Qap KLM

Gharpure Engineering & Constructions (P) Ltd.
50 MLD STP AT KALAMBOLI QUALITY MANUAL

Sr. No. 1 2 3 4 5 6 7 8 9 10 11 Description Scope of Work Quality Policy Organization Chart Project Management Structure - chart Quality Management System Management Responsibility Resources Management Product, Realization Measurement Analysis & Improvement Preamble Content 1 Guidelines for survey 2 Work instructions for survey 4 Guidelines for excavation 5 Work instructions for excavation 7 Guidelines for excavation in rock 9 Guidelines for filling 10 Work instructions filling in plinth 12 Guidelines for anti-termite treatment works 13 Work instructions for anti-termite treatment works 15 Guidelines for shuttering 16 Check list for after shuttering 18 Work instructions for shuttering 19 Guidelines for reinforcement 20 Work instructions for reinforcement 22 Guidelines for waterproofing 23 Work instructions for water proofing 25 Work instructions for plain cement concrete 26 Work instructions for Reinforcement cement concrete 27 Check list for prior to concreting 29 Work instructions for fabrication 30 Guidelines for structural steel fabrication 31 Work instructions for erection 35 Guidelines for masonry works 36 Work instructions for masonry 37 Check list for concrete block masonry 38 Check list for concrete block masonry 39 Soling 43 Guidelines for plastering 44 Work instructions for plastering 48 Work instructions for flooring 49 Guidelines for tiling and dado works 50 Work instructions for tiling and dado works 56 Guidelines for fixing of doors & windows 57 Work instructions for doors / windows 59 Check list for fixing doors & windows 60 Guidelines for painting 61 Work instructions for painting 65 Checklist for after building finishing 66 Checklist for after building finishing 67 Check list for finished pipeline work 68 Check list for finished pumping station work 69 Checklist for finished STP work Page No. 3 4 5 6-8 9-14 14-15 16-29 29-36 37 38-39 40 41 42 43 44 45 45 46 46 47 48 49 50 51 52 62-64 61 65 66-67 68-69 70 71 72 73 74 75 76 77 78-81 82 83-84 85 86-88 89 90 91-95 96 97 98 99-100 101

70 71 72 73 74 75 76 77 78 79 80 81 82 83 85 86 87 89 90 91 92 93 94 95 Concrete Pour Card Drawing Register Concreting Mix Design Concreting Mix Design Records of celebrators of cube testing machine Aggregate sieve analysis report Fine aggregate sieve analysis Cube sample report Sample and testing concrete in the field Bar Bending Schedule Work instruction for waterproofing Work instruction for Sanitary & Plumbing Work instruction for for infrastructural services Standard deviation Check list for sewage , GSB/WMM , WP for bathroom & Terrace Procedure for planning &construction process at site Quality plans Format for Register Safety plans Treated effluent Test report Staff Engaged on operaton and maintenance work Daily summary of operation at pumping station- Att -1 Daily summary of operation of equipment- Att - 2 Sewage quality monitoring at STP 102 103 104 106 106 107 108 109 110 111 112-113 114 - 115 116 - 123 124 - 125 126-132 134-141 142 -158 159 -160 161 -187 188 189 190 191 192

Designing, Providing, Constructing, Erecting and Commissioning of Average 50 MLD capacity high tech Sewage Treatment Plant(STP) including Operation and Maintenance for 5 years to treat the predominantly domestic raw sewage to 5 mg/l BOD,10 mg/l Suspended Solid,50 mg/l COD,2mg/l Ammonical Nitrogen and 1 mg/l Phosphorous standards, including facilities for sludge digestion and sludge dewatering etc. in Sector 12 at Kalamboli, Navi Mumbai on Contractors own design with Cyclic Activated Sludge/ SBR Technology . Client:- CIDCO of Maharashtra Ltd. Contract Code No C.A. No Letter of Acceptance
Work order No 01105807 12/CIDCO/EE (KLM-I)/ 2008-09 CIDCO/CE & GM(T) /2009/412 dated 25.6.09 CIDCO/EE(KLM-I)/2009/554 dated 7.7.2009
Contract Amount Construction Period For Operation & Maintenance Defects liability Period Date of issue of Work Order Date of Handing over the site Stipulated Date of completion Performance Security Total Security Deposit Initial Security Deposit Retention Money Retention Money for water proofing CAR Policy
Rs. 45,53,56,917 /24 Months including Trial run 01 Month & Commissioning 02 Months 5 Years from completion of work 5 Years from date of completion 7.07.2009 7.07.2009 06.07.2011 5 % of contract Amount ,in the form of Bank Guarantees 5 % of contract Amount Rs.2,27,67,846 /4 % of contract Amount Rs.1,82,14,277/1 % of contract Amount deducted from R.A. Bill at the Rate of 3 % Per Bill Rs. 45,53,569 /0.5 % of Contract Amount a) Total Contract amount b) Shall cover entire period of Construction c) Shall cover Defects Liability Period 10% of Contract amount
Mobilization Advance

50 MLD STP AT KALAMBOLI QUALITY MANUAL SCOPE OF THE WORK
1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 Receiving Chamber Coarse Screen Chambers Wet Well & Pump House Stilling Chamber Fine Screen Chambers Grit Chambers Flow Measuring Unit C Tech Basins Chlorine Contact Tank Chlorine Tonner Room Sludge Sump Sludge Pump House Centrifuge Platform Blowers Room 1 No 3 Nos 1 No 1 No 3 Nos 2 Nos 1 No 4 Nos 1 No 1 No 1 No 1 No 1 No 1 No
MCC & Control Room ,.,Tool Room , 1 No work shop 1 No 1 No
16 H T Substation 17 D.G.Room 18 Sewage Network 1 9 2 0 2 1 2 2 Internal Road and SW Drains Compound wall Gardening and Horticulture belt Mechanical, Electrical & Instrumentation work

Quality Policy
We at GHARPURE ENGINEERING & CONSTRUCTION believe in creating Values. Better values can be created only by hard work, Motivation & Dedication and recite for all this is a timely completed project within budget with utmost client satisfaction. Our approach to communicating and implementing these values is one of encouragement, education and training rather than policing. GHARPURE ENGINEERING & CONSTRUCTION is committed to provide competitive technical services related to its various fields of expertise, namely Environmental & Civil Engineering. We are also committed to safety of all our staff & Subcontractors.
Ashutosh Awasthi Chief Executive officer
Suresh N. Gharpure Managing Director

GHARPURE ENGINEERING & CONSTRUCTIONS (P) LTD.

Plot No.35/1, D-II Block, MIDC Chinchwad,Pune. 411019.
ORGANISATION CHART
BOARD OF DIRECTORS
MR. SHRIRAM N. GHARPURE DIRECTOR
MR.SURESH N. GHARPURE MANAGING DIRECTOR
ACCOUNT OFFICER PURCHASE MANAGER ADMINISTRATIVE OFFICER
COMPANY EXECUTIVE
AUDITOR
TECHNICAL SUPPORT QUALITY CONTROL
TENDERING&MARKETING PROGRESS MONITORING
SROFFISERS JR. OFFICERS SR. OFFICERS JR. OFFICERS SR. OFFICERS JR. OFFICERS SR. OFFICERS JR. OFFICERS
SR. ENGINEER JR. ENGINEER
SR. ENGINEER JR. ENGINEER
PROJECT DIVISION EXICUTION PROJECT MANAGER
SUPPORTING STAFF
SUPPORTING STAFF
SUPPORTING STAFF RESIDENT ENGINEER
SR. ENGINEER
JR. ENGINEERS SUPERVISORS

G H A R P U R E E N G IN E E R IN G & C O N S T R U C T IO N S (P )
C O N S T R U C T IO N O F 3 0 M L D C A P A C IT Y S E W A G E T R E A T M E N TI.NL AVN T A T G A IAF O R L ID C O P A I MUMB H NSO C
PR O JEC T M A NAG E M E NT STR U C TU R E

M A N A G IN G D IR E C T E R P R O JE C T MANAGER C O N S T R U C T IO N MANAGER PURCHASE & STORE
ACCOUNTS
VENDORS & S U P P L IE R S
S r. E N G IN E E R
Q C . E N G IN E E R
J r. E N G IN E E R
J r. E N G IN E E R
L A B . A S S IS T A N T
S U P E R V IS O R S

50 MLD STP AT KALAMBOLI QUALITY MANUAL 1.0-Qylity Management System
1.1 General Requirements
GECPL has developed a Quality Management System (QMS) to better satisfy the needs of its customers and to improve the Management of the Organization. The system helps the organization to meet customer requirements in better manner, focusing on overall development of its processes. The Quality Management System of GECPL describes Quality Policy and related System Procedures and Work Instructions through which the objectives of the quality and quality policy are implemented and maintained. The QMS streamlines various processes by providing scope for measurement, monitoring and analysis to strengthen its resources and perform better. This manual is the instructions to all the employees of the organization GECPL has defined, documented and deployed the Quality Management System that is designed to enhance customer satisfaction through the fulfillment of customer requirements. The system consists of a series of processes, procedures, formats and work instructions that are designed to ensure that the system is deployed, maintained and continually improved in accordance GECPL have: a. Identified the processes needed for the QMS and their application Throughout the organization. This is detailed in Section 4.1 Planning of Product Realization. b. Determined the sequence and interaction of these processes. This is defined in c. Determined criteria and methods needed to ensure that both the operation and control of these processes are effective. This is detailed in Section 5.2.3 Monitoring and Measurement of Processes. d. Ensured the availability of resources and information necessary to support the operation and monitoring of these processes. This is detailed in Section 3.1 Provision of Resources. e. Monitored, measured and analyzed these processes. This is detailed in Section 5.2 Monitoring and Measurement. f. Implemented actions necessary to achieve planned results and continual improvement of these processes. This is detailed in Section 5.2 Monitoring and Measurement and Section 5.5 Continual Improvement.
All outsourced products or services are controlled by GECPL to ensure that GECPL quality standards as well as GECPL customer requirements are being met.

All outsourcing are carried out through subcontractors/sub-agencies. The selection, evaluation and revaluation of these subcontractors are accomplished using criteria designed to ensure both GECPL and Customer satisfaction. 1.2 1.2.1 Documentation requirements General
The GECPL QMS has documented the Quality Policy, Quality Objectives and this Quality Manual. In addition, GECPL has established documented procedures as well as other methodologies necessary to ensure the effective planning, operation and control of its processes. Lastly, Quality Records are maintained to provide evidence of how these processes were carried out and in turn, demonstrating the effectiveness of the QMS. The documentation structure is as under:
LEVEL 1 Quality Policy Quality Objectives Quality Manual LEVEL 2 Quality System Procedures Departmental Operating Procedures LEVEL 3 Formats, Guidelines, Work Instructions etc.

50 MLD STP AT KALAMBOLI QUALITY MANUAL 1.2.2 Quality Manual
GECPL has established this Quality Manual, which provides a description of the GECPL QMS. The quality manual includes the scope of the quality management system, including details and justification for any exclusion. It includes a description of all processes and links to all supporting documentation needed for the implementation and effective operation of the QMS
Scope of the Quality Management System:

Design, Development, Engineering, Procurement & Construction of projects in the sectors of Buildings, Water & Waster Water treatment plant.
Review of Manual
Management Representative is responsible for review of this manual and shall be reviewed under the following situations : 1.2.3 Once in 12 months When new technologies or applications are deployed When inputs are received from external or internal audit process, inputs received as continual mechanism When policy statement changes When major organizational changes are carried out Control of documents
RESPONSIBILITY : MANAGEMENT REPRESENTATIVE All the documents required by the Quality Management System are controlled as per the Control of Documents Procedures. 1.2.4 Control of records
RESPONSIBILITY: ALL HODs All the records required by the International Standard are controlled as per the Control of Records Procedure.

2.0 2.1
Management Responsibility
Management Commitment
RESPONSIBILITY: MANAGING DIRECTOR The Managing Director leads the whole team in the organization by making himself as a role model and he is fully committed to the development and implementation of the QMS and continual improvement of its effectiveness that provides customer satisfaction and benefits the organization and other interested parties. The evidences of his commitment are : Communicating through various means to ensure employee awareness of the importance of meeting customer as well as statutory and regulatory requirements. Establishing Quality Policy and relevant Organizational Quality Objectives that are consistent with the Quality Policy. Conducting Management reviews on a periodic basis to ensure the continue suitability, adequacy, and effectiveness of the Quality Management System. Continually assessing the resources needed to maintain and continually improve the quality management system
2.2 Customer Focus RESPONSIBILITY: HOD (Business Development) PROJECT MANAGER Determining Customer Requirements The HOD (Business Development), ensures that customer requirements are documented and understood. Those requirements are detailed in the formal proposal at the tendering stage. |The final award of a contract to GECPL is confirmation that the customers requirements have been determined. Meeting Customer requirements The fulfillment of requirements is assured through a Contract Review Process. The central focus is on ongoing and frequent contact with the customer to assess their level of satisfaction with GECPL performance on the contract. Project Manager is responsible for meeting the customer requirements for execution and delivery of the project. Enhancing Customer Satisfaction A formal program of measuring customer satisfaction is used to identify areas where improvement may be needed.

50 MLD STP AT KALAMBOLI QUALITY MANUAL 2.3 Quality Policy
RESPONSIBILITY: MANAGING DIRECTOR GECPL has defined its quality policy. While documenting the quality policy, it has ensured that the policy is relevant to GECPL organizational goals and expectations and needs of the customer. The quality policy is framed to improve the effectiveness of the quality management system. It is ensured that the quality policy is consistent with the managements vision and strategy for the organizations future. 2.4 Planning 2.4.1 Quality objectives
RESPONSIBILIT: MANAGING DIRECTOR ALL HODs Quality objectives have been established at relevant functions and levels within the organization derived from organizational quality objectives. The quality objectives are used to communicate the critical areas of quality focus and to measure the performance. The following measurable Quality Objectives are identified to meet the Quality Policy :
To identify and define the goals, objectives and to bring out the best course of action and plans for the organization and its projects. To satisfy the customers by providing quality products & services in time ensuring enhanced value to the customer. To inculcate quality in all aspects of contract execution (i.e product delivery and services) for the customers and attain an impeccable quality consciousness among all stakeholders of the organization.
To impart best training and development practices among all personnel supported by safe working environment for operational excellence.
To endorse best practices for optimum muse of resources for better proceeds.
2.4.2 Quality Management System Planning

RESPONSIBILITY: MANAGING DIRECTOR MANAGEMENT REPRESENTATIVE ALL HODs The GECPL Quality Management System has been designed specifically to address the construction management requirements of their customers in the Government and Private Sector market place. Quality Management GECPL Quality System Approach System Planning Requirements System is planned to The GECPL Quality Management System consists of a set of core meet Customer Quality management processes and methodologies that provide the Requirements minimum requirements for managing a customer contract. Each assigned HOD is required to plan the application and use of those methodologies in fulfilling the customer requirements for a specific contract. The Project plan is the tool for the Project Manager to record the results of that planning effort. A key element of that planning is to define the quality actions and objectives that will ensure fulfillment of customer requirements. Integrity of the The Management Representative must approve all changes to the System is maintained Quality Management System. This single authority for revision during changes ensures that any changes introduced in to the system have been properly assessed to avoid any inadvertent degradation of the systems effectiveness. The Management Representative may at his discretion review changes with the top management based on the significance of the changes being made. 2.5
Responsibility, Authority and Communication
2.5.1 Responsibility and Authority

RESPONSIBILITY: MANAGING DIRECTOR MANAGEMENT REPRESENTATIVE The GECPLs top management has defined the roles, responsibilities and authorities of HODs. The HODs have defined roles, responsibilities and authorities of all the employees in their respective functions/levels and has communicated the same to these individuals. The Organization Chart shows the reporting structure and the roles of various functions at HO Office. 2.5.2 Internal Communication
RESPONSIBILITY :

MANAGING DIRECTOR MANAGEMENT REPRESENTATIVE The effectiveness of the GECPL Quality Management System is communicated to the employees through a number of arrangements and methods. They are detailed below:
Sl. No. 1 2 3 What to communicate Quality Policy And Objectives Responsibility and Authority QMS Manual, Procedures, forms, Checklists, Guidelines, Work Instructions Customer Requirements / Orders Customer Complaints Project Planning Corrective / Preventive Actions (internal / external) Internal Audit Results Management Review Meeting Decisions Training Needs Target Audience To all levels of employees To all levels of employees All concerned How to communicate Display Boards, Pocket Cards and Training Through Appointment Letters and RRAs Issue of Hard copies/ Soft copies. Hosting on the Server (Intranet) Conveying Customer Order Details Customer Complaints Register Project Schedule CAR Register, CA & PA Report Through mails / Internal Audit Schedule Through mails Through mail/letter Who should communicate Managing Director Managing Director Management Representative
4 5 6 7 8 9 10
Concerned HOD Head (Operations)/Head(Coord) / Head (Region/zone) Corporate Planning Cell Concerned HOD/ Head (Operations) Concerned HOD Managing Director / HODs / ISO Coordinators All HODs
Head (Planning) Project Manager Project Manager Management Representative Management Representative Management Representative Head HRD
To increase the effectiveness of communication and to reduce the delay in communication, resources such as internal telephone communication e-mail, intranet etc. are provided. The communication about the effectiveness of performance of the organization is displayed in the notice boards so that it reaches all the employees.

50 MLD STP AT KALAMBOLI QUALITY MANUAL Management Review 2.6.1 General
2.6 RESPONSIBILITY : MANAGING DIRECTOR / MANAGEMENT REPRESENTATIVE ALL HODs The Management reviews the QMS to ensure its continuing suitability, adequacy and effectiveness. This review includes assessing opportunities for improvement and the need for changes to the QMS, including the Quality Policy & Quality Objectives. The management reviews are conducted once in three months. Heads of concerned Departments are participants of Management Reviews of the QMS. Management Representative maintains the minutes of Management Review meetings.
2.6.2 Review Input

The agenda for the management reviews includes but not limited to : Review of followup actions from the previous management review meeting Results of internal quality audits Results of external audits carried out by certification agency Review of quality policy and quality objectives Results of preventive action Considerations for updating the quality system due to findings in the quality audits and changes brought about by new technologies, reorganization, quality concepts or other factors Review of the quality system to ensure its continued suitability and effectiveness Review of customer feedback, audits and complaints Review of process and product performance metrics Review of recommendations for improvements including corrective and preventive actions The responsibilities for preparation of management review inputs are given below :
Management Review Inputs

Quality Policy Product, Process & System Performance Quality Objectives & Metrics Customer Feedback Other Product, Process & Systems Performance Suppliers Performance Corrective & Preventive Actions Internal Audits Follow-up Actions from previous
Responsibility
Management Representative All HODs Project Manager All HODs HOD (Commercial) All HODs, Management Representative Management Representative

Management Reviews Process Improvements Status of current initiatives New Recommendations Potential Changes to the QMS Market / Business / Customer Work Environment Infrastructure Resources Impact / Needs HODs All concerned All concerned All concerned All concerned Resources, Concerned HOD
2.6.3 Review Output Management review output consists of the following:

Improvement of the effectiveness of the QMS Improvement of services related to customer requirements[ Resource needs / changes
3.0 3.1
Resource Management Provision of Resources
RESPONSIBILITY: MANAGING DIRECTOR The resources essential for the effective implementation of QMS are identified for all the activities of GECPL. This includes resources for operation and improvement of QMS and the satisfaction of customers. Resources include people, infrastructure, work environment, information, training, suppliers and partners, natural resources and financial resources. As and when required, resources are provided in time.
3.2
Human Resources
3.2.1 General
RESPONSIBILITY: MANAGING DIRECTOR HOD HRD (CO) The Human Resources (HR) Process defines the methodologies needed to ensure that all personnel performing work affecting product quality are competent and qualified on the basis of appropriate education, training, skills ad work experience.

