NATIONAL ASSESSMENT GUIDELINE. concerning the. product certificate for ARMOUR STONE. for application in Soil, Road and Hydraulic engineering

Transcription

1 BRL 9312 Dated NATIONAL ASSESSMENT GUIDELINE concerning the KOMO product certificate for ARMOUR STONE for application in Soil, Road and Hydraulic engineering Technique area BSB Approved by the BMC Committee of Experts on Aggregates and Fillers on 5 June 2008 and confirmed by the Board of the BMC Certification Institute. Accepted by the Harmonisatie Commissie Bouw of the 'Stichting Bouwkwaliteit' on 24 July 2008 Published by: Certification Institute BMC

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3 BRL 9312 Dated Certification Institute BMC Ir. P. Bloklandhuis Büchnerweg 3 P.O. Box AD Gouda Phone: + 31 (0) Fax: + 31 (0) Accredited by the Dutch Council for Accreditation PRODUCTS RvA C 004 GENERAL INFORMATION: CERTIFICATION SYSTEM : KOMO PRODUCT CERTIFICATE The general procedural requirements, as applied by BMC, are stipulated in the BMC General Regulations on product certification, process certification and technical approval. The requirements regarding the certification of the factory production control (FPC) in the scope of the CE-marking as applied by BMC, have been stipulated in the BMC Regulations on Certification of the Factory Production Control granulated materials This new edition of the assessment guideline replaces BRL 9312 dated (including the document of alterations dated ) and is valid as of the moment of acceptance by the Harmonisatie Commissie Bouw taking into account a period of transition up to 1 January 2009 for existing certificate holders. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the BMC Foundation.

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5 CONTENTS Paragraph: Page 1 INTRODUCTION Subject Field of application DEFINITIONS Delivery Customer Sub-sample Factory Production Control Geological file Coarse grading (NEN EN : coarse grading) Conformity control Factory Production Control (FPC) Supplier Light grading (NEN EN : light grading) Independent laboratory Process control Manufacturer Product group Practical training period Admission test Verification investigation Shipping document Armour stone Raw material production area Heavy grading (NEN EN : heavy grading) APPLICATION REQUIREMENTS PRODUCT REQUIREMENTS AND CONTENT OF THE KOMO PRODUCT CERTIFICATE...4 Product requirements Requirements derived from the Soil Quality Decree Requirements regarding application in civil engineering Content of the KOMO product certificate General Descriptions Product, manufacturer, supplier and origin Specifications Marks and delivery documents Suggestions for the customer CERTIFICATION PROCEDURE Admission test Inspection by the certification institute Term of validity of the quality declaration QUALITY SYSTEM Introduction Table of contents Management statement Organization Responsibility and authorization Management representative...6 i

6 6.2.3 Evaluation by the management Management procedures Documents and data management Outsourcing services Knowledge of raw materials Production management Description of the production process Product descriptions Inspection and tests General Equipment Frequency and location of assessment, sampling and testing Registration Management of non-conforming products Treatment, storage and conditioning at the production location transportation and packaging Training of employees Settling Complaints PROCESS CONTROL Grading and mass distribution Separating Joining Contaminants Storage and transshipment Storage Transshipment and internal transportation Loading the means of transport for transportation to the customer FACTORY PRODUCTION CONTROL Process control Conformity control Other test methods Sampling and testing The size of sub-sample M Assessment of results Corrective measures TEST FACILITIES Testing space Equipment Management and maintenance TRAINING EXTERNAL INSPECTIONS Admission test Issue of a KOMO product certificate Extension of the certificate Inspection visits Reduction of the number of inspection visits during a period of low production Sampling under the supervision of the certification institute Requirements regarding the certification employees QUALITY REGISTRATION OTHER OBLIGATIONS OF THE MANUFACTURER Changes in operational management...14 ii

