SOLUTION FOR COMPLEX FABRICATION · Solution for Complex Fabrication ... 10. Method Statement ... Stainless Steel Handrail 3. Stainless Steel Column Cladding 4

PRE-QUALIFICATION

SOLUTION FOR COMPLEX FABRICATION

Bilal Metal Fabrication L.L.C. Page 1

Solution for Complex Fabrication

Contents

1. Introduction: ............................................................................................................................... 2

2. Company Profile ........................................................................................................................ 4

2.1 Message from Managing Partners ........................................................................................... 4

2.2 Services: ................................................................................................................................... 5

2.3 Mission:.................................................................................................................................... 5

2.4 Vision: ...................................................................................................................................... 5

2.5 Core Values:............................................................................................................................. 6

2.6. Policies: ................................................................................................................................... 6

3. Organization Chart ..................................................................................................................... 7

4. Divisions: ................................................................................................................................... 8

4.1. Design and Engineering ...................................................................................................... 8

4.2. Sheet Metal Fabrication: ..................................................................................................... 8

4.3. Aluminum Fabrication: ..................................................................................................... 10

4.4. Stainless Steel Fabrication: ............................................................................................... 11

4.5. Structural Steel Fabrication: .............................................................................................. 13

4.6. Water Jet Cutting Service:................................................................................................. 14

4.7. Machine Shop Services: .................................................................................................... 16

4.8. Welding Department: ........................................................................................................ 17

5. Facility: .................................................................................................................................... 19

6. QA/QC MANUAL................................................................................................................... 20

7. Trade License ........................................................................................................................... 37

8. Financial Statement .................................................................................................................. 38

9. Certifications ............................................................................................................................ 38

10. Method Statement ................................................................................................................. 38

11. List of Major Project(s) ......................................................................................................... 39

12. Warranty Specimen ............................................................................................................... 55

13. Contact Us:............................................................................................................................ 56


1. Introduction: We take immense pleasure in introducing to you Bilal Metal Fabrication L.L.C. (BMF)

which is established by directors with an experienced background in designing, construction,

fabrication, operations & management. The directors are keen to provide quality services for all

kind of architectural & structural metal works and put their deep interests in the details of client

requirements. Bilal Metal Fabrication undertake the design, fabrication, manufacture and

installation of sheet metal and are fully equipped with facilities to undertake the cutting, bending,

folding & provide polishing / finishing of Aluminum, copper, mild steel & stainless steel metal

work (Example: Balustrade, handrails, architectural décor, interior & exterior staircase, canopies,

wall cladding, etc.).

Bilal Metal Fabrication is associated with Bilal Industries L.L.C. which was established in

2008 dealing with the manufacturing of seam hollow section steel (Round Pipes, Square Tubes and

Rectangular Tubes (Hot Rolled /Mild Steel/ Cold Roll/Hot Dipped Galvanized Steel). It is also

dealing with the trading of all kinds of Steel (HR/GI/PPGI)/ Aluminum / Perforated Sheets / SS

Sheets and Coils. Bilal Industries has a separate Coil Service Center that processes

(cutting/slitting) different (specs) Steel Coils as per client’s requirements.


BMF is also associated with Greenway Facilities Management & Services which was

established in Dubai since 2011, Greenway professional services provide a complete maintenance

solution of all kind of external facade. It also provides re-designing and renovation of interiors.

Greenway FMS - Maintenance and Renovation Division includes:

De-Glazing and Re-Glazing of Broken Glass; especially on High-rise buildings.

Maintenance and Replacement of Metal Cladding

Maintenance and Replacement of Stainless Steel Features

Point Fixing Glass Replacement

Re-application of weather sealants

Replacement of Weather Gasket

Replacement of Washroom Mirrors

Supply and Installation of Painted Glass and Mirrors

Replacement and Fixation of Shower Doors and Partition

Replacement of Entrance Lobby/Shops Front Manual Door with Automatic

Sliding or Swing Door.

Floor, Ceiling and Wall Decors (Aluminum, Glass, Timber, Wallpaper and

Customized as Per Request)

Other Room Decors (Room Partitions, Racks, Shelves and Etc)


2. Company Profile

2.1 Message from Managing Partners

BILAL ZAFAR (Managing Partner)

Being a Managing Partner at Bilal Metal Fabrication (BMF) which is working in close

coordination with Bilal Industries, I am proud to dictate that our vast experience and in-depth

knowledge in the fields of coil servicing, manufacturing of seam welded hollow section steel and

trading of all kinds of steel, aluminum and much more, made us the perfect fit for Greenway

Facilities and Management Services. BMF are now able to combine the expertise of both Bilal

Industries and Greenway Facilities and Management in order to deliver high quality products and

services, which meet the exact requirements of our customers. We are able to carry out the design,

fabrication, manufacture and installation of metal sheets and are fully equipped with the facilities

to perform the cutting, bending, folding & provide polishing/ finishing of aluminum, copper, steel

& stainless steel metal sheets. Thank you for your interest in BMF. I request you to look through

the website and brochure to know more about us and I hope you choose us to provide you with the

best products and services possible.

SALMAN CHAUDHRY (Managing Partner)

I am glad to announce the establishment of Bilal Metal Fabrication L.L.C. and am very

keen to take our firm to be recognized worldwide for its excellent services and promising

commitment. We have made a great start and are achieving steady progress towards our aim of

becoming a global leader in the metal fabrication industry. I would like us to acquire unrivalled

competitive strength and work to increase our corporate value. Greenway Facilities and

Management Services was established in 2011 and it provides the renovation, maintenance &

replacement of metal cladding, flooring, ceiling, wall decors & various interior fit-out works. Our

vast experience and in-depth knowledge in these various fields made us the perfect fit for Bilal

Industries L.L.C. Combining our vast experience in the fields of engineering, fabrication,

operations, designing and management and our continuous improvements in the production

facilities, BMF fabricates many customer needs exceeding their expectations and meeting their


high standards. We undertake the design, fabrication, manufacture and installation of metal sheets

and are fully equipped with the facilities to perform various activities. BMF offers high-quality

innovative services at the right price through the combination of our sourcing strategy and in-depth

knowledge of the market needs and industry standards. Thank you!

