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BBA Contractor and System Certification

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Report of: Surveillance Assessment

At: Kingspan Insulation Limited. Torvale Industrial Estate, Pembridge, Leominster, Herefordshire, HR6 9LA

Actual date of assessment: 21/01/2015

Person seen: Mr. Steve Mesham

Certificate(s) 94/2992, 94/3061,95/3126, 01/3813, 06/4372, 06/4384, 07/4450, 08/4522, 08/4582, 08/4590, 08/4615, 09/4675, 09/4646, 10/4798, 11/4870, 124921, 14/5133 & 14/5134.

Job Number(s): N/A

Order and contents:

1. Assessor’s confidential comments 2. Audit plan (letter) 3. Quality Plan - as Assessor’s notes (as required) 4. Assessor’s notes 5. Variation Report (if applicable) 6. Attachments: Yes

Number of pages: 09

Section responsible:

Energy & Ventilation - Gayetree Ramkorun

Assessor: Adrian Edwards

Report page printed: Thursday, 19 November 2020 Assessor’s signature:

PLEASE COMPLETE ALL APPLICABLE CRITERIA IN THE R/H COLUMN OF THIS TABLE

Kingspan AQP and dated 05 September 2014.

Yes

94/2992, 94/3061,95/3126, 01/3813, 06/4372, 06/4384, 07/4450,

08/4522, 08/4582, 08/4590, 08/4615, 09/4875, 10/4798, 124921, 14/5133 & 14/5134.

No

N/A

30/06/2015

Yes

Variations raised? NC = 3 OBS = 0

Admin to chase corrective action responses? Yes

If Yes - When? 05/02/15 (10 working days from date of Variation issue)

Client Contact Name: Mr. Steve Mesham

Email Address: steve.mesham~,kin.qspan.com

Client Purchase Order No. (where applicable): N/A

Quality plan reference(s):

Revisions required to Quality Plan(s)?

If Yes - which certificate(s):

Revisions done by Assessor?

Enter file name of amended PQP / AQP(s):

Updated QP(s) required by:

Source: Audit plan and assessment report

©ate of Revision: 13/05/2014

BBA00011197 0001 BBA00011197/1

Assessor’s Comments: (Please note that this may contain confidential information - FOR INTERNAL USE ONLY)

In conclusion there were 2x NEW NC’s raised during this Surveillance Inspection. (See attached Variation Report for further details).

Also noted was lx Previous NC still open;

NC.4. QUALITY PLAN ISO SCOPE;

The ISO scope seen in the latest ISO 9001:2008 Certificate differs from the scope seen in the latest Quality Plan. Awaiting NEW AQP - STILL OPEN.

Continued Certification is recommended but certainly subject to BBA Section approval of the mentioned non-conformities found during this visit.

,qouree: Audit plan and assessment report

Date of Revision: 13/05/2014

BBA00011197 0002 BBA00011197/2

Our Ref: Audit Plan

(file number) Job No. N/A

Cert Nos. 94/2992, 94/3061,95/3126, 01/3813, 06/4372, 06/4384, 07/4450, 08/4522, 08/4582, 08/4590, 08/4615, 09/4675, 09/4646 Promat TL, 10/4798, 11/4870, 12/4921, 14/5133 & 14/5134.

Date: 28/11/2014

Mr. Steve Mesham Kingspan Insulation Limited. Torvale Industrial Estate, Pembridge, Leominster, Herefordshire, HR6 9LA

Dear Steve,

IfqSIPlE I~TIIP fq Ti:ST|PlQ CE IITIFICA.TION

Bucknalls Lane, Garston, Watford WD25 9BA

Telephone: Facsimile:

Mobile: E-mail: [email protected], uk

Surveillance Assessment of Production

Products: Various Kingspan Insulation Boards both PIP, and Phenolic. Production Location: As Above Management representative: Mr. Doug Lloyd Visit Date: Wednesday 21/01/2015, intended arrival time: lO.OOam.

As agreed I can now confirm that I will be visiting your manufacturing site as detailed above. The assessment will commence with an opening meeting to discuss the format of the audit, which will only cover the product(s) or production that are subject to a BBA contract or Certificate.

