Material Management Plan

1. General
The objective of Material Management Plan is to describe planning & control procedures should be coordinated and implemented properly and effectively in order to assure that activities of material staff is effective, and material purchased & used of a construction project meet requirements of technical specifications, controllable, identified, and efficient.

2. Scope

The Material Management Plan will be applied for CONTRACTOR that in field of Engineering, Procurement, and Construction project.

This Material Management Plan is a part of Project Management Plan.
The discussions of Material Management Plan have been integrated to another project management as paragraph 3.

3. Reference
i) Project Execution Plan
ii) Engineering Management Plan
iii) Quality Management Plan
iv) Construction management Plan
v) Procurement Management Plan

4. Responsibilities
4.1. Managers of project
The responsibilities of Project manager and each manager of project exclude Material & Logistic manager shall refer to Project Quality Assurance Plan.

4.2. Material and Logistic Manager (MLM)

Material and Logistic Manager shall be responsible to the PM for overall control of materials, including receiving, checking, inspection, storing, issuance, handling over and disposal of material.

Material and Logistic Manager responsible for supervision of material allocation to ensure the intended result according to material planning.

Material and Logistic Manager has right to attend the internal meeting in coordination with the Project Manager.

4.3. Material Staff
Material Staff has responsible to report to Material and Logistic Manager about planning, realizations, and status of material requisitions.
Material Staff shall verify the back up document for material requisitions.
Material Staff shall prepare and control the numbers of material requisitions.
Material Staff shall responsible to generate cutting lay out of raw material (if required) to get material efficient in use and the part of material can be identified & traceable.

4.4. Ware House Staff
Ware House Staff has responsible to report to Material and Logistic Manager about incoming, stock, and out going material.
Ware House Staff shall identified the storage and lay down area in accordance with required material properties.
Ware House Staff shall arrange and record the material address and location.
Ware House Staff shall control special treatment of materials.

4.5. Traffic Staff
Traffic Staff has responsible to report to Material and Logistic Manager about loading & unloading equipments, transportation vehicles, and traffic possibility.
Traffic Staff shall arrange and identified the possibility of loading & unloading incoming material at site.

5. Material Planning

The roughly numbers & type of require material that will be fabricated and/or installed of a project normally has been stated of preliminary design as reference; or the roughly material may be predicted base on the latest similar projects.

The net weight can be calculated by develop Bill of Material on approved construction drawings, and the valid information of gross weight can be determined by develop cutting layout or add some percent of net weight.

6. Material Requisition
Material requisition shall be released base on gross weight of bill of material.
Quantity of each item shall be cross checked with material stock data prior the purchase requisition released.
The detail requirements refer to discussions of Purchase Requisition article

7. Material Acceptance
Materials Acceptance shall be developed to ensure that incoming material meet requirements of purchase order, and in accordance with acceptance criteria as per relevant code & standard and/or data sheet.
The detail requirements shall refer to discussions of Material Acceptance article.

8. Material Stock In
Incoming Material shall be entered to inventory stock after all requirements acceptable and prior it used.
The detail of requirements shall refer to discussions of Material Stock In article.

9. Material Storage
The efficient handling and storing of materials are required during project execution in order provide a continuous inflow and outflow of materials, parts and assemblies to the workplace and ensure that materials are available when needed.
The detail of requirements shall refer to discussions of Material Storage article.

10. Inventory Planning & Control
Plenty type & specification of materials will be stored at the same time, it need accuracy data in order to effective work for loading & unloading materials, and required quick & valid stock report for incoming & out going material will be installed. Materials or component that are used, removed or reduced must be documented.
The detail of requirements shall refer to discussions of Inventory Planning & Control article.

11. Material Handling
Material handling system shall be planned to optimize an operation sequence, and equipment required.
The detail of requirements shall refer to discussions of Material Handling article.

12. Out going Material
All out going materials from warehouse shall have a chronological record.
The detail of requirements shall refer to discussions of Out Going Material article.