2.2 Services:

Water Jet Cutting (State of Art Technology to cut any material up to 200mm thickness)

Design and Engineering

Sheet Metal Fabrication

Stainless Steel Fabrication

Aluminum Fabrication

Structural Steel Fabrication

Welding Services

Machining

CNC Grooving machine for Aluminum Composite Cladding

Plasma Machine

Stainless Steel Polishing

Punching Machine

Casting / Die Fabrication

2.3 Mission:

“Bilal Metal Fabrication (BMF) is a company providing tangible products and services with the

aim of exceeding our customers’ expectations in terms of quality, delivery and cost through

constant improvements, committed employees and close customer relationships. We work to meet

the highest standards of ethics and environmental principles and reward those who contribute

towards our success.”

2.4 Vision:

“BMF will continue to grow and eventually become a world-renowned leader in providing state-

of-the-art solutions in custom metal fabricating and manufacturing opportunities.”


2.5 Core Values:

Integrity:

We do not compromise on acting with honesty, responsibility and respect to meet client’s

requirements or for our dedicated team of employees.

Leadership:

We aim to lead not only in our industry but also in all our relationships.

Enthusiasm:

We aim to always provide a fair, challenging and enjoyable work environment for all employees in

order to meet their needs and expectations.

Work Ethic:

To attract and retain high quality capable employees who have a drive to excel and advance further

in their careers. BMF provides constant encouragement and vast opportunities for advancement in

both knowledge and practical skills.

Collaboration:

We work in collaboration with clients, suppliers, employees and others in order to reach our

mutual goals.

2.6. Policies:

HSE Policy:

We aim to always provide a safe and health working environment

All employees are trained on a regular basis to achieve the goal of zero lost time

incidents.

Keeping our environment safe and our surroundings clean are a major priority for

us. Ethics Policy:

We will act with candour, respect and responsibility towards all our customers.

We will act in accordance with our main values and expectations.

We will be friendly and honest when communicating with our clients.

We will honour the confidentiality of our clients’ information.


3. Organization Chart

Organisational Chart Management 7 Foreman/Supervisor 1 Draughtsman/Cum Engineer 2 Waterjet Operator 1 Sheering Bending Machine Operator 1 Welders 3

Helper 5 Driver 1 Office Boy/ Security/ Helper 1 22

Managing Partner

Estimation Manager

Assistantant Estimator

Design Manager

Draughtman cum Estimator

Sales Engineer

Operation Manager

Foreman/Supervisor

Waterjet (1) Operator

Sheering/Bending Operator / Welders

Helper - Logistics

Office Boy/ Helper

Project Manager

Site Engineer

Helper and Fitter

Site Coordinator

Managing Partner

General Manager

Account Department

Purchase Department

Adminstration Department


4. Divisions:

4.1. Design and Engineering

Bilal Metal Fabrication aims to provide a full and flexible engineering service, producing a wide

variety of sheet metal works and fabrication in various materials and encompassing one offs and

prototypes, small batch work and larger production runs.

Whether you supply finished drawings or we help in designing your projects, we have knowledge

and experience to execute all kind of works. We have many years of experience in structural and

sheet metal fabrication.

At Bilal Metal Fabrication, we take pride in offering the most superior engineering and design

services the industry has to offer. From design to fabrication, we stop at nothing to insure that your

order is properly filled. Once you provide us with your specific requirement, we will develop an

assembly concept and generate a full set of blue prints and assembly drawings to meet your needs.

Our knowledge and courteous engineering staff, who have developed hundreds of enclosure

designs that addresses even the most difficult requirements, are available to assist you with every

aspect of the process. For existing design work with our engineers to leverage their experience in

design for manufacturing to assist with identifying design changes that can reduce cost as well as

alleviate issues caused by tolerance stack up in assemblies

We can read/write – import/export:

AutoCAD Drawings

STEP Files

IGES Files

DXF Files

2D/3D Files

4.2. Sheet Metal Fabrication:

Our sheet metal fabrication shop is set up to accommodate many different facets of designs.

We specialize in stainless steel, aluminum and all other sheet metal shearing, brake forming and

welding to create quality custom products and fulfill all our customer’s needs. We have qualified

personnel with the experience and ability to assist in the design aspect as well. Moreover, we

specialize in perforated sheet cutting as well. Having ability to handle all your sheet metal

fabrication needs is what makes Bilal Metal Fabrication an ideal choice for this kind of work. Out

bending department maintains a wide variety of press brakes in various sizes to accommodate any

size bending or forming job quickly and accurately. We specialize in high volume work with the


ability to provide a fast run around for your parts.

Products Bilal Metal Fabrication produces from Sheet Metal Fabrication:

1. Wall Cladding:

a. Plain Sheet Cladding

b. Perforated Sheet Cladding

c. Bubbles Cladding

2. Perforated Architectural Features

3. Stainless Steel Features

4. Column Cladding


4.3. Aluminum Fabrication:

Aluminum not only offers many advantages due to its material properties. Aluminum is also

extensively adaptable to fabrication and machining processes. Generally tooling costs are lower

than with many other metals and the high speed at which certain processes can be completed, offer

even greater labor cost savings. Products Bilal Metal Fabrication produces from Aluminum

Fabrication:

1. Pergola

2. Fence (Design)

3. Aluminium Hand Rail

4. Aluminium Canopy

5. Aluminium Column Cladding


4.4. Stainless Steel Fabrication:

We specialize in making your design a reality and creating features that are a practical solution to

your design idea. Since inception we have gained extensive expertise in fabrication for the

industrial, leisure, commercial and civil sectors.

Products Bilal Metal Fabrication produces from Stainless Steel Fabrication:

1. Stainless Steel Canopy

2. Stainless Steel Handrail

3. Stainless Steel Column Cladding

4. Stainless Steel Features



4.5. Structural Steel Fabrication:

Bilal Metal fabrication is a full-service steel provider which furnishes and installs all structural

steel. We offer a full design, manufacture & installation service working closely with our partners

to deliver your project to specification, time and budget. We help you succeed by developing

innovative steel solutions to the challenges presented by today’s complex construction projects. As

a high-capacity structural steel fabricator with in-house design engineering, we are uniquely

positioned to solve the most difficult design and fabrication issues. Our proactive and integrated

approach provides you with a competitive advantage, allowing you to win more projects.