The objective of the assessment is to confirm that the product being placed on the market is consistent with the product assessed and approved by the BBA and that the production process is under due control. The assessment will visit the manufacturing plant / associated quality assurance facilities and audit quality records against the controls declared in the following documents:

¯ The Agreed Quality Plan referenced; Kingspan AQP and dated 05 September 2014.

Copies of these documents can be supplied by fax or e-mail. You will need to:

- inform relevant employees about the objectives and scope of the audit - appoint responsible member(s) of staff to accompany me - provide resources needed in order to ensure an effective and efficient audit process - arrange access to the facilities and Quality records

The assessment will be concluded by a ’closing meeting’, which will give the opportunity to discuss issues raised during the assessment and to understand / agree any consequential actions. I expect the assessment to be completed within the working day.

I look forward to meeting you.

Yours sincerely -- ~

Adrian Edwards - Management System Assessor British Board of Agr6ment

BBA Audit Cancellation Policy: If the agreed visit date above cannot be met, for UK appointments the BBA requires 10 working days’ notice to allow the audit to be re-arranged. Failure to give such notice will result in a cancellation charge being made. For overseas appointments the required notice is 30 days, and where advanced booking of non-refundable air travel and related costs has been necessary (after the visit has been agreed) visit cancellation by the client within the 30 day period will result in re-booking costs in addition to the cancellation charge(s) being passed on to the Client for payment.

,%uree: Audit plan and assessment report


BBA00011197 0003 BBA00011197/3

Assessor’s notes (or insert copy of Quality Plan to be used for manuscript revision and note taking)

An opening meeting was held to discuss the format of the assessment. Present during this meeting were:

¯ Mr. Steve Mesham - Senior Lab Technician for Kingspan Insulation Limited. ¯ Mr. Dan Ball - Technical Project Leader for Kingspan Insulation Limited. ¯ Mr Adrian Edwards - BBA Management Systems Assessor.

Not all previous Non-conformities raised during the last Assessment could be closed out during this opening meeting.

PIR Production (Line 2) was producing products during this Assessment.

Reproduction certificates

Please list all reproduction certificates and approximate volumes of material sold during the period covered by this audit: 11/4870.

Reproduction Certificates checked were: No Stock checked or orders seen.

The followinq headin,qs have been selected from the Quality Plan and should be considered as aDDroDriate,

Raw materials

Select from those detailed in the Quality Plan

Raw material

1. POLYOL Grade PS-2412 Bulk Storage

2. MDI Grade M70R Bulk Storage

3. BLOWING AGENT Grade IP 85/15 Pentane Bulk Storage 4. SURFACTANT Grade B8871 IBC Storage

5. CATALYST Grade Polycat 5 IBC Storage

6. CATALYST Grade K-Zero 3000 IBC Storage

7. FLAME RETARD. Grade Levagard PP Bulk Storage

Supplier

STEPAN

BASF

BOC

EVONIK

AIR PRODUCTS LIMITED

MOMENTIVE

LANXESS

Certification available Y/N Y

Y

Y

Y

Y

Y

Y

Material tested Y/N

Y

Y

Y

Y

Y

Y

Y

Within specification?

Yes - As per C of A.







Batch numbers checked

Lot No. 7644580-T401 Del. Date 06/01/15. Lot Qty. 27,780 kg.

Lot No.905016319058 Del. Date 13/01/15. Lot Qty. 28,000 kg.

Lot No. 2566680 Del. Date 05/01/15. Lot Qty. 27,840 kg.

Lot No. E1141306882 Del. Date 23/12/14. Lot Qty. 3,000 kg.


Lot No. 14JLVR011 Del. Date 17/11/14. Lot Qty. 5,000 kg.

Lot No. CH709015 Del. Date 15/01/15. Lot Qty. 24,020 kg.



BBA00011197 0004 BBA00011197/4

8. TOP FACING Grade Triply 30# Foil 1216mm Width

9. BOTTOM FACING Grade Triply 30# Foil 1216mm Width

10. PLASTERBOARD Grade 12.5 Tapered Pallet Storage

11. HOT MELT GLUE Grade Sikamelt 9677 Drum Supply

INTERNATIONAL CONVERTERS

INTERNATIONAL CONVERTERS

BRITISH GYPSUM

SIKA UK

Y

Y

Y

Y

N

N

N

N

Yes - As per C of C.




