CLIENT Bukaka QUALITY CONTRAL PLAN

TS-QCP-018 rev. 1
DRAWINGS
MODULAR EXPANSION JOINT
REF.: DWG NO. 4-T320-1 Project:
Jakarta Cikampek Elevated Toll Road Project
DWG No. 6-T480-1 Rev04
ITEM Activity sequence Reference documents Used Equipment Documents to be Activity frequency Notes
issued Production Techstar Client
line Headquarter
A1: ACTIVITY PERFORMED FOR 100% OF THE PIECES OR BATCHES PRODUCED R1: REVIEW OF DOCUMENTS PERFORMED ON 100% OF THE ACTIVITY PERFORMED ON THE PIECES
PRODUCED
A2: ACTIVITY PERFORMED RANDOMLY ON THE PIECES OR BATCHES PRODUCED, IN THE “NOTE” COLUMN R2: REVIEW OF DOCUMENTS PERFORMED RANDOMLY ON THE ACTIVITY PERFORMED
SPECIFY THE SAMPLING PERCENTAGE
H: HOLD POINT, NOTIFICATION IS MANDATORY TO GO ON WITH THE FOLLOWING PRODUCTION STEPS W: WITNESS POINT, WITNESS OF THE ACTIVITY IS REQUIRED TO GO ON WITH THE FOLLOWING
PRODUCTION STEPS

MATERIE PRIME – RAW MATERIALS

1 Edge Beam/Centre Beam/Support Bar
Drawings
1.1 Visual and dimension check Mill cert A2 R1 R2
ISO manual
Mechanical performances check 100% of the heat received
- Yield Strength Quality certificate to be
1.2 GB/T1591-2008 external laboratory Test report A2 R1 R2 provided by supplier;
- Tensile Strength
Testing shall be conducted on
- Elongation
each lot/shipment, so around 1
1.3 Chemical analysis check GB/T1591-2008 external laboratory Test report A2 R1 R2 of every 20-25 joints.

2 Stud Anchor/Splice Plate/Supporting Box/Pin/Pipe

Drawings
2.1 Visual and dimension check Mill cert A2 R1 R2
ISO manual
Mechanical performances check 100% of the heat received
- Yield Strength Quality certificate to be
2.2 GB/T700-2006 external laboratory Test report A2 R1 R2 provided by supplier;
- Tensile Strength
Testing shall be conducted on
- Elongation
each lot/shipment, so around 1
2.3 Chemical analysis check GB/T700-2006 external laboratory Test report A2 R1 R2 of every 20-25 joints.

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 CLIENT Bukaka QUALITY CONTRAL PLAN
TS-QCP-018 rev. 1
DRAWINGS
MODULAR EXPANSION JOINT
REF.: DWG NO. 4-T320-1 Project:
Jakarta Cikampek Elevated Toll Road Project
DWG No. 6-T480-1 Rev04
ITEM Activity sequence Reference documents Used Equipment Documents to be Activity frequency Notes
issued Production Techstar Client
line Headquarter

3 Stainless Steel Plate

Drawings
3.1 Visual and dimension check Mill cert A2 R1 R2
ISO manual
Mechanical performances check Quality certificate to be
- Yield Strength provided by supplier;
3.2 GB/T3280-2007 external laboratory Test report A2 R1 R2
- Tensile Strength Testing shall be conducted on
- Elongation each lot/shipment, so around 1
of every 20-25 joints.
3.3 Chemical analysis check GB/T3280-2007 external laboratory Test report A2 R1 R2
4 Rubber Seal (EPDM)
Drawings
4.1 Visual and dimension check Test report A2 R1 R2
ISO manual
4.2 Tensile Strength ASTM D412 external laboratory Test report R2
A1 W
4.3 Elongation at break ASTM D412 external laboratory Test report R2
4.4 Hardness(IRHD/Shore A) ASTM D2240 external laboratory Test report A2 W R2 Testing shall be conducted on
4.5 Compression set ASTM D395, Method B external laboratory Test report A1 W R2 each lot/shipment, so around 1
of every 20-25 joints.
Accelerated ageing- variation of
- hardness
4.3 ASTM D573 external laboratory Test report A2 W R2
- tensile strength
- elongation at break
4.4 Ozone Resistance ASTM D1149 external laboratory Test report A2 W R2

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 CLIENT Bukaka QUALITY CONTRAL PLAN
TS-QCP-018 rev. 1
DRAWINGS
MODULAR EXPANSION JOINT
REF.: DWG NO. 4-T320-1 Project:
Jakarta Cikampek Elevated Toll Road Project
DWG No. 6-T480-1 Rev04
ITEM Activity sequence Reference documents Used Equipment Documents to be Activity frequency Notes
issued Production Techstar Client
line Headquarter

5 Other Parts
Control Spring/Equal-Control
5.1 Drawing external laboratory TC of D.S.TechStar lnc - A2 R2
Compression Spring
5.2 Sliding Spring Drawing external laboratory TC of D.S.TechStar lnc - A2 R2
5.3 Sliding Bearing Drawing external laboratory TC of D.S.TechStar lnc - A2 R2
5.4 Pin for Control Spring Drawing external laboratory TC of D.S.TechStar lnc - A2 R2
5.5 Coil Spring Drawing external laboratory TC of D.S.TechStar lnc - A2 R2
6 Dimensional check on components
6.1 Spare Part Drawing A1 A2-R2 R2 100% of the products
6.2 Supporting box Drawing Steel ruler, range:0-600mm A1 A2-R2 R2 100% of the products
Dimensional check
Steel tape, range:0-3m
6.3 Supporting bar Drawing caliper 22871, range:0-300mm
report A1 A2-R2 R2 100% of the products
6.4 Beam assembly Drawing A1 A2-R2 R2 100% of the products
7 Welding
Visual check
- Spare Part welding TG Welding procedure
7.1 Examination report A1 A2-R2 R2 100% of the products
- Supporting box weld to beam AWS D1.1
- Splicing of beam
Non distractive test
HR-ST
- Spare Part welding Liquid penetrant test
7.2 ASTM E165 HD-ST A1 A2-R2 R2 100% of the products
- Supporting box weld to beam report
HP-ST
- Splicing of beam

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 CLIENT Bukaka QUALITY CONTRAL PLAN
TS-QCP-018 rev. 1
DRAWINGS
MODULAR EXPANSION JOINT
REF.: DWG NO. 4-T320-1 Project:
Jakarta Cikampek Elevated Toll Road Project
DWG No. 6-T480-1 Rev04
ITEM Activity sequence Reference documents Used Equipment Documents to be Activity frequency Notes
issued Production Techstar Client
line Headquarter

8 Corrosion protection
Internal inspection
8.1 Surface treatment ISO8501-1 Roughness gauge A2 A2-R2 R2
cert randomly
Hot-dip galvanizing BS/ EN standard as
8.2 - Visual check referred to in Series 1900 Thickness gauge Film inspection report A1 A2-R2 H 100% of the product
- Thickness check (≥100μm) specification

FINISHED PRODUCTS
9 Final inspection
9.1 Visual check Drawing A2 A2-R2
Dimensional check
Steel ruler, range:0-600mm 100% of the products
report; To be recorded
9.2 Dimensional check Drawing Steel tape, range:0-3m A1 A2-R2 H Dimension report to be
caliper 22871, range:0-300mm on a "Field record
provided by manufacture
sheet"
To be recorded on a
9.3 Film check ASTM A123 Thickness gauge A1 A2-R2 H
"Field record sheet"
To be recorded on a
9.4 Marking check Drawing A1 A2-R2 H
"Field record sheet"

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