Steel construction

For a steel fabricator everything revolves around EN 1090. Without a valid FPC certificate no declaration of performance may be issued and the structure cannot be CE marked. At the same time the standard is written so that requirements shift per execution class, which makes it hard to establish what really applies in your situation.

EN 1090-1 and EN 1090-2 from EXC1 to EXC4
Setting up and maintaining the FPC system
A procedure book that covers the actual work package
Welding coordinator to ISO 14731 on call

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DEHAAS works as an external welding department for steel fabricators: from setting up the FPC system and the procedure book to acting as welding coordinator and guiding you through the notified body audit.

The execution class governs everything

EN 1090-2 defines four execution classes, EXC1 to EXC4. The class follows from the consequence class of the works, the service category and the production category, and is set by the designer in the contract documents. If nothing is stated, EXC2 applies as the fallback.

The class then determines the quality requirements to ISO 3834, the extent of non-destructive testing, the quality level to ISO 5817, requirements for cut edges, tolerances and traceability. Assuming the wrong class therefore means either unnecessary cost or a structure that does not comply. See EN 1090 execution classes.

FPC: the system behind the certificate

Factory Production Control is the manufacturing control that demonstrates that what you deliver matches what was calculated and specified. It covers purchasing and material control, traceability, calibration, personnel qualifications, control of welding, inspection and handling of non-conformities.

The notified body assesses that system at the initial inspection and periodically thereafter. In practice, companies most often stumble over material traceability, expired welder qualifications and procedures that do not match the work actually performed. See FPC explained.

A procedure book that covers the work package

A common failing is a folder with five procedures written three years ago, while the shop now welds different thicknesses, different grades and different positions. Formally that work is then uncovered.

DEHAAS analyses the actual work package, establishes which qualification ranges are needed and assembles a minimum set of qualification records covering the lot. That saves qualification cost and prevents a test coupon having to be welded mid project. See WPS development and WPQR validity range.

The welding coordinator

From EXC2 a qualified welding coordinator is mandatory, with a knowledge level following from ISO 14731 and from the steel grade, thickness and class. For many mid sized fabricators that means an IWT or IWS; for heavier work an IWE.

Keeping that role in house is often not feasible for a company of ten to thirty people. DEHAAS fills it externally, with a documented allocation of responsibilities that notified bodies accept. See hire a welding coordinator.

What goes wrong at an audit

The recurring findings: no demonstrable link between certificate and applied material, welders working outside their qualification range, missing NDT reports at the prescribed percentages, and tolerances signed off without having been measured.

None of those is hard to fix, but each costs a follow-up inspection and sometimes a stop on deliveries. A gap assessment beforehand costs less than a non-conformity afterwards. DEHAAS carries one out and guides the corrective period.

Frequently asked questions

Yes, if you place load bearing steel structures covered by the harmonised standard on the market. CE marking is then mandatory and so is a certified FPC system. For non structural parts, or work realised entirely on site as construction works, the position can differ; assess that case by case.

The designer determines it, based on consequence class, service category and production category to EN 1090-2 annex B. If the specification is silent, EXC2 applies. Never assume a lower class yourself because it is cheaper.

That depends entirely on your work package. Many companies can cover almost everything with three to six well chosen qualifications, provided the coupons are selected intelligently for material group, thickness and position. Poorly chosen coupons lead to ten qualifications that together cover less.

Yes. We prepare the dossier, run an internal check beforehand and attend the inspection to answer the welding technology questions. That shortens the inspection and prevents findings based on a misunderstanding.