Roll No. 1000077144 Del. Date 08/10/14.

Roll No. 1000081503 Del. Date 08/01/15.

Del. Note 87484779 Del. Date 19/01/15. Lot Qty. 1,080 Pcs.


Where new suppfiers or materials have been added, please provide details including names of the new material and that which it replaces, where appropriate and reason for change.

See Highlighted Table

1. An alternative grade of raw materials are currently in use but not declared in the latest Quality Plan. Reference seen; Hot Melt Glue SIKAMELT 9677.

(SEE NC. 1.of attached Variation Report)

Product identification

Confirm batch numbers of finished products seen in warehouse/stockyard

Is the identification system as described in the Quality Plan? (If No give details)

Yes

1. Thermafloor TF70-2400 x 1200x 100mm, Batch 147748. Production dated 14/01/15. Clearly identified. 2. Thermawall TW55 - 2400 x 1200 x 70ram, Batch 147535. Production dated 13/01/15. Clearly identified. 3. Thermataper TT46 - 1200 x 1200 x 30/50mm, Batch 146782. Production dated 06/01/15. Clearly identified. 4. Thermaroof TR27 - 1200 x 600 x 60mm, Batch 146783. Production dated 07/01/15. Clearly identified. 5. Thermataper TT46 - 1200 x 1200 x 75/90mm, Batch 146001. Production dated 17/12/14. Clearly identified. 6. Ecotherm Eco-Versal - 2400 x 1200 x 75ram, Batch 147374. Production dated 12/01/15. Clearly identified.

All products are consistently ink marked and labelled and all can be traced back to production records based on Batch No. and date. Using this traceability can be gained right back to the raw materials and relevant mixing blend.

Method of production and process control

Is the production process & manufacturer’s documentation as described in the Quality Plan? (If No give details)

Yes

Formulations

If formulations are quoted, are they as detailed in the Quality Plan? If No please give full details; Yes

Details of formulations checked: Material Code 1880 seen on the PIR Production line and matches the Formulation in respect to raw materials and mix quantities.

The organisation works to a SAP based master Specification / Recipe File for all variants of Product.

No changes to report.



BBA00011197 0005 BBA00011197/5

Production

Production witnessed? Yes

The following product was being manufactured: TW50 (94/2992) on the PIR Production Line 2.

If no, please give details of any similar production witnessed and the last production dates for the product under assessment/review.

OMS - PIR Production Line 2. TW50 (94/2992) 1200 x 450 x 90mm. Production Batch No. 800148251 for 4370 Linear Metres. Mixing Formulation used 1880. Top and Bottom Facer Rolls Triply 30g/m2.

Each Board is ink Marked and the latest boards seen were noted as; "10000148251 90mm 10:37 21/01/2015 ML PB".

In Process Inspection and testinq

Are process controls as described in the Quality Plan? (If No, give details)

Yes

Are process controls being maintained? (If No, give details)

No

The interlaminate test results were seen for the bonding process and there is a concern that a high number of failed tests were recorded of results less than 17kPa. Data seen were as low as 9.90kPa and cases where re-sampled test results were also recorded out of specification.

(SEE NC.2.of attached Variation Report)

Final Inspection and Testinq

Are the final assessment and test regimes as described in the Quality Plan? (If No, please provide full details)

Yes

Witnessing of tests: Yes

Product under test: TW50 (94/2992) Produced on Line 2 today. Batch number: 148251

Test Witnessed Result Specification Density 30.90kgm-2 25-33 kgm-2 Width 1205mm 1200 +3mm Length 450mm 450 +3mm

Squareness 1.0mm < 2.0ram Thickness 12 places -88.18 Min- 91.18ram Max 90.0 +3.0/-2.0mm

Visual Quality Pass in all places No holes or imperfections

Other QC data reviewed? Yes

1. Thermafloor TF70-2400 x 1200x 100mm, Batch 147748. Production dated 14/01/15. All QC Records seen. 2. Thermawall TW55 - 2400 x 1200 x 70mm, Batch 147535. Production dated 13/01/15. All QC Records seen. 3. Thermataper TT46 - 1200 x 1200 x 30/50mm, Batch 146782. Production dated 06/01/15. All QC Records seen. 4. Thermaroof TR27 - 1200 x 600 x 60mm, Batch 146783. Production dated 07/01/15. All QC Records seen. 5. Thermataper TT46 - 1200 x 1200 x 75/90mm, Batch 146001. Production dated 17/12/14. All QC Records seen. 6. Ecotherm Eco-Versal - 2400 x 1200 x 75ram, Batch 147374. Production dated 12/01/15. All QC Records seen.