We can offer detail and fabrication drawings including 3D models of the works we are

undertaking which you can tour the structure or the staircase to make sure everything works the

way you envisaged. We have the capability to receive all drawings for your project – contract or

shop drawings – and provide Approval drawings electronically for quicker turnarounds and faster

steel delivery. Once drawings are approved, fabrication can begin in our state-of-the-art production

facility.

Products Bilal Metal Fabrication produces from Structural Steel Fabrication:

1. Truss

2. Canopy

3. Sheds


4.6. Water Jet Cutting Service:

Bilal Metal Fabrication provides option for cost effective precision machining with state of the art

water jets. Water jet cutting can produce a finished product in a fraction of time of other

conventional processes. Our modern equipment offers a range of capabilities. Water jets use a

water/abrasive mixture to cut though all metals, ceramic and plastic with exceptional efficiency.

Our equipment can be used as a single process or to pre machine parts destined for tighter

tolerances. Our dynamic water jets allow us to more precisely direct the abrasive flow to achieve

tolerance that rival those of other advanced processes.

Here are some of the products cut by Waterjet Machine



4.7. Machine Shop Services:

Bilal Metal Fabrication offers one of the best equipped, full service metal machine shop. Our

machining department offers a wide range of service including cutting, milling, drilling, tapping

turning facing and more. We specialize in precision machining on a production level. We have a

wide range of computerized and manual machining equipment and can accept short runs as few as

one part.

We are also interested in providing our customers with their desired shaped parts using forging,

rolling, extrusion, die casting, etc.

TYPES OF DYES

Forging: Manufacturing process involving the deforming of a metal by shaping it using forces

(hammering) or with a die.

Rolling: Most commonly used process consisting of passing the metal between two rolls causing a

reduction in thickness from compressive forces (cold-rolling and grooved rolls).

Extrusion: Process where the metal is pushed/pulled through a die of a desired cross-section.

Die Casting: Fabrication process whereby a molten metal is poured into mold cavity with the

desired shape, until it solidifies.


4.8. Welding Department:

Our welding department contains a wide variety of welding procedures including mig, tig and spot

welding. We have the capability to handle virtually any size job from smaller parts to large weld in

steel, stainless steel, aluminum as well as more exotic metals. With highly experience and skilled

team our craftsmen are complemented by modern equipment that enables them to consistently

produce the highest quality weld and assemblies which are cost effective and on time. Few types of

welding we carry out:

GAS METAL ARC WELDING or MIG WELDING

is a type of semi-automatic/automatic process that uses a continuous wire feed where the electrode

is fed to the weld via the welding handgun. MIG welding is comparatively a faster type of welding

and capable to weld many metals of different thicknesses with fewer human error elements.

GAS TUNGSTEN ARC WELDING or TIG WELDING

is a manual welding process that uses a non-consumable tungsten electrode to produce the weld.

This type of welding is used for many types of metals, as well as alloys, especially for welding thin

materials. It is a state of art welding known for its precise and stable arc providing customers with

high quality and clean welds.


MANUAL METAL ARC WELDING

WELDING is a type of welding that uses electric current to strike an arc between the material and

consumable electrode. This process is more versatile and relatively inexpensive option for the

customers, more suited for field works. Arc welding is generally limited to ferrous materials.


5. Facility:

Machines Capability

WaterJet Cutting

Cutting Capacity – 2000x4000x200mm

thick

X Y and Z Axis

Cuts any Material

CNC Hydraulic Press Brake

Capacity 160ton

Bending Length – 3100mm

Inside Frames- 2550mm

Bending Thickness – 8mm

Throat Gap – 410mm

CNC Hydraulic Swing Beam Shearing Shearing Capacity – 8mm

Cutting Length- 3060mm

Notching Machine

Cutting Length – 200mm

Cutting Capacity – 6mm

Cutting Angle – 5*

Drilling and Milling

Drilling Capacity – 32mm

Face Mill Capacity – 76mm

End Mill Capacity – 20mm

Swing – 430mm

Iron Worker

Punching Capacity – 27 dia

Angles – 75mm x 75mm x 9mm

Plate Shear – 13mm x 305mm

Tig and Mig Welding Tig, Mig and Spot Welding


6. QA/QC MANUAL

Document No. : BMF – QAC – 2014 – 0 Date : 1st September 2014. Document Title : QA/QC MANUAL Revision : 0 “Quality is fitness for the purpose.” Reliability is the ability to continue to function to our accepted quality standard.” PLEDGE:

BMF delegates the necessary responsibilities with authority and organizational freedom to all its

members under independent departments performing QA/QC functions to ensure high quality

standards and identify quality related problems and to initiate, recommend and provide solutions to

maintain Quality Standard.

MOTTO:

Establish and maintain the right level of the Quality Standard for all the activities which may

influence the quality of the services and production rendered by BMF and that quality will be

planned and built into a product/service, and verified by means of review, inspection and testing,

to satisfy the customer.


TABLE OF CONTENTS 1. QUALITY ASSURANCE PROGRAMME

1.1 Quality Assurance 2. QA MANUAL

2.1 Manual Control 3. QA/QC PROCEDURES

3.1 QA General procedures

3.2 QA/QC Functional procedures 4. QUALITY CONTROL

4.1 Visual Inspection of structural Steel and piping

4.2 Non – Destructive Examinations (NDE)

4.3 Leak Testing / Hydrostatic testing

4.4 Inspection of Surface Treatment

4.5 Dimensional Control 5 DETAIL INSTRUCTIONS


CHAPTER - 1

QUALITY ASSURANCE PROGRAMME

In matters affecting quality Control, a Quality Control team shall carry out all aspects of inspection

as specified by the Quality Assurance Engineer, which would meet the specification and implied

requirements of the customer.

This manual shall be the Core for quality of all the activities of the Company.

