the submitted U-value calculations. Compliance with this scheme will be considered as supporting evidence when demonstrating compliance with wall U-value requirements of the Estidama PRS. Also, compliance with this scheme must NOT be construed as automatic approval of the U- value requirement as this is dependent on the thickness of the compliant product used in the wall section and other elemental wall components. The QCC's market surveillance inspectors actively ensure the integrity of the Trustmark for Environmental Performance is maintained through market surveillance and testing of products bearing the Trustmark. Advisory note: A number of factors additional to the characteristics addressed in this Conformity Assessment Scheme may influence the performance of products, e.g. installation, maintenance, modification, incorrect operation. Such factors are beyond the scope of the product certification described in this document. The QCC recommends that suitable precautions, such as the use of competent and/or accredited/approved building designers, insulation products installers, commissioners and building maintenance managers, to improve the likelihood of continued compliance of installed products. The requirements herein may from time to time be varied by one or more QCC Notices issued as controlled documents to certificate holders. Page 2

6 4 REFERENCES The following standards and specifications are referenced as acceptable means to demonstrate compliance with the minimum performance requirements outlined in Section 5.2. Familiarity and/or access to these documents, dependant on the product(s) applying for certification, is expected of the applicant. In all cases, the most recent edition of the document shall apply: ASTM C150: Standard Specification for Portland Cement ASTM C 518: Standard Test Method for Steady-State Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus ASTM C 1363: Standard Test Method for the Thermal Performance of Building Assemblies by Means of a Hot Box Apparatus ASTM E119: Standard Test Methods for Fire Tests of Building Construction and Materials BS : Fire tests on building materials and structures. Methods for determination of the fire resistance of load bearing elements of construction BS : Fire tests on building materials and structures. Methods for determination of the fire resistance of non-load bearing elements of construction BS 1881: Part 124 Method for analysis of hardened concrete BS EN 197: Part 1 Cement Part 1: Composition, specifications and conformity criteria for common cements BS EN 934: Part 2 Admixtures for concrete, mortar and grout Part 2: Concrete admixtures Definitions, requirements, conformity, marking and labelling BS EN 1008 Mixing water for concrete BS EN : Fire resistance tests for non-loadbearing elements. Walls BS EN ISO 6946 Building components and building elements Thermal resistance and thermal transmittance Calculation method BS EN 11925: Part 2 Reaction to fire tests Ignitability of building products subjected to direct impingement of flame Part 2: Single flame source test BS EN Aggregates for concrete BS EN Thermal performance of building materials and products Determination of thermal resistance by means of guarded hot plate and heat flow meter methods dry and moist products of medium and low thermal resistance BS EN Thermal performance of building materials and products Determination of thermal resistance by means of guarded hot plate and heat flow meter methods products of high and medium thermal resistance BS EN :2007+A1:2009: Fire classification of construction products and building elements. Classification using test data from reaction to fire tests BS EN ISO 8990 Thermal insulation Determination of steady-state thermal transmission properties Calibrated and guarded hot box PD :2009+A1:2013 Aggregates. Aggregates for concrete. Guidance on the use of BS EN Page 3