All QC Results seen were noted as all within all nominated specifications.



BBA00011107 0006 BBA00011197/6

KOOLTHERM Declared k-values

1. T= 15~24mm:/~9o/9o < 0.023 - Latest declared Average results seen are at 0.0186 which is less than 0.023.

2. T= 25~44mm: /~9o/9o < 0.021 - Latest declared Average results seen are at 0.0184 which is less than 0.021.

3. T _> 45 mm:/~9o/9o < 0.020 - Latest declared Average results seen are at 0.0179 which is less than 0.020.

PIR BOARDS Declared k-values

GAS OPEN;

1. T= <80mm: ~9o/9o < 0.026 - Latest declared Average results seen are at 0.0194 which is less than 0.026.

2. T= 80~119mm: A9o/9o < 0.025 - Latest declared Average results seen are at 0.0189 which is less than 0.023.

3. T= >120mm: A9o/9o < 0.024 - Latest declared Average results seen are at 0.0192 which is less than 0.023.

GAS TIGHT;

1. T= <35ram: A9o/9o < 0.021 - Latest declared Average results seen are at 0.0188 which is less than 0.021.

2. T= >_35ram:/~9o/9o < 0.020 - Latest declared Average results seen are at 0.0190 which is less than 0.020.

Measurinq and Test Equipment used

Is there a regular calibration regime for test and measurement equipment? Yes

Test equipment checked

Equipment Identification Calibration date / Due date PIP, Line No.2 - 300ram VC. Serial No V030 Ext. Cert.156681 Last 06/03/14 Next due 03/15. Every 12 M PIP, Line No.2 - Table Scales Serial No. "4Y" - Ext. Cert. 6840 Last 19/05/14 Next due 05/15. Every 12 M QC Lab. Compression Tester SIN H5KS1513 Ext. Cert KR042A02 Last 20/03/14 Next due 03/15. Every 12 M QC Lab. Density Scales SIN SCA004 Ext. Cert KR045A02 Last 19/05/14 Next due 05/15. Every 12 M Board Cutting & Packing Line Serial No. 4V - Ext. Cert. 6478 Last 19/05/14 Next due 05/15. Every 12 M Board Cutting Line - 300mm VC. Serial No V030 Ext. Cert.156696 Last 19/05/14 Next due 05/15. Every 12 M

Packaqin,q and labellinq

Are the details as described in the Quality Plan?

Is batch identification clear and legible?

Is the BBA logo used on the product packaging?

If so, is the correct certificate number used?

Yes

Yes

Yes

Yes

1. Thermafloor TF70-2400 x 1200x 100mm, Batch 147748. Production 14/01/15. BBA Logo clear & legible. 2. Thermawall-RN55 - 2400 x 1200 x 70ram, Batch 147535. Production dated 13/01/15. BBA Logo clear & legible. 3. Thermataper TT46 - 1200 x 1200 x 30/50mm, Batch 146782. Production 06/01/15. BBA Logo clear & legible. 4. Thermaroof TP,27- 1200 x 600 x 60mm, Batch 146783. Production dated 07/01/15. BBA Logo clear & legible. 5. Thermataper TT46 - 1200 x 1200 x 75/90mm, Batch 146001. Production 17/12/14. BBA Logo clear & legible. 6. Ecotherm Eco-Versal - 2400 x 1200 x 75mm, Batch 147374. Production 12/01/15. BBA Logo clear & legible.

Phenolic Line samples checked in the Warehouse;

1. Kooltherm K3 (08/4522) Production dated 07/01/15. BBA Logo clear & legible. 2. Kooltherm K5 (94/3061) Production dated 10/12/14. BBA Logo clear & legible. 3. Kooltherm K8 (94/3047) Production dated 06/01/15. BBA Logo clear & legible. 4. Kooltherm K10 (09/4675) Production dated 16/01/15. BBA Logo clear & legible. 5. Kooltherm K12 (08/4615) Production dated 06/01/15. BBA Logo clear & legible. 6. Kooltherm K15 (08/4582) Production dated 12/12/14. BBA Logo clear & legible.

