FPC system (factory production control) for EN 1090
An FPC system is the documented and working factory production control of a steel or aluminium fabricator. It records how you purchase, make, check and record, so that each component has the performance you promise in your declaration of performance. For EN 1090 certification, a certified FPC system is the core of the process.
According to Bouwen met Staal (Dutch steel construction information platform) , a construction company must set up, document and maintain an FPC system, and have it assessed by a notified body. Under the Bouwproductenverordening (Construction Products Regulation), this system is called 2+: the notified body carries out an initial inspection of the factory and the FPC, and then provides ongoing surveillance. This is also set out in the explanation from European Accreditation . Only then may you use a declaration of performance and CE marking. You work out the material, marking and checks in the pages on 3.1 material certificates, traceability and marking and the inspection and test plan. It is best to choose your notified body before you request a quote.
In short: the FPC system is your quality system for the workshop, tailored to EN 1090-2 or EN 1090-3. If you already have ISO 9001, you build on that. You mainly add the steel construction requirements and the welding work.
What must an FPC system for EN 1090 contain?
An FPC system covers the whole chain from order to delivery. In addition, EN 1090-1 requires two things that you do not find in a standard quality system:
- Initial type testing (ITT): you show once that your working method delivers the promised properties, for example with qualified welding procedures and material certificates.
- Initial type calculation (ITC): if you design or calculate the structure yourself, you show how you control that.
Kiwa names ITT, ITC and an FPC management system as the three components you need for the EN 1090-1 certificate.
Example procedure overview for an FPC system
Below is a fictional procedure overview for a steel fabricator with 25 employees working to EXC2. Use it as a starting point. Adjust the numbering, names and content to your own working method.
| No. | Procedure | What do you record? | Evidence at audit |
|---|---|---|---|
| FPC-01 | Contract review | Execution class, tolerances, protection and delivery time per order | Completed order checklist |
| FPC-02 | Design and calculation | Who calculates, which Eurocodes, check by a second person | Calculation with initials |
| FPC-03 | Purchasing and suppliers | Requirements for steel, bolts and welding consumables | Purchase order, supplier assessment |
| FPC-04 | Incoming inspection | Check material certificates (EN 10204, type 3.1 where required) | Signed-off certificates |
| FPC-05 | Identification and traceability | How you mark and find plates and profiles | Mark on the part, link to certificate |
| FPC-06 | Cutting, drilling and punching | Settings and periodic checks of the processes | Record of suitability check |
| FPC-07 | Welding | WPSs, welders, welding coordination according to ISO 3834 | Overview of welding procedures, welder matrix |
| FPC-08 | Mechanical connections | Bolts, tightening torques, pre-tension | Tightening record |
| FPC-09 | Protection | Surface preparation, coating system, coating thickness | Coating thickness measurements |
| FPC-10 | Dimensions and tolerances | Check against drawing and EN 1090-2 | Dimensional report |
| FPC-11 | Inspection and testing | Visual weld inspection, additional testing, final inspection | Inspection report |
| FPC-12 | Measuring equipment | Calibration and checks of measuring tapes and coating thickness gauges | Calibration overview |
| FPC-13 | Nonconforming products | Report, assess, repair or reject | Nonconformity register |
| FPC-14 | Declaration of performance and CE | Drawing up the DoP and CE label per delivery | Example DoP with label |
| FPC-15 | Personnel and training | Qualifications, competences, training plan | Competence matrix |
| FPC-16 | Documents and records | Version control of drawings and procedures, retention periods | Document list |
Sixteen procedures sounds like a lot. In practice they are often short work instructions or one-page checklists. A small workshop may combine procedures, as long as every subject is covered.
Example of one completed procedure
This is how FPC-04 (incoming inspection) can look in practice:
| Part | Content |
|---|---|
| Purpose | Only material with the right properties enters the workshop |
| Responsible | Warehouse manager, or the production planner if in doubt |
| Method | Delivery note checked against purchase order, certificate checked against steel grade and heat number, visual check |
| Nonconformity | Set the material aside with a red label and report it in the nonconformity register |
| Recording | Store the certificate digitally under the order number, with initials and date |
| Retention period | At least as long as the declaration of performance must be kept |
What does the notified body check in your FPC system?
The notified body does not only check your paperwork. According to European Accreditation, the auditor must verify that the processes they see match the processes you normally use for your CE-marked products. They will therefore often follow an order through the workshop:
- Does the execution class on the drawing match what happens in the workshop?
- Can you trace, from an installed girder, which material certificate belongs to it?
- Are the welders and welding procedures for this order qualified?
- Is the final inspection recorded before the component leaves the building?
- Is there a declaration of performance for this delivery that matches it?
After the initial inspection, periodic surveillance follows. You can read how often on the costs and timeline page.
FPC system and ISO 9001: avoiding duplicate work
An FPC system based on ISO 9001 is possible, provided you supplement it with the requirements from EN 1090. Many subjects overlap: purchasing, document control, nonconformities and internal audits. Add the EN 1090-specific parts as separate procedures within the same system.
What ISO 9001 does not cover is steel construction technology. You must add tolerances, welding methods, protection and the declaration of performance yourself. Also read how to set up document control for ISO 9001, because the same approach works for your FPC records.
Common mistakes with the FPC system
A bought manual that nobody knows. A standard FPC manual is quick to buy. But the auditor asks the workshop manager how they work. If that does not match the manual, it is a nonconformity.
Traceability that stops at the sawing line. After sawing, the mark is often lost. Record how you transfer the mark to the cut parts.
No contract review. If the execution class or the protection system is missing from the order, you only notice at final inspection. A short checklist at the start prevents this.
Not recording nonconformities. “We just sort it out” is not a record. The auditor wants to see that you look for causes, for example with a root cause analysis.
Checklist: is your FPC system ready for the initial inspection?
Work through these questions before you invite the notified body. If you can answer “yes” to all of them, the chance of major nonconformities is small.
| Question | Yes/no |
|---|---|
| Does every order state the execution class, and has it been checked? | |
| Are all welding procedures used qualified and recorded in an overview? | |
| Has a welding coordinator been appointed with a suitable knowledge level? | |
| Can you find the material certificate for at least one delivered component? | |
| Are measuring instruments calibrated or checked, with records? | |
| Is there a nonconformity register with completed causes and actions? | |
| Have you carried out an internal audit and followed up the findings? | |
| Is there a sample declaration of performance with a CE label? |
Frequently asked questions about the FPC system
Must the FPC system be on paper, or may it be digital?
Both are allowed. The standard requires a documented and maintained system, not a particular form. A digital order system with photos and scanned certificates works well, as long as you can find your records and they cannot be changed without trace.
Does the FPC system also apply to work on the building site?
The FPC system concerns the production of the components you deliver with CE marking. If you also weld or assemble on site, include those activities in your welding procedures and inspections. Discuss with your notified body which activities fall under the certificate.