7 5 CERTIFICATION REQUIREMENTS 5.1 General Requirements In order to receive the Trustmark for Environmental Performance, the product applying for certification must be assessed according to the QCC s criteria (clause 5.2). The general requirements for certification, along with the terms and conditions for QCC certification of products and license of the Trustmark are contained in the application form included in Appendix A. In addition, the applicant shall provide the following: Valid UAE Trade License Authorisation letter from the manufacturer to deal with the product(s) seeking certification (if applying on the manufacturers behalf). 5.2 Specific Requirements Mandatory Performance Requirements In order to gain certification, the Precast Concrete-Insulated Sandwich Panels shall meet the minimum performance requirements outlined in Tables 1 and 2 below, when tested in accordance with the defined test procedure. In order to demonstrate compliance, test reports must be provided from an ISO/IEC certified laboratory where the applicable test standards is within the scope of certification. The certification body which provided the ISO/IEC certification to the laboratory must be a signatory to the International Laboratory Accreditation Cooperation Mutual Recognition Agreement (ILAC-MRA). Alternatively, the testing facility shall have obtained QCC recognition based on the scope of the testing sought. Test reports validity: In all cases, the test reports submitted must not be older than 12 months on the day of submission. Physical testing analysis or equivalent: Test reports shall demonstrate applicability and traceability to the products sold in the UAE. Use of alternative test standards: Test reports using alternative standards to those listed in Tables 1 and 2 will be considered and reviewed by the QCC to determine if the standard is comparable to, and/or meets the intent of, the test standards required by relevant sections concerning Precast Concrete-Insulated Sandwich Panels given in the applicable codes and regulations Constituent Materials Specifications The constituent materials of the precast concrete panels shall comply with the requirements outlined in Table 1. Page 4

8 Table 1. Constituent Materials Specifications Material Requirements Design Mix Standard / Specification Cement The cement to be used in the manufacture of precast concrete sandwich panels shall be sulphate-resisting Portland cement Type-V, or ordinary Portland cement with partial cement replacement by supplementary cementitious materials such as fly ash and ground granulated blast-furnace slag (GGBS), and microsilica, etc. The cement content shall be a minimum of 220 kg/m 3 ASTM C150 BS EN 197 Part 1 Aggregates The aggregates to be used in the manufacture of the precast concrete sandwich panels shall be crushed rocks from reliable sources. The sand shall be washed and free from deleterious substances. The aggregate shall not contain harmful material such as coal, mica, shale or similar laminated materials which cause strength deterioration. Conform to the requirements of BS EN and the recommendations of PD 6682 Part 1, except for the grading requirement. BS EN 12620:2002 +A1:2008. PD 6682 Part 1 Admixtures The admixtures shall be free from chlorides. Conform to the requirements of BS EN 934 Part 2 BS EN 934 Part 2 Water The water to be used in mixing and curing the precast concrete panels shall be of drinking quality, clean and free from injurious substances of sewage, oil, acids, strong alkalis, vegetable matter, clay and other such substances harmful to the finished product Thermal Insulation Core The water cement ratio shall be a maximum of 0.42 BS EN 1008 The thermal insulation core material incorporated in the precast concrete panel, shall have valid QCC Trustmark certification, and shall have the same length and height of the surrounding concrete layers Reinforced Steel The reinforced steel incorporated in the precast concrete panel, shall have valid QCC Trustmark certification Wythe Connectors Wythe connector systems should be made of composite material, having low thermal conductivity to eliminate cold bridging and thermal transfer. Wythe connectors must have directional-tested confirmed shear and tension values along with test embedment depths. Page 5

9 5.2.6 Physical Properties The physical properties of the precast concrete-insulated sandwich panels shall conform to the requirements outlined in Table 2 taking into account the following criteria: The manufacturers may achieve the physical properties specified herein for their products through various means such as addition of mineral and/or chemical admixtures to the concrete mix. Products shall be adequately cured, as specified, so that they comply with all the physical and mechanical properties upon delivery to site. Table 2. The QCC minimum performance requirements for Precast Concrete-Insulated Sandwich Panels certification Product Properties Parameters Requirements Test Procedure 1 Dry density The net dry density of concrete shall be greater than 2,000 kg/m 3. BS 1881 Moisture movement The linear shrinkage shall not exceed 0.6 mm/m ASTM C Physical properties Compressive Strength The compressive strength shall be declared in N/mm 2 and shall be greater than the following: Average compressive strength: >7.3 N/mm 2 Individual compressive strength: >6.0 N/mm 2 The panels shall maintain their integrity during testing and shall not show evidence of separation between the insulation core and the outer concrete wythes. BS 6073 Part 2 Fire properties Fire resistance The Precast Concrete-Insulated Sandwich Panels shall pass NFPA 285 with minimal damage to the foam insulation in the core of the panel. The panels shall comply with the most up to date Fire Code applicable in Abu Dhabi. NFPA 285 Thermal properties Thermal performance The core insulation material incorporated in the precast concrete block, shall have QCC Trustmark certification Demonstrate the provision of continuous insulation Provide thermal performance calculations in accordance with BS EN ISO 6946 to demonstrate effective U-value of the final product. 1. Comparable test procedures would be accepted by the QCC after assessment on a case by case basis BS EN ISO 6946 Page 6