13. Material Traceability
Traceability is the ability to identify, verify the history, location, or application a specific piece of steel in a structure, throughout the life of the structure. Material traceability is required to prevent the use of incorrect or defective materials that could seriously injure the user. The required identification of the item is maintained by heat number, part number, serial number, or other appropriate means, either on the item or on records traceable to the item as required, and that required markings are on the item. It will be used for performing risk analysis on the finished products, materials, and on the components of such product to determine the need for traceability.

The detail of requirements shall refer to discussions of Material Traceability article.

14. Material Identifications
The purpose of this section is to ensure that all products, including materials used in the manufacture of finished products are properly identified. The requirement is intended to help prevent inadvertent use or release of unacceptable product into manufacturing including field activities.
The detail of requirements shall refer to discussions of Material identifications article.

15. Packaging Requirements
Materials, assembly parts, and fabricated equipments shall be packaged by supplier or manufacturer, and deliver it to project site in good condition. In this section will discuss some requirements of packaging for attaining uniformity, simplicity, adequacy, and economy in the domestic shipment.
The detail of requirements shall refer to discussions of Packaging Requirements.

16. Delivery Materials
Supplier or manufacturer shall guarantee that the construction materials in accordance with requirements of purchase order before delivered to project site; and CONTRACTOR shall assure that the materials meet requirements of project specifications for both the material physically and back up administrations data.
The detail of requirements shall refer to discussions of Delivery Materials.

17. Disposal of Waste Material
The disposal of waste materials also shall be planned in order area of project site or site fabricated area free from unused materials.
The detail of requirements shall refer to discussions of Disposal of Waste Materials.

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Material Acc of Bolts and Nuts

This discussion is part of Material Acceptance - Steel Material for describe additional requirements of BOLT & NUT

a) It required for both bolts and stud (including nuts and accessories)
b) Ordering Information
Information items to be considered in the purchase order are not limited to the following:
i) Specification designation (the year date should be included0.
ii) Name of product (bolt or stud)
iii) Grade
iv) Quantity (number of pieces by size, including nuts))
v) Size and length.
vi) Washers – specify quantity and size
vii) Finish coat
viii) Supplementary requirements.
ix) Certification

c) Marking
All bolt heads and one end of studs shall be marked with unique identifier by manufacturer to identify the manufacturer.

The grade identification shall be marked of bolt in accordance with relevant material specification.

Marking location and methods:
- Bolt shall be marked on the top of the bolt head.
- Where stud have both coarse thread and fine threads, all marking shall appear on the coarse thread end or, if preferred, the manufacturer’s identification shall appear on the fine thread end and the grade marking on the coarse thread end.
- Continuous thread studs may be marked on either end.
- All marking may be raised or depressed at the manufacturer’s option.
- Grade and manufacturer’s identification shall be separate and distinct. The two identifications shall preferably be in different locations and when on the same level shall be separated by at least two spaces.

d) Surface Quality

Each lot of bolts and/ or studs shall be visually inspected for free of burrs, laps, seams, cracks, and other injurious material or manufacturing defects which would make them unsuitable for the intended application

Surface discontinuity limits shall be in accordance with specification.

e) Certification
Manufacturer or supplier shall certify and furnish a test report which includes the following:
- Product description, grade, quantity, material specification number and issue date.
- Alloy grade, heat analysis, heat number, and type of quench.
- Result of hardness, tensile and proof load test, as applicable.
- Statement of compliance to protective coating specification (if applicable) and baking time and temperature, if not baked, state “not baked”
- Statement of compliance with the surface discontinuity requirements refer to the relevant specification.
- Statement of compliance dimensionally.
- Report, describe, or illustrate manufacturer’s marking and their location.
- Lot number, purchase order number, and date shipped.
- Country of origin, and
- Title and signature of the individual assigned certification responsibility by the company officers, with complete mailing address.