7 13.2 Data to be supplied to the customers Product specifications document Shipping document Geological file LIST OF DOCUMENTS Product standards Test standards Other...17 Appendix A Environmental section Armour Stone...19 A.1 INTRODUCTION...19 A.1.1 Subject...19 A.1.2 A.2 Field of application...19 DEFINITIONS...19 A.2.22 Shaped building material (S-building material)...19 A.2.23 Unshaped building material (U-building material)...19 A.2.24 Dynamically stable structure...19 A.2.25 Emission...19 A.2.26 Batch...19 A.2.27 Increment...19 A.3 APPLICATION REQUIREMENTS...20 A.4 PRODUCT REQUIREMENTS AND CONTENT OF THE KOMO PRODUCT CERTIFICATE...20 A Requirements derived from the Soil Quality Decree...20 A Determining whether a building material is shaped...20 A.4.2 Content of the KOMO product certificate...20 A.5 CERTIFICATION PROCEDURE...20 A.5.1 Admission test...20 A Verification investigation...20 A.5.2 Inspection by the certification institute...21 A.5.3 Term of validity of the quality declaration...21 A.6 QUALITY SYSTEM...21 A.7 PROCESS CONTROL...21 A.8 FACTORY PRODUCTION CONTROL...21 A.8.1 A.8.2 General...21 Sampling...21 A Sampling admission test...21 A Sampling process control...22 A.8.3 A.8.4 Components to be determined...22 Determination methods...22 A Determination of the composition of organic compounds...22 A Determination of the emission of inorganic components...22 A Diffusion test for S-building material...22 A Column test for S-building material and U-building material...23 A Availability test for S-building material and U-building material...23 A Abridged measurement method...23 A.8.5 Inspection frequency...23 A Principle of the k-value...23 A Initial inspection frequency...24 A Inspection frequency after granting of the certificate...24 A Transition from spot-check to a batch testing regime...24 A Transition from batch testing to a spot-check regime...25 A Handling measurement values lower than the limit of determination...25 A.8.6 Production stops...25 A.9 TEST FACILITIES...25 A.10 TRAINING...25 A.11 EXTERNAL INSPECTIONS...25 A.11.1 Admission test...25 iii

8 A.11.4 Inspection by the certification institute...26 A.11.5 Supplementary tests...26 A.12 QUALITY REGISTRATION...26 A.13 OTHER OBLIGATIONS OF THE MANUFACTURER...26 A.13.3 Shipping document...26 A.13.5 Making available the test results...26 Appendix B Tables belonging to Appendix A...27 Appendix C Underpinning of assessment guideline BRL Appendix D Sampling plan for Armour stone belonging to Appendix A...31 D.1 GENERAL...31 D.1.1 Sampling plan...31 D.1.2 Sampling objective...31 D.1.3 Sampling location...31 D Admission test...31 D Process control...31 D.2 MATERIAL...31 D.2.1 Nature of the material...31 D.2.2 Batch size...31 D Admission test...31 D Process control...31 D.3 SAMPLING...32 D.3.1 Sampling method...32 D.3.2 Realization...32 D.4 PRELIMINARY TREATMENT OF SAMPLES...32 D.4.1 Actions prior to conducting the tests...32 D Prior to transportation (at the raw material production area)...32 D Packing...33 D Storage...33 D Transportation...33 D.4.2 Making samples ready for analysis/tests...33 Appendix E Assessment of measurement results...35 E.1. Sub-samples...35 E.1.1 Action limits...35 E.2 Combination of the results of sub-samples...35 E.2.1 Assessment...35 E.2.2 Action limits...35 E.3 Corrective measures...35 Appendix F Joint admission test and verification...39 F.4.2 Content of the KOMO product certificate...39 F.5 CERTIFICATION PROCEDURE...39 F.5.0 Certification of a cluster...39 F.5.1 Admission test...39 F.6 QUALITY SYSTEM...39 F.8 FACTORY PRODUCTION CONTROL...39 F Sampling admission test...39 F Sampling process control...39 F Initial inspection frequency...39 F Inspection frequency after granting of the certificate F.11 EXTERNAL INSPECTIONS...40 F.11.4 Inspection visits...40 F.13 OTHER OBLIGATIONS OF THE CLUSTER MANAGER...40 F.13.4 Geological file...40 iv

9 Appendix G Example of a KOMO product certificate for armour stone...41 Appendix H Agreement between manufacturer and supplier...43 Appendix I Certification of a storage site...45 v

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11 1 INTRODUCTION 1.1 Subject The requirements included in this assessment guideline will be used by the certification institutes, accredited by the (Dutch) Council for Accreditation, when handling applications for and/or the continuation of a KOMO product certificate for armour stone for application in Soil, Road and Hydraulic Engineering. The requirements that follow from the Dutch Soil quality decree and the related certification regulations that have to be met by armour stone have all been included in Appendix A - Environmental Section Armour Stone. These requirements and regulations have been included separately in order to keep apart the civil engineering and the environmental requirements. Additional requirements regarding the certification of a cluster in which joint admission tests and verification are conducted, have been included in Appendix F. Appendix I includes the requirements regarding the certification of a storage location where the production process primarily consists of storing in bulk and dividing batches of armour stone that have already been delivered under certificate. No requirements have to be met in the scope of the Building Order. The assessments conducted in the scope of this assessment guideline will use the information available for other certification systems to the maximum possible extent. The following documents will be used when handling a manufacturer's application for a KOMO product certificate: 1. The General Regulations of the certification institute, including the general procedural requirements for certification. 2. This assessment guideline, which includes the specific requirements regarding the certification regulations for armour stone. The quality certificate to be issued will be denoted as: - KOMO product certificate (including Appendix A) 1.2 Field of application This assessment guideline is intended for the certification of armour stone of natural origin. Artificially manufactured armour stone (such as phosphorus slag) is not included in this assessment guideline. 2 DEFINITIONS 2.1 Delivery Delivery is understood to be: the transfer of the armour stone to the customer (see 2.2). In the scope of the certification of armour stone this is always the first moment that (part of) a batch: - is unloaded, or - is transshipped with the objective of further delivery of the batch in separate, subdivided batches. Up to that moment the manufacturer is always responsible for the quality of the product. Transshipment into another means of transport for further transportation with the objective of delivering the complete original load to the buyer is expressly included in the responsibility of the manufacturer. 1