3.2.1 Competence, awareness and training

RESPONSIBILITY: HOD HRD (CO) GECPL has documented recruitment, competency and training processes in the Human Resource Processes to meet the competence / technological awareness and training related requirements. Each function defines and updates their domain skill set requirements. Qualified personnel for management, performance of work and verification activities are identified and assigned to projects as per the requirements by the heads. The processes for hiring, training and performance management of personnel, which ensure that competent personnel are allocated for carrying out project / functional activities, are documented in the Human Resource Processes. 3.2 Infrastructure RESPONSIBILITY : MANAGING DIRECTOR HEAD RESOURCES HEAD HR GECPL has identified, provided and maintained the infrastructure needed to achieve product conformity. The list of equipment and machinery including their maintenance is available in the Resource Management Department. The list of supporting services & communication facilities to employees is available with HR Department. Provision of workspace and facilities, office building maintenance and housekeeping are taken care by HR Department. 3.2 Work Environment RESPONSIBILITY: HOD HRD PROJECT MANAGER GECPL has ensured that the work areas are clean, safe and organized so that the quality and personnel performance are not affected. GECPL has identified and manages the human and physical factors of the work environment needed to achieve conformity of product and service requirements. GECPL encourages a creative environment.

50 MLD STP AT KALAMBOLI QUALITY MANUAL 4.0
4.1 Product Realization P1anning of product realization
RESPONSIBILITY: ALL HODs PROJECT MANAGER GECPL has planned and developed the following processes needed for product realization : Business Development process Tendering process Corporate Planning Process Zonal / Regional Planning Process Project Planning, Budgeting and Control Process Project Execution and Site Management process Design and Engineering process Procurement processes Human Resource Management process Resource Management process Quality Control process Material Accounting, Control and Stores related process Finance and Accounting process Management System process The above processes are developed keeping in view the customer project related requirements. While developing these processes, the following requirements are also addressed: a) Quality Objectives and requirements for the product; b) The need to establish processes, documents and provide resources specific to the product; c) Required verification, validation, monitoring, inspection and test activities specific to the product and the criteria for product acceptance; d) Records needed to provide evidence that the realization processes and resulting product meet requirements. 4.2 Customer related processes 4.2.1 Determination of requirements related to product
RESPONSIBILITY : HEAD (BD) PROJECT MANAGER The Tendering Process is initiated and the following activities are performed while determining the requirements related to product:

News papers, construction journals, e-procurement and other sources are scanned for project related tenders. Suitable tenders are identified and the tender documents are obtained after seeking the advice of the management. It is ensured that the tender documents are analyzed, rates are worked out and evaluated and all specific requirements of tenders are met before submission. It is ensured that tenders/quotes are submitted in time and tender pre-bid/opening/negotiation meetings are attended and minutes are recorded, as and when necessary.
In determining the requirements relating to the customer request, this process will ensure that the following will be considered: Requirements specified by the customer, including the requirements for delivery and post delivery activities, if applicable. Requirements not stated by the customer but necessary for the specified or intended use, where known. Statutory and regulatory requirements related to the product or service. Any additional requirements determined by the organization.
Requirements related to product while construction, if any are determined and delivered by Project Manager.
4.2.2 Review of requirements related to product

RESPONSIBILITY: HEAD (BD) PROJECT MANAGER Prior to quoting a product or accepting an order, GECPL reviews the order or the proposed order and its requirements. During this review, GECPL ensures that the product requirements are clearly and completely defined that GECPL is able to meet those requirements and that any deviations from the customers expectations are clearly spelt out. GECPL keeps the records. Where actions arise from these reviews, they will be included in the records. In instances where orders are taken verbally, GECPL obtains written confirmation of the order later from the customer prior to its commencement. In instances where orders are taken verbally, GECPL obtains written confirmation of the order later from the customer prior to its commencement. In instances where the order changes after its acceptance, GECPL amends the order related documents appropriately and ensures that the relevant people are made aware of the changes.

4.2.3 Customer communication RESPONSIBILITY : HEAD (PROPOSALS / BD) MANAGING DIRECTOR / HEAD PROJECT MANAGER The requirements are received in written from, verbal form or through electronic media (e-mail etc.). Clarifications on product requirements, acceptance criteria, acceptance on deviation if any, amendments, order schedule are in the form of letters. Attending to customer complaints is the responsibility of Project Manager and replying to the customer queries is in the form of letters. 4.3 Design and Development RESPONSIBILITY; CONCERNED HODs Design & Development is done in various stages. Once GECPL accepts a new product where the designs and drawings are supplied by the customer, construction is done on the basis of received designs and drawings. Where designs and drawings are not supplied by the customer in cases such as Lumpsum or EPC (Engineering, Procurement and Construction) contracts GECPL either design its own where design is in GECPL scope or outsource the same. The design is out sourced wherever applicable to professional architectural/ structural design consultants who take professional responsibility as per industry practice but certain aspects are controlled by GECPL. In case design and development is done by GECPL, Design Engineer prepares plans for each design and development stage. The plan describes or references these stages and is updated as design and development progresses. The design & development phase involves all the necessary inputs and information which is documented, transmitted and regularly reviewed by concerned HOD. The design involves the organization and technical interface wherever required and these are well defined.
4.3.1 Design and Development Planning

The design and development stages are Site topo survey, subsoil survey, ground water survey, preparation of reports by GECPL or service provider Identification of statutory & regulatory requirements to be satisfied by GECPL Preparation of brief to design consultant by GECPL (when outsourced)

4.3.2 Architectural and structural design by Architect / Structural Engineer; checking, verification by GECPL and approval by client. Preparation of construction drawings, bill of quantities, estimates by design engineer of GECPL or service provider; checking, verification and approval by GECPL Design and Development Inputs
The inputs are defined in brief to the architectural/structural design engineer / consultant as per the contract requirements. The requirements/inputs provided to the engineer / consultant are complete, unambiguous and not in conflict with each other. As the design proceeds the inputs are reviewed and modifications communicated to all concerned in writing and recorded. The source for the design and development inputs is any or all of the following: a) b) c) d) Survey inputs, hydraulic particulars, land particulars, soil characteristics etc. Customer specifications / drawings Details gathered from marketing personnel Details gathered from previous similar designs and competitors products
Design input includes statutory and regulatory requirements which are identified as applicable to the product under development. Such design inputs are records and these are reviewed for adequacy. Any details arising out of Contract Review activities are also taken into consideration while preparing the design input. The HOD concerned is responsible for reviewing inputs for adequacy in their respective areas of functioning depending upon the stage of the design process.
4.3.2
Design and Development Output
The design output is generally in the form of drawings, specifications and/or procedures. The design output is documented and expressed in terms that can be verified and validated against the design input requirements. While preparing the design output, the following are ensured: a) Design output meets design input requirements b) Design output provides appropriate information for purchasing, production and for service provision c) Design output contains or makes references to acceptance criteria to various stages d) Design output identifies those characteristics of the design that are crucial for safe and proper functioning of the product. These characteristics are generally requirements for operations, storage, handling, maintenance and disposal.

The design engineer / consultant prepare layout drawings, architectural design, landscaping plan etc. Thereafter the design engineer / consultant completes structural design, prepares estimates and specifications, Detailed construction drawings are also prepared. Design output record is reviewed by the authorized person. This is discussed in GECPL and approval is obtained from client. These ensure compliance to requirements specified in the input, provide adequate information for purchase of materials for construction, building components, and contain acceptance criteria. 4.3.4 Design and Development review
Systematic reviews of design and development are performed. The design engineer / consultant participates in the review operations as required, and modifications required are communicated to him. Records of the results of the reviews and actions taken are maintained. While reviewing the following are ensured: a) To evaluate the ability of the results of design a development to meet requirements. b) To identify any problems and propose necessary actions.
4.3.5
Design and Development verification:
After the design engineer / consultant submit all plans, site layout, landscaping, facilities, specifications, estimates, they are verified by the HOD concerned. Records of verification and actions taken are maintained. Design verification activities include the following: a) b) c) d) performing alternate calculations Comparing the new design with a similar proven design, if any Undertaking tests and demonstrations, if applicable Reviewing the design stage documents before release
4.3.6
Design and Development validation
Each project for construction and development is unique. Ensuring compliance to requirements specified in the inputs for design for the completed project and approvals by statutory authorities ensure that the project is suitable for handing over / occupation. Therefore no validation process can be carried out. 4.3.7 Control of Design and Development changes

Need for design changes arise only under a few circumstances. Design changes needed are identified, reviewed and verified and approved before implementation. Where necessary suitable drawings / work orders are prepared and communicated to all concerned. Records of such changes and the actions taken are maintained. 4.4 Purchasing 4.4.1 Purchasing Process RESPONSIBILITY : MANAGING DIRECTOR HEAD (Commercial) PROJECT MANAGER GECPL ensures that purchased materials and services conform to specified requirements. All existing suppliers are evaluated based on their past performance on Quality, Delivery and Response to improvement. Supplier details are collected in the supplier registration for evaluation. On identification of a new supplier, data is collected on supplier registration form and based on the information collected: the suppliers premises are visited to assess the capability to meet the product requirements and delivery schedules. An approved suppliers list is prepared with details such as name and address of supplier, contact persons, telephone no, fax no., e-mail etc., categorized under each type of product/service. Performance evaluation of suppliers is done once in six months to assess the continued capability to meet the specified purchase requirements. The purchase of products and services are initiated through the completion of a signed purchase Indent/requisition. The Managing Director /HOD (Operations/Zonal/Regional/Coordination) / Project Manager is responsible for approving the purchase indent. All the purchase indents are reviewed for adequate information and approval. The purchase limits are defined in the Limits of Purchasing Authority. Enquiries are prepared as per purchase specifications once after the purchase indents are approved and sent to approved suppliers. Quotations are received from them and a Comparative statement is prepared and decision on purchase order is taken by the purchase committee. Purchase department assigns a unique purchase order number to the authorized purchase indent. The purchase order is generated and printed. Purchase order approval will be taken before releasing to the suppliers. The purchase department is responsible for ensuring that all purchase orders are placed on approved suppliers and the purchase order / document defines the requirements of GECPL.

All Bulk materials like Cement, Steel etc. are purchased from Corporate Office, where as local materials like aggregates, sand etc. are purchased at Site level subject to purchase limits and budget approvals. In the event of non-availability of the required items with the approved sources, emergency purchases can be made from sources recommended by the approved source or from any other source with proper authorization, provided the item meets the quality requirement. Work orders are prepared and issued by Purchase department to suppliers where supplies including installations & commissioning or to Original Equipment Manufacturers (OEMs) / their approved agents for Annual Maintenance Contracts / Services.
4.4.2
Purchasing information
RESPONSIBILITY: HEAD (Commercial) PROJECT MANAGER The Purchase order clearly states the type of material / service and quantity required. If any inspection/test certificate is required, it is mentioned in the purchase order. Packing procedure if any, specially required other than normal and mode of dispatch are also mentioned. Before releasing the purchase order, it is scrutinized for completeness of data and then signed. The purchase order copies are sent to the Site/Department concerned for their information. 4.4.2 Verification of purchased product
RESPONSIBILITY: QAC ENGINEER On delivery of product or service, the users / receivers verify that delivery slips / documents agree with product/ service delivered and initials it. All products and services are visually inspected on receipt, unless otherwise indicated. All the purchased products are verified for suitability to the specified purchase requirements at receipt as per Inwards Quality Plan. The results of such inspection are recorded on Goods Arrival cum Inspection Report raised by the stores in-charge. Responsibility of acceptance of the items is vested with the QAC Engineer/Indenter and the QAC Engineer/Indenter authorizes on Goods Arrival cum Inspection Report for acceptance. In case of deviation to specified purchase requirements, the same is forwarded to Project In-charge for review and disposition as required.

4.5 Production and service provision 4.5.1 Control of Construction and service provision RESPONSIBILITY: HOD (ZONAL/REGIONAL/OPERATIONS) PROJECT MANAGER The quality system ensures that all activities involved in the creation and delivery of products and services are carried out under controlled conditions. Those methods for ensuring this consistency are detailed in the chart below: Key Elements Methods of Control controlled Availability of Product Documented in the Tender Document Information Validated and supplemented as appropriate, in the Project Plan Availability of work Documented in the Tender Document and customer supplied Instructions drawings, instructions as appropriate. Work Instructions, Guidelines and Checklists developed for the work to be carried out. Validated and supplemented as appropriate, in the Project Plan Use of suitable Use of construction equipment such as Earth movers, Concrete Equipment mixers, scaffolding materials, etc. Availability and Use of The characteristics of the developed property are defined in Monitoring and construction drawings and specifications developed by the Measuring Equipment architect for each property developing project. GECPL ensures the availability of the measuring equipment either with them or with the contractor. The inspection is done jointly by the authorized representative of GECPL and the Customer Engineer. In case non conformities are found : 1) The contractor is instructed in writing / verbally to Correct the non conformity. 2) After the non conformity is corrected, it is re-inspected and checked. The papers are filed in `Site Instructions file / register maintained at the Project office site. Implementation of The in-process inspection during construction is jointly done by Monitoring and GECPL and the Customer Engineer. Measurement The records relating to these checks are maintained in the Project office. Criteria for conformance and tolerances, if any, are as per relevant drawings, where applicable. ZONAL / REGIONAL HEAD is the authority to decide on the conformance to tolerances in case of deviations. Major non conformities, as may be decided by the ZONAL / REGIONAL HEAD (on the basis of factors such as costs, time, recurring defects, etc.) are recorded in the Non-conforming Report (NCR) form and are processed as per Procedure for

Control of Non conforming Product A copy of the NCR is filed in the concerned contractors file at the project office. The feed back from the NCRs is analyzed and used for improving the system. Implementation of The property / project is handed over the customer after due Release, Delivery and inspection of the completed property / project. Customer is also Post-Delivery provided the required services after delivery of property / project Activities as per Contract agreement. 4.5.2 Validation of Processes for Construction and service provision
GECPL is providing the construction services as per the customer requirements under supervision of customer representatives; GECPL is ensuring validation of processes for construction and services as per its QAC documentation namely Quality Assurance Plan & Quality Assurance Instructions wherever/whichever is applicable. 4.5.3 Identification and traceability RESPONSIBILITY : STORES IN-CHARGE SITE SUPERVISOR The inspection and test status of materials, components and fittings is indicated by storing them in separate marked locations indicating the status as ùnder test, `ready for use and `rejected. Materials like concrete aggregates stored in stacks are marked suitably as follows and as appropriate: 1) `Ready for use, 2) Ùnder Rectification, 3) Ùnder Test, 4)`Rejected The inspection and test status are recorded in Inspection reports, Daily diary of the Inspecting officer and written instructions for corrective action as Work order. The `go ahead for carrying out the next item of work is issued to the contractor in the form of a memo or recording in inspection records. Indication of conformity to requirements in those records gives `go ahead signal. Records maintained as per the documents referred above, provide evidence of conformance to this procedure. 4.5.4 Customer property
GECPL exercise care with the customer drawings and other intellectual property while it is in its control or in use. It is properly identified, verified, protected and safeguarded. The same would be duly registered and maintained in its records.

50 MLD STP AT KALAMBOLI QUALITY MANUAL 4.5.5 Preservation of product
RESPONSIBILITY: STORES IN-CHARGE PROJECT MANAGER GECPL preserves conformity of product / services with customer requirements during internal processing and delivery. This includes where applicable, identification, handling, packaging, storage, and protection of identified product / service or constituent parts of it. When the work on property developed is declared complete after final inspection, it is preserved by keeping it locked. Construction materials, components, fittings etc. are stored at site to follow the procedures recommended in IS 7969 Safety Code for Handling and Storage of Building Materials. It is so arranged that materials arrive just in time. Materials are handled in such a way that they are preserved and not damaged in any way. Damaged materials are not used in construction and are discarded. These details are entered in Scrap Stock Register. The table below gives the different activities involved and the method used in each stage: S. No. 1 2 Stage Incoming InProcess Final
Identification
Tags/Labels Not applicable
Handling Packaging Manual Original Packing Manual Not applicable Not applicable
Storage Protection per On wooden As instructions or as reapers/bins

per requirement As per As per instructions instructions or as or as per per requirement requirement As per Not instructions or as applicable per requirement
Project Code Manual
The stock Ledger for raw materials is maintained.

50 MLD STP AT KALAMBOLI QUALITY MANUAL 4.6Control of monitoring and measuring devices
RESPONSIBILLITY: PROJECT MANAGER HEAD (Resources) A list of all monitoring and measuring equipments is prepared with details of unique number of equipment, range, accuracy, frequency of calibration and agency of calibration. All monitoring and measurement equipment are periodically calibrated as per the frequency against measurement standards traceable to international operational measurement standards. Where traceability to international measurement standards is not available, the basis used for calibration is recorded in the calibration report. The monitoring and measurement equipment calibrated are affixed with stickers to identify calibration status. Monitoring and measuring equipment are safeguarded against adjustments that could impair the calibration. All monitoring and measuring equipment are protected against damage and deterioration during handling, maintenance and storage. The frequency of calibration is monitored based on the results of subsequent calibration. It any instrument is found out of calibration, the recent most inspected parts available are re-inspected to asses the conformity of products. GECPL uses measuring metallic Tapes, Tri-squares, Plumb lines, Dumpy level / Auto level and Theodolite / Total Station for measuring purposes.
Product Realization Processes Business Development and Customer related Process : Generating and development of new business, new and existing customer relations, customer support, customer suggestions and feedback management, customer satisfaction and its measurement, support to other related processes mainly tendering process and operations. Tendering Process: Converting leads to potential customers, pre-tender registrations and qualifications, search & screening of tenders & customer enquiries, determination and review of customer requirements, proposals and submission of tenders, participation in pre-bid meetings, final negotiations, order booking, inputs & feedback to project planning process and management. Corporate Planning Process: Corporate planning involves setting strategic targets, goals & budgets for the company as a whole, reviewing its performance & achievements and coming up with suitable plans of action. Corporate planning cell initiates with the project award information, and reviews, verifies & validates the project plans prepared by the zonal planning cell. It coordinates with the zonal planning cell regarding various projects, from where project information is collected, compiled, analyzed and the performance reports are forwarded to the management. Strategic plans, operating procedures, review/assessment techniques & systems are revised and issued as required to zonal planning cells.


