The article the requirements of the Factory Production Control (FPC) dedicated to construction products (including metal, i.e. ribbed bars, steel pipes, shapes, sheets and metal constructions) introduced to the single market of the European Union, was presented. Meeting the requirements of legal regulations with regard to these products is an important issue for metallurgical companies placing their products on the EU market. These enterprises are required to effectively implement and supervise the FPC system, supervised by a party independent of the manufacturer (third party). The aim of the article is to present the requirements of the FPC and refer them to the requirements of industry standards for metal products – shapes

Małysa, T.

Pawlak, Sz.

English

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167METALURGIJA 62 (2023) 1, 167-169SZ. PAWLAK, T. MAŁYSAFACTORY PRODUCTION CONTROL (FPC) AND ITS REQUIREMENTS FOR THE METALLURGICAL INDUSTRYReceived – Primljeno: 2022-04-28Accepted – Prihvaćeno: 2022-07-15Preliminary Note – Prethodno priopćenjeThe article the requirements of the Factory Production Control (FPC) dedicated to construction products (including metal, i.e. ribbed bars, steel pipes, shapes, sheets and metal constructions) introduced to the single market of the European Union, was presented. Meeting the requirements of legal regulations with regard to these products is an important issue for metallurgical companies placing their products on the EU market. These enterprises are re-quired to effectively implement and supervise the FPC system, supervised by a party independent of the manufac-turer (third party). The aim of the article is to present the requirements of the FPC and refer them to the require-ments of industry standards for metal products – shapes.Key words: metallurgical industry, product, control, standards, PolandISSN 0543-5846METABK 62(1) 167-169 (2023)UDC – UDK 669-338.96.002.6:658.562:389.64:438 = 111INTRODUCTIONThe requirements for factory production control date back to the end of the 1980s and were set out in Council Directive 89/106/ EEC [1], which was replaced by Regulation (EU) 305/2011 of the European Parlia-ment and of the Council [2] establishing harmonized conditions for the marketing of products construction, which include, among others, ribbed bars, pipes, sheets, sections and metal structures obtained in the process of plastic processing. Factory production control means the documented permanent and internal control of pro-duction in a manufacturing plant, in accordance with the applicable technical specifications [2]. Its imple-mentation is aimed at ensuring supervision over the production process and the finished product in a manner ensuring compliance with the legal provisions. The FPC is dedicated to construction products, which are under-stood as each product or set manufactured and placed on the market for permanent incorporation in construc-tion objects or their parts, the properties of which affect the performance of construction objects in relation to the basic requirements for construction objects [2].The basic reference documents covering the guide-lines necessary to be met by manufacturers of construc-tion products include: national standards, harmonized standards, as well as National Technical Assessments. The scope of the requirements to be met by the manu-facturers depends on the type of product being manu-factured and reference documents. The scope of the control carried out in production plants includes, among others: input material control, supervision of the pro-T. Małysa: tomasz.malysa@polsl.pl – Silesian University of Technol-ogy, Katowice, PolandSz. Pawlak: szymon.pawlak@polsl.pl – Silesian University of Technol-ogy, Katowice, Polandduction process and process control, supervision of measuring equipment, assessment of personnel compe-tences and confirmation of compliance with legal re-quirements in terms of performance. The assessment of the company in terms of the implementation of the FPC system is carried out regularly at agreed time intervals by external units, independent of the manufacturer. Su-pervision over the system and verification of compli-ance with requirements takes place through inspections at the production plant.METHODOLOLOGYThe implementation of the assumed goal of the study was possible thanks to the development of the methodology of own work. The first stage consisted in specification of legal requirements dedicated to prod-ucts such as: ribbed bars, pipes and welded closed sec-tions made of unalloyed and fine grain steels.The second stage consisted in assigning the products which are the subject of the analyzes of the assessment and verification system for performance (system 1 +, 1, 2 +, 3 and 4). Establishing the system of assessment and verification of performance made it possible to define the scope of responsibility of the manufacturer, as well as the notified body / laboratory. The requirements of the standards dedicated to the products in question were also specified. As part of the third stage, practical ac-tivities necessary for the implementation of the FPC system for closed sections with seams were presented (activities in accordance with the legal requirements and the PN-EN 10219-1: 2007 standard [3]).A step-by-step, structured approach to the FPC sys-tem based on the developed methodology allows for an effective assessment of products and meeting