This Manual is essentially set to meet the requirements of ISO 9000.

No deviations from the methods set forth herein are permitted, unless clearly authorized by the

quality Assurance Engineer or the appropriate authority.

Conflicts arising between Quality Assurance Engineer and other departments in matters affecting

Quality are resolved by the appropriate authority without negating the requirements of the

standards.

1.1 The Quality Assurance is divided into three parts :

- QA Manual (Part 1)

- QA/QC Procedures (Part 2)

- Instructions (Part 3)

Each Division/ Department head in BMF is responsible for ensuring that the personnel in his

section are familiar with the QA program and that his Division/ Department complies with

applicable procedures.


CHAPTER – 2

QA MANUAL

QA Manual is the overall document of the QA system that describes the Quality Requirement and

its principal accomplishment.

2.1 Manual Control

This manual shall not be revised to meet client’s specifications. All additional requirements

imposed by the client shall be covered in the QC plan for that particular project.

Distribution of QA Manual may be done as follows: -

- Controlled QA Manual

This Manual shall be distributed to individuals and departments within BMF for direct use in their

work. Such copies shall be subject to automatic revisions.

- Uncontrolled QA Manual

This Manual shall in its current status, be distributed to individuals/organizations outside BMF for

information and review and will not be revised.

Request for changes and revisions to be directed to Quality Assurance Department.

No changes will be made without approval of the management of BMF and the Quality Assurance

Department.

Changes shall be indicated giving all pages of the chapter and a new revision no. and date in the

title block. Revised chapters / pages will be distributed to the holders of the controlled QA

Manuals, who shall be responsible for exchanging the chapters in the QA Manuals.


CHAPTER – 3

QA / QC PROCEDURES

QA/QC procedures as part 2 comprise of general and functional procedures.

3.1.1 QA general procedures are needed to control administration of the Quality Assurance

activities within BMF.

- Document preparation, review, distribution and control.

- Record retention

- Non conformity records

- Quality Audit & Management review

The above general procedures, which are required routinely in each division /

Department are described briefly as below:

3.1.2 Document preparation, Review, Distribution and Control:

These procedures provide the guidelines for preparation, Review, distribution of documents,

drawings Specifications, procedures, correspondence handled by all the sections of the company.

This also covers the documents received from and sent to clients, vendors, sub-contractors and

others The Drawings/Documents (Specifications and procedures) shall be checked by project,

engineering, operations QA/QC and safety for initial check for errors, omissions, interference and

adequacy etc. comments shall be passed on to clients for possible revision / response. The revised

drawings / documents approved by clients shall be distributed to the above stated departments. All

the obsolete drawings shall be collected and stamped “ VOID ”/ “ SUPERCEDED ”.The

documents prepared by each department are to be checked before issue within or outside the

company. The document shall have identifiable number for easy identification.

The documents generated by the company or received from outside client, vendor, sub-contractor

or others shall be distributed through a nodal point, which is responsible for recording and

distribution of the documents. Every department is responsible for safe keeping of the generated

document and received documents.

The projects shall be solely responsible for maintaining the copies issued to various departments.

The projects shall issue to the fabrication department details of cutting lists, templates and shop

fabrication drawings generated by the engineering department. The QA/QC personnel shall liaise

with the project, engineering, fabrication, and operation, fabrication documentation and weld

plans. After fabrication, all construction drawings shall be updated and stamped “as-built”.

All documents pertaining to the project shall be handled by the project engineer and transmitted to

engineering, fabrication and QC personnel as required. Records of revision in the fabrication

procedures shall be maintained by the project engineer. All revisions shall be dully notified to the


relevant personnel.

3.1.2 Record Retention:

This section provides guidelines for retention of documentation completed /received after

completion of the activity and maintaining the records for future reference.

On completion of the job / project, copies of all reports, records and documentation shall be

submitted to the client. The final documentation shall contain:

- Design Specification and Calculations

- Drawings

- QC Plan

- Welding procedure records

- Welding operators records

- Test certificates for materials and others

- Hydro test Records and Reports

- As-Built Drawings

- Spare parts details

- Operation & Maintenance Manuals

- Any other documents/ records related.

Company shall keep all correspondence, documentation for a period as specified/requested by

client. After this retention period, the client shall be notified of disposal of any documents.

Important and essential documents are retained and safeguarded.

3.1.3 Non-Conformity Records:

Non-conformity is any condition of document, material or workmanship, which does not comply

with the governing code or specification or requirement and requires correction or elimination for

acceptance.

Material not conforming to the requirement and cannot be rectified shall be removed from location

with an appropriate identification record shall be made of the defective material rejected. If the

non-conformity falls within framework of an approved procedure for rectification of the

conditions, the fabrication shall rectify the condition strictly as per the procedure, subject to the

approval of the concerned authority from the client.

3.1.4 Quality Audit and Management Review:

This section provides guidelines for ensuring that all the departments of the company shall strictly

follow the Quality procedures in order to maintain the high quality expected in the output.

Quality audit for any particular activity is carried out by a team, headed by appropriate authority

from QA/QC department. The team shall be aware of the operations of the department being


audited. The audited department shall cooperate with the team. A joint review meeting is held by

the head of QA/QC department, relevant department heads and the appropriate authority from the

management. Any corrective actions for non-conformity shall be prescribed. Any changes or

updating of quality measures/procedures if required is finalised and the same are incorporated in

the quality manual with approval from the appropriate authority.

3.2 QA/QC FUNCTIONAL PROCEDURES

These comprise of procedures, which describes the practical accomplishment of the QA/QC

requirements, related to the different activities performed:

Contract Review

Planning & Engineering.

Material Control

Production Control

Inspection Program

Equipment Check & Instrumentation Calibration

Vendor & Contracts Evaluation.

3.2.1 CONTRACT REVIEW :

This procedure outlines briefly the activities to be carried out by various departments for review of

the contract During the bid review stage, the client’s drawings, documents, and other specifications

and requirements are reviewed thoroughly for any errors, omissions, contradictions, adequacy and

sensibility.

