Architectural Metalwork
QA inspection checklist

Fabrication & Delivery

1. 1.

   Items match approved shop drawings
   What to look forEach item carries an identification mark cross-referenced to the shop drawings. Profile, dimensions, fixing positions, and welds match the latest IFC drawing revision. Stainless grades (304/316) and finish (satin / brushed / polished) confirmed on label.
   Acceptable whenPer BS EN 1090-2 (steel) / BS EN 1090-3 (aluminium) execution class — typically EXC2 for architectural metalwork. Dimensional tolerance ±2 mm in cross-section, ±5 mm in length up to 5 m. Fabricator must hold BS EN 1090-1 FPC.
   StandardBS EN 1090-1:2009+A1:2011 — Conformity assessment. BS EN 1090-2:2018 (steel) / BS EN 1090-3:2019 (aluminium). BS 6180:2011 (barriers).
   Common defectsItem built to old drawing — fixing holes do not alignWelds in different position than shown — load path differentMark missing — wrong item installed in wrong locationCross-section out of square — visual faultStainless 304 supplied where 316 specified for external use — corrosion
2. 2.

   Finish correct — colour, texture, coating type
   What to look forFinish matches approved sample — RAL/BS colour, gloss level, texture. Powder-coat with no orange-peel, runs, or matt patches. Polished stainless directional grain consistent. Galvanised finish smooth, no zinc spikes. Anodised aluminium uniform shade.
   Acceptable whenPowder coat to BS EN 13438 / Qualicoat — DFT 60-100 µm. Galvanising to BS EN ISO 1461 — coating mass per section thickness (typically 70-85 µm). Anodising to BS EN 12373 / Qualanod. Stainless No 4 satin per BS EN 10088. Visual against approved control sample.
   StandardBS EN ISO 1461:2009 — Hot dip galvanising. BS EN 13438:2013 — Powder coatings. BS EN 12373 — Anodising. Qualicoat / Qualanod / Qualisteelcoat schemes.
   Common defectsColour off from sample — different RAL or different glossPowder coat thin at edges (Faraday cage) — premature corrosionGalvanised spikes left, sharp edgesPolished grain runs both ways — visible on assembled itemAnodising patchy / streaky — pre-treatment fault
3. 3.

   No damage, scratches, or defects
   What to look forNo transit damage — scratches, dents, knocks. Edges and arrises sharp and clean. Welds dressed flush where exposed. No pickling stains on stainless. Protective film still on polished surfaces until install. Edges rounded per design.
   Acceptable whenPer BS EN 1090-2 Annex D / BS 6180: visible welds dressed; no scratches > 0.5 mm depth on visible surfaces; edges chamfered or radiused per drawing; surface finish matches approved sample.
   StandardBS EN 1090-2:2018 Annex D. BS 6180:2011. Manufacturer / fabricator quality plan.
   Common defectsCrane-strap dent in tube — visible in final positionStainless contaminated with mild steel particles — rust frecklesWeld grinding marks not blended into parent metalSharp edges left — cuts hands, fails Approved Document MProtective film removed too early — finish marks during install
4. 4.

   CE/UKCA marking where required
   What to look forItems declared as structural under CPR (e.g. balustrade posts, structural canopies, structural balconies) carry CE/UKCA mark with DoP. Non-structural decorative items exempted. Fabricator FPC certificate covers the work scope.
   Acceptable whenPer Construction Products Regulation: any item declared "structural" requires CE/UKCA. Balustrades to BS 6180 — barriers are structural. DoP includes execution class (EXC2 typical). Aluminium items to BS EN 1090-3.
   StandardConstruction Products Regulation. BS EN 1090-1:2009+A1:2011. BS 6180:2011 — Barriers.
   Common defectsNo DoP on balustrade — non-compliant, design liability gapCE on EXC1 fabricator certificate but EXC2 specifiedMark missing — Building Control rejectsDoP for wrong product code — does not cover this item

Installation

1. 5.

   Fixings to structure correct per design
   What to look forFixings match design — chemical anchor, expansion anchor, through-bolt, cast-in, or welded plate. Anchor type, diameter, embedment depth match calculation. Edge distance and spacing per anchor manufacturer. Torque applied per ETA.
   Acceptable whenPer ETA / BS EN 1992-4 (anchors in concrete): anchor depth, diameter, edge distance, and torque per manufacturer specification. Pull-out tests where required (typically 1 in 10, or first 3 plus 1 in 20). Substrate strength confirmed adequate.
   StandardBS EN 1992-4:2018 — Eurocode 2: Design of fastenings for use in concrete. ETA assessments. CFA Guidance Note GN37 (anchor pull-out).
   Common defectsEmbedment too shallow — full design capacity not achievableEdge distance < spec — concrete cone-out failureWrong anchor (mechanical in cracked concrete needing chemical)Torque not applied or over-torquedNo pull-out tests carried out — capacity unverified
2. 6.

   Items level and plumb

   Record: Deviation (mm)
   What to look forLong runs of handrail level with spirit level / laser. Posts plumb in two orthogonal directions. Top rail follows constant height above stair pitch line / floor. Joints aligned in line of sight.
   Acceptable whenPer BS 5606: handrail level / aligned ±3 mm in 3 m run. Posts plumb ±3 mm in storey height. Joints at gauge ≤ 1 mm step. Stair handrail follows nosing line within ±5 mm. NHBC tolerance for fitted joinery.
   StandardBS 5606:1990 — Accuracy in building. NHBC Standards Chapter 8.4.
   Common defectsLong handrail visibly waved — single packers used at postsPosts splayed — bottom and top fix not alignedJoints stepped — lazy fitter, looks cheapStair handrail height varies — non-compliant for grip
3. 7.