12 Explanation 1: Armour stone is generally delivered via a supplier in which case a transfer of property of the armour stone to the supplier also takes place. The judicial responsibilities originating from this transfer of property are not included in the responsibilities as referred to in this assessment guideline. Explanation 2: To guarantee the quality of the product during transportation the supplier has to meet a number of quality requirements. Since the transportation is conducted under the responsibility of the manufacturer, the manufacturer decides what the requirements imply. The quality requirements will be stipulated in an agreement between the manufacturer and the supplier. This agreement must at least satisfy Appendix H. 2.2 Customer The legal body receiving the KOMO certified armour stone. This can be a supplier or the end-user who processes the armour stone for the final destination. 2.3 Sub-sample A quantity of material taken in one or more increments. 2.4 Factory Production Control Part of the factory production control which, in accordance with the stipulations in 8.3 of NEN-EN , is the minimum to be set up by the manufacturer. 2.5 Geological file Document, drawn up by or at the request of the manufacturer, which includes relevant information regarding a raw material production area and the material present in this area 2.6 Coarse grading (NEN EN : coarse grading) Grading with a nominal upper limit between 125mm and 250mm. 2.7 Conformity control Continuous quality control of the final product for assessing the quality of the products delivered, conducted by or under the responsibility of the manufacturer or the intermediary. 2.8 Factory Production Control (FPC) The factory production control includes all actions to be performed by the manufacturer to ensure that the product quality is guaranteed. Apart from the process control and the conformity control, the factory production control also includes the other subjects described in Chapter 5. The factory production control is recorded in the quality manual. 2.9 Supplier A supplier is understood to be an independent unit of a business, who organizes the transportation of armour stone from the processing installation of the manufacturer to the customer. The transportation objective is to transport (or have transported) products that meet the requirements at the transfer of property, in such a way that these products still meet the requirements at the moment of delivery Light grading (NEN EN : light grading) Grading with a nominal upper limit between 25 kg and 500 kg Independent laboratory A laboratory accepted by the certification institute, where the samples for the verification investigation are tested. The laboratory must be able to demonstrate that it meets the requirements in NEN-EN ISO for the tests involved. 2

13 2.12 Process control Continuous control of the production process, raw materials and intermediate products, conducted by the manufacturer on behalf of the process management Manufacturer The manufacturer is understood to be an independent unit of a business, exploiting a processing installation. The objective of the processing installation is to process raw materials originating from a raw material production area in such a way that products are obtained that meet the stated requirements Product group In the scope of this assessment guideline three product groups can be distinguished: - coarse grading: grading indicated by sieve mesh sizes, - light grading: grading indicated by mass - heavy grading: grades also indicated by mass Practical training period A period of at least 3 months prior to the possible granting of a product certificate, that will be assessed with regard to the way in which measurements are conducted and the results of these measurements for the conformity control. The extent of the investigations to be conducted during this period depends on the situation and will be specified in mutual consultation with the manufacturer Admission test Investigations in the scope of the product certification procedure on the basis of which approval is granted to a manufacturer and one or more certificates are issued. In general, the investigations will include an inspection of the production location, (verification) investigation of products and an assessment of the results of the conformity control of the manufacturer during the practical training period Verification investigation Investigation of samples, taken and investigated on-site by the manufacturer under the supervision of the certification institute, to assess the measurement results obtained by the manufacturer. If possible or necessary the investigation concerned will also be conducted in an independent laboratory Shipping document A document drawn up by the manufacturer that includes information to identify a load. Further requirements regarding the content are included in Armour stone Coarse particle-shaped material that is used in hydraulic engineering structures and other civil engineering works Raw material production area A raw material production area is understood to be a continuous geographically determined area for which an exploitation permit has been granted. The area is described in the geological file Heavy grading (NEN EN : heavy grading) Grading with a nominal upper limit of more than 500 kg. 3 APPLICATION REQUIREMENTS For the use of armour stone no application requirements have to be met. 3

