Welding Consumables
according to CPD/EN 13479 or EN 14532
The Certification proces – an informative guide
Content
Part 1: reinforcement steels according to DS 13080/13082/13083
Part 2: welding consumables according to CPD/EN 13479 or EN 14532-series
prPart 3: welded profiles according to BKR, method c) or d)
prPart 4: Steel and aluminium constructions according to BKR, method c) or d)
FORCE Certification issues product certificates to manufacturers of welding consumables according to:
EN 13479: Welding consumables - General product standard for filler metals and fluxes for fusion welding of metallic materials
EN 14532-1: Welding consumables - Test methods and quality requirements - Part 1: Primary methods and conformity assessment of consumables for steel, nickel and nickel alloys
EN 14532-2: Welding consumables - Test methods and quality requirements - Part 2: Supplementary methods and conformity assessment of consumables for steel, nickel and nickel alloys
EN 14532-3: Welding consumables - Test methods and quality requirements - Part 3: Conformity assessment of wire electrodes, wires and rods for welding of aluminium alloys
The technical regulations for mechanical testing and product design are stated in the product standards.
For manufacturers who have fulfilled the requirements to product certification according to Annex A a certification agreement between the manufacturer and FORCE Certification A/S is prepared. This certification agreement states the conditions for current production control, inspections by FORCE Certification A/S, the extent of testing and methods. Only when both parties sign the certification agreement, FORCE Certification A/S can issue a product certificate to the manufacturer.
Two types of product certificates may be issued:
· A FPC Certificate (Factory Production Control) according to EN 13479/Construction Product Directive
· Or a Product Certificate according to the EN 14532-series.
The product certificate verifies that the welding consumable has been correctly tested and that the testing result fulfils the requirements given in the EN 13479 and/or EN 14532-series. Furthermore, that on the date of issue FORCE Certification A/S is confident that the manufacturer's quality system fulfils the minimum requirements of EN 13479, EN 12074 or EN ISO 9001.
The purpose of conformity assessment of welding consumables as described in this document is to
- fulfil the specified requirements of CPD as specified in EN 13479 in order to CE the product, or
- to obtain product certificate according to EN 14532-series (product certificate)
The principle of an approval of a welding consumable is shown schematically in Annex A, from which it will appear that the issue of a product certificate is based on two separate factors:
- type examination of the product
- audit of the manufacturers quality system
Requirements for the type examination of the product are described in chapter 4. A type examination is valid until changes are made to the product specification, designation or classification. The type certification is independent of production site.
However, it must be verified by an "on site audit" at each production plant, that the consumable is manufactured under a quality system fulfilling the requirements of EN 12074 or EN 9001. All relevant production sites must be audited. Requirements on quality system audits are detailed in chapter 6 and 9.
The following activities have to be carried out when a manufacturer applies for a product certification of a welding consumable:
- The manufacturer forwards an application formula (annex B) together with information (product specification) about the welding consumable as specified in par. 5.2 of EN 14532-1/3.
- FORCE-Dantest CERT prepares a testing program according to the EN 14532-series and/ or EN 13479 for a mutual confirmation
- FORCE-Dantest CERT prepares an agreement of the quality system audit program
- Both parties agree on the schedule for welding, testing (if required) and audit
- Travel and accommodation is arranged for the examiner
Conformity assessment of welding consumables according to CPD is described as a 2+ procedure, which specifies type testing performed by the manufacturer and Factory Production Control (FPC) performed by a notified body (see annex A).
However, it is possible to combine conformity assessments according to EN 14532 and CPD (see annex C). A FORCE Certification A/S inspection of the type testing will then be required.
The test results are presented to FORCE Certification either before the FPC visit or during the visit. All tests shall be carried out on third party calibrated test machines, which will be examined during the FPC visit.
A product certificate is issued once documentation for type examination and quality system audit is approved by the certification manager.
A product certificate stays valid provided that:
- no changes of the product and to the basis for the type examination are made
- the quality system is successfully maintained and documented by on site audits
- the requirements given in EN 14532-1/3, annex N/H are fulfilled.
Requirements on product certificate maintenance are given in chapter 8.
Type testing at the manufacturer's facilities includes the following activities:
a) sampling of consumables at random from stock
b) survey of welding and testing in order to verify that all welding specification procedures, test procedures and test programs are being followed. Normally, this will be carried out during two or more visits to the manufacturer
c) examination of testing results against the requirements given in the product specification, EN 13479 and/or the EN 14532-series and the appropriate EN-classification standard
d) audit of the manufacturers quality system. This may be carried out during the visits specified in b) or c)
This product certification process does not invalidate previous welding consumable certifications made to former national standards or specifications, providing the intent of the technical requirements are satisfied and the previous product certifications are relevant to the applications for which the consumable is sought.
The following two cases can be subjected for acceptance:
a) If the welding consumable is already certified by FORCE Certification, but supplementary tests are required according EN 14532-series, previously executed tests can be accepted provided:
- the tests are carried out in accordance with the specified standard and the results fulfil the specified requirements
- the tests are carried out under supervision of a third party inspection body approved by FORCE Certification
- the original test reports are correctly filled in, stamped and signed by the third party inspection body in question
b) If a welding consumable is already certified by another European EA-accredited test laboratory the type testing can be accepted, provided the above-mentioned requirements from 1) are met, and that the certification has been prolonged continuously without interruptions since the type testing was carried out.