   Joints clean and consistent
   What to look forWelded joints dressed flush and refinished. Mechanical joints (sleeve, flush-tee) tight, no visible step or gap. Sealant beads (where used) consistent width and clean. No visible mastic smears. End caps fitted and bonded.
   Acceptable whenPer BS 6180 / project specification: visible welds ground flush, refinished to match parent metal. Mechanical joint gap ≤ 1 mm. Sealant per BS 6213 — minimum 6 mm bead, struck off neat. End caps bonded with stainless rivets or two-part adhesive.
   StandardBS 6180:2011. BS 6213:2000+A1:2010 — Sealants. Manufacturer system spec.
   Common defectsWeld bead visible after polish — not dressed flushJoint gap visible from 2 m — cheap finishSealant smeared onto adjacent metal — not cleanedEnd caps loose — fall off in serviceStainless joint with mild steel rivets — galvanic corrosion
4. 8.

   Handrail height correct

   Record: Height (mm)
   What to look forHandrail height measured from finished floor to top of rail. Stair handrail measured perpendicular from pitch line. Two-tier handrails for accessibility check both heights. Continuous height — no dips at landings.
   Acceptable whenPer Approved Document K: 900-1000 mm on stairs (top of rail above pitch line); 1100 mm guarding to landings/balconies (residential); 1100 mm to non-domestic stairs. Approved Document M: second handrail at 600 mm for accessibility on certain stairs.
   StandardApproved Document K (Protection from falling). Approved Document M (Access). BS 6180:2011. BS 8300-2 (accessibility).
   Common defectsStair handrail < 900 mm — non-compliant gripGuarding < 1100 mm to balcony — Building Control rejectStep in height at landing — trips and fallsNo second handrail where AD M requiresHeight measured to bottom of rail not top
5. 9.

   Balustrade infill spacing compliant (max 100mm)

   Record: Gap (mm)
   What to look for100 mm sphere cannot pass through any opening in barrier or balustrade. Vertical bar spacing < 100 mm. Glass infills full panel — no gaps at edges > 100 mm. Climbable horizontal rails avoided in domestic up to 1.1 m.
   Acceptable whenPer Approved Document K / BS 6180: 100 mm sphere shall not pass any opening (barrier loading and gap criterion). No climbable elements between 150 mm and 750 mm above standing surface in dwellings. Glass infill to BS 6206 / EN 12600 Class 1B1 minimum.
   StandardApproved Document K. BS 6180:2011. BS 6206 / BS EN 12600 (safety glass).
   Common defectsVertical bar > 100 mm centres — child can fall throughHorizontal rails climbable in domestic — child accident riskGlass infill gap at base > 100 mmGlazing impact-class B2 used where B1 specifiedFrameless glass with fixings allowing > 100 mm gap to floor
6. 10.

   Touch-up to site damage/fixings
   What to look forSite damage to powder coat retouched with manufacturer touch-up paint matching colour and gloss. Galvanising scuffs touched up with cold-galvanising spray. Stainless polished out to original finish. Touch-up barely visible — not just felt-tip overspray.
   Acceptable whenPer coatings specification: touch-up uses manufacturer-approved repair material (powder fusion patch, zinc-rich aerosol per BS EN ISO 1461 Annex C, polishing compound). Touch-up DFT > 80 µm. Visual match acceptable from 3 m.
   StandardBS EN ISO 1461:2009 Annex C — Galvanising touch-up. BS EN 13438. Manufacturer touch-up procedure.
   Common defectsTouch-up obvious — wrong RAL or gloss levelCold-galvanising paint used at unrepaired area not blendedStainless polished with wrong grit — visible swirlTouch-up missed exposed fixing headsNo record of touch-up — defects re-emerge after handover

Loading & Compliance

1. 11.

   Load test completed per BS 6180
   What to look forPull-test of completed balustrade with calibrated load cell — design line load applied for design duration. Permanent set on release within tolerance. Test on representative panels including end posts. Recorded with photos.
   Acceptable whenPer BS 6180:2011 / BS EN 1991-1-1: barrier line load 0.36 kN/m (residential) up to 3.0 kN/m (assembly). Test load 1.5× design. Permanent set ≤ 1 mm at typical post; rail does not yield. Test certificate signed.
   StandardBS 6180:2011 — Barriers. BS EN 1991-1-1 / NA — Loads. CWCT TN 67 (glazed balustrades).
   Common defectsNo test carried out — design liability exposedTest load less than 1.5× designPermanent set > 1 mm — anchor or post yieldingTest only on field panels, not end posts (highest stress)Test record missing photos / load cell calibration
2. 12.

   Test certificate provided
   What to look forTest certificate from competent test house / installer engineer covering each balustrade run. Identifies design loading, test method, results, and pass/fail. Includes anchor pull-out tests. Held in O&M file.
   Acceptable whenPer BS 6180 / project specification: test certificate by competent person identifying design load, test load, deflection, set, and result. Cross-reference to anchor pull-out test record. Issued to client and inspecting officer.
   StandardBS 6180:2011. CWCT Standard for Systemised Building Envelopes (Section 8 testing).
   Common defectsNo certificate handed over — Building Control may rejectCertificate covers only some runsAnchor pull-out tests not cross-referencedTest by uncompetent person — engineering sign-off missing

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