14 4 PRODUCT REQUIREMENTS AND CONTENT OF THE KOMO PRODUCT CERTIFICATE 4.1 Product requirements Requirements derived from the Soil Quality Decree All requirements related to the Dutch Soil Quality Decree are included in Appendix A - Environmental Section Armour Stone. The certification regulations included in A.1.1 are also part of these requirements Requirements regarding application in civil engineering Depending on the intended application, certified armour stone has to meet the criteria below: - Product properties meet the product specification of the manufacturer; - Product properties have been determined in accordance with Chapters 4 through 7 of NEN- EN ; 4.2 Content of the KOMO product certificate General The product certificate includes a statement of the certification institute, technical (product) specifications, rules for use of the certification mark and suggestions for the customer, as explained in more detail below. The specific content as regards the Dutch Soil Quality Decree are included in A Descriptions These parts of the certificate include the product description, the manufacturer, the supplier, the origin of the armour stone (raw material production area), specifications and a simple petrographic description of the product (such as basalt, limestone, etc.) and the use of the certification mark on the delivery documents Product, manufacturer, supplier and origin The certificate includes a survey of the certified product group and the grades it comprises, the name and the correspondence address of the manufacturer and of the supplier and the origin of the armour stone by specifying the name/place of the raw material production area. If a raw material production area includes more than one rock formation, which necessitates that a distinction be made, this must be stated on the certificate. Either the manufacturer or the supplier who arranges for the transportation can be stated as the supplier. Obviously, in all cases the manufacturer remains responsible for the product quality in accordance with 2.1. If a manufacturer wants to state the name of the supplier on the certificate, he has to make an agreement with the supplier that meets the requirements in Appendix H. When this agreement, signed by both parties, has been positively assessed by the certification institute, the supplier can be stated on the certificate Specifications The requirements met by the armour stone are indicated under the header Specifications, with reference to the relevant standards and/or the product specification documents of the manufacturer. Furthermore, the text below will be used to indicate the validity of the certificate (also refer to Appendix G): "This certificate is valid up to the first moment that (part of) a batch: - is unloaded, or - is transshipped with the objective of further delivery of the batch in separate, subdivided batches." Marks and delivery documents The certificate states that the products will be delivered with a shipping document including at least: - the information as referred to in Appendix ZA.3 of NEN-EN and as further described in 13.3; - KOMO certification mark 4

15 4.2.3 Suggestions for the customer The header "Suggestions for the customer" includes various relevant points of attention as a service to the customer. 5 CERTIFICATION PROCEDURE 5.1 Admission test The admission test for the product certificate includes: 1. assessment of the quality system of the manufacturer: the certification institute verifies whether the quality system meets the requirements in 6 and assesses the effectiveness and the correct application; 2. assessment of the geological file; 3. assessment of the product regarding the product requirements in The admission test will be conducted by the certification institute in accordance with Inspection by the certification institute When a quality declaration has been issued, the certification institute will conduct inspections in accordance with Term of validity of the quality declaration The term of validity of the quality declaration is unlimited, unless the certification regulations of the certification institute set out another term of validity. The certification institute continuously assesses whether or not the certificate can be continued on the basis of the results of the periodical inspection. 6 QUALITY SYSTEM The manufacturer needs to have an updated and maintained quality system recorded in a quality manual. The objective of this manual must be to ensure that the products and services provided by the manufacturer meet the stated requirements. The manual has to include the procedures for the quality system or must refer to them and must explain the structure of the documentation used in the quality system in the language of the country of production. If desired, the certification institute may require a translation into Dutch, German or English. Agreements regarding the responsibility up to the moment of delivery (see 2.1) must be made with the supplier. All obligations resulting from these agreements have to be included in the quality system. Apart from the issues indicated in Appendix D of NEN-EN , which together represent the requirements regarding the Factory Production Control, the quality system also has to include the issues in 6.1 through 6.11: 6.1 Introduction Explanation: The section numbers below agree with the section numbers in Appendix D of NEN-EN It is indicated per section which supplements are required as compared to NEN-EN Table of contents The described quality system must include a survey of all parts of the quality manual, including the latest revision date Management statement The quality system has to include: 5