Zonal Planning, Budgeting & Control Process: The zonal planning cell has its activities concentrated on various projects under it, which include preparing detailed construction plan for projects, planning with regard to the Resources (Material, Manpower & Machinery), schedules and budgets. Project kickoff meetings are conducted in concurrence with the functional heads to discuss various aspects of the awarded project. The targets for valuation and billing are set in coordination with the project teams. Monitoring, review & control of the projects are done with respect to scope, time & cost. The plans of action are prepared & implemented in consultation with the corporate & project planning cells. The zonal planning cell oversees project / zone specific fund management & preparation of annual budgets. Project Planning, Budgeting and Control Process: Receiving Tender and other details of projects awarded, Preparation of Project Award Information, conducting initial kick-off meeting with all concerned and management, preparation of overall project plans, various budgets for construction / execution, overall resource planning, contract planning, and overall project monitoring & control. Project Execution and Site Management Process: Project Planning, resource planning and allocation, mobilization, sub-contracting if any, execution, site setup, supervision and management, meeting customer requirements as per specifications while execution, liaison with customer and various other concerned parties.
Design and Engineering Process: Design planning (Stages, Content and Planning), design inputs, identifying design outputs, design review, verifications and validations as required, design changes if any, customer approved designs and drawings, if applicable. Procurement Process: Inputs from project planning, budgeting & control process, and project execution and site management processes for procurement of various materials, plant & equipment, machinery and others as required, supplier selection, evaluation and re-evaluation, maintaining supplier databank and supplier relations, logistics, liaison with other processes and concerned, supply chain management. Human Resource Management Process : Manpower planning, recruitment, training & development, competency gap analysis, roles & responsibilities, establishment of authority, internal communications, efficiency and effectiveness, performance appraisal, personnel & statutory requirements, payrolls, personnel databank, insurance, transfers, disciplinary actions, various organizational policies, work environment & facility management, and general administration Resource Management Process : Resource Planning (own or hired), Allocation, Utilization, operations & maintenance, preventive & break-down maintenance schedules, monitoring and control of operating costs, spare parts, calibration schedules, disposal of plant & equipment, internal transfers. Quality Control Process : Quality Assurance of incoming/purchased raw materials, quality control of in-process works and activities in projects, quality control of completed works and projects, calibration of measuring, monitoring and testing instruments, quality assurance plan and schedules, quality assurance instructions and checklists.

Material Accounting, Control and Stores related process : Materials storage and preservation, inventory control and accounting, liaison with procurement process and Project Execution and Site Management Process Finance and Accounting Process: Corporate Finance Planning, Capital Procurement and funding, Financial & Project Accounting, invoicing, payments & collection, fund management in cash and bank, follow up with clientele and other concerned.
General principles for storage of construction materials, components, fittings etc.

1. Cement i) Stored above ground in raised platform ii) Stored in a covered shed / space with minimum of openings iii) Ensured that there is no ingress of water iv) Stacked one bag above the other / or one drum above the other date wise of receipt so that it can be used on FIFO basis. The date of receipt is painted on the peripheral bags. v) If the cement in the bag has hardened into lumps the bag is rejected Steel Reinforcing steel is stored diameter wise suitably labeled Angles and channels are stored size wise suitably labeled Rejected / unusable steel is stored away from the main sore and carted away at the earliest Ingress of water is prevented into the store area. Wood Wood is stacked in a shed above ground away from direct sun in such a way that there is air flow in around the stack. Ingress of water and dampness is prevented Concrete aggregates Stacked separately size wise Door shutters Stacked one over the other and not slanting against wall Ingress of water and dampness is prevented Stacked so that there is free flow of air around stacks Door frames Stored size wise one over the other horizontally and not sianting Stored on wooden planksor GI/MS sheets. Direct sun is avoided Support is provided at the ends and middle of the frame. Builders hardware Stored in their packages category wise and size wise in shelves Ingress of water and dampness prevented
2.
3.
4. 5.
6.
7.

8. Pipes and fittings Pipes are stored horizontally in stacks size and duty wise as indicated by colour bands Ingress of water prevented Fittings are stored in their packing size wise, preferably in shelves
9.
Building blocks of concrete / brick etc Not thrown while unloading from transport vehicle Stored on level ground Stored in Stacks, size wise Various flooring tiles, wall tiles Stored on level ground in covered area Water ingress and direct sun avoided Stored category wise, shade wise, brand wise and size wise Suitably labeled for easy location and access CP Fittings Stored in their packages, preferably in shelves properly labeled Stored in secure locked sheds / rooms Sanitary ware Stored in covered sheds n/ rooms for easy location and access Stored category, size shade and brand wise as sets to match shades Direct sun and water ingress prevented Electrical wiring conduits Stored away from plumbing pipes, size wise Direct sunlight, ingress of water prevented Drainage ipes, stoneware pipes, ventilating pipes and fittings Stored horizontally on level surface Stored size wise and brand wise Stored away from other tubular products
10.
11.
12.
13.
14.
5.0 Measurement Analysis and Improvement

5.1 General
RESPONSIBILITY; MANAGING DIRECTOR ALL HODs Project Manager

The GECPL quality management system incorporates key measurement, analysis and improvement activities to : Demonstrate Conformity of the Product: The delivery of Product / Service is monitored and measured to ensure that customer requirements are being met. the Operations Head and Zonal / Regional Head have the responsibility to manage these activities and to resolve all issues or non-conformances resulting from these activities. Unless otherwise stated, the Project Manager is the controlling authority for the release of all products to the customer. Ensure Conformity of the Quality Management System: The Internal Audit Process provides an ongoing assessment of the level of conformance to requirements of the quality management system. Continually Improve the Effectiveness of the Quality Management System: Key elements of the quality management system are designed to interact within the process structure of the system to ensure that the system is continually reviewed and improved. An assessment of the monitoring and measurement methods and the resulting data from those methods has determined that there aare no statistical techniques needed to carryout any required analysis, other than simple tabulation and graphing of the data summaries. 5.2 Monitoring and measurement 5.2.1 Customer satisfaction RESPONSIBILITY; MANAGING DIRECTOR ALL HODs ZONAL HEAD / REGIONAL HEAD Information relating to customer perception as to whether GECPL is meeting customer requirements is a key measure of the performance of our quality management system. The methods used in the collection of this information include: Formal Customer Feedback: The customer feedback is obtained from the client on completion of the project either in the form of letter from client or GECPL format for management review and analysis, wherever possible. Day to day interaction with Customer / Customer Representative Documentation of customer complaints / suggestions - both positive and negative Data from the above activities are recorded, analyzed and acted upon as appropriate through the Corrective action, Preventive Action and Management Review Processes.

50 MLD STP AT KALAMBOLI QUALITY MANUAL 5.2.2 Internal Audit
RESPONSIBILITY: MANAGEMENT REPRESENTATIVE ALL HODs ZONAL HEAD / REGIONAL HEAD GECPL has established and maintains a documented procedure for internal quality audits to determine whether the quality management system: a) conforms to the planned arrangements established b) Is effectively implemented and maintained. Internal Quality Audits are planned once in 3 months on the basis of status and importance of the processes and areas to be audited as well as the results of the previous audits. GECPL Management avails the services of External Consultants to assess the Quality Management System, which will give the benefits of an outsider to view the Quality Management System of the Company. The audits are planned and arranged by the Management Representative. The results of the audits are recorded and reported to the Management responsible for the area being audited. The corrective and preventive actions are taken in time to eliminate non-conformity and their causes. The Management Representative follows up the verification of action taken and their effectiveness. The results of the Internal Quality Audit forms will be an input to the Management Review.

50 MLD STP AT KALAMBOLI QUALITY MANUAL 5.2.3 Monitoring and Measurement of Processes
RESPONSIBILITY: MANAGING DIRECTOR ALL HODs Suitable Process Measures have been developed, documented and monitored by GECPL to ensure continued suitability and promote increased effectiveness of processes. Following are the Process Measures identified: Sl. Process for Unit of Criteria / No. effectiveness / Measurement Target efficiency 1 Documents Days Within 5 change period working days 2 3 4 5 On time implementation of MRM action On time conducting of Internal audit Out of calibration situations Supplier Monitoring Delivery performance
Enquiry realization
Monitoring Method Document Issue log / amendment history MRM Action plan Audit Plan Calibration Results Delivery Rating Quality Rating Delivery plan Vs Invoice
Enquiry register
Frequency Quarterly
Responsible Department MR/HODs
Days Nos. Nos. %
Zero delay Audit Plan Vs. Actual Zero Supplier rating should be 80% 100%
No. of enquires Vs No. of orders should be greater than 20% Number of incidents of delay in implementation of CA Same problem repetition should be zero Zero Max. 2 Days Incidents should be zero Submission Date Vacancy Position Training
Quarterly Quarterly Monthly Monthly
MR/HODs MR RESOURCES PURCHASE
6
7
%
%
Monthly
Quarterly
OPERATIONS
BUSINESS DEVELOPMENT / PROPOSALS MR
Delay in implementation of Corrective Action Problem repetition Customer complaints GAIR clearing Construction stopped due to supplier delay Tender Submission Recruitment HR Induction &
Nos.
Non Conformance Report Customer complaints Customer complaints report GAIR Register Construction Schedule Tender Documents Approved Organogram Annual
Monthly
9 10 11 12 13 14 15
Nos. Nos. Days Nos. Days Nos. Days
Monthly Monthly Monthly Monthly Quarterly
OPERATIONS OPERATIONS STORES PURCHASE PROPOSALS HUMAN RESOURCES HUMAN
Quarterly

Orientation 16 17 18 19 20 21 22 Training Feedback Budget Preparation Project Management Plans MIS Reports Contract Billing Testing & Inspection Purchase of Materials Days Days Days Days Activity wise Nos. Nos. Schedule Training Project Award Information Project Award Information Monthly Review Meeting Work done against planned Manufacturers instructions BOQ Specifications and Approved Purchase Indents Delivery Schedule Material Requisition Training Calendar Training Feedback Form Budget Approval Approved PM Plans MIS Reports & MRM Report RA Bills Test Certificates Quarterly Approved Purchase Order Purchase Order MRIS RESOURCES Monthly Quarterly Monthly Monthly Monthly Quarterly Quarterly HUMAN RESOURCES PLANNING PLANNING PLANNING PROJECT MANAGEMENT QAC PURCHASE
23 24
Delivery of Materials Issue of Materials
Nos. Nos.
Quarterly Quarterly
PURCHASE STORES
These process measures are also reviewed in the Management Review Meeting. When planned results are not achieved, suitable corrective / preventive actions are initiated. 5.2.4 Monitoring and Measurement of Product (Construction) RESPONSIBILITY: HOD (COMMERCIAL) STORES IN-CHARGE PROJECT MANAGER QAC ENGINEER A systematic approach is in place to inspect all the critical inputs before they are used in the process. Incoming products are received, suitably identified, inspected and only after they are approved, released for construction. Physical verification of the incoming product is done by the Stores Personnel. Quality Control is informed of the receipt of the material through the Goods Arrival cum Inspection Report. Receiving Inspection is carried out as per the Inwards Quality Plan. All the Inspection activities are documented. Test certificates received from the suppliers are considered. In process, inspection is carried out at regular intervals based on Quality Assurance Plan/ Instructions. Products not conforming to the required specifications are identified by means of tags and are segregated / reprocessed / corrected suitably before commencement of the next stage of operation.

Quality Assurance & Control Engineer is responsible for conducting the Final Inspection and the Project Manager is authorized for release of the product. The Final Inspection Report encompasses all the Inspection requirements carried out and that the results meet the specified requirements. Product upon completion is released for occupation only after all inspections are conducted and the results are complying with the acceptable criteria. The records of all inspections and tests conducted are maintained. The records identify the inspection authority for the release of product by virtue of their signatures. The records clearly indicate the status and acceptance criteria for that product. 5.3 Control of non conforming product RESPONSIBILITY: HOD (COMMERCIAL) PROJECT MANAGER Those products, not conforming to requirements, are identified and controlled at various stages to prevent its unintended use or delivery. Non conforming materials / products are rectified if possible and re-verified for conformity. The non-conforming products are dealt in one or more of the following methods: 1) 2) 3) Taking action to eliminate the detected non-conformity Release the product under concession with the approval of the Management and if required with the customer approval Taking action to reject or rework
Details of non-conformity, action taken including concessions and other disposal details are recorded and maintained. If non-conforming product is corrected, it is re-verified before put to use. If nonconformance is detected after dispatch of products or after product is put into use, suitable actions are initiated, based on the effect or potential effect of non conformity.

50 MLD STP AT KALAMBOLI QUALITY MANUAL 5.4 Analysis of Data
RESPONSIBILITY: MANAGING DIRECTOR MANAGEMENT REPRESENTATIVE To demonstrate the suitability and effectiveness of Quality Management System and to areas requiring continual improvement of the effectiveness of Quality Management System, Data is collected in the following areas: 1) 2) 3) 4) 5) 6) Customer satisfaction Non conformity of product Project performance Orders v/s quotations Delivery performance Suppliers
The data collected is analyzed for root cause, corrective action and preventive action by methods such as Brainstorm sessions. The record of such deliberations is maintained. 5.5 Improvement
RESPONSIBILITY: MANAGING DIRECTOR MANAGEMENT REPRESENTATIVE GECPL believes in the continual improvement at various levels at all stages. This is augmented in the areas of corrective actions, preventive actions, audit reports and management reviews. 5.5.1 Continual Improvement
RESPONSIBILITY: MANAGING DIRECTOR MANAGEMENT REPRESENTATIVE The organization continually improves the effectiveness of the quality management system through the use of the quality policy, quality objectives, audit results, analysis of data, corrective and preventive actions and management review. These improvements result in changes to Quality Management System processes.

5.5.2 Corrective action
RESPONSIBILITY: ALL EMPLOYEES Corrective action is initiated to eliminate the cause of non conformity and to prevent reoccurrence of the same. Corrective actions are taken appropriate to the effect of the non-conformity reported. Procedure for corrective action is established and the following methodology is adopted: a) b) c) d) e) 5.5.3 Reviewing non conformities (including customer complaints) Determining the causes of non conformities Evaluating the need for action to ensure that non conformities do not occur. Determining and implementing actions needed Reviewing corrective action taken
Preventive Action
RESPONSIBILITY: ALL EMPLOYEES Preventive action is initiated to eliminate the causes of potential non conformities and to prevent their occurrence. These preventive actions taken depend upon the impact of potential problems. Procedure for Preventive action defines the following methodology: a) b) c) d) e) Identifying the potential non-conformities and their causes. Evaluating the need for action to prevent occurrence of non-conformity Determining and implementing action needed Records of results of action taken and Reviewing preventive action taken

PREAMBLE
This Construction Manual deals with the Civil Engineering Works and their procedures with instructions. Checklists for various items of works have also been formulated. In Civil Engineering Works the procedural hierarchy for achieving quality of works can be done by carefully following the processes to be followed to achieve quality. To achieve qualitative output, the Input i.e. raw materials should be as per specifications and qualitatively very good. The Input raw materials are subjected to a procedure / process of working as per technical requirements and when the Input and Process is qualitatively as per requirement the output will be as per the specification required. So this process approach leads to qualitative products, which enhances Customer Satisfaction. Normally in Civil Engineering Works in spite of precautions taken at all levels, sometimes poor workmanship will reduce the quality. Hence the workman should be properly selected and trained if necessary to improve quality in construction. If proper delivery process is maintained, the quality initiatives will drive the change in construction industry. Buyers pressure to increase value and function with cost reduction, which is leading to more qualitative Civil Engineering Projects with new technologies and system integration.

GUIDELINES FOR SURVEY S. No. 1 2 3 Description All instruments proposed for utilization shall be calibrated. After primary drawing release preliminary civil works shall be carried out to find out the obstacle. After finalizing of survey scheme, execution of survey work shall be carried out in reference to existing survey grid pillar of the project and the available preliminary drawing and accordingly reference & governing, pillar shall be said at site. After layout of pillars and closing the traverse the same shall be checked. Establishing the reference governing pillars, layout of structures shall be carried out drawing and inspection shall be made accordingly. Control layout after making the individual area on ground, diagonal of rectangular or square layout to be checked.
4 5 6

WORK INSTRUCTIONS FOR SURVEY 1 2 3 4 5 6 7 8 9 10 Direction of the site to be marked Control grid of Survey of India to be verified with site Corner Benchmarks to be constructed Boundary of the site to be marked and survey grid pillars are to be prepared Level 100.00 Benchmark to be conveniently fixed Grid benchmarks at equal intervals to be constructed and level to be marked Spot levels at 3m interval of the site to be plotted Use of appropriate survey equipment for various jobs like plane table, leveling instrument and Theodolite to be used based on requirement Accuracy in Theodolite marking and leveling All reference pillars to be verified for accuracy

GUIDELINES FOR EXCAVATION Sr. No. 1 2 3 4 5 6 7 8 9 Description Based on soil analysis data or quantum of excavation arrange the required manpower, machinery & tools. Skill labor shall be deployed to avoid non-uniform cutting or excess cutting. Coordinates of area to be excavated shall be identified. Mark the area with proper means like string or chalk powder. Crosscheck the given marking & Coordinates with drawing / specification. Periodical measurement of depth shall be made to avoid excess excavation of depth. Elevation of ground & final depth shall be recorded. Excavated earth shall be stacked at least 500 mm from edge of excavation. Proper shoring shall be done to avoid collapse or damage of excavation in different exposed conditions.