In order to receive a product/FPC certificate the manufacturer must fulfil the requirements to quality system documentation specified in EN 13479, EN 12074 or EN ISO 9001:2000. The manufacturer has the following possibilities:
- Auditing of his quality system according to EN 12074 and/or EN ISO 9001:2000 without certification of the system.
- Audit of the quality system and production according to FPC only.
- Certification of his quality system according to ISO 9001:2000.
- Certification of his quality system according to EN 12074.
The manufacturer's quality system must as a minimum be documented as specified in EN 12074. The quality system must embrace recording of complaints, claims, internal audits etc. These records are to be kept in the entire period of validity of the product certificate and must show:
- which complaints have been made
- the technical nature
- what measures have they entailed
- who has taken the measures
- the effect of the measures taken
To maintain the validity of the product certificate, the manufacturer must at least maintain his quality system at this level during the entire term of the product certificate's validity.
Prior to the agreed date for the type testing the manufacturer forwards an application form and a copy of the documentation mentioned in EN 14532-1/3, par. 5.2, to FORCE Certification (please see annex III).
If the manufacturer does not have any welding consumables previously approved by FORCE Certification, he shall also forward a copy of his quality manual or equivalent documentation. In this case an examination by FORCE Certification of the documentation includes the certification application and quality manual. The purpose of such an examination is to ascertain whether the manufacturer's quality system fulfils its quality policy and the requirements of EN 12074 or EN ISO 9001:2000 to an extent which provides reasonable certainty that the certification process can be completed without appreciable delay and lead to a positive end result.
For further information about certification of the manufacturer's quality system, please see the FORCE Certification A/S web page "Kvalitetsystemer" and our general terms "ABC/Sys".
For a product certificate to be valid, the manufacturer must at all times operate in accordance with its quality policies and EN 12074 / EN ISO 9001:2000. FORCE Certification monitors compliance by carrying out surveillance audits of manufacturer's quality system within a maximum of every 12 months.
However, if the manufacturer also holds a FORCE Certification quality system certificate, the examiner performs audit of the quality system in accordance with the FORCE publication ABC/Sys.
Requirements to production check tests are specified in EN 14532-1 or -3, annex N/H, and the results of these check tests shall regularly be presented to FORCE Certification. We will be as flexible as possible in using electronic transferred test results to us for examination. Special agreements shall be established for each individual customer.
In order to maintain the product/FPC certificate annual surveillance audits must be carried out and involved the following activities:
- arrangements are made in a way that the annual surveillance audit can take place between three months before and three month after the planned date. Deviation from this period can be accepted if this is necessary for the manufacturer. Extensions must be confirmed in a letter from FORCE Certification describing the accepted length of the extension period. Extensions of more than four month can normally not be given
- FORCE Certification performs the surveillance audit
In case of significant nonconformity FORCE Certification sets a time limit for the corrective action to be carried out.
FORCE Certification issues a letter confirming the prolongation of the product/FPC certificates. These audits follow an audit program prepared by the examiner. The program ensures that activities at all addresses covered by the certificate and all areas of the manufacturer's quality system are audited at least once during the time the product/FPC certificate is valid. The program otherwise depends on the specific rules laid down by FORCE Certification for audits according to EN 13479, EN 12074 or EN ISO 9001:2000.
FORCE Certification must give the manufacturer at least 2 weeks notice prior to a surveillance audit. A surveillance audit generally follows the same program as the initial audit in selected areas.
FORCE Certification will be as flexible as possible in order co-ordinate audits, welding and testing in the most efficient way.
Should FORCE Certification become aware of circumstances requiring extraordinary audits, such audits may be made with a 3-day notice.
It is the obligation of the manufacturer to immediately notify FORCE Certification in the case of foreseen modification of the welding consumable. Any changes may affect the product certificate.
The definition of major changes in the welding consumable specification is described in EN 14532-1/3, par 12. If major changes are made the following activities shall be performed:
- the manufacturer forwards the revised product specification to FORCE Certification
- agreement on a supplementary test program will be prepared and the program must be executed as described in 4.4
- after completion with satisfactory results FORCE Certification approves the documentation
FORCE Certification forwards the product certificates or amendment to the manufacturer
Minor changes in the product specification are changes, which are not covered by EN 14532-1/3, par. 12.
The following activities shall in this case be performed:
- the manufacturer forwards the changes to FORCE Certification, who evaluates, stamps and signs the documentation
- the manufacturer receives a letter with acceptance of changes
Changes in the manufacturer's quality system shall be reported to FORCE Certification.
The actual prices are stated in the FORCE Technology’s price list.
All services provided by FORCE Certification in connection with assessment of conformity are invoiced according to time consumption and possible hotel and travelling expenses.
The manufacturer shall be aware of the special issues that is relevant in the certification process. This also applies to changes in the standards/guidelines, such changes can make the certificate invalid. These special issues are described in our General Terms, ABC-Weldcons.
Some of the issues are shortly summarised here.
Edition 2 - 28. juli 2010