16 - A statement by the management regarding the policy, objectives and commitments with regard to the product quality; - a statement by the management that the quality system as recorded in the quality manual has been approved by the management and is normative for the process management. 6.2 Organization Responsibility and authorization No supplements Management representative The management representative to be appointed by the manufacturer must, irrespective of other responsibilities, have clearly defined authorities and responsibilities to ensure that the quality system, as recorded in the quality manual, will be maintained and that the stipulations in this assessment guideline will be met. The management representative will be the initial contact for the certification institute Evaluation by the management Visits to the company in the scope of the KOMO certification by the certification institute qualify as audits. 6.3 Management procedures The quality manual also has to include all aspects mentioned in this Chapter of the assessment guideline Documents and data management One person must be appointed who is responsible for managing the documents (document manager). The document records must show which versions of the documents are valid Outsourcing services No supplements Knowledge of raw materials No supplements. 6.4 Production management No supplements Description of the production process The quality system has to include: - A description of the production process from the basic raw materials up to the moment of delivery, with references to procedures and operating instructions for all parts of the process; - A description of the control criteria for the process control; - A record of specific production flows; - A record of the measures to prevent undesired mixture of raw materials, semi-manufactured and/or final products Product descriptions The quality system has to include: - A description of all finished and semi-finished products manufactured by the manufacturer; - A record of external limit values, internal target values, warnings and/or action limits. 6.5 Inspection and tests General No supplements. 6

17 6.5.2 Equipment No supplements Frequency and location of assessment, sampling and testing This schedule has to include: - which official conducts the sampling and where. - the sampling frequency. - the sampling method and the amount of material per sample. - the preparations to be made and the properties to be measured with reference to the operating instructions/measurement methods. - Sampling the final products, as referred to in table 1, has to be conducted in agreement with Chapter 4 of NEN-EN Registration No supplements. 6.7 Management of non-conforming products The requirements stipulated in NEN-EN must be materialized and included in a procedure. 6.8 Treatment, storage and conditioning at the production location The requirements stipulated in NEN-EN must be materialized and included in a procedure. 6.9 transportation and packaging The responsibility of the manufacturer always extends to the first moment that (part of) a batch (also see 2.1): - is unloaded, or - is transshipped with the objective of further delivery of the batch in separate, subdivided batches Training of employees No supplements Settling Complaints The quality system must include a procedure for the way in which complaints from suppliers and/or customers are dealt with. Complaints must be recorded in a complaints file. One complaints form per complaint, stating the status of the resolution. At a minimum the complaints form must include: - the date on which and the way in which the complaint was submitted. - the particulars regarding the complainant. - the nature of the complaint. - the way in which the complaint was investigated. - whether or not the complaint was justified, plus an explanation. - if applicable: internal corrective measures to prevent similar complaints. - if applicable: the way in which the complaint was satisfied. - date on which the complaint was settled. - All correspondence related to the complaint has to be stored in the complaints file. 7 PROCESS CONTROL In the scope of the process control the manufacturer has to take all steps required to deliver products that meet the requirements. 7.1 Grading and mass distribution Separating If a separating system is used for the production of armour stone, this system must function in such 7

18 a way that the intended separation is also achieved in case of varied composition of the supplied raw materials Joining If armour stone is manufactured by joining semi-manufactured products, this joining has to be conducted in such a way that a homogeneous final product is obtained. This has to be checked at a frequency specified in the quality manual and has to be attuned to the product properties stated in the product specification. 7.2 Contaminants The manufacturer has to be able to remove contaminants during the production process in such a way that the product requirements are met. 7.3 Storage and transshipment Storage During the storage of semi-manufactured and/or final products in silos and/or storage depots, separation and/or contamination have to be prevented as much as possible. Furthermore, mixing with other semi-manufactured and/or final products may not occur Transshipment and internal transportation The manufacturer must have efficient equipment for transshipment and internal transportation of semi-manufactured and/or final products. The quality of the products may not be adversely affected by transshipment or internal transportation Loading the means of transport for transportation to the customer Before the manufacturer begins loading a means of transport, the manufacturer must: - (in case of ships)always establish through visual inspection that the means of transport does not contain any contaminants and is suitable for loading the specific product and - (in case of lorries) if possible have established through visual inspection that the means of transport does not contain any contaminants and is suitable for loading the specific product. The results of these checks are registered. Only in case of lorry loads this registration may read "not inspected". Explanation: A means of transport is suitable for loading when the product quality cannot be adversely affected by the properties of the means of transport during loading, transportation and unloading. The loading will be conducted in such a way that it does not adversely affect the quality of the supplied products. The manufacturer must at least conduct a visual inspection, always in case of shiploads and if possible in case of lorry loads. 8 FACTORY PRODUCTION CONTROL 8.1 Process control The manufacturer has to decide how the process control is arranged for. The process control has to include the relevant aspects mentioned in Chapter Conformity control The conformity control is conducted for all certified products with a minimum frequency: - per product as stipulated in Table 1, determinations 1 through 7, or - per raw material production area as stipulated in Table 1, determinations 8 through 13. This frequency depends on the total amounts to be shipped per product. However, sampling and testing also have to be conducted if prompted by the results of a visual inspection by the manufacturer or by any other indications. 8

