Module 3: Compliance & Quality Assurance 

1. Regulatory Inspections & Non-Conformance Reporting

Post-Installation Checks

• Alignment & Tolerances:

• Verify frame squareness (±2mm per metre) and glass alignment (no visual distortion).

• Check opening mechanisms (smooth operation, no excessive force required per BS 6375-2).

• Sealing & Weatherproofing:

• Inspect gaskets and sealants for continuity (no gaps >3mm).

• Confirm drainage weeps are unobstructed (critical for curtain walls).

Identifying Non-Compliance with Building Regulations

• Part L (Thermal Performance):

• U-value non-compliance (e.g., >1.4 W/m²K in new builds).

• Thermal bridging at junctions (infrared thermography helps detection).

• Part Q (Security):

• Test door hinges/locks for PAS 24 compliance (resists 3-minute attack).

• Verify laminated glass in critical zones (impact-resistant to BS EN 356).

• Documenting Non-Conformities:

• Classify defects as critical (safety/regulatory breach), major (functional issue), or minor (cosmetic).

• Issue Non-Conformance Reports (NCRs) with photographic evidence and remediation deadlines.

2. Quality Assurance in Fenestration

Factory Production Control (FPC) Audits

• Key Checks:

• Raw material certifications (e.g., thermal break insulation quality).

• Welding integrity (aluminium frames) and glass processing (edge deletion).

• Batch testing of hardware (cycles tested to BS EN 13126 for durability).

• Documentation Review:

• Ensure CE/UKCA marking files are complete (DoP, FPC records).

• Traceability of components (serial numbers for critical parts).

Sitework vs. Off-Site Fabrication Checks

3. Handover & Certification

Completion Certificates

• FENSA/CERTASS:

• Mandatory for self-certified installations (replaces Local Authority Building Control sign-off).

• Valid only if installer is registered with the scheme.

• BSI Kitemark:

• Optional premium certification for enhanced quality assurance.

• Requires annual audits of manufacturing and installation processes.

Client Reporting Best Practices

• Photographic Evidence:

1. Time-stamped images of defects (close-ups + context shots).

2. Annotations highlighting non-compliance (e.g., "Sealant gap exceeds 5mm at head joint").

• Report Structure:

1. Executive Summary (key findings, compliance status).

2. Defect Schedule (location, classification, recommended fix).

3. Regulatory References (e.g., "Breach of Part L1B due to missing thermal breaks").

4. Appendices (test certificates, installation drawings).

Key Takeaways

• Regulatory Inspections must verify both product standards (e.g., EN 14351) and sitework quality (e.g., sealing).

• FPC Audits prevent defects at source, while on-site checks catch installation errors.

• Certification (FENSA/BSI) provides legal compliance; detailed reports protect against disputes.