,~ouree: ,4udit plan and a,~’,~’e,~’sment report


BBA00011197 0007 BBA00011197/7

Complaints

Are details as described in the Quality Plan? Yes

Have any complaints been received about the certified product(s)? Yes (If yes, give details)

Customer Complaint Register examined during this visit. Although substantial complaints against various BBA Products all seem to be commercial issues and not product Related. Issues raised and show no signs of trends to be concerned about.

Traininq

Are details as described in the Quality Plan?

Are records available to confirm competence of staff?

Training records comprehensive in all aspects. Samples noted during Assessment;

1. Mr. Bradley Scott - OMS PIR Line No.2 Production Line Laydown Operative. 2. Mr. Dave Cotton - OMS PIR Line No.2 In-Line QC Operative. 3. Mr. Mike Bevan - Bonding Line No.3 Production Line Teamleader. 4. Mr. Mike Wilson - Bonding Line No.3 Production Line Operative.

Records for relevant Staff are satisfactory.

Yes

Yes

ISO Reqistration

Are details as described in the Quality Plan? No

The ISO scope seen in the latest ISO 9001:2008 Certificate differs from the scope seen in the latest Quality Plan.

(SEE PREVIOUS NC.4.of attached Variation Report)

Is the certificate valid? Yes

Last Assessment carried out by LPCB on 23rd September 2014. Report made available during this assessment.

LPCB Assessment Report viewed and contained 4x minor NC’s raised.

A closing meeting was held to discuss the assessment result / findings, observations and non-conformities raised.

Present during this meeting were:

¯ Mr. Steve Mesham - Senior Lab Technician for Kingspan Insulation Limited. ¯ Mr. Dan Ball - Technical Project Leader for Kingspan Insulation Limited. ¯ Mr Adrian Edwards - BBA Management Systems Assessor.

It was agreed that the BBA would be advised of the corrective actions to be taken as some were indicated.

Assessor (Name): Adrian Edwards

Signed: ~- ~"~~"~~

Date: 23rd January 2015.



BBA00011197 0008 BBA00011197/8

British Board of Agrdment

Kingspan Insulation Ltd. Torvale Industrial Estate, Pembridge, Leominster, Herefordshire. HR6 9LA

Variation Report

Date of visit: 21/01/2015

Agr~ment Certificate number(s): 94/2992, 9413061, 95/3126, 01/3813, 06/4372, 0614384, 07/4450, 08/4522, 08t4582, 08/4590, 08/4615, 09/4675, 11/4798, 10/4798, 12/4921 14/5133, 1415134 & 09/4646.

Job Numbers: N/A

Observations should be identified by "Obs", Non Conformities to be identified by ’NC’

PREVIOUS VISIT;


Tl~e 1SO scope seen ir~ the latest tSO 9001:2008 Certificate differs from the scope seen in the latest Quality Pla~. - STILL OPEN

THIS VISIT;

NC.I. PURCHASING DATA TABLE;

An alternative grade of raw materials are currently in use but not declared in the latest Quality Plan. Reference seen; Hot Melt Glue SIKAMELT 9677.

NC.2. IN-PROCESS INSPECTION & TESTING;

PREVIOUS VISIT;


Client to submit corrective actions within the Next 10 days,

THIS VISIT;

NC.1. PURCHASING DATA TABLE;

The interlaminate test results were seen for the bonding process an~ there is a concern that a high number of failed tests were recorded of results less than 17kPa. Data seen were as low as 9.90kPa and cases where re-sampled test results were also recorded out of specification.

Signed by BBA Inspector~_~ .~:~

Name: Mr. Adrian Edwards

Date: 21101/2015

Client to submit corrective actions within the Next 10 days.

NC.2. IN-PROCESS INSPECTION & TESTING;

Client to submit corrective actions within the Next 10 days.

Corrective actions should be advised to the BBA Customer Services; customerservice(~bba.star.co.uk

Within 10 days from the date of issue.

Signed by Management Representative:

Name: Mr, Steve Mesham

Date: 21/01/2015



BBA00011197 0009 BBA00011197/9

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