WORK INSTRUCTIONS FOR EXCAVATION 1 2 3 4 5 Check the gridline and dimensions of the trench/foundation with the drawing. Provide allowance for working space as per requirement. Take proper care to check R.L. of bottom of pit/foundation grade. Ensure3 removal of all loose earth, roots of plants/trees etc. Check the dimensions at bottom of foundation pit before proceeding to the next activity. Provide sufficient working space for workman when work is to be executed from outside. Maximum 600mm working space is sufficient for shuttering of R.C.C. walls, basement, UGT, waterproofing etc. for more excavation depths, adequate side slope / berms must be considered to retain the sides. Take care to maintain correct dimensions of pit during excavation. Take care to dump the excavated earth away from the edge of excavation Proper barrication, shoring shuttering must be provided to safety where ever required. Ensure technical safety by maintaining proper slope of cut depending upon the soil characteristics. Any kind of water flooding near the pit is to be avoided.
6 7 8 9 10
Calibrated instruments Records
: leveling instruments : Measurement book

GUIDELINES FOR EXCAVATION IN ROCK

Sr. No. 1 2 3 4 5 6 7 8 9 Description Study the Soil Investigation report, procure drawing and specification from client and make detailed study. Prepare Method statement. Get it approved by client. . Calculate the quantity of excavation, manpower and machinery requirement. Obtain necessary permissions for blasting from appropriate Government Authorities. Evaluate and select the licensed sub-contractor as per procedure for evaluation and selection of subcontractor to carryout the blasting work. check for any underground or overhead utilities with client and obtain clearance from them for blasting work. clear site, check that loose material, surplus explosives are at safe place and ensure that tools, drilling equipment etc. are not left on the rock surfaces to be blasted. Sort out the area, fix the control lines and take the original ground levels. Check that the duly approved work permit is obtained. Incase of any defects, rectify the same and obtain approval again on the permit. Precaution Before and After Blasting : All approaches to the blasting operation area : 1) Shall be sign-posted for warning people and indicating the days and timing when blasting is proposed to be carried out. 2) Shall be closed by barriers at a distance of not less than 400 meters, 10 minutes before fixing and flagmen posted at important points. 3) Positive loud signal from the Blasting In-charge shall be sounded on the siren not less than one minute duration to warn the public flagging the signal as determined. Carryout the Blasting operation The end of firing operations must be followed by sounding All Clear signal on the siren as a continuous long note of not less than one minute duration. If the charge does not fire then the following steps are to be followed ; a) If the misfire is due to a faulty cable or a faulty electrical connection, the defect shall be remedied and the shot fired. b) The stemming shall be floated out by use of water or air jet from hose until the hole has been opened to within 60cm of the charge, whereupon the water shall be siphoned or pumped out, then a fresh new charge placed and duly detonated and c) A new hole shall be drilled 60 cm away from the old bore and parallel to it and about 30 cm less in depth and the new hold charged and duly fired. the drilling and cutting along the blasted area is to be done as per requirement. Get the approval of founding strata and take levels for records. If it is not O.K. then rectify and get it rechecked by clients. Keep the joint record of strata level and client approval. Clear the site for further works.
10 11 12
13 14 15

GUIDELINES FOR FILLING Sr. No. 1 2 3 4 5 Description Arrange the required manpower, machinery & tools. Identify the filling material, method of filing, compaction requirements. Check Filing material is free from boulders, large roots & excess amount of soda or vegetable mater & lumps. Do Filing in layers Each layer of filing shall be compacted on wetting continuously. WORK INSTRUCTIONS FOR BACKFILLING OR FILLING IN PLINTH Execute backfilling or filling in layers of 20cm to 30cm. for site grading filling work layer thickness can be upto 400mm. 2. each layer is to be properly spread, watered and compacted. Decide the thickness of each subsequent layer by taking into account the type of rammers / compactors to be used. Type of Rammers / Compactors / Rollers a. b. c. 3. 4. 5. 6. Heavy type - layer thickness 30-40 cm. Medium type - layer thickness 20-30 cm. light type - layer thickness 10-15 cm. Consolidate the filling upto 90 to 95% density at optimum moisture content. Take care to ram near walls, columns and plinth beam sides in layers of 15 cm thickness properly. Ensure that the consolidated top[ layer is dressed to required slope and level. Provide for shrinkage/settlement at the rate of V2 per foot depth. 1.

GUIDELINES FOR ANTI-TERMITE TREATMENT WORKS

Sr. No. 1 2 3 4 5 6 7 8 9 10 Description Study drawing, specification and method statement duly approved by client Decide on type of chemical to be ordered and place orders on approved sub-contractor. Receive material at site & inspect as per incoming material inspection procedure. Review on-conforming material. if material is as per specifications, take stock and issue to site identify the areas to be treated i.e., Top surface of Plinth filling, Junction of wall & floor, external perimeter of building, soil surrounding 3ipes, expansion joints, etc. Prepare the chemical solution by mixing the chemical with the appropriate quantity of water to obtain a chemical emulsion of specified concentration. Apply the emulsion though spraying on surfaces to be treated or channeling or roding as specified for different surfaces as per the technical specifications. Follow the rates as specified. Check as per checklist at the end of application for specified rates of dosage, uniform coverage of chemical emulsion, etc. Review and take corrective actions in case of non-conformities. Proceed with backfilling or other sequential activities.
WORK INSTRUCTIONS FOR ANTI-TERMITE TREATMENT WORKS

1 2 3 4 5 Holes on the total area of the building and outside the building to be made as per chemical manufacture instructions The chemical and its concentration before commencement of work to be verified Chemical should be injected into the holes of sufficient quantity using spraying equipment as per manufactures recommendations. Ensure there is uniform application around and inside the building. Check whether any greenery or drinking water is nearby and take appropriate precautions that it is not polluted / contaminated.

GUIDELINES FOR SHUTTERING Sr. No. 1 2 3 4 5 Description Procure drawing and specification from client and make a detailed study. Estimate the quantity of various shuttering items required Prepare design and selection of material to be used for shuttering assembly. Place indent of shuttering material as per Purchase Procedure In case shuttering material is procured, then receive material as per procedure for material recipt, acceptance and storage. The material is inspected as in-coming material inspection. If the material is not as per specifications, then Project In-charge should be consulted and authorization to be obtained from PIC for acceptance of material after rework or with concession. If the material is as per specification, then make stock entry and issue to site. Evaluate and select Labour sub-contractor as per procedure for fixing the shuttering assembly. Clean, oil and fix the shuttering assembly. Check for line level and plumb of shuttering plates and props as per checklist. If not acceptable the repair and re-inspect to see if the defects are rectified. Place reinforcement as per drawing and procedure for reinforcement and concrete. Decision he date of de-shuttering as per specification and keep ready arrangements for de-shuttering. Carry out de-shuttering after specified period. Check the quality of concreting as per procedure for concreting. Check the condition of the de-shuttered materials. If it is directly useable then clean oil and stack. If not then either repair the same and stack.
6 7 8 9 10 11 12 13

CHECK LIST FOR AFTER DE-SHUTTERING
SITE: LOCATION: DATE:
Ref. Drwg. No. ------------S.NO. 1 2 Description Check whether concrete quality is free from defects after de-shuttering Check condition of various parts of shuttering assembly Check the condition of Shuttering assembly Are repairs earned out to damaged plates and other components of shuttering assembly? Clean, oil and stack shuttering material for future use? YES NO NA
3 4 5
CORRECTIVE ACTION PROPOSED
SIGN. OF SITE ENGINEER

WORK INSTRUCTIONS FOR SHUTTERING 1. use formwork, which is rigid and closely fitted, with sufficient strength to support wet concrete. 2. ensure that centering plates, planks or plywood are properly cleaned. 3. take care to apply suitable form release agent after proper cleaning of form work, before placing reinforcement. 4. Ensure proper check for line, level and plumb before starting concreting activity. 5. Shuttering to be checked in stage-wise i.e. as per the approved shuttering scheme 1st - beam bottom alignment and level and rigidity of staging to take the load. IInd - beam sides. IIInd- Slab shuttering and levels. IVth Fixing of side supports, bhida, etc. for rigidity. 6. Special care should be taken to check column caps supports at junction of beams. 7. Pockets, insert to be carefully placed and check before placing concrete. Fixing of pockets and inserts should be rigid to avoid displacement during concreting. 8. Use of magic tape for gap filling. 9. Provide extra supports at joints of wall plates beam bottom. Proper care must be taken to prevent bulging of centering 10. Leave slab formwork undisturbed till concrete gains 70% of required strength. 11. Take care not to damage the concrete while striking the centering off. 12. Time period for removal of shuttering should be as detailed below: (a) (b) (c) (d) Walls columns and vertical side of beams Slab Beam soffits (props left under) Removal of props under the slab spanning upto 4.5m spanning more than 4.5 m Removal of props under beams and arches spanning under 6 m spanning over 6 m 16 to 24 hours 3 days 7 days 7 days 14 days 14days 21 days
(e)
13. After disconnecting all the materials should be properly stacked and cleaned for next repetition.

GUIDELINES FOR REINFORCEMENT S.No. 1 2 3 Description Study drawing, specification and method statement. From the drawings estimate the quantity of steel required diameter wise. Prepare bar bending schedule by referring relevant drawings and get the approval. If any discrepancy noted in the BBS then the same is to be rectified and indent for the material is placed after seeking approval. If the material is supplied by clients follow the procedure for control of customer supplied product. Otherwise based on incoming material inspection report and test report, receive the material. If the material is as per specification, then make stock entry and issue to site. Evaluate and select Labour sub-contractor as per relevant procedure. Carry out the cutting & bending of reinforcement steel by mechanical or manual means. Fix the reinforcement as per BBS and drawing. First GECPL shall check the placing of reinforcement and its adequacy. If it is not o.k. the same shall be rectified. If it is o.k. check by cliet is carried out to check the adequacy as per the specification. If any defects are noticed by client, same shall be rectified and rechecked by client.
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WORK INSTRUCTIONS FOR REINFORCEMENT 1. Ensure that reinforcement bars are clean free from grease, oil, paint, rust, dust or any other objectionable foreign material. 2. ensure that all the reinforcement rods are thoroughly cleaned before fabrication, pitted and defective rods are rejected. 3. Ensure that straightening of bars is done without damaging the configuration. a. Cutting, bending should be as per Bar Bending Schedule (B.B.S.) 4. Ensure that the vertical distance between the successive layer of bars in beams or other members are maintained by providing mild steel spacers at required interval. 5. Check reinforcement for size, spacing, location, numbers, overlaps, welding joints, hooks, beatups, rusting, greasing and ties as per drawings and bar bending schedule. 6. Ensure staggered overlaps, cold bending and anchorage, wherever necessary. 7. Ensure that the reinforcement is kept in position by ghodies, chairs etc. during placing and compaction of concrete. 8. Ensure proper placement of cover blocks, embedded inserts and cut outs if any. 9. Ensure that cat ladders are provided on the reinforcement to avoid displacement of reinforcement. 10. Ensure that before placing the concrete; the reinforcement is checked for bent up bars, lap length, hooks, rings and distribution bars, etc. 11. Ensure proper binding of reinforcement. 12. Ensure that the lap joints of bars are staggered in about 40% to 50% in column, walls, etc. or as specified.
: leveling instruments : Bar Bending Schedule

GUIDELINES FOR WATERPROOFING S.No. 1 2 Description Study drawing, specification and method statement duly approved by client. Evaluate and select an agency, which has to do the water proofing work as per Procedure for Evaluation and selection of Labour Subcontractor. After deciding the agency to be do the water proofing, Indent is prepared as per Procedure for Site Purchase. The material is received and inspected as per procedure for incoming material inspection. Based on incoming material inspection report and test report, check the material. If it is not as per specifications then either accept it after rework or repair. If the material is as per specification, then make stock entry and issue to site. Issue the material to selected agency to carry out water proofing work. Clean area and make the preparatory arrangement or water proofing work at site. Surface preparations as specified in the customer specification should be completed before commencement of water proofing work. Fix the levels and get it approved by clients. If not o.k. then rectify it and get it reinspected by client Start laying brickbats and fill up the joints. Do the final finishing of the waterproofing works and check for the water tightness. If it is o.k. then cure as per specification. If not o.k. The repair and rework to ensure water tightness
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WORK INSTRUCTIONS FOR WATER PROOFING IWP for terrace 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Ensure that the item and specifications of the work are studied before carrying out the work. Water proofing material must be of make as specified / directed. check that the recommended water proofing compound is mixed with mortar, which is used for Roda fixing as well as final top finishing layer. (IPS). The parapets, walls, must be plastered before application of water proofing material. Suitable vata and nose to be made as part of treatment. Ensure surface scrapping and cleaning before start of activity. (Thorough cleaning of terrace). Before starting this activity, ensure that the proper slope and level is checked for drainage. Ridge and valleys to be marked properly and rain water down take points to be finished with kimra. The IWP construction joins must be pressure quoted before starting. The finished top surface must be smooth with Dori mark in both direction to give 1xl pattern. The openings, needs inverted kerbs to end IWP with Vata. Av. Recommended thickness for IWP is 115 mm-any extra thickness required for longer slopes to be planned in advance. For better water run off, max slope can be provided upto 1:1 20. IWP thickness at lowest valley point (i.e. at the RWP mouth) should be 2V2.
BOX TYPE WATER PROOFING 1. For providing and laying Box type waterproofing treatment to floors and external surfaces of under ground structures. Will comprises of waterproofing layer, average 50/100mm thick for floors, using layers of kotah stones placed diagonally with staggered joints. 2. Rough kotah stone shall conform to specification. 3. 100 mm thick waterproofing layer consist of the following layers : a) 15mm thick 1:3 cement mortar bedding wih approved waterproofing chemical. b) 20mm thick rough kotah stone laid diagonally with staggered joints. Joints shall be sealed by 1:1 cement mortar with approved waterproofing chemical. c) Repeat in the same manner as described above in (a) and (b) to form 2nd layer. d) The final layer of 30 mm thick I.P.S. shall be laid with approved water proofing chemical having desired finish as directed.

WORK INSTRUCTIONS FOR WATER PROOFING 4. Box type waterproofing treatment to external vertical surfaces of under groung structures the treatment shall comprise of rough coat of water proof plaster to walls. Allow to set and arc at least for 3 days. Thin rough stones ( @20mm) are fixed with neat cement paste in horizontal layers with open joint of 25mm (approx.) 2nd and 3rd layer above is fixed in same way with staggered joint pattern. All joints are granted with 1:1 cement mortar. Next day pressure granting is done in the cavity between the rough wall plaster and the stone in vertical plane. Top is sealed with CM 1:1 5. Comer laps in vertical and horizontal plane needs proper overlapping of the stone. 6. On final completion of stone fixing smooth water proof cement plaster is done over the rough stone. 7. Proper watering for 7 days required. TAR FELT Application Methodology 1. Surface Preparation Cement grading should be carried out to provide a required slope. The number of drainage outlets should be adequate and the size of the outlet should not be less than 100 mm The bitumen to be used as binding material should be prepared by heating to the correct working temperature and should be spread on the roof with a rubber squeeze or cloth brush (kutchda). Rolls of Tarfelt should be laid over the hot bitumen and pressed properly to avoid air gaps. A minimum overlap of 100 mm and 75 mm should be made at the end and sides of the strips of Tarfelt respectively. For double layer treatment, the joints between the two layers should be staggered. For junction on roof and parapet wall, a cement concrete filet should be prepared at the junction, Tarfelt should be laid over the same and then should be tucked into the groove (500mm x 50mm) made in the parapet wall. The groove should then be filled with cement mortar (1 : 4) The top coat of stone grit or gravel (6 mm size) should be laid by spreading hot bitumen and laying the grit / gravel over the same.
2. 3. 4. 5.
6.

WORK INSTRUCTIONS FOR WATER PROOFING Chemical Waterproofing APPLICATION DATA : 1 Surface Preparation Ensure Concrete surfaces are structurally sound and have been cured for at least 28 days If surface laitance is found this must be removed by acid etching, using a mixture of 1 part Muriatic Acid to 3 parts water by volume. The acid solution should be scrubbed into the surface with a stiff broom while it effervesces (approximately 2 minutes). Hose off and broom the acid solution and slurry residue thoroughly with fresh water and allow to dry completely.
2. 3. 4. 5. 6.
The substrate must be completely dry. A coat of recommended primer should be applied prior to application of water proofing compound. Water proofing compound should be stirred well and then applied by means of a wide fine hair brush or a short nap roller in 2 (two coats at a minimum spreading rate of 0.5 litre m2 per coat with an interval of about 24 hours in between coats. At perimeter cove or other areas where vertical walls meet horizontal slabs, waterproofing membrane should be turned up at least 300mm and finished in a groove. In accessible areas, where pedestrian traffic conditions are expected the membrane should be sandwiched by providing a suitable cover to prevent it from getting physically damaged.

WATER PROOFING WITH HESSIAN BASED BITUMEN FELTS / FIBRE GLASS TISSUE REINFORCED FELT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. The roof slab shall be scrapped cleaned of all dust, dirt, rubbish etc. It shall be made reasonably smooth either by chipping of projects or by applying a thin coat of cement mortar if slab surface if too rough. Over the hardened and finished surface of the roof slab, a thin layer of approved bitumen primer shall be first brushed over the roof surface and allowed to dry. The felt shall be first cut to the required lengths and laid out flat on the roof in position at right angles to the direction of run-off gradient and shall be brushed clean of dusting materials. Each length of felt thus laid in position shall be rolled up for a distance of half of its length. Then the bonding material heated to correct temperature shall then be poured on to the roof across the full width of the rolled felt as the latter is steadily rolled out and pressed down. Excess bonding material shall be squeezed out at the ends and removed as the laying proceeds. When the first half of the strip of felt has been bonded to the roof, the other half shall be rolled up and then unrolled on to the hot bonding material in the same way. Minimum overlaps of 100 mm shall be allowed at the end and the sides of strips of fell. All overlaps shall be firmly bonded with hot bitumen. the laying of the second layer of felt shall be so arranged that the joints are staggered with those of the layer beneath it. More No. of layers are recommended depending on the requirement (3 layer, 5layer, 7layer is regular pattern). On completion of felt layers, 6mm and down grade Grit or river shingles are spread over the surface for protection. (PERMAGUARD) WATER PROOFING 1. 2. 3. Permaguard is an aluminum foil/strip laminated with polythene film on both sides. The edges of the strips are overlapped and sealed by a heat-sealer or hot molten bitumen to make it a continuous sheet. As a part of surface preparation, scrapping, cleaning and washing of terrace slab is must. Cement mortar plaster/screeding to be done for providing water run off the slope and smooth finish. A coat of molten bitumen of desired temperature is then applied on the area equal to the width of the permaguard strip to be laid subsequently.

4. If the Permaguard strips are to be heat-sealed, then the overlaps are kept free of bitumen. Alternatively, molten bitumen is also applied over the overlaps before pressing the strips together. Permaguard strips are laid so that the first strip of Permaguard is laid along the bottom of the slope. The subsequent strips are laid in the same manner, ensuring that the lower edge of the second strip overlaps on the upper edge of the first strip, overlap width being min. 50mm. wide. These overlaps are sealed with heat-sealer or molten bitumen to make a continuous sheet of Perm guard. When there is a parapet wall, a groove/niche shall be made (50mm. in depth and 125mm. above roof level) all along the parapet. While laying Permaguard, leave an extra 175mm. (both lengthwise and widthwise) after the end of the roof. Apply molten bitumen all along the parapet wall covering the asrea upto the groove and the groove itself. In sert the 50mm. (of 175mm) of Permaguard into the groove and press the remaining 125mm. onto the wall. Seal the groove with cement concrete 1:2:4. For laying Permaguard near/around drain pipes, Observe the following : Make a circular tube of Permaguard overlapping one end over the other. The tube should approximately be of the same dia. As that of the pipe. Insert this tube into the pipe leaving 100mm. projection out, keeping the lap joint of the tube on lop. Cut this 100mm. at right angles to each other to make 4 strips. 3 of these are flushed on the parapet wall and the 4th into the roof with hot molten bitumen. The 125mm thk. Permaguard pressed onto the parapet wall shall have a hole cut slightly smaller than the opening of the drain pipe so that the pipe is not blocked and the materials is flushed into the pipe over the already laid Permaguard tube with hot molten bitumen. Lastly brush the mouth of the pipe liberally with bot molten bitumen. Over the Permaguard apply molten bitumen using sprinkler and brush. Sprinkle coarse sand evenly on top of the bitumen layer. This will help to bond the Permaguard to the top finishing layer of either screed concrete or any other desired finish.
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WATER PROOFING OF ROOFS WITH BRICK LIME CONCRETE AND PRESSED FLAT TILES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. The exposed surfaces of the roof slab shall be thoroughly cleaned. A layer of brick lime concrete shall be laid over the cleaned surface. Brick lime concrete shall be 1:2:4 by volume using 20 mm down graded brick bats. The slope of the lime concrete layer shall be 1:100 and the minimum thickness shall be 50mm. The slope of the draining surfaces shall be formed on all the sides as necessary. Care shall be taken to check the quantity of water. The quantity of water shall be so as to make the concrete just workable Cement sand mortar 1:3 with 2% mixture of approved equivalent water proofing agent shall be laid over the under bed to a thickness of 20 mm. Pressed flat tiles are set over the mortar and painted with cement mortar 1:3 with 2% approved equivalent water proofing agent. The surface level shall be such as to allow quick draining of water without leaving any pool anywhere. The finishing course shall be fully secured and shall have an even density. There shall not be any bubble formation or crushed or squeezed insulation or under bed.