Bidding section shall confer with projects, engineering, fabrications, operations, QA, safety and

other relevant departments in finalising the tender proposal and its meeting with various

requirements of the client .Any ambiguity or inadequacy in the design and contractual documents

shall be clarified with the client and documents.

3.2.2. PLANNING & ENGINEERING

This procedure describes the requirements to be followed for planning and engineering during the

bidding stage as well as project execution stage. A planned schedule is prepared during the bidding

stage with all the activities required for complete scope of work as per tender information mile

stones set by client.

A comprehensive program with the help of Bar Charts/CPM/PERT TECNIQUES with project key

dates are prepared and enclosed in company proposal as per tender requirement engineering

section reviews the tender document or the technical scope of work, specifications, procedures,

drawings for various activities.


After award of the contract, the planning and engineering activities are revised/modified/updated

to suit the requirement of the contract. Detail procedures, Bill of Materials, Scope of work with all

activities is then laid down.

Certain guidelines are to be followed for the above activities. These are summarized as follows:

- The Engineering Personnel shall prepare all drawings and documents (planning, package,

calculations, analysis, specifications, procedures, reports, etc.) files under separate names &

numbers, assigned as per established procedure and norms.

- These shall be issued to tender section of the Project as the case may be for review and onward

transmission to client.

- After the documents /drawings are approved by the client /clients representative as per

requirement, the engineering shall record the approved and issue for distribution, these documents

to all relevant sections by the projects.

- The engineering personnel shall maintain a logging record off all these copies made for

distribution to various sections.

- The project shall distribute the required number of copies of the approved drawings/document to

relevant sections.

- Project shall maintain a strict record of number of copies distributed and a list of personnel,

copies were distributed to along with track record of revisions made and issued.

- Based on the client approved drawings /document the engineering shall raise the bill of materials

along with detail specifications, inspections/testing

- equipements as per contract requirements and inputs from fabrication, QA and operation.

- The bill of materials shall specify the quantity, size and condition in which the material shall be

used for fabrication. Incase material is not provided by the or is not available, the requisition are

raised for procurement.

- All incoming materials shall include relevant conformance certificate, indicating the as-received

condition, and expected properties after completion of fabrication. This includes both the

purchased materials as well as the client supplied material.

- Details of additional testing or requirements shall be clearly specified in the purchase requisition,

by the engineering.

- During the course of fabrication, if the material is to undergo any welding or heat treatment, the

engineering shall indicate the details.

- If the fabrication involves qualifying new welding procedure and welder’s Procedures and

welders performance qualification, the Bill of Material shall include material required for the

same. QA/QC shall review these procedures & release for client approval.

- Conformance certificate shall be verified by the project / fabrication / QA Engineers, prior to

acceptance of the material.

- Once the material is received, the material controller takes charge of all material during entire


fabrication and subsequent activities.

- If the project involves fabrication/execution at site, (onshore or offshore) the project

&engineering personnel along with the relevant personnel shall conduct a site survey, prior to bid

as well as before fabrication of assemblies to be installed on site. Based on the site –survey input to

be incorporated in the fabrication drawings to engineering.

3.2.3. Material Control

This is the procedure for verification of receiving, quantity, storage and traceability of material in

use.

Engineering department will prepare the bill of materials, identify the scope of supply of materials

by client and BMF and send to projects/stores for verifying if any material with required

specification available in stock with relevant certificates. Available materials shall be issued by

stores on requisition and for remaining materials as approved by the engineering department shall

be forwarded to purchase department.

Purchase department shall raise enquiries, get quotations, and do necessary technical / commercial

evaluation shall issue local purchase order duly authorized by project. Before placing the order it is

to be ensured that the material and its documentation meet the job specifications and the delivery

meets the project schedule.

Receiving of Material

- Receiving, inspection and storage of material shall be handled by the material controller (MC)

- MC shall check the delivery notes against the requisition and confirm that quantity supplied is in

accordance with the requisition.

- MC shall ensure that relevant mill/test certificate is attached. Projects shall arrange for mill

certificates from the client-supplied material.

- MC shall check that the markings on the material are genuine and comply with mill/test

certificates and material specifications

- MC shall ensure that the material satisfies the specification as per the requirements of the

customer/client.

Inspection and Acceptance of Material

Mills/test certificates shall be verified against the marking on material.

Thickness and other dimensions shall be checked to ensure that they comply with the

specifications and are within the tolerance limits.

Plate Inspection

Visual inspection shall be conducted to examine for indications of corrosion, pitting, surface

laminations and damage during handling etc.

Pipe Inspection

Visual inspection shall be conducted to examine externally and if possible internally for


indications of pitting, surface laminations, mechanical damage etc.

Structural Sections

Visual inspection shall be conducted for corrosion, pitting, surface laminations dimensional

tolerances etc. Visual inspection shall also incorporate measures to ensure that the flanges are at

right angles to the web.

Fittings (Flanges, Elbows, Tees etc.) Inspection

Visual inspection shall be conducted to check for indications of corrosion, pitting, manufacturing

defects, mating face distortions etc.

Valve Inspection

Visual Inspection shall be conducted to check for corrosion, pitting and manufacturing defects etc.

Welding Consumable Inspection

Consumable inspection shall be conducted to ensure that all welding consumables meet the

specifications and classifications as described on approved welding procedures. Consumables in

unsealed or damaged containers shall be rejected.

Material Controller shall accept only those materials approved by the QC Personnel and enter into

the inventory. Only accepted material shall be issued for fabrication.

In case of defect in supplied items, the QC personnel shall make a defective material report and

forward to the projects through the QA Engineers. Standard format shall be used to report

defective materials.

Materials with equivalent specifications may be used subject to the approval of the projects/

Engineering / QA / QC and the client. Supplementary test reports or certificates of compliance if

required, shall be submitted to the clients to support the equivalent material.

Storage of Materials

Material, equipment’s, packages etc. susceptible to environmental damages and deterioration shall

be protected from any kind of damage.

Flanges, bolts, gaskets, valves etc. shall be stored in the covered areas.

Bulk material like steel sections, plates, pipes etc. can be stored in the open on timber bearers.