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Material Acc of Pipe Fittings

This discussion is part of Material Acceptance - Steel Material for describe additional requirements of ELBOW, REDUCER, TEE, CAP

a) Ordering Information
Information items to be considered in the purchase order are not limited to the following:
i) Specification designation (the year date should be included0.
ii) Quantity
iii) Size and pressure class or dimensions (standard or special).
iv) Seamless or welded
v) Supplementary requirements.
vi) Certification

b) Marking
i) Each fitting shall have the prescribed information stamped or otherwise suitable marked in accordance with relevant specification.

ii) Identification marks consisting of the manufacturer’s symbol or name, schedule number or nominal wall thickness designation, size, fitting designation, and the heat number.

c) Surface Quality
Surface discontinuities shall refer to relevant material specification.

d) In the case where there are surface imperfections, the manufacturer may remove or repair the defect by grinding, machining and welding.

d.1. Repair by grinding or machining
The wall thickness at the point of grinding, or at imperfections shall not be less than the minimum specified or required wall thickness.

d.2. Repair by Welding
- Discontinuities shall be completely removed before welding.
- All welds shall be made by welders, welding operators, and welding procedure qualified under the provisions of ASME Section IX and heat treated after welding in accordance with relevant specification.
- Defects shall be completely removed by chipping or grinding to sound metal as verify by magnetic particle inspection prior to welding.
- After repair welding, the area welded shall be ground smooth to the original contour and shall be completely free of defect as verified by magnetic particle or liquid penetrant inspection.

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Material Acc of Flanges

This discussion is part of Material Acceptance - Steel Material for describe additional requirements of Flanges

a) Ordering Information

Information items to be considered in the purchase order are not limited to the following:

i) Specification designation (the year date should be included).
ii) Quantity
iii) Size and pressure class or dimensions (tolerances and surface finishes should be included).
iv) Supplementary requirements.
v) Certification

b) Marking

Identification marks shall be forged or legibly stamped on each piece, and in such a position as not to injure the usefulness of the flanges.

Identification marks consisting of the manufacturer’s symbol or name, the heat number or manufacturer’s identification, designation of service rating.

When test reports are required for larger products, the markings shall consist of the manufacturer’s symbol or name, this specification number, and such other marking as necessary to identify the part with the test report.

c) The flange shall be cleaned to remove all scale and processing compounds prior to final surface examination, the cleaning process shall not injure the surface finish, material properties, or the metallurgical structure. The cleaned flange shall be protected to prevent recontamination.

The protective coatings shall be suitable for subsequent welding without removal of the coating.

d) In the case where there are surface imperfections, the manufacturer may remove or repair the defect by grinding, machining and welding.

d.1. Repair by grinding or machining

The wall thickness at the point of grinding, or at imperfections shall not be less than the minimum specified or required wall thickness.

d.2. Repair by Welding
- Discontinuities shall be completely removed before welding.

- All welds shall be made by welders, welding operators, and welding procedure qualified under the provisions of ASME Section IX and heat treated after welding in accordance with relevant specification.

- Defects shall be completely removed by chipping or grinding to sound metal as verify by magnetic particle inspection prior to welding.

- After repair welding, the area welded shall be ground smooth to the original contour and shall be completely free of defect as verified by magnetic particle or liquid penetrant inspection.

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Material Acceptance - Steel Material

1. Scope
i. This Section provides a number of requirements, recommendations, and information that supplements the section 1 – General.

ii. It covers minimum requirements for inspection activities of incoming raw materials that will be fabricated, assembled and installed in accordance with “Issued for construction” drawings.

iii. This Material Acceptance describes verification method of the actual dimension, visual, and identification of incoming raw material in accordance with purchase order requirements, mill certificates and relevant codes & standards.

iv. This discussion will be purposed for new raw steel material, such as: Plates, Structural Shapes, Sheet Piling, Bar, Pipes, Flanges, Pipe Fittings, and Bolts & Nuts.

