Section 7 Inspection, workmanship and testing procedures

7.1 General

7.1.1 The minimum requirements in respect of inspection, workmanship and testing are contained within Pt 6, Ch 2 Construction Procedures, Pt 7, Ch 2 Construction Procedures and Pt 8, Ch 2 Construction Procedures, of the Rules for craft constructed in steel, aluminium alloy and composite respectively.

7.2 Construction standards

7.2.1 Construction standards for all materials are to be in accordance with National Standards or these Rules whichever are the higher.

7.2.2 The design requirements for welding and structural detail are to be found in Pt 6 Hull Construction in Steel and Pt 6 Hull Construction in Steel of the Rules for craft constructed in steel and aluminium alloy respectively.

7.2.3 The design requirements for the bonding of all structural detail of composite materials are contained in Pt 8 Hull Construction in Composite.

7.3 Testing procedures

7.3.1 Definitions. For the purpose of these procedures the following definitions apply:

Protective coating is the coating system applied to protect the structure from corrosion. This excludes the prefabrication primer.
Structural testing is a hydrostatic test carried out to demonstrate the tightness of the tanks and the structural adequacy of the design. Where practical limitations prevail and hydrostatic testing is not feasible, hydropneumatic testing, see (e), may be carried out instead.
Leak testing is an air or other medium test carried out to demonstrate the tightness of the structure.
Hose testing is carried out to demonstrate the tightness of structural items not subjected to hydrostatic or leak testing, and other components which contribute to the watertight or weathertight integrity of the hull.
Hydropneumatic testing is a combination of hydrostatic and air testing, consisting of filling the tank with water and applying an additional air pressure. The conditions are to simulate, as far as practicable, the actual loading of the tank and in no case is the air pressure to be less than given in Pt 3, Ch 1, 7.3 Testing procedures 7.3.4.

7.3.2 Application. The testing requirements for tanks, including independent tanks, watertight and weathertight compartments, are listed in Table 1.7.1 Testing requirements. Tests are to be carried out in the presence of the Surveyor at a stage sufficiently close to completion such that the strength and tightness are not subsequently impaired.

7.3.3 Structural testing. The attachment of fittings to oiltight surfaces is to be completed before tanks are structurally tested. Where it is intended to carry out structural tests after the protective coating has been applied welds are generally to be leak tested prior to the coating application.

For welds other than manual and automatic erection welds, manual fillet welds on tank boundaries and manual penetration welds, the leak test may be waived provided that careful visual inspection is carried out, to the satisfaction of the Surveyor, before the coating is applied. The cause of any discolouration or disturbance of the coating is to be ascertained, and any deficiencies repaired.

7.3.4 Leak testing. This is carried out by applying an efficient indicating liquid (e.g. soapy water solution) to the weld or outfitting penetration being tested, while the tank or compartment is subject to an air pressure of at least 0,15 bar (0,15 kgf/cm²).

It is recommended that the air pressure be raised to 0,2 bar (0,2 kgf/cm²) and kept at this level for about one hour to reach a stabilised state, with a minimum number of personnel in the vicinity, and then lowered to the test pressure prior to inspection. A U-tube filled with water to a height corresponding to the test pressure is to be fitted for verification and to avoid overpressure. The U-tube is to have a cross-section larger than that of the air supply pipe. In addition, the test pressure is to be verified by means of a pressure gauge, or alternative equivalent system.

For tanks constructed of steel or aluminium, leak testing is to be carried out, prior to the application of a protective coating, on all fillet welds and erection welds on tank boundaries, excepting welds made by automatic processes and on all outfitting penetrations.

Selected locations of automatic erection welds and pre-erection manual or automatic welds may also be required to be tested before coating, at the discretion of the Surveyor, taking account of the quality control procedures of the shipyard. Where exempt from this requirement, leak testing may be carried out after the protective coating has been applied, provided that the welds have been carefully inspected to the satisfaction of the Surveyor.