GUIDELINES FOR PLAIN CEMENT CONCRETE S. No. 1 Description Study drawing, specification and method statement. Estimate the Pour Quality. If the method statement or contract document requires concreting by RMC, then evaluate and select vendor who can supply RMC if concreting is proposed to be done using conventional means (Batching Plant or Concrete mixer) then the quantities of various material required for pour is estimated based on approved mix design. Select the RMC supplier based on their capability to supply the material. Obtain the Mix design from the RMC supplier as per requirement of clients specification and the method statement prepared. Carry out the trials of mix design to check the compatibility of mix design and check on workability and the strength of concrete for respective grade of concrete. If the parameters of concrete mix design are acceptable then place the order as per requirements of the site. If the parameters are not acceptable then inform the RMC supplier to make the necessary changes to achieve the necessary the necessary objectives. Receive the RMC at the site as per the order requirements. If concreting is to be done by conventional means the Labour sub contractor who will do the concreting has to be evaluate and select as per relevant procedure. Material required for concreting viz., fine aggregate, Coarse aggregate, Cement, water and admixtures if any are to be indented after estimating the quantities required for the pour. In case any material is supplied by client viz., cement or admixtures then the same is controlled as per procedure for control of customer supplied material.
Based on the mix design and incoming material inspection reports for quality, receive material and check pile the same at appropriate designated areas. Take necessary stock entry before accepting he material. If the material received is not as per specification the PIC reviews the use of such material based on its inspection report and recommends to accept it with concession for alternate use or may recommend to scrap it.
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Before approval for the concreting is given make a thorough checking of shuttering assemble, layout of reinforcement, cleaning of area, provision of necessary equipment for concreting viz., spare mixers, concrete pump, vibrators

etc. if a any discrepancy is noted at this stage, the same is attended to immediately and approval obtained from concerned authority. 10 11 12 13 14 15 16 17 Place the requisition for required quantity of concrete either in house or from RMC supplier Prepare the concrete in Batching plant or mixer machine if in house concreting is to be done. Transport and place the concrete in the appropriate structural element with the help of concrete pump of manual as per the need of the site and quantum of work. Take required number of concrete cubes as per instructions of clients. However minimum number of concrete cubes shall be minimum 6Nos. While the concreting is in progress in respective structural elements make sure to compact the same with the help of vibrators and proper leveling is done. After finishing the concreting clean the surrounding areas and equipment and accessories. Removal of formwork and shuttering assembly should be carried out after specified period as per specifications and in consultation with clients. After removal of shuttering check the surface of the concrete for line, level and finish. If not acceptable then rectify and repair the same as per clients instruction. Carry out the curing of concreted structural element as per specification. The testing of concrete cubes after 7 days of concreting shall be carried out to check the compressive strength if the same is within the limits prescribed maintain the concrete cube register duly signed by the client / client representative. If the strength at 7 days is not within prescribed limits then carry out testing at 28 days. If strength is still not ok then take necessary action as per clients instruction.
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Any change to this QM will be intimated by MR to above persons and they will be responsible for keeping their hard copies of QM updated in Co- ordination with MR. all the above mentioned persons are responsible for implementing the changes made in this QM in their respective departments

WORK INSTRUCTIONS FOR PLAIN CEMENT CONCRETE 1. 2. 3. 4. 5. 6. 7. 8. Excavation dimension must be checked before start of P.C.C. and necessary shuttering must be done, if requited. Remove all loose earth from foundation pits before placing of P.C.C. Ensure that measurement boxes are ready before starting this activity. Take care to sprinkle water and ram in foundation pit before placing concrete. Ensure availability of chute, panja, koba, etc. before start. Compaction of P.C.C. should be properly done to get smooth even leveling course. Loose Coarse aggregate can be picked up from the surface. Excavation dimensions to be checked before start of PCC and necessary shuttering to be done if required. Proper thiyas for level to be taken before start of work.

WORK INSTRUCTIONS FOR REINFORCED CEMENT CONCRETE WORK (A) 1. 1. 2. 3. MATERIALS : Cement : Use cement of approved quality and ensure that it is not older than 90 days. Store cement bags in a completely waterproof godown having standard specified features. In case cement bags are required to be stores in open as a temporary requirements, ensure that they are stacked on a dry platform made of wooden planks or railway sleepers resting on a brick masonary/ concrete / dry sand / aggregate platform about 150 mm above the ground. The number of bags must be just sufficient for days consumption. 4. Ensure that entire stack is covered by tarpaulin or polythene sheet, with an adequate overlap. This procedure is to be adopted during cloudy or rainy season. II. 1. 2. 3. III. 1. 2. Aggregates (Coarse aggregate and Fine aggregate): Use aggregates which have been tested and approved by Q.C. labs. Adequate quantity of aggregate is required before start of work. Necessary correction for bulking of sand to be done on day to day basis. Water : Do not overload a batch. Carryout batching of materials by weight. If it is required to batch materials on volumetric basis, make use of measurement boxes in units of 0.035m3 equivalents to 50 Kg. cement bag. 3. 4. 5. 6. 7. Batching of cement must be done by weight considering 50 kg. per bag. Exact measured quantity of water to be added to the batch as per w/c ratio. Apply necessary correction for bulkage of aggregate. Garry routine checks of weights as well as sensitivity of balance. Addition of admixtures-Ensure addition of recommended admixtures in specified proportion.

WORK INSTRUCTIONS FOR REINFORCED CEMENT CONCRETE WORK
(C) 1. MIXING : When mixer machine is used check for rpm of mixer, hardened material, number of blades inside the drum, working of discharge chute and hopper, leveling, raising emptying and release of hopper. 2. 3. (D) 1. 2. 3. (E) 1. 2. 3. 4. 5. 6. 7. (F) 1. 2. 3. Minimum mixing time required is 1V2 to 2 minutes for the drum. Ensure proper leveling of weigh batcher and mixer machine. TRANSPORTING : Keep the mixer as chose as possible to the placement site to reduce transportation. Place the concrete in position prior to the initial setting time. Avoid segregation and setting of concrete. PLACING : Before starting concrete fix the position of construction joint. Sequence of concreting must be finalized. Ensure placement of concrete in its final position before setting starts. Avoid segregation of materials of adopting minimum drop. Take care while placing to avoid displacement of inserts, pockets etc. Lay concrete in suitable layers without any break in continuity, maintaining the thickness of layers. Proper walkways are to be provided in advance. COMPACTION : Use suitable type of Immersion, surface or form vibrators. Avoid over-vibration and bleeding. Insert Immersion vibrator minimum 100mm away from the shuttering face vertically to the depth, do not drag, withdraw vertically and slowly. Dont allow the needle to touch the reinforcement. 4. (G) 1. 2. Keep enough spare vibrators and needless. FINISHING : Finishing is carried out after a little stiffening of concrete has occurred with suitable tools . Provide green cut immediately after finishing a particular layer of concrete by using wire brush and small brooms and clean it thoroughly. In case of preceding concrete surface

being old, chipping must be done with 10-15 mm depth and should be thoroughly cleaned using air or water jets before placing the subsequent layer of concrete. (H) 1. a) b) CURING : One or a combination of the following curing methods can be adopted depending on site conditions, availability of curing materials, type of job, economic etc.: Methods to prevent loss of water in concrete during the early stage of hydration by ponding, water spraying or saturated wet coverings. Methods to prevent loss of water in concrete by sealing the exposed surface i.e. covering the exposed surface with sheets of plastic or other impervious materials, applying membrane forming compounds etc. 2. 3. The curing period of ambient temperatures above 20o C should be for minimum 7 days, or the time necessary to attain 70 percent of the specified compressive strength. The use of curing compounds are useful on vertical surfaces, or in the event of water shortage. III. 1. COVER : Keep various thickness cover blocks ready as per the requirement of the structural drawings well in advance. Use proper mould and mortar mix for casting.
: Weigh batcher : Measurement book

CHECK LIST FOR PRIOR TO CONCRETING
SITE :KALAMBOLI
S.No. 1 . 2 . 3 . 4 . 5 . 6 . 7 . Check for Provision of ACCESS PLATFORMS & WALKWAYS. Check for SUPPORT to forms and rigidity of the assembly. Is it O.K.? Check for COMPLETION OF OTHER PRECEDING ACTIVITIES such as Fixing of inserts & embedment and service conduits. Etc. Check for FORMWORK & REINFORCEMENT Check for CLEANLINESS of the area to be concreted. Is it O.K.?
LOCATION :
Description
DATE :
Yes No NA
Check that relevant drawings/ specification are referred to?
Check whether location of expansion joints is as per drawings?
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Check for readiness for concreting regarding following items :
Provisions and WORKING CONDITION of Concrete Aids such as : a) Vibrators Is it O.K.? b) Needle Is it O.K.? c) Concrete Pumps Is it O.K.? d) Any other accessories Is it O.K.?
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Protective covers against rain provided a) Availability of sufficient no. of cube moulds? b) Availability of slump cone apparatus?
12.
A. MADE OF CONCRETING PROPOSED (Mixer m/c. Batching Plant. RMC) B. GRADE OF CONCRETE. C. TOTAL QTY. OF CONCRETE.

D. DATE OF CONCRETING.
Signature of Contractor
CIDCO

WORK INSTRUCTIONS FOR FABRICATION 1. 2. 3. 4. 5. 6. 7. 8. 9. 3. 4. 5. 6. 7. 8. 9. 10. Estimate the power requirement for peak quantum of work. Ensure availability of sufficient space for fabrication yard and adequate lighting arrangement for night work. The Platform for fabrication is to be prepared before starting the work. The approach road for unloading of the materials and carrying the fabricated materials to the site has to be proper and prepared in advance. The site office and store space for fabricator must be completed in advance. Suitable distribution board for power supply above to be provided. Estimation of quantity of the structural steel must be carried out from approved shop drawings. Carry out the analysis for cutting lengths to reduce the wastage. Skilled qualified welder, fitters, gas cutter and technicians must be recruited for the job. The welding, gas cutting, grinding, etc. procedure must be approved before the start the work. The welding rods must be of approved make and quality, suitable for type of fabrication. Adequate stocks to for all consumables to be maintained. The layouts are to be checked and the zig is to be approved after assembling. The centre lines are to be checked before erection and the erection sequence and procedure is to be approved before start. The members are to be properly aligned with proper tightening of bolts bracing sag rods, ties etc. to be erected simultaneously before alignment. Grouting of the base is to be carried out after erection alignment. Grouting holes to be provided in base plates. Samples must be collected for establishing rolling margins weight difference and is required to be recorded. Average 3 samples from every incoming lot of steel must be collected. Dimensional differences in rolled sections to be pointed out and recorded, (if more than tolerance level are found in material supplied). BOQ for nut and bolts for connections to be prepared. Safety measures should be strictly followed.

11. The above work shall be checked by the Engineer for Structural Fabrication. Directions for any rework to meet the specified requirements shall be given by the Structural Manager. 12. The sub-assembled material shall be checked by the Clients Engineer. Any comments/ corrections or suggestions received from the clients shall be incorporated into the works for rectification. 13. The final assembly shall be made near to the erection site with the help of the subassembled components. The welding and bolting shall be completed prior to release for inspection. 14. The final assembly shall be checked for accuracy in accordance with the shop drawings. The Structural Manager shall instruct for any rectification desired to meet the specified requirements. Subsequently, the final assembly shall be inspected by the Clients. 15. 16. 17. The approved final assembly shall be welded with approved quality welding electrodes. The assembly shad be welded by taking precautions to avoid distortions. The whole assembly shall be descaled, debarred, deslagged and degreased to ensure thorough cleaning prior to panting. Apply the primer coat as per the specifications. The final assembly shall be jointly inspected along with the Clients Engineer, after the painting. The sectional details are marked on the sections for identification purposes, after the inspection results are satisfactory. 18. The fabricated elements shall be released for erection after inspection. The same shall be transported near to the erection site. All transportation arrangements shall be coordinated with the Engineer for Structural Erection.

GUIDELINES FOR STRUCTURAL STEEL FABRICATION S.No. 1. Description Design Drawings for Structural Steel Works shall be issued by the Clients. The Scope of Works and the Design Drawings shall be studied by the Planning Engineer and the Structural Engineers. Detailed method statement has to be prepared and Clients approval obtained. 2. Based on the Quantity Take-off Structural Steel, the procurement shall be raised by the Site. The Procurement shall be ensured by the Central Purchase Department at the Regional Office. 3. The selection of the Sub-contractor for Structural Steel Fabrication & Erection shall be done by the Regional Office. The Regional Office shall place the order for Structural Steel Fabrication & Erection on the approved sub-contractor. The Copy of the records. 4. Shop Drawing Preparation for the Structural Steel Fabrication shall be ensured by the Structural Engineer. The Design Drawings issued by the clients shall be the basis for this. The Shop Drawings for fabrication shall also feature the bill of materials. 5. The Shop-Drawings for Fabrication shall be submitted for the approval of the clients and the Structural Consultant. Any suggestions, corrections or comments issued by the client/ structural consultant shall be incorporated into the shop drawings. The amend. 6. The approved shop drawings shall be issued to the site for execution. The same shall be recorded into the Drawings Issue Register. Copies of the approved shop drawings shall also be available with the Engineer responsible for Billing. 7. 8. The Structural Steel for the Fabrication shall be issued by the Stores Section to the Structural Engineer. All issues shall be recorded in the Stores section. The straight need sections shall be taken up for fabrication Appropriate, layout shall be made on the working platform for sub-assembly / and main assembly if required. This layout shall be checked be the Structural Manager for accuracy. 9. After the approval of the layout and cutting methodology, the sections are cut as per the making plan referring shop drawings. The cut material is deburred and destageed. The marking for the holes is then taken up. The location of the holes is then marked. 10. Laying and marking for subassembly shall be done on the working platform prior to the fitting of the components.

GUIDELINES FOR STRUCTURAL STEEL ERECTION S.No. 1. 2. Description Study drawings, specifications and approved method statement. The fabricated structural steel shall be transported to the erection site. The same shall be stacked such that the item that is required first is on the top. All structural elements shall be identified with unique identification numbers marked with hard punching. 3. The fabricated structural steel shall be erected in accordance with the approved method statement comprising of the erection sequence, plant & machinery and safety precautions. The members viz. Main columns. The beams, Portals, Purlins etc. shall be erected sequentially. During erection the members shall be braced/ tied with guy wire ropes for stability against horizontal forces. 4. The alignment of the structural members shall be done so as to ensure accuracy in the following parameters (as applicable) 1. Centre Distance, 2. Bolt grouting, 3. Levels, 4. Plumb, 5. Base plate grouting, 6. Bolt tightening of the base 7. Encasting etc. site. 5. The erected structure shall be subjected to joint checking by SPCL and the client/ client representative and conformance to construction drawings shall be judged. The inspection shall be recorded in the checklist for erection. Appropriate Corrective action shall be taken in case of non-conformities. 6. Maintain all records for inspection in the form of checklist.

WORK INSTRUCTIONS FOR FABRICATION / ERECTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Estimate the power requirement to peak quantum of work. Ensure availability of sufficient space for fabrication yard and adequate lighting arrangements for night work. The platform for fabrication is to be prepared before starting the work. The approach road for unloading of the materials and carrying the fabricated materials to the site has to be proper and prepared in advance. The site office and store space for fabricator must be completed in advance. Suitable distribution board for power supply above to be provided. Estimation of quantity of the structural steel must be carried out from approved shop drawings. Carry out the analysis for cutting lengths to reduce the wastage. Skilled qualified welders, fitters, gas cutter and technicians must be recruited for the job. The welding, gas cutting, grinding etc. procedure must be approved before the start of work. The welding rods must be of approved make and quality, suitable for type of fabrication. Adequate stocks to for all consumables to be maintained. The layouts are to be checked and the Zig is to be approved after assembling. The centerlines are to be checked before erection and the erection sequence and procedure is to be approved before start. The members are to be properly aligned with proper tightening of bolts bracing sagrods, tiles etc. to be erected simultaneously before alignment/ Grouting of the base is to be carried out after erection alignment. Grouting holes to be provided in base plated. Samples must be collected for establishing rolling margins weight difference and is required to be recorded. Average 3 samples from every incoming lot of steel must be collected. Dimensional differences in rolled sections to be pointed out and recorded. (if more than tolerance level is found in material supplied). BOQ for nut and bolt for connections to be prepared. Safety measured should be strictly followed.

GUIDELINES FOR MASONRY WORKS S.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Description Study drawing, specification and method statement duly approved by client. Material (stone, block or brick etc.) which has to be used for masonry work is selected from the customer specifications. After deciding the material to be used for masonry, indent is prepared as per Procedure for Site Purchase. The material is received and inspected as per procedure for incoming material inspection. Based on incoming material inspection report and test report, receive the material. If it is not as per specifications then either accept it with concession for alternate use or reject. If the material is as per specification, then make stock entry and issue to stores. Evaluate and select labour sub-contractor as per relevant procedure to carry out masonry work. Issue the approved material for use to site. Clean area, line out and make the preparatory arrangement for masonry work at site. Carry out Masonry work at site. Provide openings for doors, windows, ventilators etc. and conduits sleeves. Check masonry work for line, level and plumb as per drawings and client requirement. The same is approved by clients, do the curing and raking of joints. If not approved then carry out necessary rectification work as per instruction of clients.

GUIDELINES FOR BRICK WORK S.No. 1. 2. 3. 4. Description All bricks shall be kept stacked at a point nearer to work to decrease movement time. All bricks shall be soaked in water for one hour before lying. Usage of cut bricks shall be avoided to the maximum extent possible. Each brick shall be property bedded as set in position by slightly pressing while lying, so that the mortar gets in to all their surface pores to ensure proper adhesion. 5. All head and side joints shall be completely filled by applying sufficient mortar to brick already placed & brick already placed & placed to placed. 6. 7. 8. 9. 10. All joints shall be flushed & packed with mortar so that no hollow spaces are left. Brickwork shall be done true to plumb or in specific batter. Green work shall be protected from rain. Plastering shall be started from top and worked down. The plaster shall be finished off with a wooden straight edge.