the re-quirements of legal regulations.168  METALURGIJA 62 (2023) 1, 167-169SZ. PAWLAK et al.: FACTORY PRODUCTION CONTROL (FPC) AND ITS REQUIREMENTS…FACTORY PRODUCTION CONTROL  - STEEL PRODUCTSThe basic legal act in the field of Factory Production Control is the regulation [2], which lists the basic re-quirements for manufacturers of construction products, including ribbed bars, pipes, sheets, sections and steel structures. Table 1 lists the obligations of the percent-ages in relation to: preparation of the declaration of per-formance, technical documentation, CE marking and product marking.In the case of ribbed bars (system 1 +), the manufac-turer was obliged to implement and maintain FPC, as well as test ribbed bars in accordance with the require-ments of reference documents. In terms of testing, de-pending on the steel grade, manufacturers should en-sure compliance with the following standards:• PN-EN 10080: 2007 [4], which summarizes the general requirements for ribbed steel,• PN-H 93220: 2018 [5], which defines general re-quirements and performance properties for weld-able reinforcing steel - type B500P,• PN-H 93250: 2018 [6], which specifies general requirements and performance properties for weldable reinforcing steel - type B500N.In terms of this type of products, the role of a noti-fied body (third party) independent of the manufacturer is important. The third party within the FPC: defines the product, performs the initial assessment of the produc-tion plant and FPC control, supervises and evaluates the system, and takes samples for testing.For pipes covered by system 1, the manufacturer was obliged to implement and maintain the FPC system and to test in accordance with the requirements of sam-ple reference documents (Table 1). On the other hand, the third party defines the product type, conducts its initial assessment of the production plant and FPC. The external unit also conducts constant supervision over the implemented and documented system compliant with the reference documentation (Table 1). Sections Table 1  Obligations of a manufacturer of metal products, including the assessment and verification of the constancy  of performance [own elaboration based on 2]Product Manufacturer’s obligationsConstruction products(metal)-  Obligation for the manufacturer to draw up a declaration of performance.-  Obligation to mark the product placed on the market with the CE mark.-  Obligation to prepare technical documentation describing all essential elements of the applied system of assessment and verication of constancy of performance.-  Obligation to keep the declaration of performance and technical documentation for a period of 10 years from the moment the product is placed on the market.-  Obligation to ensure that the declared performance of the product is maintained in series production.-  Obligation to test products in accordance with the requirements of reference documents.-  Obligation to consider complaints (register of complaints), non-conforming products and products withdrawn from users.-  Obligation to mark the product (batch, type or serial number, or other information allowing for their identication).Product type (Assessment system)Assessment and verication of constancy of performanceResponsibilities  of the manufacturerResponsibilities of the notied body Sample reference documentsRibbed bars(system 1 +)Implementationand maintaining the Factory Production ControlTests of ribbed bars / tubes  as required by the reference  documentDening the product typeInitial Assessment of the Manufactur-ing Plant and Factory Production ControlConstant supervision and evaluation  of the FPC systemControl testing of samplesPN-EN 10080:2007 Steel for concrete reinforcement. Weldable reinforcing steel. General provisions [4]PN-H 93220:2018 Steel for concrete reinforce-ment - bonding reinforcing steel B500SP [5]PN-H 93250:2018 Steel for concrete reinforce-ment - B500SN bonding reinforcing steel [6]National Technical Assessments Pipes(system 1)Dening the product type-Preliminary assessment of the produc-tion plant and factory production control.-Permanent supervision and evaluation of the FPC systemPN-EN 10216-1:2014 Seamless steel tubes for pressure purposes [7]PN-EN 10217-1: 2019Welded steel tubes for pressure purposes [8]Sections(system 2 +)Determining the product typeImplementation and maintenance of the FPCExamination of sections in accor-dance with the requirements of reference documentationInitial Assessment of the Manufactur-ing Plant and Factory Production ControlConstant supervision and evaluation  of the FPC systemPN-EN 10219-1:2007Cold formed welded hollow sections of unal-loyed and ne grain structural steels [9]Table 2  Manufacturer’s activities and FPC requirements  for closed sections with a seam [own elaboration]Process step Actions taken FPC requirements1 Input material control in accordance with the assumed requirementsControl plan2 Continuous control of the param-eters of the production processControl planTechnological documentation with specied pro-cess parameters3 Performing tests in accordance with the control plan and the require-ments of point 7.3 of the PN-EN 10219-1: 2007 standard [9]Protocols from tests conrming product compli-ance4 Determining the methods of storage and protection of the surface in a manner ensuring against surface damage and appropriate marking - point 10 of the PN-EN 10219-1: 2007 standard [9]Procedure169SZ. PAWLAK