RMC PLANT & LAB AUDIT OBSERVATIONS

a. List of IS codes to be updated as per the scope of works. Ex: List doesnt
cover the codes related to cement / water.
b. List of IS codes to be updated with the correct document descriptions.
c. Available IS codes are not properly organised neither in electronic format nor
in hard copy. Documents are partially available in a scattered manner.
d. GC shall maintain the updated codes in a central server to have access to the
key department managers.
e. ITP controlling document sections are to be updated with relevant part nos.
on raw material testing.
f. Available training records have not covered all the test methodology briefings
to the deployed technicians.
g. Training attendance form shall be a standard or controller as per GC QMS.
h. Filing system: File indexing and standard labelling shall be applied.
i. Updated master list of record not in place.
j. Quality records (Internal / external / routine test reports) shall be marked with
reviewer name and signature.
k. Test guidelines are to be prepared for the entire tests being conducted in the
lab. Shall be displayed at the test equipment locations for reference.
l. Routine tests: Sieve analysis test results are observed out of tolerances
randomly, GC shall retest the samples to confirm the compliance.
m. No evidence of test records per IS 4926 on alkali-aggregate reactivity /
petrography.
n. Chemical admixture (CAC Hyperfluid H3): Ref: 002496, Dated: 01/03/2017
MTC vs Delivery chalanas are corrected by hand.
o. Above item No chalanas available with MTC, Dated : 20/06/2015
p. No material inspection records are available for materials being delivered as
per the approved quality plan. GC shall follow internal quality form for the
materials delivered for the RMC production.
q. Cement test reports: No evidence of 28 days test reports. GC shall maintain
the 28 days reports for all the deliveries.
r. Cement bulker seals: Seal ref: 008989, Veh: MH46AF0899 / Invoice:
6985386403, Dated: 22/02/2017 No evidence of QA/QC reviewer name &
signature.
s. Flyash test reports: MTC noted with some typo errors. GC shall inform the
mfg. and maintain the updated reports henceforth.
t. Lab. Test reports are to be updated with relevant test code references.
u. Aggregate sampling shall be done as per IS 2386, Part-1: Sampling by
quartering or by means of a sample divider.
v. Admixture compatibility test shall be performed for all the admixture vs
cement combinations as per the approved mix designs.
w. Lab equipment serial no. for oven / sieve shaker / impact test equipment No
metal tags by the mfg. or no document evidence available from the
manufacture to confirm the current practice.
x. No digital thermometers fixed with the concrete cube curing tanks to confirm
the water temperature is being maintained per code requirements.
y. Cube sample register (Headings) are to be updated with the units.
z. Moisture content test for the aggregates: 2 times in a day to be performed to
control the RMC production quality.
aa.Silt content test: Test conducted but no evidence of compliance / acceptance
criteria noted.
ab.All the test lab reports shall be signed by the technicians. No signature
available on cement compressive strength test report dated : 18/06/16
ac. BASF Admixture storage is directly exposed to sun, not in accordance with
the mfg. recommendations.
ad.Plant maintenance records :
a. Mfg.(Stetter) recommended maintenance checklist is not in place.
b. Routine checklists items are being verified, but no conclusive remarks
made.
c. Correlation matrix between IS 4926 Vs current checklist and the
compliance to be prepared for verification to confirm the code compliance.
d. Final check list shall be established covering GC QMS Manual / Stetter
recommended checks / IS 4926 requirements.