19 The frequencies stated in Table 1 may be adapted in consultation with the certification institute depending, among other things, on the size of the batch and whether or not any possible deviations occur. The certification institute will report adaptations to the Board of Experts on Aggregates and Fillers. 8.3 Other test methods If a method other than the standardized method is used in the scope of the conformity control: - A description of the other method has to be recorded in a written instruction; - A reliable relationship between the measurement results of the other method and the standardized method has to be established; - The validity of the relationship between the method used by the manufacturer and the standardized method must be checked at least once a year by means of a calibration investigation. The certification institute will assess the described method and the established relation together with the supplied measurement results. The certification institute will report the use of another method to the Board of Experts on Aggregates and Fillers. 8.4 Sampling and testing Samples have to be taken in accordance with Chapter 4 of NEN-EN , in such a way that the sample is representative for the final product. The sampling for the conformity control is assumed to be based on a more or less continuous supply of armour stone over a certain period of time. The results of an investigation of 5 sub-samples (all with a size M, see 8.4.1) are arithmetically 1 combined into one sample that is representative of at most the number of tons in Table 1 column 4. The sub-samples are equally distributed over the population, in such a way that a representative impression is obtained of the properties of the population concerned. Every sub-sample is tested for the properties in accordance with the determinations 1 through 7 in Table 1. The properties stated under 8-15 in Table 1 will be determined per grading at the stated frequency. If the properties resulting from determinations 8-13 are shown to be equal for all grades, the determination of these properties for only 1 grading will suffice in future The size of sub-sample M When sampling the coarse grading M is the size of the sub-sample in kg. The size of every subsample in kg is equal to at least twice the nominal upper limit of the grading in mm (compare 5.3 of NEN-EN ). When sampling the light grading M is the number of stones per sub-sample. M is larger than or equal to 40 and smaller than or equal to 50. When sampling the heavy grading M is the number of stones per sub-sample. The value of M is in between the values specified in the table below: grading(kg) minimum number of stones M per sub-sample maximum number of stones M per sub-sample The basic principles for this arithmetic calculation: - The mass distribution and the average mass based on all individual measurement values of the stones that are part of the sub-samples concerned. - The particle size distribution based on the arithmetic average of the measurement results of the sub-samples. 9

20 Preferably, the entire sub-sample must be assessed. Consequently, the increment size has to be attuned to the size of the sub-sample. If it turns out to be necessary to reduce the size of the subsample, this has to be done randomly. The manufacturer has to record per grading the value of M and the way in which sub-samples are reduced in the sampling procedure. 8.5 Assessment of results The assessment whether the supplied armour stone meets the requirements is conducted by testing both the individual and the combined results against the requirements, all this in accordance with the description in Appendix E. 8.6 Corrective measures As soon as a manufacturer finds that action limits are exceeded, the sampling frequency has to be doubled, if necessary in combination with a corrective measure in the process management. If the requirements are not met, corrective measures have to be taken. A temporary halt to deliveries can be considered a corrective measure. 10

21 Table 1 Conformity control schedule determination 1 particle size distribution test method in accordance with NEN-EN visually minimum frequency per grading every load 5 of NEN-EN per tons 1, consisting of 5 sub-samples 2 mass distribution visually every load 6 of NEN-EN per tons 1, consisting of 5 sub-samples average mass 6 of NEN-EN per tons 1, consisting of 5 sub-samples 3 shape 7 of NEN-EN Visual assessment allowed During the determination of the particle size distribution of fine grades, the shapes of at least 100 stones per tons are assessed. During the determination of the mass distribution of light and heavy grades the shape of all stones is assessed. 4 cracks and veins visually During the determination of the mass distribution, every stone is registered when it shows cracks, veins or other deviations 5 clay and loam visually if it concerns a bound application: every load 6 other contaminants visually every load 7 Content of broken surfaces 4.4 of NEN-EN only if the material does not originate from broken stones and if it is required in view of the final application: 1 per tons 1, consisting of 5 subsamples determination test method in accordance with NEN-EN minimum frequency per raw material production area 8 density 8 of NEN-EN per year 2 9 crush resistance NEN-EN 1926:1999, Appendix A 1 per 5 years 10 wear resistance NEN-EN only if the material will be exposed to sediment erosion in the final application: 1 per 2 years 11 petrographic description NEN-EN per 5 years 12 water absorption 8 of NEN-EN per year frost/thaw resistance 9 of NEN-EN if the water absorption > 0,5% 3 13 sunburn 10 of NEN-EN Only for basalt if there are indications for the presence of sunburn: 2 per year With a maximum of 1 sample per week and a minimum of 1 per 2 months during which production takes place. If the product information in this respect deviates from the usual values or includes a supplement, the frequency of this test will be adapted in consultation with the certification institute. The frost/thaw resistance must be determined every year on every individual piece of rock that shows excessive water absorption. If the manufacturer can demonstrate that the average water absorption is usually higher than 0,5%, and the material nevertheless shows sufficient frost/thaw resistance, the frequency of the frost/thaw resistance test can be reduced to 1x per 2 years, in consultation with the certification institute. 11