et al.: FACTORY PRODUCTION CONTROL (FPC) AND ITS REQUIREMENTS…METALURGIJA 62 (2023) 1, 167-169are subject to the 2+ system, under which the manufac-turer was obliged to determine the product type, imple-ment and document the FPC system, test the product in accordance with the requirements of reference docu-mentation (Table 1).REQUIREMENTS FOR PRODUCERS  IN THE FIELD OF FPC (CASE STUDY)In the case of closed sections with seams made cold from structural steels subject to the 2+ rating system, the manufacturer at individual stages of the production pro-cess implements the production process and product quality assessment system, in accordance with the re-quirements of PN-EN 10219-1: 2017 [3]. The activities carried out under the FPC system are to lead to the repro-ducibility of the obtained parameters of the finished product. The production process of hollow sections cov-ered by the FPC system concerns, among others: material acceptance and control (1), production process (2), fin-ished product inspection and testing (3) as well as mark-ing and storage (4). The activities of the manufacturer and the requirements for the FPC as part of the produc-tion process of sections are summarized in Table 2.In order to identify inconsistencies of the input ma-terial or discrepancies in its chemical composition, a documented control of the supply of the input material is necessary. The manufacturer prepares documentation describing the parameters of the manufacturing process in order to ensure the repeatability of the manufactured product in accordance with the control plan. It also car-ries out tests of the finished product in order to verify compliance with the requirements described in the ref-erence documentation, i.e. PN-EN 10219-1:2017 [3] (Table 3). The manufacturer defines the requirements for the method of storing finished products and imple-ments a uniform system ensuring proper labeling of the product, enabling its traceability. Ensuring the repeata-bility of the activities carried out in the field of storage and labeling of the product should be described in the FPC documentation in the form of a procedure.In addition, the manufacturer is obliged to provide ap-propriate equipment necessary for the implementation of the production process and its control. Measuring instru-ments should have a valid calibration certificate. Produc-tion personnel responsible for the implementation of FPC tasks should have appropriate qualifications (education, training). The scope of the manufacturer’s obligations as part of the FPC system also includes: activities related to the supervision of a non-conforming product, corrective actions, production equipment and the design process. According to the adopted definition of the FPC, all areas should be documented.CONCLUSIONSThe introduction of metal products such as: steel pipes, ribbed bars, sections to the single EU market is related to the fact that manufacturers have an implemented and doc-umented system of Factory Production Control. The im-plementation of the system is focused on the production of products compliant with the requirements of reference documents, as well as full supervision of the product, in-cluding the non-compliant product. The Factory Produc-tion Control System ensures orderly and consistent activi-ties within the realized production tasks. Depending on the type of product, the requirements on the manufacturer differ and regular third party inspections ensure adequate supervision of the proposed system solutions.AcknowledgeSilesian University of Technology (Faculty of Ma-terials Engineering), supported this work as a part of Statutory Research BK-207/RM1/2022 (11/010/BK_22 /0038)REFERENCES[1] Council Directive of 21December 1988 on the approxima-tion of laws, Regulation and administrative provision of the Member States relating to constructions product (89/391/EEC).[2] Regulation (EU) No 305/2011 of the European Parliament and of the Council of 9 March 2011 laying down harmonized conditions of the marketing of construction product.[3] PN-EN 10219-1:2007 Kształtowniki zamknięte ze szwem wykonane na zimno ze stali konstrukcyjnych niestopowy-ch i drobnoziarnistych - Część 1: Warunki techniczne do-stawy.[4] PN-EN 10080:2007 Steel for concrete reinforcement. Wel-dable reinforcing steel. General provisions.[5] PN-H 93220:2018 Steel for concrete reinforcement - bon-ding reinforcing steel B500SP[6] PN-H 93250:2018 Steel for concrete reinforcement - B500SN bonding reinforcing steel.[7] PN-EN 10216-1:2014 Seamless steel tubes for pressure purposes.[8] PN-EN 10217-1: 2019 Welded steel tubes for pressure pur-poses.[9] PN-EN 10219-1:2007 Cold formed welded hollow sec-tions of unalloyed and fine grain structural steels.Note:  Szymon Pawlak is responsible for English language, Katowice, PolandTable 3 Mechanical properties for hollow sections of unalloyed and fine grain structural steels [3]Steel grade The minimum yield strength Rm / MPaMinimum yield strength Re / MPaMinimum  elongation A / %Minimum breaking energy KV / JMark Number Nominal thickness / mm Test temperature≤ 16 > 16 ≤ 40 < 3 ≥ 3 ≤ 40 ≤ 40 -20 oC 0 oC 20 oCS235J 1.0039 235 225 360 - 510 360 - 510 24 - - 27S275J0H 1.0149 275 265 410 - 580 410 - 560 20 - 27 -S355J0H 1.0547 255 345 510 - 680 470 - 630 20 - 27 -

Factory production control (FPC) and its requirements for the metallurgical industry

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