2. Reference
- Purchase Order
- Material Acceptance

3. Conflicting Requirements
In case of conflict between this discussion and specifications, the following order of precedence shall govern:
- The requirements of the purchase order
- Material Requisition Sheet
- The individual material specification
- General specification.

4. Requirements of Inspection
i. Requirements for acceptance of material shall be furnished by the material manufacturer or material supplier in complete compliance with a material specification, such as: a report of test result, manufacturing method, ordered dimension, quantity, supply condition, and heat no.

ii. When some requirements or provisions applicable to materials exceed or supplement of the material specification, the material examiner shall examine the material test reports or certificates of compliance and shall determine that it represent the material and meets requirements of the material specification.

iii. When CONTRACTOR request the presence at the inspection, prior agreement with manufacturer shall be necessary, the attendant shall exercise care not to hinder the work of manufacturer.

iv. In the case where there is any harmful defect on the surface of material, the material manufacturer shall maintain an inspection program to inspect the work to see that:
- Imperfections have been completely removed
- The limitations specified have not been exceeded
- Establish welding procedures have been followed
- Any weld deposit is acceptable as requirements of specification.

v. The inspection items and acceptance criteria shall conform to the requirements specified in relevant material specifications.

5. Supporting Documents

5.1. Purchase Order
It shall describe vendor name, consignee, shipment schedule, material specifications, shape, sizing, quantity, etc.

5.2. Packing List
It shall have detail additional information and identifications, such as: manufacturer name, heat no, materials no, weight, etc.

5.3. Mill Certificates
Material manufacturer shall furnish a certificate of inspection stating that the material has been manufactured, sampled, tested, and inspected in accordance with material specification (including year of issue), and has been found to meet the requirements.

6. Inspection
The incoming material shall be inspected by several steps depend on the material characteristics; generally evaluation will be done as follows:
i. Quantity Check
It shall refer to section 1 – General

ii. Visual Examination
a) The test method shall refer to The Visual Examination.
b) The material shall be free from defects that are detrimental to practical use, such as: scale, crack, slag, rust, moisture and grease.
c) The finish material shall be reasonably straight.
d) The actual observation of raw material shall be recorded and documented.
e) All materials to be used in constructing a pressure part/equipment shall be examined before fabrication for purpose of detecting, as far as, imperfections which would affect the safety of part/ equipment.
- Particular attention should be given to cut edges and other parts of rolled plate which would disclose the existence of serious laminations, shearing cracks, and other imperfections.
- All materials that are to be Charpy impact tested shall be inspected for surface cracks by magnetic particle testing.

iii. Dimensional Test
a) The test method shall refer to the Dimensional Test.
b) The permissible variations for dimensions shall not exceed the applicable limits in accordance with relevant material specifications.
c) One of material from each bundle or each specific material shall be taken for test specimen.
d) The inspection apparatus as below:
- Thickness meter, accuracy 0.05 mm
- Mechanical caliper, accuracy 0.05 mm
- Steel Roll Meter, accuracy 0.5 mm
e) The actual measure of raw material shall be recorded and documented.
f) Material outside the limit of size and/or thickness given of the specifications may be used if the material is in compliance with the other requirements of the specification that it no size or thickness limitation is given in the stress tables of material specification.
g) The tolerances on shape and dimension shall refer to the relevant material specifications.
h) The following information shall be included of Receiving Material Inspection record:
- Project Title, Customer Name, Contract No.
- Job No., Purchase Order No, Material Receiving Report No, Packing List No.
- Date of Inspection, Location of Inspection
- Material Specification
- Reference of dimensional and tolerances; and Visual acceptance
- Actual Identification of material
- Actual measure of dimensional and visual observation
- Test result
- Material Examiner Name, Authorize Inspector (If required), Owner (If required).

iv. Magnetic Particle Examination

It for material plates 38 mm over in nominal thicknesses that it subject to stress due to a pressure which is to be formed and welded.

v. Ultrasonic Testing
It for material plate 100 mm and over in nominal thickness.

vi. Test Report
Test reports for each heat material are required and material manufacturer or material supplier shall report the following:
a) The specification designation, including year of issue, and the grade.
b) The heat number, chemical analysis, and nominal sizes.
c) The result of tensile strength
d) The report of heat treatment (if required)
e) The result of all other tests required by the material specification, applicable supplementary requirements, and the order.