22 9 TEST FACILITIES 9.1 Testing space The manufacturer has to have a separate space available at the production site, set up specifically for this purpose, in which process control tests and conformity control tests can be conducted. If the tests for various production installations are conducted elsewhere, the conditions for this location will be established in consultation with the certification institution on the basis of 9.2 and 9.3. This will be reported to the Board of Experts on Aggregates and Fillers in general terms. 9.2 Equipment The room(s) where the tests are conducted must at least include the equipment required for conducting the tests 1-7 in Table 1, column Management and maintenance A management and maintenance system for the measurement equipment has to be formulated and complied with. This system has to include a diagram listing all equipment plus statements regarding: - the control parameters. - the inspection method. - the inspection and maintenance frequency. - the name of the official conducting the maintenance After inspection the official conducting the inspection must initial the diagram. 10. TRAINING The tests conducted by the manufacturer have to be conducted under the supervision of an official trained at the Intermediate Vocational Education level or equivalent, who has sufficient practical knowledge of the material technology in the opinion of the certification institute. The staff actually conducting the tests must have had an internal training and must have clear written instructions. In order to successfully complete the training referred to, the staff must be capable of correctly conducting all the tests used in the conformity control and to record the results in a well-organized administration. 11. EXTERNAL INSPECTIONS 11.1 Admission test The certification institute will start the admission test, consisting of an assessment of the production process and the related quality system as recorded in the quality manual, on the basis of a request submitted by the manufacturer. Moreover, the beginning of the practical training period, during which it will be assessed whether the manufacturer is capable of conducting the required tests and supplying products that meet the requirements, is established in consultation with the manufacturer. At the beginning of this period the manufacturer has to submit the geological file referred to in During this period one sub-sample will be taken from every grading and investigated under the supervision of the certification institute. This investigation is intended to verify the sampling and measurement techniques used by the manufacturer, as well as the results of the investigations previously conducted by the manufacturer Issue of a KOMO product certificate A KOMO product certificate is issued when the admission test shows that all requirements in the assessment guideline have been met. The certificate, including a statement on the indication of the certified grades, will be issued for one or more of the product groups stated in 2.17, 12

23 depending on the extent to which the certification institute has been able to assess the quality system, the (conducting of the applicable) procedures and the measurement results obtained Extension of the certificate Extension of the certificate to include a non-certified product within a product group as indicated in 2.17 will occur when the manufacturer has shown that the product meets the requirements. To achieve this the inspection frequency indicated in Table 1 can be raised. Explanation: The particle or mass distribution has to be determined at least once in accordance with 5 or 6 van NEN-EN , respectively. During this measurement the total sample must be subdivided into 5 representative sub-samples, so that the 5 most recent sub-samples from the population can always be arithmetically (see 7.4) combined into one sample during future process controls. Extension to include a product belonging to another product group will occur: - following an assessment by the certification institute of the production process and the associated inspections involved; - when the measured results show that the produced (and delivered) material meets the product requirements Inspection visits Subsequent to issuing the first certificate to a company, 5 inspection visits will be paid annually to check whether the product and/or the production process still meets the requirements. One of these annual inspection visits will be announced in advance. During this visit all aspects related to the documentation and the implementation of the factory production control will come up. The other visits will be unannounced. The Committee of Experts on Aggregates and Fillers may reduce the number of inspection visits per certificate holder to a minimum of 4 per year. In that case the certificate holder must propose to adapt the number of inspection visits on the basis of the results of the conducted inspection visits. If the company possesses a FPC certificate that was not issued by the certification institute, and the certification institute is allowed access to the reports of the Notified Certification Body concerned, the announced inspection visit may be cancelled. The aspects of the factory production control that do not come under the FPC certificate will then be brought up during the other inspection visits (at least 4 per year). To allow for an efficient inspection by the certification institute, the certificate holder will keep the certification institute informed with regard to the progress of the production. The way in which this will be done will be recorded in the certification agreement. No regular inspection visits will be paid to suppliers. Should there be a cause, the certification institute may decide to pay an announced or unannounced inspection visit to a supplier mentioned on the certificate. If the certification institute finds a deviation at the manufacturer's that is related to one supplier, this may influence the other certificates issued to that manufacturer. If the certification institute finds a deviation at one manufacturer that is related to a supplier, this may influence the other certificates issued to that supplier Reduction of the number of inspection visits during a period of low production If the total annual production of armour stone (including uncertified material) is less than 40,000 tons, fewer inspection visits will be paid annually. This is shown in Table 2. In that case the manufacturer must inform the certification institute when production takes place, so that the 13