10 5.2.7 Optional Sustainability Attributes In addition to the above mandatory requirements, the QCC certification can be used to support compliance with the following Estidama Pearl Rating System optional credits: PBRS SM-9 / PVRS SM-4 Regional Materials: the QCC certificate will state the country where the product was manufactured. PBRS SM-10 / PVRS SM-5 Recycled Materials: the applicant shall submit evidence related to the recycled content in accordance with the credit requirements, details of which could be included in the QCC certificate if deemed acceptable. 5.3 Quality Management System Requirements The manufacturer of the product (not the importer, or distributor, or retailer) must be certified according to ISO 9001, the certificate being issued by a certification body accredited according to ISO/IEC 17021:2012 by an accreditation body signatory to the International Accreditation Forum Multilateral Recognition Agreement (IAF MLA). 6 ASSESSMENT OF THE APPLICATION The assessment is based on the submitted documentation defined in clauses 5.1, 5.2 and 5.3, including additional product information such as; product specifications, product descriptions and product photo documentation, which is evaluated for consistency, completeness and overall quality. 7 IDENTIFICATION AND LABELLING Each certified product must be provided with an evident label bearing the QCC Trustmark for Environmental Performance (depending on product and subject to agreement with the QCC Communications department), in accordance with brand guidelines specified in the Application, Terms and Conditions and License for Certification. 8 SURVEILLANCE / AUDIT PROCEDURES 8.1 General At a minimum, the surveillance and audit requirements listed under this section shall be applied to the certified product(s) on an annual basis. When the validity of a certificate is to be demonstrated; this includes the validity of the accreditation of the certificate issuer. 8.2 Quality Management System Proof of continued compliance (certification) is to be presented to the QCC annually or 30 days after expiry of the submitted ISO 9001 certificate (whichever comes first). Page 7

11 8.3 Testing and Inspection Products carrying the QCC Trustmark of Environmental Performance will be subject to the following unannounced inspection activities: Annually, the QCC will undertake market surveillance activities to test certified products available in the Abu Dhabi market. Samples can be inspected i) on-site at installed locations of Abu Dhabi government/municipal owned buildings, ii) at point of entry to the Abu Dhabi Market, and/or iii) at the manufacturers facility. Samples will be assessed for compliance to selected specific requirements given in Clause 5.2. The sampling schedule will target previously untested products on a year-on-year basis to ensure eventual testing of all certified products. If any product fails to meet the certification requirements during inspection the product certification in question will be withdrawn and the applicant required to perform testing of an agreed number of samples to verify compliance. If one of these additional samples also fails to meet the certification specifications, the certification status of all products from the applicant will be reviewed. Proof of continued compliance to the requirements of the QCC certification must be provided if; i) a referenced standard listed in clause 4 has changed, or ii) the product has been modified, or iii) annually following issuance of the first certificate, whichever comes first. In cases i) or ii), new test reports shall be provided; in case iii) an affidavit shall be provided by the applicant and the manufacturer that the production system has not been modified and the specification of the product remains unchanged. 9 SCHEDULE OF FEES The applicant shall pay the necessary fees in accordance with the Schedule of Fees issued by the Abu Dhabi Executive Council, which is available in the QCC website ( under the respective product certification scheme. Page 8

12 APPENDIX A APPLICATION, TERMS AND CONDITIONS, AND LICENSE FOR CERTIFICATION Page 9