WORK INSTRUCTIONS FOR MASONRY (A) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. BRICK WORK : Ensure to have information regarding specifications of cement mortar. Soak the bricks before starting the brick work. Mixing of mortar must be done properly and thoroughly with specified proportion of ingredients on an impervious platform. Keep the frog up, while placing the brick. Fill the joints between the bricks properly. Ensure to carry out RADO at every 4th layer. Supervise line, level and plumb from time to time during the days; progress. The joints must be raked to an average depth of 10mm when mortar is green,. If plaster or pointing is not to be done, the joints should be struck flush. Proper hacking of RCC surface in contact with brick masonry must be done for proper bond. Courses must be truly horizontal with suitable bond pattern to break the vertical joints. English bond is preferable. Suitable toothing or grooves or stepping to be provided for continuation of brickwork. Thickness of joint must be uniform and not more than 13mm. Specified cement mortar must be placed within 30 minutes after addition of water. Bricks on edge must not be used unless specified. Disallow vertical joint filling by spreading mortar. Masonry may be raised upto 150 cm in a day. Raising with all connected brick work be carried out at one level. For 230mm thick wall, maintain one face in line. This face can be preplanned to take all kinds of single coat plasters. For higher thickness walls both faces should be in line. First mark up layer or brick work needs to be laid in direct supervision for door/ window/ any other openings to be kept accurately as per the drawings or layout. The buttress, counter-forts should be built simultaneously, maintaining proper bond with main wall and not added after wards. Curing must be done at least seven days or as laid down in specification. Old or dry surface must be thoroughly cleaned and wetted. The joints should be raked before starting new construction.

(B) 1. 2. RANDON RUBBLE MASONRY: Rubble must be as per specification. It must be hard, durable and tough. The stones must be soaked before use. It must be roughly dressed and uniformly coloured and of equal size. The masonry work will be carried out as far as possible at one uniform level throughout, but where breaks are unavoidable the joint will be made in good long steps so as to prevent cracks between old and new work. 3. 4. 5. 6. 7. Through stones must be staggered at regular intervals in staggered manner. The stones must be arranged to break joints as much as possible and long vertical lines must be avoided in face work. Spawls are to be used wherever necessary to avoid thick mortar beds for joints and shall not exceed 20 per cent. The wooden mallet must be used to hammer down stone in the position and solidly bed it in the mortar. Iron templates are to be used to compact the mortar in joints.
Records
Measurement book

WORK INSTRUCTIONS FOR SOLING (a) 1. 2. 3. 4. 5. 6. 7. Rubble Soling : The rubble should be hard, durable and free from other defects. The rubble should be suitable size and shape to give the required compacted thickness. The rubble is laid in vertical position of the sub-grade but closely packed by arranging the stones. The filling of the interstices shall be done with quarry spawls/ metal simultaneously with the placing of the rubble. Ramming near the walls and column shall be done properly to the required level/ slops, camber etc. Compaction must be carried out with 10 tonne static roller. The finishing of the surface shall be done by trimming to required level/ slope as per requirement. Rubble shall be laid from edge to crown for road rubble soling and surface rolling also to follow the same pattern to achieve the required camber. Camber board shall be used for the purpose. (b) 1. 2. 3. 4. Brick Soling The bricks shall be laid on edge or flat as specified in the item with suitable interlocking pattern. The bricks shall be placed as close as possible in proper grade and level. Broken bricks shall to be used for closing the line. The joints between the bricks should be properly filled with sand or earth as specified. : Measurement book
Records

GUIDELINES FOR PLASTERING S.No. 1. 2. 3. 4. Description Study drawing, specification and method statement only approved by client. Material which as to be used for plastering work is selected from the customer satisfaction. After deciding the material to be used for plastering, Indent is prepared as per procedure for Site Purchase. The material is received and inspected as per procedure for incoming material Inspection. Based on incoming material inspection report and test report, receive the material; If it is not as per specifications then either accept it with concession for alternate use or reject. 5. 6. 7. 8. 9. 10. Make necessary stock entry and issue the material to site. Evaluate and select Labour sub contractor as per relevant procedure to carry out plastering work. Cleaning the surface of masonry and joints, sprinkle water over the masonry walls and prepare the surface for plastering work at site. Prepare the cement sand mortar with the required proportion of admixture if any. Keep the mortar ready for application. Plaster the inner coat with appropriate thickness as per specification or the instruction from client. Check plastering work for line, level and plumb as per drawings and client required. The same is approved by client. If any defect are noticed then carry out necessary rectification work as per instruction of instruction. 11. Apply the final coat of plaster with appropriate thickness as per specification or the instruction from client. In case of internal plaster apply neeru or gypsum as per requirement or specification. 12. Check the line, level and plumb of plastered surface. If any defect are noticed then carry out necessary rectification work as per instruction of clients. Carry out the curing as per specification or client instruction. clients. Carry out the curing as per specification or client

WORK INSTRUCTIONS FOR PLASTERING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. The type of plaster, number of coats, thickness required and cement mortar proportion shall be as per specifications. Ensure to water the brick wall properly before start of plastering. Ensure that the measurement box is ready for usage prior to start of work shall be done. Deep and close hacking of the R.C.C. surface for purpose of plastering must be done. Chicken mesh at brick wall and R.C.C. member must be provided. Select suitable sand for different types of plasters. Ensure that proper dry mixing of cement and sand is done on impervious platform. Holes provided for scaffolding while executing brick work must be plugged or double scaffolding must be used. Level marking must be done in advance (plaster thiya). Supervise line, level and plumb from time to time before plaster starts setting. All the necessary tools required for execution of work must be available with the mason. Watch the plaster line, level and plumb. Chip off concrete surface before starting plaster and provide suitable groove. Gaps around door and window frames must be filled properly. Check the base coat of plaster prior to application of finishing coat of neeru, sagol or cement. While executing final coat of sand faced plaster or aggregate plaster due care must be taken as to where the joints are to be provided at the end of days work.
Records
Measurement book

WORK INSTRUCTIONS FOR FLOORING
1. 2. 3. Scrapping cleaning and washing of the surface should be done before starting the activity. Panel size and panel layout shall be first frozen on plan. No panel dimension to exceed 20m. Dividing strips of PVC/ Glass/ MS shall be fixed as per the panel layout to correct line and level Top of the strip must match with the required slope and finishing floor level. Strip fixing can be done with mortar at least one day in advance. 4. 5. 6. At the wall and floor junction suitable size of skirting with at least 4 wide floor IPS residue strip to be planned. Casting of the IPS panels shall be done in chequered sequence only, Diagonally opposite inn-Is shall be casted on first day and other panels on next day. Base coarse concrete of given thickness shall be finished rough in first stage. Top 10 to 12mm thick second layer concrete needs a richer mix with zero fines,. (i.e. rich mix as specified with only 6mm aggregate, cement and hardener if recommended. No sand to be used). 7. W/C ratio to be controlled in top layer to achieve manual traveling. Cement slurry and excess water floats on the surface which dried off with continuous traveling within 3 to 4 hours. But in no case dry cement spraying should be allowed. Masons have to continue traveling till surface hardens on its own and top finish is achieved. 8. 9. Masons have to patch up the depressions in the panels, if any, during finishing operation also ensure edges and corners are properly finished. Normal curing by ponding water, sprinkling water is done for 7 days.
TREMIX FLOORING : 1. 2. Initial suitable layout of construction joints and isolation joints shall be decided prior to start of Tremix flooring. The surface of the guide channels (on which the surface vibrator is supported), shall he cleaned for concrete. Align the guide channels to true required level. Panel casting layout shall be strictly followed as per step1. 3. 4. 5. Concrete shall be placed and distributed evenly and as near the final level as possible. Concrete will be vibrated with an immersion vibrator in front of screed vibrator heaping concrete in front of screed vibrator will be avoided. Ensure that the areas close to channels and stop ends are carefully vibrated. Ensure not distribute the concrete with the poker vibrator as it would create a risk of over vibration and segregation.

3. 4. 5. Surface vibration should start as soon as there is enough concrete in front of the screed vibrator. Screed Vibrator is to be pulled from both ends. The filter pads as soon as the sufficient concrete surface is vibrated. Vacuum dewatering process must start within 30 minutes from the time of start of concrete pouring. The filter pads are placed in such a way that there is at least 100 mm 94) fresh concrete visible around the filter pads on all four sides. Filter pads should be overlapped with each other by at least 250 mm (10). 6. Suction pad must be rolled open over the filter pads and dewatering must then start. Extent of dewatering is related in thickness of flower concrete i.e. Average less dewatering not advisable. 7. While repeated dewatering process subsequently, suction pad must be rolled out at least 300 mm over the vacuum dewatered area. Before spreading the suction pad on dewatered area, it is essential to give one pass of skimfloater (with the disc) along the edge of the dewatered concrete. 8. The central pipe of the suction pad shall the suction house which in turn shall be connected to the vacuum pump. When the pump is started, vacuum will be created between the top cover and filter pads. Excess water from the concrete will be taken into the vacuum pump tank and discharged through a pipe away from fresh panel. 9. 10. 11. 12. 13. 14. 15. After Vacuum dewatering, scrapping operation shall be made diagonally in two directions over the concrete surface. The Concrete which is collected during scrapping shall be used for adjusting small surface irregularities of the vacuum treated surface. The first finishing operation shall be done by floating with the skinfloater attached with a disc. The second finishing operation shall be trowelling with skinfloater attached with the troweling blades. Normally, trowelling is to be continued till the smooth surface finish is achieved without floater marks. Curing can be done by ponding, covering with plastic sheet or gunny bags. Curing must be done for at least 7 days. Groove cutting for construction joints or isolation joints shall follow the sequence of tremix flooring without much time lapse. Groove filling can be done with any elastomeric material subsequently. Groove cleaning and drying needs to be ensured. 4 min. per inch thickness OR physical check of dewatered surface which should not give foot print while walking to be seen. Excess/

WORK INSTRUCTIONS FOR FLOORING Polishing Kota Stone flooring (P.K.S.) 1. Polished Kota stone shall be selected from good quarry (source) where stone available is uniform in shade, hard and homogenous in texture, lamination; Stone shall be machine polished at source and of required size and thickness. 2. 3. 4. 5. FARMA shall be true size and right angle (with zero tolerance ) and should be approved by the engineer. Average out the sizes, from the supply and make suitable FARMA. For getting maximum size and for rationalization of sizes to at least 3 FARMAS to be decided jointly with the mason. Hard dressing OR machine cutting of the edges shall be planned as per the requirement hand dressed stones shall be grinded in suitable channel with fine sand paper for obtaining, sharp, straight edges. Initial check shall be done for colour shade by washing the surface in yard itself to be followed by stack the finished stone with at least 3 different mark I/II/HI. While laying due care should be taken to use assorted stones in different seems. By this way color variation shall be adjusted room/area wise. 6. 7. 8. All broken edges/ comer stones to be suitably used. Area shall be scrapped/ cleaned/ washed before starting the mortar bedding, after finalizing flooring pattern. Preparation of mortar to the required proportion is essential. The thiayas shall be made to required level and slope well in advance laying of mortar to suitable thickness keeping reference thiyas in line dori shall be supervised from time to time. 9. Neat cement Paste shall be spread over mortar bedding and around the edges of the stone. Then the stone shall be fixed closed to the previous stone and shall have a hair line joint Stone surface shall be pressed/ tapped gently with the wooden mallets till the stone is in true line and level cement paste at the edges will try to come out from joint which should scrapped off. Again joints shall be filled up with neat cement pate to fill up the gaps and surplus mortar removed suitable color pigment to be used for joint sealing to match with the stone color. 3. 4. 5. 6. (a) Flooring shall continue at least 10mm inside the wall plaster line. Any irregularities ( othas) due to natural bends in stones should be restricted to 2mm at joints. Curing of floor shall be carried out for 7 days by sprinkling water or by wetting. Polishing activity to follow only after adequate curing the sequence of polishing will be as under. 1st cut with rough emery stone 80 No. to polishing m/c. (heavy ) which should even out all irregularities (othas) plus OR minus, Normal cut of 2mm is achieved with this emery. Floor shall be washed and ragada is removed to check the joints. All joints shall be regrouted with cement paste. Setting shall be allowed for atleast 2 days. (b) 2nd and 3rd cut with finer emery stone. 120/120 no. Joint qrouting shall be attended for every cut of polishing; normally 1mm cut is achieved. Surface is fairly in level and without any scratch or chakkar lines of the machining.

Final light coat of polishing shall be done with masala (Oxalic Acid) to achieve the scratchless finished surface. Light polishing coat shall continue till the acceptable result is achieved. Marble / Granite flooring 1. 2. 3. 4. Marble/ granite stone shall be selected fromgood quarry (surface ) where stone available is uniform is shade, hard and homogenous in texture, with less lamination. FARMA shall be true size, right angle with zero tolerance area should be approved by the engineer, Marble/ granite stone slabs are machine cut at the edges for required size. Marble/ granite stone slabs are machine cust at the edges for required size. ( No hand dressing). Initial check for color shade shall be done by washing the surface in yard itself to be followed and stock the finished stone with at least 3 different mark I/II/III. While laying due care should be taken to use assorted stones in difference rooms. By this way color variation is adjusted room/ area wise. 5. 6. All broken edges/ corner stones to be suitably used. Area shall be scrapped/ cleaned/ washed before starting the mortar bedding. The flooring pattern shall be finalized. Preparation of mortar to the required proportion is essential. The thiayas to required level and slope well in advance. 7. Preparation of mortar to the required proportion with min. water is the first step. Make the thiyas to required level and slope well in advance. Laying of mortar to suitable thickness keeping reference thiayas in line dori to be supervised from time to time. 8. Neat cement paste shall be spreaded over mortar bedding and around the edges of the stone. Then the stone shall be fixed close to the previous. Stone shall have a hair line joint. Stone surface shall be pressed tapped gently with the wooden mallets till the stone is in true and level. Cement paste of the edges will try to come out from joints which should be strapped off. Again joint shall be filled up with neat cement paste to fill up the gaps and surplus mortar shall be removed. 9. 10. 11. 12. (a) Flooring to continue at least 10mm inside the wall plaster line. Any other due to natural bends in stones should be restricted to 2mm at joints. Curing of flooring for 7 days by sprinkling water or by wetting. Polishing activity to follow only after adequate curing. The sequence will be as under. 1st cut of rough emery stone 80 No. to polishing m/c. (heavy) which should even out all irregularities (othas) plus OR minus. Normal cut of 2mm is achieved with this emery. Floor shall be washed and ragada shall be removed to check the joints. All joints to be regrouted with cement paste. Setting shall be allowed for at least 2 days. (b) 2nd Mosaic tiles flooring and 3rd cut with finer emery stone. 120/220 no. Joint grouting shall be attended for every cut of polishing, normally 1mm cut is achieved. Surface should now be fairly in level and without any scratch or chakkar lines of the machining.
GUIDELINES FOR TILING AND DADO WORKS

S.No. 1. 2. 3. 4. 5. Description Study drawing, specification and method statement duly approved by client. Selection of material to be used depends on requirements. Indent for the same. Receive material at site Check material with specifications. Follow incoming material inspection procedure. Testing of material. Review of non-conforming products as per NC review procedure. Look for possible reworking to meet specified requirements. Materials not fulfilling any of these requirements to be rejected. 6. 7. 8. 9. 10. 11. 12. Take stock and issue to site. Mark the locations for Electrical Conduits, Junction boxes, Pipes etc. Mix mortar in the required proportion as per specifications. Spread in specified thickness. Refer the approved tiling pattern and start laying and jointing of tiles. Check work, review and rectify, if required. Continue curing Proceed with cleaning of joints and polishing of the surfaces.

WORK INSTRUCTIONS FOR TILING AND DADO WORKS Mosaic Tiles Flooring 1. 2. 3. Mosaic tiles are factory made, hydraulically pressed, hence laying of tiles in any pattern starts immediately after mortar bedding is ready to receive tiles. Selection/ approval of the tile sample is the pre require, Normally tile size, thickness, colour and chip size are the parameters for selection. Reliable vendor manufacturer only to be ordered who can guarantee the final result as per the sample approved. 4. 5. Area must be scrapped/ cleaned/ washed before starting the mortar bedding, conclude the flooring pattern. Preparation of mortar shall be as per the required proportion. The thiayas shall be made to required level and slope well in advance. Laying of mortar to suitable thickness keeping reference thiyas in line dori to be supervised from time to time. 6. 7. 8. 9. (a) Flooring to continue at least 10 mm inside the wall plaster line. Any other undulations due to natural bends in stones should be restricted to 2mm at joints. Curing of flooring for 7 days by sprinkling water or by wetting. Polishing activity to follow only after adequate curing. Sequence of polishing will remain same as for marble granite flooring: 1st cut of rough emery stone 80 No. to polishing m/c (heavy) which should even out all irregularities (othas) plus or minus. Normal cut of 2mm is achieved with this emery. Floor is washed and ragada is removed to check the joints. All joints to be regrouted with cement paste. Allow to sq for at least 2 days. (b) 2nd and 3rd cut with finer emery stone. 120/220 no. Joint qrouting to be attended for every cut of polishing. Normally 1mm cut is achieved. Now surface is fairly in level and without any scratch or chakkar lines of the machining. (c) Final light coat of polishing to be done with masala (Oxalic Acid) to get the scratch less finished surface, (no waxing to be done for shining). Light polishing coat can continue till the acceptable result is achieved.

WORK INSTRUCTIONS FOR TILING AND DADO WORKS Ceramic/ Glazed/ Granite tiles 1. 2. 3. 4. 5. 6. 7. Plaster must be true line, level plumb and right angle. Roughening plaster must be carried out. Line marking shall be done on plastered surface as per the given pattern, if requires skill for adjustment of residues. These tiles can be fixed in dado/ floor which do not need any polishing. All concealed works have to be completed and tested before starting the tile work. Tiles shall be fixed with neat cement paste and fixed with wooden mallate in such a way that cement paste in uniformly spread on the back of the tile. At the end of the days work, all joints are to be sealed with suitable coloured/ white cement neatly and excess paste is to be wiped off. Right angle corners needs tani joint very skillfully done to give straight edge. Tile cutting, grinding requires a special tool. Ensure that the tools are in good condition before use. Curing is required for few days.

GUIDELINES FOR FIXING OF DOORS & WINDOWS S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Description Study drawing, specification and method statement duly approved by client. Material which has to be used for fixing of doors and windows work is selected from the customer specifications and the quantities are worked out. After deciding the material to be used for fixing of doors and windows. Indent is prepared as per the Procedure for site Purchase. The material is received and inspected as per procedure for incoming material inspection. Based on incoming material inspection report and test report, receive the material. If it is not as per specifications then either accept it with concession for alternate use or reject. If the material is as per specifications, then make stock entry and issue to stores. Evaluation and select Labour sub contractor as per relevant procedure to carry out fixing of doors and windows work. Issue the approved material for use to site. The doors and windows are fixed firmly into the masonry openings. Seal the joint with the appropriate material. Check fixing of doors and windows work for line, level and plumb as per drawings and clients requirements. The same is approved by client, do the cleaning of doors and windows to remove mortar stains and curing and raking of joints. If not approved then carry out necessary rectification work as per instruction of clients. 11. Carry out the curing of joints, painting of doors and windows, fixing glazing and keep ready for final checking by clients. Any rectification suggested by clients shall be attended to.