Material is systematically arranged for easy identification.

Marking of Material

All material shall be marked with marker or hard stamped for identification of applicable material

specification and heat number. Sectioning of material shall be done with each section duly

identified prior to sectioning.

Process pipeline spools shall be marked with line and spool numbers hard stamped on metal tags

and tied around individual spools with wire.


Material Traceability

Each section of the material shall be marked and identified in accordance with the documents at

the time of acceptance. Such markings shall be properly maintained during storage for traceability.

3.2.4. Production Control :

Scope :

This section describes the procedures, to be followed for onshore construction for production

control in translation of the raw material into a finished product including fabrication,

documentation etc.

Production Planning & Execution:

Material Controller shall make available all materials required for the necessary operations

according to the material take-off list, as requested by the site and directed by the Engineering.

The site manager and the project / engineering department shall first review the working drawings

to determine the sequence and method of fabrication. A detail job route sheet is developed. Copies

of the Job Route Sheet and QC plan Shall be available with the site, QA/QC, Foreman` s and the

project. The drawings and documents are delivered to the site for the operations to be started.

Site Supervisors / Foreman is responsible to ensure the correct usage of material or equipment

while operation. The combination of the work shall be in accordance with the JRS. The QC shall

work in parallel to ensure the quality with respect to the specifications as per the drawings and

calculations. The welding / Fabrication activities shall be notified of all major discrepancies.

They shall be handed as per procedure for non-conformity.

Welding and fabrication inspection shall be handled by the QC personnel after completion of the

same, as per procedures for examination and inspection.

The site supervisor/foreman after completion of the welding and fabrication shall rise requisition to

the QC personnel to conduct the Non-destructive examination of the components as per QC plan.

After completion of the inspection, the components shall be dispatched/permitted for further

operation if any.

In case of any defects observed the same shall be documented and reported.

Repairing or reworking done accordingly to comply with the specifications given

Documentation

- All the documents pertaining to the release of the component shall be prepared and signed by the

project engineering supported by the QA department.

- As built drawings are prepared by engineering/project based on the records supplied by

fabrication supervisor/foreman and QC personnel.


- Consolidated inspection record for the project shall be compiled by the QA Engineer and

submitted to projects.

- The projects shall ensure that all documentation is completed in due course and made available to

the client after the completion of the project.

Responsibility

- It shall be the responsibility of the projects to ensure that the various members of the line

management are fully conversant with the relevant drawings and specifications that govern the

project.

- It shall be the responsibility of QC personnel to ensure the quality control plan is adhered to

during the entire course of the project.

- Site foreman/supervisor shall be responsible for the progress of the fabrication.

3.2.5 CONSTRUCTION

Scope:

This section details procedure involved for offshore projects. Section 3.2.4 is applicable for all the

activities of these projects, which are carried out in the fabrication site of the company.

The following are the guidelines and requirements to be adhered for overall works to be carried

out:

Planning & Execution:

The projects, engineering &offshore operations review the working drawings to determine the

scope, sequence & method of fabrication at yard and erection at site. QA Engineer confers with

projects on welding sequence & processes required.

A QC plan is prepared &documented by the QA engineer. Copies of production & QC plan are

distributed to QA engineer, Project and job foreman, as well as site foreman.

As per material take off list, the material controller makes available all materials as requested .

Foreman is responsible to ensure material used as per working drawings. Bevelled ends shall be

cleaned prior to welding. Fitter/fabrication foreman should ensure that the fits up of components

are in accordance to the applicable working drawings before releasing components for welding.

Also QC personnel shall have to ensure compliance of components to working drawings in all

respect.

Welding foreman shall supervise the welding activities. He is responsible for assigning the right

welders, welding operators &welding procedures for the relevant procedure.

After completion of welding &fabrication, barge based QC to conduct NDE. After inspection the

component shall be dispatched for further operations with a material identification list.

If queries regarding fabrication are not clarified at site, same shall be sent to base office.

Incase if the project is related to the hook-up then the project department should ensure the pre-


fabricated and after fabrication documents b received for the records and reference from the client.

Any queries can be passed to the client for clarification before the next step for planning starts.

Documentation:

All documents pertaining to the release of the components shall be prepared & signed by QA.

As-built drawings are prepared by engineering at base, based on the records supplied by QA/QC

from barge.

A consolidated inspection record for the project shall be complied by the QA engineer and

submitted to the projects.

The projects shall be responsible for maintenance of all documents and submission of documents

to the client at the end of the project.

Responsibility

For every project, it shall be the responsibility of the projects to ensure that the various members of

the line management are fully conversant with the relevant drawings and specifications that govern

the projects.

It shall be the responsibility of the QA section to establish the quality control for the project.

It shall be the responsibility of the QC personnel to ensure that during the entire course of the

project the quality control plan is adhered to.

Foreman shall be responsible for the progress of the fabrication, erection & installation at site.

However, QC personnel shall ensure that the component is cleared after inspection for further

operation. Quality Assurance Engineer shall monitor the performance quality of the works carried

out at site and of QC personnel.

3.2.6 INSPECTION PROGRAMME

This section outlines the procedures to be followed by the quality control personnel during the

course of fabrication, erection and installation in fabrication yard or on the site in ensuring the

conformity to the quality plan. Quality plan for the particular project shall be laid down and

documented. This shall be prepared by the QA/QC section, on the basis of the input supplied by

the project.

The personnel involved in quality control activities:

- Shall be suitably qualified to execute the responsibilities entrusted upon him.

- Shall be supplied with suitable instruments to execute this work.

- Shall be properly informed of his scope of work as related to the particular job. Information

pertaining to a job may reach him either through the project, fabrication superintendents. QA

engineer or his immediate supervisor.

The QC plan shall form the basis for the inspection program for the project. Any deviation from


the QC plan shall obtain approval from the QA/QC section and the client’s representatives, if

required.

- non-destructive examination shall be carried out in line with QC procedure under:

- QC personnel shall compile a consolidated report for the stage wise inspection conducted on the

job with the reports approved by the client/client’s representative. After approval all original

documents and graphs are retained in archive and copies submitted to the client.