24 inspection visits can be attuned to the period of production. A reduction of the number of inspection visits always starts at the beginning of a certification year. Should the production increase significantly during the running certification year, the number of inspection visits will be increased immediately. Table 2 - Reduced number of inspection visits annual production [tons] number of inspection visits up to 10, ,000-20, ,000-40, , Sampling under the supervision of the certification institute At every inspection visit samples may be taken by or under the supervision of the certification institute to assess whether the product requirements are being met: - by the manufacturer and/or, if there is reason to do so, - by an independent laboratory. This assessment may include investigation of all the aspects specified in Table 1. In practice, the assessment will focus on determinations 1 through 7. The certification institute will assess the quality of the delivered products in this way at least 2 times per year. The results of the tests by the independent laboratory may also be used for the assessment of those properties that have to be determined at low frequencies and for which the measurements are not conducted by the manufacturer Requirements regarding the certification employees An inspector must have completed a training relevant to the subject of this assessment guideline - at least (1) a training or course in the field of the Soil Quality Decree and (2) a training or course in the field of granular materials and/or the use of granular materials in civil engineering. Furthermore an inspector must have at least 2 years of relevant working experience, for example by (1) executing other certification regulations based on the Soil Quality Decree or (2) executing other certification regulations in the field of granular materials. An inspector must have professional and intellectual skills at Higher Vocational Training level. Training and experience of inspectors must be demonstrably documented. 12. QUALITY REGISTRATION The results of the conformity control are recorded in writing and have to be available for inspection by the certification institute. In consultation with the certification institute a well-organized administration will have to be maintained, in which the results of all the control activities are recorded, including the corrective measures taken. 13. OTHER OBLIGATIONS OF THE MANUFACTURER 13.1 Changes in operational management Fundamental changes in the installation, the origin of the used raw materials and the personnel 14

25 employed (such as the management representative and the person responsible for the quality control/visual selection of grades) must be reported to the certification institute within one month Data to be supplied to the customers All batches of armour stone have to be accompanied by a shipping document issued by the manufacturer. This document has to state at least the information as described in Appendix ZA.3 of NEN-EN , in the way described in section It is allowed to send the original shipping document to the customer via the supplier, for example in the form of an unalterable digital document. Certified products may not be delivered without the KOMO certification mark Product specifications document Moreover, the manufacturer has to have a product specification sheet available for every product that can be handed to the customer upon request. Only the properties entered in the product specification sheet will be included in the assessment by the certification institute Shipping document The manufacturer may supply only one, and just one shipping document per delivery. This document will include at least the following information: - the number of the certificate; - the date of loading; - the name of the ship or in case of road or rail transportation the registration number; - the name and the address of the manufacturer; - the name of the supplier; - the product information in agreement with the certificate; this concerns: the simple petrographic description as referred to in 4.2, the raw materials production area, and the grading; the number of the product specification sheet delivery in agreement with NEN-EN mass of the batch (per product); - in case of delivery by road or rail: serial number of the shipping document; - KOMO certification mark; - classification (shaped / unshaped building material) in accordance with the Soil Quality Decree, as stipulated in A The shipping document must be available at the customer's at the moment of delivery (see 2.1) and because of the included reference to the certificate this document also serves as proof of origin in accordance with RAW A supplier does not provide shipping documents Geological file A geological file has to be available for the raw materials production area exploited by the manufacturer. This geological file has to include information on the following subjects: 1. The location, shown on a topographical map at such a scale that the raw materials production areas can clearly be distinguished from the adjacent areas. Coordinates of the raw material production area. 2. Stratigraphic identification (statement on time period, formation or possible lower units) 3. Information on samples obtained on-site, especially: - the qualitative and quantitative petrographic surveys as described in NEN-EN 932-3; - the possible presence of sunburn or contaminants such as clay and loam; - the results of the availability tests in accordance with NEN 7371 (if conducted) 15