WORK INSTRUCTIONS FOR DOORS / WINDOWS DOORS/ WINDOWS (WOODEN) 1. 2. 3. 4. 5. 6. 7, 8. 9. 10. Ensure that woods used for the works is as per quality specified. BOQ of wood sizes should give adequate allowance for cutting and smoothening. BOQ needs to be double checked with carpenters before ordering. Only approved fixtures to be used. Check whether verticals of doors frames are minimum 50mm below finished floor level. With bottom spacer patti fixed, surface of window/ door frame coming in contact with brick work/ concrete needs to be painted with the material specified before fixing of the frame. The frame hold fast must be grouted with cement mortar rigidly. Ensure that the glass is free from waves, bubbles and other defects. Check the thickness of glass before fixing. Check that doors/ windows frames are erected in plumb, line, level and diagonals. Ensure that the work of painting/ oiling is started after approval of completed wood work. Glazing must be fixed with out play with suitable wooden beading.
Doors/ windows (Steel) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Suitable standard rolled sections or sheet metal to be used as specified. Dimensions of doors/ windows must be as per drawings and checked by the engineers before ordering. Sample needs to be checked. Only approved fixtures must be used. Ensure that the slots for tower bolts, locks are as per drawings and specifications. Check whether vertical of doors frames are minimum 50mm below finished floor level with a bracing tie to be embedded in the floor. Surface of window/ door coming in contact with brick work must be painted with the material specified. The frames hold fast must be grouted with cement mortar rigidly. The corner joints of frames must be free from welding clots. Ensure that the glass is free from waves, and other defects. Check the thickness of the glass before fixing. Check that doors/ windows frames are erection in plumb, line, level and diagonals. Ensure that the work of painting/ oiling is started after approval. Glazing must be fixed without play with suitable beading.

WORK INSTRUCTIONS FOR DOORS/ WINDOWS Doors /Windows (Aluminum ) 1. Aluminum section shall be as per the sectional drawings provided or as specified in the items. Each member of the D/W shall be well defined for its size, shape, weight per metre, profile and finish surface. 2. 3. 4. Fabricator shall get fabrication drawings before starting the work. Aluminum section shall be defined for manufacturers like, Indal, Jindal, Hindalco or equivalent. Aluminium sections to be used for fabrication shall be well defined for anodizing (Matt finish or Glossy finish), natural or colour anodizing, section with powder coating in different colour etc. 5. 6. 7. Aluminum doors and windows shall be specified for panel material like Glass / Laminated board. / Box type aluminum lamination etc. Only approved hardware fixtures shall be used as per the specification and tender items. Finished opening sizes should match perfectly with prefabricated D/W sizes. To ensure about the exact dimensions, make up sample or templates (either from wood material or M.S. material) shall be used. 8. 9. 10. 11. In case, dimensions dont match with the material supplied, opening shall be rectified. Arrangements for all approved hardware fittings as per the drawing shall be ensured before fixing of the material.\ Glazing shall be fixed to the extruded sections by means of extruded aluminum beading. Glass panes shall be provided with rubber lining before fixing. The aluminium frames shall be fixed to the masonry by means of aluminium lugs fixed to the frame (by counter sunk galvanized machine screws) and the hole/ pocket will be grouted with M-15 grade concrete as per drawings. In case of concrete wall, the frames shall be fixed by 96mm long, 12mm dia metallic fasteners. Any steel material coming in contact with aluminium shall be galvanized. 12, 13. The windows/ ventilators/ doors shall be checked to ensure smooth operation, perfect level and plumb. All aluminium D/W section should have protective film or coating. This film or coating can be removed only at the time of handing over (on completion of all civil work including painting.).

WORK INSTRUCTIONS FOR DOORS / WINDOWS ROLLING SHUTTER 1. Check that the dimensions and gauge of the material. Used for the shutter are as per drawings. Normally shutter gauge rails gauge, hood gauge needs to be specified. Only approved vendor to supply for maintenance of free service. 2. 3. 4. 5. Check whether the welding done is perfect and junctions are properly grooved. Ensure that inserts, bolts, fixtures, fastening fittings are fixed in them position accurately and in alignment. Painting must be done by quality paint and number of coats should be as specified . Before placing and indent for procurement check the following : a) b) c) d) e) f) Brick work opening size. Minimum 9 brick columns on both sides. Rolling shutter is to be fixed from inside or outside. Gear operation system for more than 10m2 size. Top shaft fittings eg. Springs, bearings, bush, gear warm Adequate clearance above lintel for fixing top shaft and hood cover.

CHECK LIST FOR FIXING DOORS & WINDOWS SITE :
Ref. Drwg. No. YES 2. 3. 4. 5. A B D E G H 6. 7 8. Check for PLUMB for the Windows Frame with reference to Masonry opening. Check for FASTENING OF WINDOW FRAMES to walls by screws, Check for DIMENSIONS of Jambs & Reveals Check for the Provision & proper FUNCTIONING of the following. HINGES PEG STAYS OTHERS FINAL CHECK for PAINT, SURFACE FINISH, GLAZING EPDM RUBBER GASKETS OTHERS ( PLEASE SPECIFY) FINAL CHECK for PAINT,SURFACE FINISH, GLAZING Check for overall SATISFACTORY FUNCTIONING of windows Check for Removal of Protective coating & CLEANING of the Aluminium Window before Handing over. NO NA
LOCATION :
DATE
CORRECTIVE ACTION PROPOSED
SIGN. OF SITE ENGINEER

GUIDELINES FOR PAINTING S. No. 1. 2. 3. 4. 5. Description Study drawing, specification and method statement duly approved by client. (Method statement to include manufactures instructions and contract specifications. Material which has to be used for Painting work is selected from the customer specification. After deciding the material to be used for Painting, Indent is prepared as per Procedure for Site Purchase. The material is received and inspected as per procedure for incoming material inspection. Based on incoming material inspection report and approved shade etc. receive the material, If it is not as per specifications then either accept it with concession for alternate use or reject. 6. 7. 8. 9. 10. 11. 12. If the material is as per specification, then make stock entry and issue to stores. Evaluation and select Labour sub contractor as per relevant procedure to carry out painting work. Clean area and make the preparatory arrangements for Painting work at site. Check the surface predatory arrangements. If not O.K. rectify it. Supply the primary coat and carry out painting as per the Method Statement. Carry out Joint Inspection by SPCL and clients. Any suggestion made by client shall be incorporated or rectified to clients satisfaction. Clean the area where the work is carried out.

WORK INSTRUCTIONS FOR PAINTING White Wash 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. The wall to be painted must be thoroughly scrapped with sand paper. The first coat of white wash is to be done within 7 days of plaster. The slaked lime must be screened through coarse cloth and the adhesive must be added as specified. Lime must be soaked for 24 hours in advance. Application by spray, brush, coirbrush to be decided in advance. Lime coat must be applied with a brush and the desired sequence must be as under: One stroke of brush from downwards and another from bottom upwards over the first. Similarly one stroke from right and other from the left over the first before the first dries. Brush application needs criss-cross painting to avoid brush marks. Machines, doors, windows, floors etc. shall be covered from being splashed upon. The cracks and holes are required to be filled with proper adhesive after the first coat. Small quantity of ultra marine is to be added in last two coats of white wash. Three coats are to be applied over the plastered surface. Subsequent white wash is to be applied only after the preceding coat has become sufficiently dry. Colour Washing 1. 2. 3. 4. 5. 6. Follow steps 1 to 11 as white wash. The wash shall be prepared by adding required quantity of colour pigment to the lime wash prepared under the head white wash. The mineral colours not affected by lime shall be added to white wash. The colour wash shall be done after preparation of a sample of colour wash. The surface to be colour washed shall be first treated with a priming coat of white wash. Minimum two to three coats of colour shall be applied to attain uniform shade over the whole surface.

WORK INSTRUCTIONS FOR PAINTING CEMENT PAINT : 1. 2. 3. Get the cement paint and shade approved. The surface should be thoroughly cleaned and all loose materials be removed. The surface should be watered thoroughly and should be allowed to drain off before starting the cement painting Application is by brush in criss cross direction till uniform colour shade is obtained. 4. 5. 6. The second coat shall be started after 24 hours of the first coat. The entire surface shall be moist cured for seven days. Grey and Blue pigment tend to fade off, so discuss with customer and clarify.
SANDTEX PAINT 1. 2. 3. 4. 5. Get the sand tax paint and shade approved. Follow the points 2,3,4 of cement paint as mentioned above. Apply primer coat recommended by manufacturer. 2nd and 3rd coat of tax is applied over 1st coat which does not require moist curing. These paints are more durable, non-fading, thicker coating, greater opacity high degree of flexibility and strong adhesive properties. Hence more suitable for intermixing of shades is possible to obtain intermediate shades. PREMEABLE FOR DECORATIVE PAINTS Preparation of surface : 1. 2. 3. 4. The plastered surface shall be thoroughly cleaned with a brush to remove dust, dirt, grease, mortal-dropping and other foreign matter and sand subsequently smooth with sand paper. New Plaster surface shall be allowed to dry for at least four motnhs bfore application of distemper or one coat of white wash with white cement shal be done prior to painting. All unnecessary nails, hooks etc. shall be removed. Pitting in plaster shall be made good with plaster again and papered with a fine grade sand paper and made smooth. A coat of paint shall be applied over the patches. The surface shall be allowed to dry thoroughly before the regular paint is applied. The surface affected by moulds, moss, fungi, algae lichens, efflorescence etc. shall be treated. 5. A priming coat of cement primer of approved manufacture shall be applied over the plaster surface in case of new work.

6. The primer shall be applied with a brush on the clean, dry and smooth surface. Horizontal strokes shall be given first and vertical strokes shall be applied immediately afterwards. This entire operation will constitute one coat. 7. A coat of putty (lapi) shall be applied to the entire surface. Putty shall be prepared by mixing whiting chalk, primer/ paint in required proportion as directed by the Engineer-in-charge and Architect. The second coat of primer and putty shall then be applied and it shall thereafter be allowed to dry for at least 48 hours. Fine sand papering is required for both lapi coats. 8. Painting is not recommended to be applied within four months of the plastered surface. Any moisture in plaster will create problem of pealing off or swelling. Due cautioning to be given to clients/ consultant it they insist on painting to start during initial four months of drying. Fine sand papering is required for both lapi coats. Oil bound distemper/ Water bound distemper/ Acrylic bound distemper : Application : 1. The distemper shall be diluted with mineral turpentine oil or any other prescribed thinner in manner recommended by the manufacturer only, sufficient quantity of distemper for days work shall be prepared. 2. On any surfaces, after the primer coat has dried for at least 48 hours, the surface shall be lightly sand papered to make it smooth for receiving the distemper, taking care not to rub out the priming coat. 3. All loose particles shall be dusted off after rubbing. Minimum two coats of distemper shall be applied with brushes in horizontal strokes followed immediately by vertical strokes which together shall constitute one coat. The subsequent coats shall be applied after a time interval of at least 24 hours between 2 consecutive coats to allow proper drying of the preceding coat. The finished surface shall be even and uniform without patches, brush marks, distemper drop etc. 4. Sufficient quantity of distemper shall be mixed to finish one room at a time. The application of a coat in each room shall be finished in one operation and no work shall be started in any room which cannot be completed on the same day. 5. 15 cm. double bristled distemper brush shall be used. After a days work, brushes shall be thoroughly washed in hot water soap solution and hung down to dry. Old brushes which are dirty and caked with distemper shall not be used on the work.

Protective measure : The surface of doors, windows, ventilators, articles of furniture and machines etc. and such other part of the buildings which are not to be distempered shall be protected from being splashed upon. On completion surfaces shall be cleaned of distemper splashes, if any. Plastic Emulsion Paint Application: 1. Before pouring into small containers for applying, the paint shall be stirred thoroughly in its container. Also, the paint shall be continuously stirred in the smaller container, so that its consistency is kept uniform. 2. The paint shall be laid on every and smoothly by means of crossing and laying off. The crossing and laying off consists of covering the areas over with paint, brushing the surface for the first time, then brushing alternately in opposite directions two or three times and then finally brushing lightly in direction at right angles to the same. In this process, no brush marks shall be left after the laying off is finished. The full process of crossing and laying of will constitute one coat. No hair marks, from the brush or clogging of paint puddles in the corners of panels, angles of molding etc. shall be left on the work. 3. The paint shall be applied with brush for first two coats and final finishing shall be done with roller. Precautions: 1. Old brushes, if they are to be used with emulsions paints, shall be completely dried to turpentine or oil paint by washing in warm soap water. Brushes shall be quickly washed in water immediately after use and shall be kept immersed in water during break periods to prevent the paint from hardening on the brush. 2. 3, 4. In the preparation of walls for plastic emulsion painting, no oil base putties shall be used in filling cracks, holes etc. Splashes on floors etc. shall be cleaned without delay as will be difficult to remove after hardening. Washing of surfaces treated with emulsion paint shall not be done with 3 to 4 weeks of application.

Enamel Paint Glossy, Flat, Pearl luster and Matt as desired application : 1. Brushing operation is to be adjusted to the spreading capacity advised by the manufacturer of particular paint., The paint shall be applied evenly and smoothly by means of crossing and laying off. The crossing and laying off consists of covering the areas over with paint, brushing the surface hard for the first time, then brushing alternately in opposite directions two or three times, and then finally brushing lightly in direction at right angles to the same. In this process, no brush marks shall be left after the laying off is finished. The full process of crossing and laying off will constitute one coal. 2. Each coat shall be allowed to dry completely and lightly rubbed with very fine grade of sand paper and loose particles shall be brushed off before next coat is applied. Each coat shall vary slightly in shade and shall be approved from Architect and Engineer-in-charge before next coat is started. 3. Each coat all be lightly rubbed down with sand paper of fine pumice stone and cleaned of dust before the next coat is applied. No hair marks from the brush of clogging of paint, puddles in the corners of panels angles of mouldings etc. shall be left on the work. 4. Special are shall be taken while painting over bolts, nuts, rivets, overlaps etc.
Precautions: 1. 2. 3. In the preparation of walls for enamel painting, no oil base putties shall be used in filling cracks, holes etc. Splashed on floors etc. shall be cleaned out without delay. The surface of doors, windows, ventilators, articles, of furniture and machines etc. and such other part of the buildings which are not be painted shall be protected from time being splashed upon. On completion surfaces shall be cleaned of distemper splashes, if any. 4. Washing of surfaces treated with enamel paint shall not be done within 3 to 4 weeks after application.

CHECKLIST FOR AFTER BUILDING FINISHING
SL. NO. _________________ SITE : LOCATION : DATE
Ref. Drwg. No. _____________________________________________________________________ YES 1. 2. 3. 4. 5. 6. Check for the internal painting of wall, window, doors, ventilators, ceiling etc. Check for external painting? Check for proper working of door, window, ventilators, etc. including looks, latch, tower bolts, stays handle stoppers etc. Check for floor finishing slope, cleanliness etc. Check for the water supply and sanitary fittings? Check for the satisfactory working of Electrical items ? NO NA
SIGN OF QCE. AFTER RECHECKING SIGNATURE OF SITE ENGINEER

CHECKLIST FOR AFTER BUILDING FINISHING
Ref. Drwg. No. _____________________________________________________________________ YES 1. 2. 3. 4. 5. 6. Check for finishing levels as per drawing and certified from consultant/ clients? Check for final Dimensions as per drawing and certified from consultant/ client? Check road marking done as per requirements? Check for sing boards located as per drawings ? Check for commissioning of Electrical works such as street light. Signal light etc. Check whether the Engineer satisfied with all works? NO NA

CHECKLIST FOR FINISHING PIPELINE WORK
Ref. Drwg. No. _____________________________________________________________________ YES 1. 2. 3. 4. 5. 6. 7. 8. 9. Check whether pipe joints properly done? Check whether the top level of the pipe in within the tolerance as specified in drawings? Check the interior pipeline property cleaned? Check whether pressure tests completed? Any defects found white testing? Check whether the back filling material got approval Levels has checked by the engineer incharge? Checks whether engineer given permission for backfilling? Check the filling has been done with proper compaction ? NO NA

CHECKLIST FOR FINISHED PUMPING STATION WORK
Ref. Drwg. No. _____________________________________________________________________ YES 1. 2. 3. 4. 5. 6. 7. 8. 9. Check whether all invert levels checked by Engineer-in-charge Check all interconnecting pipe line connected property? Check necessary protection erosion / corrosion is take? Check all water retaining structures hydraulically tested? Check electrical installation as per single line diagram? Check electrical installation as per standard electricity rule? Check all electrical system is covered with earthing system? Check whether all Mechanical Equipments have been tested for zero, 50% load & full load? Check entire mech/ elect installations has been carried out as per the manufacturer installation manual? NO NA

CHECKLIST FOR FINISHED PUMPING STATION WORK
Ref. Drwg. No. _____________________________________________________________________ YES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Check whether all invert levels checked by Engineer-in-charge Check whether the material for filter media got approved ? Check all interconnecting pipe line connected property? Check necessary protection erosion/ corrosion is take? Check all water retaining structures hydraulically tested? Check water levels throughout the system as per hydraulic flow diagram? Check electrical installation as per single line diagram? Check electrical installation as per standard electricity rule? Check all electrical system is covered with earthing system? Check all building elevation as per dwg. & with in factory inspection limits? Check whether all Mechanical Equipments have been tested for zero. 50% load & full load? Check entire mech/ elect installations has been carried out as per the manufacturer installation manual? NO NA
SIGNATURE OF ENGINEER

CHECKLIST FOR FINISHED STP WORK
Ref. Drwg. No. _____________________________________________________________________ YES 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Check whether all invert levels checked by Engineer-in-charge Check whether the material for filter media got approved ? Check all interconnecting pipe line connected property? Check necessary protection erosion/ corrosion is take? Check all water retaining structures hydraulically tested? Check water levels throughout the system as per hydraulic flow diagram? Check electrical installation as per single line diagram? Check electrical installation as per standard electricity rule? Check all electrical system is covered with earthing system? Check all building elevation as per dwg. & with in factory inspection limits? Check whether all Mechanical Equipments have been tested for zero. 50% load & full load? Check entire mech/ elect installations has been carried out as per the manufacturer installation manual? NO NA

CONCRETE POUR CARD DATE : DRAWING No: STRUCTURE : LOCATION:
FORM WORK CHECKED (ALIGNMENT/ ELEVATION) REINFORCEMENT CHECKED ( Dia / SPACING ) ELECTRIC / FIRE PROTECTION CONDUITS CHECKED OTHER INSERTS REQUIRED? 1 TOTAL VOLUME OF CONCRETE 2 SOURCE OF CONCRETE 3 GRADE OF CONCRETE 4 CEMENT CONTENT AS PER MIX DESIGN 5 W/C RATIO AS PER APPROVED MIX DESIGN 6 NUMBER OF CUBES TAKEN: 7 SLUMP TEST: mm 8 REMARKS:
PREAPERED BY GECPL
CHECKED BY CIDCO Drawing Register
S. No.
Drwg. No.
Title
Received from SNG
Send to SNG
Send to OPT
Received from OPT
Approval Remark
Issued for Execution
Sig Ag
Re

CONCRETING MIX DESIGN I) 1. 2. 3. 4. 5. 6. CONTRACT REQUIREMENT Location of the pour Characteristic strength Standard deviation (SD) (REF, Form : : : :
QC-1) Margin = 1.65 x SD : Target near strength (=Characteristic : strength + Margin) Cement a) Type b) Make Aggregate type a) Coarse b) Fine :
7.
: Crushed / Shingles River sand / Crushed

8. 9. 10. 11. II) 1. Maximum aggregate size Maximum free W/C ratio Maximum cement content Maximum cement content Ref. Form No. QC-1 TEST DATA FOR MATERIALS Cement a) Setting time b) Compressive strength (kg. / cm2) : : : : : Initial ____________________ min. Final _____________________ min. ___________________________________ 3 days (i) As per manufacturers certificate 2. (ii) As per field test Bulk density Coarse aggregate 3. Fine aggregate Specified gravity Coarse aggregate Fine aggregate ____________ ____________ 7 days ___________ ___________ Kg. / m3 Kg. / m3 ___________________________________ ___________________________________ Kg. / m3 Kg. / m3
A)
Course aggregate Graded 40 mm / 20 mm / 12.5 mm PERCENT PASSING THROUGH I.S. SIEVE SIZES 40 mm 20 mm 12.5 mm 10 mm
63 mm
4.75 mm
B)
Fine aggregate Sand / Quarry dust PERCENT PASSING THOUGHT I.S. SIEVE SIZES 4.75 mm 2.36 mm 1.18 mm 600/u 300/u 150/u ZONE
10 mm

III. 1. 2. 3. 4. Details of Mix : Free Water / Cement ratio Aggregate / Cement ration Course/Fine aggregate ratio Quantities required for concrete mix Cement Coarse aggregate Fine aggregate Water : : : : : : : :
Kg. Kg. Kg. Lt.
NOTE: All aggregates should be prepared so as to be surface bry while used for ratio mix.