7. Evaluation
i) QA/QC engineer shall verify between the actual identifications & inspection record; and mill certificates; and relevant material specification.

ii) If all items complied, the material shall be accepted; QA/QC engineer shall publish Material Acceptance Notice and it shall be distributed to Material and Logistic Manager for inventory and Procurement Manager for information.

8. Rejection
i) Any rejection based on product analysis made in accordance with the material specification.

ii) Material that shows imperfections capable of adversely affecting subsequent to its acceptance at the fabrication or installation work.

iii) Any rejection material shall be reported to Procurement Manager for corrective action and Material and Logistic Manager to separate it.

9. Related Document
9.1. Instruction sheet of Material Receiving Report
It shall be published by Material and Logistic Department; and it shall be distributed to QA/QC Department for inspection.

9.2. Instruction sheet of Visual Examination
It shall be published by Material Examiner; and it shall be distributed to QA/QC Engineer for verification.

9.3. Instruction sheet of Dimensional test
It shall be published by Material Examiner; and it shall be distributed to QA/QC Engineer for verification

9.4. Instruction sheet of Material Acceptance Notice
It shall published by QA/QC Engineer; and it shall be distributed to Procurement Department; and Material and Logistic Department.

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Material Acc of Steel Plate

This discussion is part of Material Acceptance - Steel Material for describe requirements of Steel Plate

a) Material steel plates that it subject to stress due to pressure shall have material test report or certificate of compliance as provided in the material specification.

The material examiner shall examine the material test report or certificate of compliance and shall determine that it represents the material and meets requirements of the material specification.

b) Identification of plate

b.i) Required plate marking

Plate shall be legibly marked minimum with the following: applicable grade; heat number; width and length and thickness; color marking; brand of the manufacturer.

The size of steel strip shall expressed by thickness and width.
b.ii) Types of Marking

Any required color marking shall be by paint marking, unless otherwise specified.

b.iii) Location of Marking
The required markings shall be in at least one place on each finished plate.
b.iv) Color Marking

It shall refer to material specification; Color markings shall be distinct and of sufficient size to be clearly visible.

c) In the case where there is any harmful defect on the surface of steel plate and sheet, the manufacturer may remove or repair the defect by grinding or welding.
In this case, the operation shall as follows:
c.i. Conditioning with grinding

- The thickness of the steel plate and sheet after conditioning shall fall within the tolerances on thickness.

Shallow imperfections on the top or bottom surface shall be subject to limitations that the area ground is well faired without abrupt changes in contour and the grinding does not reduce the thickness of the plate under the nominal thickness.

- The conditioned parts of the steel plate and sheet shall be finished neatly, and the boundary between the repaired portions on the as rolled surface shall be smoothly finished.

c.ii. Repair by welding

- The harmful defects of the steel plate and sheet shall be removed thoroughly by suitable means such as chipping or grinding prior to welding. The depth of the removed part shall refer to relevant material specifications.

- The repair by welding shall be carried out by suitable means for the kind of steel product.

- The heat treated steel plate and sheet themselves shall be heat treated once again after the repair by welding.

- When the material shall be repaired by welding, the surface to be welded shall be inspected using a magnetic particle method or liquid penetrant method to verify that the imperfections intended to be removed have been completely removed.

The welds and adjacent heat affected zone shall be sound and free of cracks, the weld metal being thoroughly fuse to all surface and edge without undercutting or overlap. Any visible cracks, porosity, lack of fusion, or undercut in any layer shall be removed prior to deposition of the succeeding layer.

