Inspection and test plan for EN 1090: template with example

An inspection and test plan (ITP) is the overview of which checks you carry out on a project, when, by whom and with what result. Under EN 1090, many companies work with an ITP per project, so that they can demonstrate the process from material to final inspection. Below is a template with a completed example that you can adopt.

The ITP is the project version of your FPC system. Where the FPC describes the general working method, the ITP records what must happen on this specific project. The welding checks follow from ISO 3834, and the execution class of the project determines how much testing you must do. According to Bouwen met Staal (Dutch steel construction information platform) , the factory production control is assessed by a notified body.

Short answer: an ITP is a table that lists, for each step, the check, the requirement, the moment and the record. Put “hold points” in where the work may only continue after approval.

What is a hold point?

A hold point is an inspection moment at which work stops until someone has approved it. A witness point is a moment at which someone may be present, but the work does not have to stop. The distinction determines what you may and may not continue.

Typical hold points in steel construction are: approval of the WPS before welding starts, final inspection of the weld seam before painting, and checking of the dimensions before erection. Which points are mandatory is stated in your project specification and in the standard.

Example: completed ITP for a steel column and beam structure

The example below is fictional. It shows the structure. The requirements and tolerances are illustrative and not intended as production instructions.

Step	Check	Requirement	Moment	Type	Record
1	Material certificate 3.1	Steel grade and batch match	On receipt	Hold	ITP-01, signed off
2	Batch number marking	Number is on the material	At sawing	Witness	ITP-02
3	WPS approval	WPS linked to WPQR	Before welding starts	Hold	WPS-01 rev. 2
4	Welder qualification	Welder valid for the WPS	Before welding starts	Hold	Welder matrix
5	Visual weld inspection	No undercut or porosity visible	After each weld	Witness	Weld inspection form
6	Non-destructive testing (NDT)	According to the requirements of the execution class	After welding	Hold	NDT report
7	Dimensions	Within the tolerances on the drawing	Before erection	Hold	Measurement form
8	Final inspection and CE link	Everything signed off, quality checked	Before delivery	Hold	Delivery file

The “Type” column is the most important. Hold points are the places where you really stop the work. Without hold points, the ITP is a list that nobody follows.

How do you build it up?

You make an ITP per project, not per company. You start with the requirements from the project specification and add your own working method. The sequence below works well in practice.

Take the requirements from the project specification

Note the steel grade, the execution class and the requirements for welding and testing. Ask the designer for any missing classes or requirements before you start.

List all process steps

From purchasing to delivery. Think of receipt, sawing, drilling, welding, straightening, coating and erection.

Set a check for each step

Each step gets at least one check, with a requirement, a moment and a record. For welding, refer to the WPS, and for material, refer to the 3.1 certificate.

Choose the type of check

Decide for each check whether it is a hold point, a witness point or a routine check. Hold points are the steps you only continue after approval.

Have the ITP approved

The welding coordinator or the person responsible for quality signs off the ITP. On a project with an external client, that client may also need to approve it.

What does the auditor want to see in the ITP?

The auditor chooses a project and asks for the ITP. They then check whether the recorded execution matches the plan. They go through the hold points and ask whether they were actually carried out.

They look at three things. First, whether every hold point is signed off, with date and name. Second, whether the records exist and belong to the project. Third, whether the ITP suits the execution class of the project. An ITP for EXC1 used on an EXC3 project is a nonconformity.

Common mistakes

A generic ITP for all projects. A template is a good starting point, but every project has its own requirements. An ITP that does not fit the project becomes obvious at audit.

Hold points that are not signed off. The work continues and the signature is missing. This is the most common finding on an ITP.

NDT not linked to the class. Non-destructive testing must suit the execution class. See the page on execution classes for the choice per class.

Records on loose sheets of paper. If the records are in a drawer, nobody can find them. Store them in your file, linked to the project.

Frequently asked questions about the ITP

Is an ITP mandatory under EN 1090?

The standard requires a systematic control of production through your FPC system. An ITP is the practical form of this per project. Many notified bodies expect one, but the exact requirement follows from your FPC system and the standard.

Who makes the ITP?

Usually the welding coordinator or the quality officer, in consultation with the project manager. The designer supplies the requirements.

What is the difference from a WPS?

The WPS describes how you weld. The ITP describes when and how you check, and refers to the WPS as part of that check.

May I reuse an ITP for a next project?

Yes, as a template. Adjust the requirements, the execution class and the hold points for each new project. A copy without changes will result in a finding at audit.