3.2.7. EQUIPMENT CHECKS & INSTRUMENT CALIBRATION

This section outlines the procedures to be followed by equipment checks and calibration of the

instruments used in quality control.

Measuring instrument and equipment shall be tested and calibrated by using a standard reference.

Typical measuring instruments & equipment shall include

- Pressure Gauges

- Load Cells

- Ammeters / Volt Meters / Ampere meters

- Recorder Units

- Ultrasonic Testing Equipment

- Theodolite & Level Instruments

- Welding Machine

It is the responsibility of the foreman handling the project to get equipment's checked for their

required performance and the instruments calibrated.

Calibration of instruments may be conducted by a recognized testing agency. The agency shall

issue certificates of calibration. The certificates shall contain details of the instruments, model,

serial number, calibration, reference used for calibration, and date of calibration.

Records of inspection/check/test of the equipment's and calibration certificate shall be maintained

by QA. QC personnel shall ensure proper functioning of the equipments/instruments, and validity

of calibration. Records shall be available for client’s review.

Measuring tapes and level gauges shall be visually inspected for damage and checked using a

known reference.

3.2.8 VENDOR /SUB-CONTRACTOR EVALUATION

This section describes the procedure to inspect and evaluate vendor/subcontractor for the supply of

materials, equipments or render services as a part of the project work.

Evaluation shall be conducted prior to the award of contract. This enables the vendor/sub-

contractor to provide services suitable to the work/specification supplied by the company.


Sub-Contracting:

The evaluation shall be conducted by a team consisting of QA/QC, projects and engineering,

thorough inspection of the sub contractor’s premises and facilities is done to ensure the suitability

of equipment, manpower and other facilities they have. The team should ensure that the work

force/personnel involved in carrying out the sub contract work is suitably qualified. Documental

evidence to be taken and if necessary may individually interviews the personnel. The team shall

ensure that the equipments used are up to the reasonable standards of serviceability for the work.

The team shall review the quality control program, storage facilities and any others. After

completion of the defined work, the project shall receive the documentation accompanying the

service rendered.

Material Supplier

The team shall carryout a detail inspection of the supplier facilities to ensure that materials

supplied for a particular project meet the specifications as detailed by the engineering, and all the

certificates pertaining to the quality of the material is made available prior to delivery.

All materials shall have relevant information pertaining to identification, grade place of

magnification, size, specifications, schedules heat numbers colour coding and other necessary

required information as specified. The information shall be stamped or printed on suitable location.

The material controller shall ensure that the material supplied have correct documentation and all

in accordance with the specifications QC should ensure that subcontractor adheres to all check

points to maintain the required level of quality for the services / products rendered.

CHAPTER - 4

QUALITY CONTROL

SCOPE:

This section describes methods and requirements for Quality Control. The purpose of QC is to

check for complying of requirements, and to identify non-conformance and to ensure quality is

achieved as per specifications and requirements.

The different method for achieving the quality for different operations shall be as explained below:

4.1 Visual Inspection of Structural Steel and Piping

Personnel performing visual inspection shall have available all relevant codes and documents

pertaining to the work, such as applicable codes, specifications, welding procedures etc. It is the

responsibility of each inspector to ensure that the inspection is performed in accordance with


applicable codes, specifications and procedures.

The inspectors have the authority to stop work, which is not carried out to the standards of relevant

codes and specifications. The extent of the inspection required is generally governed by contract

requirements. However this does not limit the inspector’s responsibility and he shall attend and/or

inspect all operations and completed work as necessary to ensure specified quality.

Visual inspection can be divided into three main stages, i.e. preventive inspection, follow-up

inspection and final inspection. All structural steel, piping material, welding repairs included, is

subjected to inspection in all three stages.

Upon visual acceptance of the welding it is the QC inspector’s responsibility to schedule and

initiate the required.

Non-Destructive Examinations. The “Request for NDE” prepared by the QC inspector may serve

as a visual inspection release.

When reporting before and during welding; the inspector determines the extent of its report by his

own judgement. Deviations, which might affect product quality, shall be reported. This shall be

done in writing to the Inspection Engineer with copy to the production supervisor.

Reporting after final inspection shall provide a record of the structures and items that have been

inspected and approved. In case of non-approval, a punch list shall be complied including all

remarks concerning unsatisfactory or unfinished work]

4.3 Leak Testing / Hydrostatic Testing

Leak testing and hydrostatic testing of tanks, vessels and piping systems will be performed

according to written procedures, and in compliance with code requirements and contract

specifications. The test system will be blinded and two calibrated pressure gauges will be fitted.

Normally water containing corrosion inhibitor, oxygen scavenger and brocade if specified, will be

used for testing. When all air pockets are vented, the pressure will be raised slowly up to the

design pressure and all joints/connections will be inspected for leaks. Correction of any leakage

will be carried out and the pressure then raised to full hydrostatic test pressure, which shall be

maintained for a period, specified in the test procedure. A visual inspection of all joints will be

performed. There should be no drop of pressure during testing. Temperature of the test media will

be recorded during the test and will be compared with the pressure readings. If the test is found

acceptable the pressure test report and other test documents will be signed and approved by the

QA/QC and client’s representative.

4.4 Inspection of Surface Treatment

Inspection of surface treatment will be carried out according to written procedures, covering all

surface treatment processes. It is the responsibility of the Engineer/Foreman in charge to ensure

that the work is carried out according to the valid procedures, that equipment and consumables for

surface preparation and coating are used and stored as prescribed, and that the test logs stated in

the procedures are correctly maintained.


The Plant Inspector will ensure that approved procedures and specifications are adhered to, by

performing regular and random inspections. He is responsible for reporting of the work.

The QAD is responsible for systematic filing of all reports point lists and releases to be part of the

final documentation.

4.5 Dimensional Control

The extent of dimensional control will be established by QA according to contract requirements.

QA is responsible for preparing the necessary instructions and sketches, which will be subject to

client’s approval. Generally the Project Engineer in charge, is responsible for adequate

dimensional control and for ensuring that piping or structural items are assembled within specified

tolerance.