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Material Acc of Structural Steel

This discussion is part of Material Acceptance - Steel Material for describe additional requirements of Structural Shape, Bar, Sheet pilling

a) Identification of Shape
a.i) The material shall be accepted as complying with the material specification if the material specification provides for the marking of each piece with the specification designation, including the grade, type, the heat number, Size of section, length, and mill identification on each piece; the manufacturer’s name and brand.

a.ii) Each structural shape shall be marked the color in accordance with material specification on one cut end or across the rolled face of one flange or leg, adjacent to one cut end. Color marking shall be distinct and of sufficient size to be clearly visible.

a.iii) If the material specification does not provide for the marking of each piece, the material shall be accepted as complying with the material specification provided the following requirements are met:
- Each bundle or shipping container is marked or substantially tagged showing the identification in accordance with the specification designation, including the grade, type, the heat number, Size of section, length, and mill identification on each piece; the manufacturer’s name and brand.

- The handling and storage of the material shall traceability to specific lot and order. It shall refer to inventory procedure of Material Management.

b) In the case where there is any harmful defect on the surface of steel plate and sheet, the manufacturer may remove or repair the defect by grinding or welding. In this case, the operation shall as follows:
b.i. Conditioning with grinder
- The thickness of the materials after conditioning shall fall within the tolerances on thickness.
Shallow imperfections on the top or bottom surface shall be subject to limitations that the area ground is well faired without abrupt changes in contour and the grinding does not reduce the thickness of the plate under the nominal thickness.
- The conditioned parts of the materials shall be finished neatly, and the boundary between the repaired portions on the as rolled surface shall be smoothly finished.

b.ii. Repair by welding
- The harmful defects of the materials shall be removed thoroughly by suitable means such as chipping or grinding prior to welding.
- The depth of the removed part shall refer to relevant material specifications.
- The repair by welding shall be carried out by suitable means for the kind of steel product.
- The heat treated steel plate and sheet themselves shall be heat treated once again after the repair by welding.
- When the material shall be repaired by welding, the surface to be welded shall be inspected using a magnetic particle method or liquid penetrant method to verify that the imperfections intended to be removed have been completely removed.
The welds and adjacent heat affected zone shall be sound and free of cracks, the weld metal being thoroughly fuse to all surface and edge without undercutting or overlap. Any visible cracks, porosity, lack of fusion, or undercut in any layer shall be removed prior to deposition of the succeeding layer.

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Material Acc of Steel Pipe

This discussion is part of Material Acceptance - Steel Material for describe additional requirements of Steel Pipe

a) It required for both seamless and welded pipe that it subject to stress due to a internal pressure.

b) Ordering Information
Information items to be considered in the purchase order are as follows:

- Specification designation
- Quantity (feet, meters, or number of length)
- Grade and Type
- Finish (Black or galvanized)
- Size (NPS and weight class or schedule number, or both; outside diameter and nominal wall thickness)
- Length (specific or random)
- End finish (plain end or threaded)
- Certification
- End use of material
- Specific requirements.

c) The material shall be accepted as complying with the material specification. Each length of pipe may be marked by rolling, stamping, or stenciling in accordance with material specification to show: the manufacturer’s name and brand; the specification designation, the grade & type, Size (NPS, schedule number, or wall thickness, length), the heat number.

d) If the material specification does not provide for the marking of each piece (NPS 1½ and smaller), the pipe shall be accepted as complying with the material specification provided the following requirements are met:
- Each bundle shall be marked or substantially tagged showing the identification in accordance with the specification designation.
- The handling and storage of the material shall traceability to specific lot and order. It shall refer to inventory procedure of Material Management.

e) In the case where there are surface imperfections, the manufacturer may remove or repair the defect by grinding, provided that the remaining wall thickness is within specified limits.

f) The section of pipe containing the defect may be cut off within the limits of requirement on length.

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