Table 1.7.1 Testing requirements

Item to be tested	Testing procedure	Testing requirement
Double bottom tanks	Structural⁽¹⁾	The greater of:
		- head of water up to the top of the overflow
		- head of water up to the margin line
		- head of water representing the maximum pressure experienced in service
Cofferdams	Structural⁽¹⁾	The greater of:
Forepeak and aft peak used as tank⁽³⁾	Structural	- head of water up to the top of the overflow
Forepeak and aft peak used as tank⁽³⁾	Structural	- 1,8m head of water above the highest point of tank⁽⁴⁾
Tank bulkheads	Structural⁽¹⁾	The greater of:
Deep tanks	Structural⁽¹⁾	- head of water up to the top of the overflow
Scupper and discharge pipes in way of tanks	Structural⁽¹⁾	-1,8m head of water above the highest point of tank⁽⁴⁾ - setting pressure of the safety valves, where relevant
Double plate rudders	Leak, see Note 5	See Pt 3, Ch 1, 7.3 Testing procedures 7.3.4
Watertight doors (below freeboard or bulkhead deck) and watertight hatches when fitted in place	Hose⁽²⁾	See Pt 3, Ch 1, 7.3 Testing procedures 7.3.5
Watertight doors (below freeboard or bulkhead deck) when fitted in place	Hose⁽⁶⁾
Weathertight hatch covers and closing appliances	Hose⁽⁸⁾
Fore peak not used as tank	Hose⁽²⁾
Shell doors when fitted in place	Hose⁽⁷⁾
Chain locker	Structural⁽⁹⁾	The greater of: head of water up to the top of the spurling pipe head of water up to the exposed weather deck⁽⁹⁾
Separate fuel oil tanks	Structural	Head of water representing the maximum pressure which could be experienced in service, but not less than 3,5m
After peak not used as tank	Leak	See Pt 3, Ch 1, 7.3 Testing procedures 7.3.4
Note 1. Leak or hydropneumatic testing may be accepted, provided that at least one tank of each type is structurally tested, to be selected in connection with the approval of the design. (See also Pt 3, Ch 1, 7.3 Testing procedures 7.3.9 and Pt 3, Ch 1, 7.3 Testing procedures 7.3.10). Note 2. When hose testing cannot be performed without damaging possible outfittings already installed, it may be replaced by a careful visual inspection of all the crossings and welded joints. Where necessary, dye penetrant test or ultrasonic leak test may be required. Note 3. Testing of the aft peak is to be carried out after the sterntube has been fitted. Note 4. The highest point of the tank is generally to exclude hatchways. In holds for liquid cargo or ballast with large hatch openings, the highest point of the tank is to be taken to the top of the hatch. Note 5. If leak or hydropneumatic testing is carried out, arrangements are to be made to ensure that no pressure in excess of 0,30 bar (0,30 kgf/cm²) can be applied. Note 6. See also SOLAS Chapter II-1 Regulation 16 - Construction and initial tests of watertight closures. Where the door or hatch has been subject to the full hydrostatic test before installation, the hose test may be replaced by careful visual examination. Note 7. For shell doors providing watertight closure, watertightness is to be demonstrated through prototype testing of the seal system before installation. The testing procedure is to be agreed with LR. Note 8. On yachts, as defined in Chapter 1, a minor seepage of water up to 0,5 litres within 3 minutes, through the door, is permissible. Weathertight hatch covers and closing appliances to be tested are those on the weatherdeck in the forward 0,25L _R and those specified in Pt 3, Ch 4, 6.5 Companionways, doors and accesses on weather decks 6.5.2.(b) and Pt 3, Ch 4, 6.5 Companionways, doors and accesses on weather decks 6.5.2.(c) of the Rules for Special Service Craft. Note 9. For yachts up to 500GT, the chain locker arrangement fitted forward of the collision bulkhead may be accepted, based on the structural plans and leak testing.

7.3.5 Hose testing. This is to be carried out at a maximum distance of 1,5 m with a hose pressure not less than 2,0 bar (2,0 kgf /cm²). The nozzle diameter is not to be less than 12 mm. The jet is to be targeted directly onto the weld or seal being tested.

7.3.6 Hydropneumatic testing. When this is performed, the safety precautions identified in Pt 3, Ch 1, 7.3 Testing procedures 7.3.4 are to be followed.

7.3.7 For tanks of composite construction, leak testing is to be carried out to air pressures as indicated in Pt 3, Ch 1, 7.3 Testing procedures 7.3.4.

7.3.8 Structural testing may be carried out afloat where testing using water is undesirable in dry-dock or on the building berth. The testing afloat is to be carried out by separately filling each tank and cofferdam to the test head given in Table 1.7.1 Testing requirements. Alternate tanks and cofferdams may be filled to the test head and the bottom and lower side shell in the intermediate empty tanks and cofferdams and all boundaries are to be examined and the remainder of the bottom and lower side shell and boundaries examined when the water is transferred to the remaining tanks.

7.3.9 Where permitted by Table 1.7.1 Testing requirements, complete structural testing may be replaced by a combination of leak and structural testing, as follows. The leak test is generally to be carried out on each tank while the craft is in dry-dock or on the building berth.

Double bottom tanks and cofferdams may be leak tested on the berth, and structural tests carried out afloat.
All deep tanks are to be structurally tested. However, where a number of similar tanks is involved, one typical tank is to be structurally tested and for the remaining tanks the Surveyor may, at his discretion, permit leak testing in lieu of structural testing.
Interconnecting deep and double bottom tanks and "flume" type stabilisation tanks are to be structurally tested to the test head given in Table 1.7.1 Testing requirements.

7.3.10 Equivalent proposals for testing will be considered.

7.3.11 Trial trip and operational tests. The items listed in Table 1.7.2 Trial trip and operational tests are to be tested on completion of the installation or at sea trials.

Table 1.7.2 Trial trip and operational tests

Item	Requirement
Sliding watertight doors	To be operated under working conditions.
Windlass	An anchoring test is to be carried out in the presence of the Surveyor. The test is to demonstrate that the windlass with brakes etc. functions satisfactorily and that the power to raise the anchor can be developed and satisfies the Rule requirements. For Rule requirements, see Pt 3, Ch 5, 8 Anchor windlass design and testing.
Steering gear, main and auxiliary	To be tested under working conditions, to the satisfaction of the Surveyors, to demonstrate that the Rule requirements are met. For Rule requirements, see Pt 14, Ch 1 Steering Systems.
Davits and deck cranes	To be tested under working conditions to proof load to the satisfaction of the Surveyors.
Fire flaps	To be operated under working conditions to the satisfaction of the Surveyors.
Means of escape	Alternative means of escape from machinery and accommodation spaces is to be proven to the satisfaction of the Surveyors. For Rule requirements, see Pt 3, Ch 2, 4.10 Means of escape.