Quality Control Plan Template

Welding & Fabrication Quality Control Plan Template 2026

Create comprehensive quality control plans for welding & fabrication work. Includes inspection test plans (ITPs), hold points, and QA/QC checklists.

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Quality management system principles built in.

Hold Points Defined

Critical inspection points for your specific work scope.

Welding & Fabrication Quality Checkpoints

ITP Inspection Points

Welder qualification check
Material certification review
Fit-up inspection
In-process weld inspection
Final NDT and visual inspection

Quality Control Measures

Welder qualification verification
WPS/PQR documentation
Visual weld inspection
Non-destructive testing (NDT)
Dimensional verification
Surface finish inspection
Final documentation

What's Included in Your Welding & Fabrication QCP

Quality Control Plan

Project quality objectives
Roles and responsibilities
Document control procedures
Non-conformance management
Corrective action procedures

Inspection Test Plan (ITP)

Activity-specific inspections
Hold, witness & review points
Acceptance criteria
Reference standards
Required documentation

Applicable Standards

OHSA Construction Regulations 2014

SANS 1554 (Welding of structures)

AWS/ISO welding standards

Hot Work Permit requirements

ISO 9001 Quality Management

CIDB Requirements (ME, GB)

Welding & Fabrication Activities Covered

MIG/MAG welding

TIG welding

Arc welding (SMAW)

Oxy-acetylene cutting

Plasma cutting

Grinding and finishing

Steel fabrication

Pipe welding

Welding & Fabrication Quality Control in South Africa

Welding and fabrication in South Africa is governed by SANS 2001-CS1 (structural steelwork), SANS 44 (welder qualification), and the OHSA General Machinery Regulations for pressurised equipment. Government tenders for structural steel, pipeline, and pressure vessel work require detailed Welding Procedure Specifications (WPS) qualified per SANS 44 or AWS D1.1, along with proof that all welders hold valid coded welder certificates. The South African Institute of Welding (SAIW) is the primary certification body, and SAIW qualifications are referenced in most government tender requirements. CIDB classes CS (Structural Steelwork) and ME (Mechanical Engineering) cover different welding applications. Non-Destructive Testing (NDT) must be performed by SANAS-accredited operators per SANS 17024. For pressure equipment, the Pressure Equipment Regulations under OHSA require that all welding is pre-qualified and that NDT is performed per the applicable vessel code (SANS 347 for classification, ASME VIII Div 1 or PD 5500 for design).

QCP Critical Points for Welding & Fabrication

✓Welder qualification: verify every welder's coded certificate is current and covers the WPS range (process, position, thickness, material group) for their assigned work

✓Material certification: check mill certificates for all structural steel and filler metals. Verify material grades match design specifications before cutting commences

✓Fit-up inspection: verify joint preparation, root gap, alignment tolerances per WPS before welding. Take photographs. No welding without inspector sign-off

✓NDT results: all reports must reference the applicable standard (SANS 11666 for acceptance levels), identify the operator's SANAS accreditation, and disposition each indication

✓Post-weld: verify final dimensions against fabrication drawings, check for distortion, and confirm all temporary attachments are removed and ground smooth

Common Welding & Fabrication QCP Mistakes to Avoid

✗Using a WPS that hasn't been qualified with a PQR for the actual material combination and thickness range used on the project

✗Not verifying welder certifications cover the required welding positions — a welder coded for flat (1G) cannot weld overhead (4G)

✗Omitting preheat requirements for thick sections or high-strength steel — this causes hydrogen-induced cracking that may not show up until weeks later

✗Using generic NDT acceptance criteria instead of the standard specified in the contract (SANS 11666 vs AWS D1.1 have different acceptance levels)

✗Failing to maintain weld maps and NDT traceability — every weld must be uniquely numbered and traceable to the welder, WPS, and NDT report

Key Legislation for Welding & Fabrication Quality Control

Legislation / Standard	QCP Requirement
SANS 2001-CS1	Structural steelwork fabrication and erection — covers welding procedures, welder qualification, NDT requirements (Table E.1), tolerances, and material specifications for SA construction.
SANS 44 (ISO 9606-1)	Qualification testing of welders — defines test requirements for manual and semi-automatic welding by process, material, thickness, and position. Certificates valid for 2 years with continuous employment.
Pressure Equipment Regulations (OHSA)	All welding on pressure equipment must use pre-qualified WPS. NDT per the applicable vessel code. SANAS-accredited inspection body must approve the manufacturer's quality plan.
SANS 347	Categorisation and conformity assessment of pressure equipment — classifies equipment into hazard categories determining the level of third-party inspection and certification required.

Welding & Fabrication Quality Control Plan FAQ

What is the difference between WPS and PQR?

A WPS (Welding Procedure Specification) is the documented instruction for welders specifying parameters (current, voltage, travel speed, preheat, filler metal). A PQR (Procedure Qualification Record) is the physical test that proves the WPS produces acceptable welds — it includes test coupon welding and mechanical testing results.

Do all welders need coded certificates for government tenders?

For structural steelwork (SANS 2001-CS1) and pressure equipment, yes. All welders must hold valid coded certificates per SANS 44 covering the specific process, material, thickness, and position of their assigned work. The SAIW is the primary certification body in SA.

What NDT is required for structural steel connections?

SANS 2001-CS1 Table E.1 specifies: 100% visual inspection of all welds, plus various percentages of volumetric (UT or RT) and surface (MT or PT) testing depending on weld type, loading category, and fatigue class. Full-penetration butt welds typically require 10-100% UT or RT.

What CIDB class covers welding and fabrication?

Structural steelwork falls under CS (Structural Steelwork). Pipeline and process plant welding may fall under ME (Mechanical Engineering) or CS depending on the primary work type. Your grading must cover the contract value of the welding/fabrication portion.

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