CHAPTER - 5

DETAIL INSTRUCTIONS

5.1 Detail instructions as part 3 are made for each activity of the company and describe in detail,

how BMF will comply with quality assurance requirements of customers / contracts / order,

Design specification, Drawings, Processes, Fabrication, Inspection, Tests and Documentation by

records, from the acceptance of contract/order to final approval by client’s / customers /

authorities.

Note: These procedures may be amended for a particular project to satisfy the specific

requirements of the project with proper permission from the management and QA department.

Assigning the authority with responsibility and accountability, allowing for perfect

involvement in the job to achieve the objectives by informing beforehand the process and

limitations gives the way for the Quality and Reliability.

For any clarifications please contact the QA/QC department.


7. Trade License


8. Financial Statement

The establishment of Bilal Metal Fabrication L.L.C has been almost a year, hence we are not in

position to provide any financial statements as yet.

9. Certifications

The Approved Certificates will be provided to Liable Clients depending on the scope of work.

10. Method Statement

Method Statement of the carried out work will be provided to the Client depending on the scope of work.


11. List of Major Project(s)

1. Al Wasl Dome Park, Dubai

Scope Supply, Fabricate and Assist in Installation of Steel Nodes & SHS

Boxes for the Box Park Dome of height 9 meter and base diameter

of 13 meter (approx 40 sqm)

Contractor ALICO Aluminium & Light Industries L.L.C.

Date of Completion December 2014

Value AED 445,000

Remarks Structural Steel Fabrication


At Present, The Dome (Nodes and Boxes): March 2015


2. Nord Angolia International School, Dubai

Scope Supply, Fabrication & Installation of Sophisticated designed

3mm thk Aluminium Perforated Sheets, 3.6m x 3m; on our

New Generation Water Jet Machine

Contractor The Workshop Design (Architect)

Date of Completion December 2014

Value AED 90,000

Remarks Perforated Sheets designed as Albert Einstein, Nelson Mandela,

Miu, Ennis, Callis and Mariam.




3. Hook Brackets – Waterjet Cutting

Scope Waterjet Cutting of Multiple of Hook Brackets & Aluminium

Sheets

Contractor Industrial Metal Unit L.L.C.

Date of Completion November 2014 - Ongoing

Value AED 100,000


4. Packing Angles

Scope Fabrication of Packing Angles

Contractor Arabian Importers & Exporters

Date of Completion November 2014

Value AED 15,000

5. Die Making & Extruder Die

Scope Fabrication of shaft blocks of Various Diameters & Extruder Die

support brackets of various length.

Contractor Mulk Holdings, Sharjah

Date of Completion March 2015

Value AED 10,000


Shaft fixed block

∅40mm , ∅38mm,

∅50mm


Extruder die support bracket 450mm, 300mm & 150mm.


6. King Fahad Medical Center

Scope Fabrication of approx. 15,700 sqm of Backpans (11,715 Nos) –

Fabrication included Shearing, Bending, Notching & Drilling on

all backpans.

Contractor ALUMCO GROUP, DUBAI

Date of Completion 2014-2015 (ongoing)

Value AED 85,000

Remarks Galvalized Iron Backpans (Shearing, Notching, Folding)



7. T-Stiffners for Address Hotel, DownTown


8. Etisalat & Du decorative Tower Fence

Scope Fabrication and Supply of Aluminium Decorative Site fence &

Chain link fence for the boundary of Telecommunication poles Contractor INTEGRAL EXPRESS GENERAL, Abu Dhabi & Dubai Date of Completion February 2015 – Present (ongoing) Value Aed 40,000 Remarks Fences covering Plot Area of 8m x 6m , 8m x 8m , 10m x 10m , 12m x

10m

Chain Link Fence: 10m x 12m x 2.5m Height.

20 Site Locations in Dubai.


CHAIN LINK FENCE, FRONT & SIDE VIEW

60 x 60 SHS + 150mm Dia poles. Plot size: 8m x 6m x 2m height


Cast Aluminium Fence: 10m x 10m x 2.2m Height

3 Site Locations in Dubai & Abu Dhabi.

9. Damac Heights – 30th floor structural steel works

Scope Fabrication and Supply 7.2 Tonnes of Steel + Brackets for the

30th

Floor Steel Layout – inclusive of I-beams, U-beams, Box

Sections. Contractor Damac Gulf Properties, Dubai Marina Date of Completion April 2015 – Present (ongoing) Value AED 75,000



12. Warranty Specimen

W A R R A N T Y

PROJECT TITLE

xxxxxxxxxxxxxxxxxxxxxxx

OWNER/CLIENT

xxxxxxxxxxxxxxxxxxxxxxxx

CONSULTANT/ENGINEER

xxxxxxxxxxxxxxxxxxxxxxxxxxx

MAIN CONTRACTOR

xxxxxxxxxxxxxxxxxxxxxxxxxxxx

“SUBJECT”

“ STEEL FABRICATION ”

In accordance with the general requirements of Contract Specification, we, BILAL METAL

FABRICATION LLC., hereby warrant the “ FABRICATED STEEL WORKS ” carried out by us for the

above-mentioned project/subject against defective materials, products, workmanship, water tightness,

design, performance and due to defective engineering fabrication and installation.

The defects shall include but not necessary limited to:

Structural failures including, but not limited to, excessive deflection.

Noise or vibration caused by thermal movement.

Adhesive or cohesive sealant failures.

Failure of system to meet performance requirements.

Deterioration of metals, metal finishes, and other materials beyond normal weathering.

Water leakage.

We agree to repair or replace defective materials during the warranty period at no additional cost to the

Employer.

The warranty does not include defects caused by vandalism, normal wear and tear, or natural conditions

exceeding the performance requirements and manufacturer’s recommendations.

This warranty is valid for 1 (One) year period following date of Substantial Completion of the Work.

*SIGN AND STAMP

for BILAL METAL FABRICATION LLC.


Contact Us:

Al Jurf Industrial Area 2

P.O.Box 8337

Tel - +971 6 748 7794

Fax - +971 6 748 7795

Email – [email protected]

Website – www.bmf.ae

mailto:[email protected]