RECORDS OF CELEBRATORS OF CUBE TESTING MACHINE
Description of the machine
Date of calibration
Date of new Calibration
Agency
Remarks
Sign
GECPL
CIDCO

AGGREGATE SIEVE ANALYSIS REPORT Coarse aggregate : Graded 40 mm / 20 mm / 12.5 mm Source of supply: _______________ weight of Sample : _______________________Kg. IS Sieve size 63 mm 40 mm 20 mm 12.5 mm 10 mm 4.25 mm -10 35 0-5 -35 35 0-10 100 40 85 0-10 Weight (kg) Cumulative % retained (kg) 100 95 100 30 70 --100 -95 100 ----100 -90 % % Passing as per IS 383 40 mm 20 mm 12.5 mm Remarks
retained weight
Retaining Passing

FINE AGGREGATE SIEVE ANALYSIS Fine aggregate Source of Supply : _____________________ Weight of Sample: __________________ Kg. Is sieve size 10 mm 4.75 mm 2.36 mm 1.18 mm 600 u 300 u 150 u 70 15 34 5 20 0 10 90 35 59 8 30 0 10 100 60 79 12 40 0 10 100 80 100 15 50 0 15 95 30 100 55 100 75 100 90 100 60 100 75 100 85 100 95 Weight (gms) Cumulative % (gms) % g I 100 90 II 100 90 III 100 90 IV 100 95 Passing for zone Remarks
retained retaining
Retaining Passin

Compressive Strength Report

Date RMC Docket No No. of samples taken: 7 days test Date: ID Mark: _______________________________ __________________________________________________________________ : ----------------Nos 28 days test: ------------Nos Date: : ___________ : _____________ Grade of Concrete: M -
Sr.No
Date of Casting
Age ( Days)
Size of cube (MM)
Weight ( Kg)
Crushing Load ( KN)
Compressive Strength N/MM2
Average Strength N/MM2
1 2 3 4 5 6 7
GECPL
CIDCO

SAMPLING AND TESTING CONCRETE IN THE FIELD Sampling and Testing of Concrete shall conform to IS : 456 2000 a) Facilities required for sampling materials and concrete including The following equipment with operator will be made whether proof buildings to house the facilities in the field, will be provided by the GECPL at no extra cost. i) available in serviceable conditions. Concrete cube-testing machine suitable for 15 cm cubes of 100 tones capacity with providing calibration ii) iii) iv) v) vi) vii) ring Cast iron cube moulds 15 cm size Slump cone complete with temping rod BIS sieves for coarse and fine aggregates Flakiness gauge Calibrated glass jar 1.0 liter capacity Laboratory balance of 2 kg capacity and sensitivity of 1 gm. 1 no. 6 nos. (min) 1 set. 1 set 1 no. 2 nos. 1 no.
b)
At least 6 test cube of each class of concrete shall be made of every
50 cum concrete or part thereof or form different batches as directed by Engineer-incharge. Such samples shall be drawn on each day for each type of concrete. Of each set to 6 cubes, three shall be tested at 7 days age and three at 28 days age. The cubes must be casted from various batches to arrive at an average strength. The laboratory test results shall be tabulated and furnished to the Engineer. The Engineer will pass the concrete if average strength of the specimens tested is not less than the strength specified, subject to the condition that only one out of three consecutive testes may give a value less than the specified strength but this shall not be less than 90% of the specified strength. c) Consistency: Slump tests shall be carried out as often as requested
by the Engineer and invariably from the same batch of concrete from which the test cubes are made. Slump tests shall be done immediately after sampling.

Name of work: Designing, Constructing, Erecting and commissioning of average 30 MLD Capacity Sewage Treatment Plant including Operation & Maintenance for 5 years at Sector 14 & 15, Ghansoli, Navi Mumbai. BAR BENDING SCHEDULE Sr. No. Item Shape of the bar Bar Marked Dai of the Bar Cutting (M)
length Nos.
GECPL CIDCO
113

TITLE : WORK INSTRUCTION FOR WATERPROOFING
1.0
2.0
SCOPE: This work instruction covers activities involved in waterproofing of terrace & toilets. PROCEDURE A) Terrace I) 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Cement based waterproofing treatment. The details of waterproofing treatment shall be studied as mentioned in specifications. Terrace shall be cleaned & all loose material shall be removed. Cement grouting shall be carried out wherever necessary. Cement grouting is not required for terraces having Siporex Roof slabs. Water spout bends for down take of rain water shall be fixed in the wall at required location & level. The internal plaster of parapet, stub columns, water tanks, machine room, etc. shall be completed before terrace water proofing is taken in hand. Required quantity of brickbat/bricks shall be stacked near location of work & same shall be soaked. Waterproofing treatment along with proper covering shall be done on the junction of the walls & roof floor, stub columns& roof floor, water tank columns& roof floor. Water tank columns shall be treated up to the height as shown in the drawing. Plastered surface shall project over the water proofing surface. The brickbat shall be laid as per the standard practice to the required slope, so that proper ridge portions are formed. The smooth cement plaster shall be done along with water proofing compound or tiles shall be laid as specified. Proper slope shall be mentioned, so that water is collected towards rain water downtake bends.
2.8 2.9 2.10
114

TITLE : WORK INSTRUCTION FOR WATERPROOFING
2.11 2.12
Curing shall be carried out for 7 days. Testing of proofing treatment shall be done with ponding the water for minimum 7 days. If any leakage or dampness is observed the same shall be rectified. China mosaic flooring shall be provided on terrace. B) Bathroom & toilet water proofing.
4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21 4.22 4.23 4.24
The surface shall be cleaned by removing all loose materials. Pressure grouting shall be carried out wherever necessary & specified. Nahani trap, P/S traps shall be fixed at required level. Proper & tight sealing of joints between trap & the pipe as well as between outlet pipe & wall shall be ensured. the first coat of plaster shall be done 300mm above the wall so as to ensure that no leakage occurs through joint between wall & toilet slab. 12 to 20 mm size metal shall be embedded in the first coat. Water shall be filled for minimum 2 days & leakages observed if any, shall be rectified immediately. Brickbat coba shall be filled up with waterproofing compound to required height. A piece of G.I. pipe (min. 15 mm dia.) shall be provided with one end in the brick bat coba & the other end open to the atmosphere, where required. Final layer shall be laid with concrete or mortar layer with water proofing compound. waterproofing plaster on the walls shall be completed simultaneously to avoid separation. Testing of waterproofing treatment shall be carried out by ponding water for 7 days. If any leakage or dampness or observed, the same shall be rectified immediately. Bathroom & toilet waterproofing treatment shall be recorded in checklist for bathroom & toilet waterproofing QC -02-12. C) Other water retaining structures. Waterproofing of other water retaining structures like underground water tank, overhead water tank, lift pits, basement etc. shall be done as per the steps mentioned from cl.4.1 to 4.10 as applicable or as specified.
115

TITLE : WORK INSTRUCTION FOR INTERNAL SANITARY AND PLUMBING SERVICES 0.1 2.0 SCOPE: RESPONSIBILITY : This work instruction covers activities involved in internal sanitary and plumbing services. PM is responsible for review, establish and maintain this work instruction, PM/Site in charge shall be responsible for ensuring that this Work instruction is effectively implemented by Engineers/Supervisors.
4.0 4.1
PROCEDURE A) Sanitary The approved design and layout of sanitary scheme shall be prepared and got approved from CIDCO. Approved drawing shall be studied carefully & shop drawings if required are prepared, prior to starting actual work. The sample flat shall be prepared as per the approved drawing. If any changes are required as per site conditions, the same shall be incorporated in the drawing immediately. The required materials as per the approved sample shall be made available before start of work, as far as possible. Sleeves for the outlet provided in the precast units and RCC wall shall be rechecked. P/S Nahani trap shall be fixed as per location and level shown in the drawing. Nahani trap shall have long neck to avoid joints in the wall. The joints shall be properly sealed with cement / fiber reinforced solvent cement/cement mixed with epoxy mortar, as specified and tested before they are concealed in coba or dado. Water test / smoke test shall be carried out to ensure perfects joints. The outlets from bathroom and WC of all the floors shall be exactly in line and plumb to have proper alingnment of drainage line. P/S/ Nahani trap shall be temporarily closed with cotton waste while work is in progress to avoid blockage due to mortar or concrete going inside. The pipes shall be fixed firmly on the wall at collar position by providing clamps of appropriate size and material, wherever required.
4.2
4.3 4.4 4.5 4.6
4.7 4.8 4.9
116

TITLE : WORK INSTRUCTION FOR INTERNAL SANITARY AND PLUMBING SERVICES
4.10 4.11 4.12 4.13
Smoke test shall be carried out for vertical stacks (refer Appendix A- smoke test for soil/ waste water pipes ) before fixing WC Pans. W.C. pans and other ceramic fixtures shall be fixed preferably after entrance and balcony door shutters are fixed with locking arrangements to avoid thefts / breakages. The joints between pan and P/S/ Nahani trap shall be sealed properly. Necessary G.I. / PVC drainage spouts shall be provided just above the sunken slab in W.C. / bath area. B) Plumbing Water supply pipeline diagram shall be prepared and got approved from CIDCO. The availability of required material of approved specifications shall be checked before starting the work. G.I. Pipes shall be fixed in plumb. mechanical cutter. Pipes shall be concealed by chasing wall with
4.14 4.15 4.16 4.17 4.18 4.19 4.20
The openings around the GI Pipes shall be sealed properly to match with the external plaster / internal plaster and such joints shall be cured adequately. G.I. Pipe network shall be tested by hydraulic test as per the requirements. In case of concealed G.I. Lines, proper protection with bitumen & hessain cloth to be ensured to avoid rusting. Fixtures like bib cock, mixers etc. shall be fixed only after door shutter are fixed with locking arrangements to avoid thefts/ damages. Inserts for inlet, outlet and overflow pipes for underground / overhead tanks shall be fixed at the desired location as per required sizes before concreting of under ground / Overhead tanks.
117

TITLE : WORK INSTRUCTION FOR INFRASTRUCTURAL SERVICES. 1.0 SCOPE : This work instruction covers activities involved in infrastructural services like water supply, sewerage, storm water drain, compound wall, roads, fire fighting system, external electrification and common services. 2.0 RESPONSIBILITIES: Project Manager / Site Incharge shall be responsible for ensuring that this work instruction is effectively implemented by engineers / supervisors. 3.0 Procedure A) Water Supply
3.1
The approved water mains layout/pumping main layout shall be studied in detail. The designed and layout shall be prepared and got approved from CIDCO. 3.2 Requirement of materials like C.I. (LA/A/B class) / G.I. (C Class) pipes and fittings, pumps, lead for jointing etc. shall be worked out and the required materials for the work in hand shall b made available before start of work. 3.3 Agency carrying out the work shall be selected on the basis of their past performance experience and technical knowledge. 3.4 The detail programme of work prepared should commensurate with the overall programme. 3.5 Line out: The detail line out shall be carried out as per the layout plan. The width of trench shall be decided considering the working space required for laying water line.
118

TITLE: WORK INSTRUCTION FOR INFRASTRUCTUREAL SERVICES 3.6 Excavation : The excavation shall be carried out manually or with the help of machine like JCB etc. upto the required depth. 3.7 The bed shall be prepared by cleaning trench bottom and compacting by hand compactor. Sand bed of required thickness shall be provided, if specified. 3.8 The fittings shall be placed in position. The alignment and level of the line shall be ensure and then jointing by lead / Rubber tighten joint, as required shall be done. Necessary supports shall be provided at the appropriate points 3.9 The hydraulic testing shall be carried out at 1.5 times working pressure by hydraulic pump for particular portion of pipeline. Necessary test reports shall be obtained. 3.10 After satisfactory testing, back filling shall be carried out along with the compaction in layers. 3.11 3.12 Water supply work shall be recorded in checklist for water supply (QC-02-13) The detail measurements shall be recorded for each activity, where applicable. B) Sewerage 3.13 Sewerage design and layout shall be prepared and got approved from CIDCO. Sewerage layout shall be studied in detail, including invert levels, drops, top levels of chamber. 3.14 Requirement of materials like fittings, RCC pipes of required class bricks etc. shall be worked out and the required materials for the work in hand shall be available before start of work.
119

TITLE: WORK INSTRUCTION FOR INFRASTRUCTUREAL SERVICES
3.15
Agency carrying out the work shall be selected on the basis of their pst performance, experience and technical knowledge.
3.16
Line out : The detail line out shall be carried out as per the layout plan. The width of the trench shall be decided considering the working space required for laying sewerage line.
3.17
Excavation: The excavation shall be carried out manually or with the help of machine like JCB etc. up to the required depth prior to excavation the location of other services and their junctions to be studied properly and due care to be taken to avoid any damage.
3.18
Trench bottom shall be cleaned and leveling course shall be laid in the form of plain cement concrete of specified grade or otherwise precast concrete bed blocks of required dimensions shall be laid along the sewer line.
3.19
SWG/RCC pipes of required diameter shall be laid in line and level along with the fittings wherever necessary.
3.20
Jointing shall be done with spun yarn soaked in cement slurry and / finished with cement mortar 1:1.
3.21 3.22
Curing of jointing shall be carried out for specified period. Hydraulic testing / smoke test for pipe line shall be done and necessary test reports shall be maintained & testing for chamber cover to be carried out as per relevant methods.
3.23
Concrete encasing shall be carried out as per the specifications.
120

TITLE: WORK INSTRUCTION FOR INFRASTRUCTUREAL SERVICES 3.24 3.25 3.26 Back fitting shall be carried out in layers along with compaction. Sewerage work shall be recorded in checklist for sewerage (QC-02-14). The sewerage line shall be handed over to statutory bodies / clients / PMC.
C) Storm water drain 3.27 3.28 Storm water drain layout shall be prepared and got approved from CIDCO. Requirement of materials like stone rubble, bricks sand, cement, shall be worked out and the materials required for the work in hand are available before start of work. 3.29 Agency carrying out the work shall be selected on the basis of their past performance, experience and technical knowledge. 3.30 Line out : The detail line out shall be carried out as per the layout plan. The width of trench shall be decided considering the working space required for laying storm water drain line and the adjacent compound wall, if any. 3.31 Excavation: The excavation shall be carried out manually or with the help of machine like JCB etc. upto the required depth. (Para no. 4.18 as applicable) 3.32 The trench bottom shall be cleaned. Leveling course in the form of plain cement concrete of required grade shall be laid as per the required slope. 3.33 Open drain / pipe drains / RCC drains shall be constructed as per the drawing and specifications.
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3.34 Smooth finish plaster shall be done to the internal surface of storm water drain, if specified prior to work and after completion of work. 3.35 3.36 3.37 3.38 Curing shall be carried out for the specified period. Construction approval shall be obtained from CIDCO / clients. Storm water drain work shall be recorded in checklist for storm water (QC-02/15/ Storm water drain shall be handed over to CIDCO.
D) Compound wall 3.39 Approved layout drawing and working drawing for compound wall shall be studied in detail. It shall be ensured that the materials and agency for work is available before commencement of the work. 3.40 Agency carrying out the work shall be selected on the basis of their past performance, experience and technical knowledge. 3.41 Line out: The line out shall be done carefully as per the layout drawing. Plot boundaries shall be verified carefully. 3.42 Excavation : Excavation shall be carried out in the trench of required dimensions as per the drawing. 3.43 Excavation shall be carried out separately or along with the storm water drain as per the requirement of site.
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3.44
The trench bottom shall be cleaned and leveling course shall be laid in the form of plain cement concrete of required grade and thickness with reference to structural drawing.
3.45 3.46 3.47 3.48
Masonry shall be carried out as per the drawings and specifications. RCC coping shall be constructed at required height as per the drawing. Painting shall be carried out on the both faces as per the specifications. Painting shall be done, if specified. E) Roads
3.49 3.50 3.51
The approved road layout and cross-sectional drawing shall be studied in detail. Required materials shall be available at site from reliable sources. The detail line out shall be done for demarcation of road shall be do0ne as per approved drawing to carry out the work.
3.52
Cutting of filling to the level required as per the drawing shall be carried out manually or with the help of machines. If filling is involved, the same shall be done in layers of specified thickness along with the compaction.
3.53
If cutting is involved, excavation surface shall be compacted by roller. The surface shall be prepared as per the required level.
3.54
Pipes shall be provided in sub-grade at various crossings for services as shown in the drawing. TITLE: WORK INSTRUCTION FOR INFRASTRUCTUREAL SERVICES
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3.55 Compaction of the sub-base shall be checked with Proctor density apparatus or CBR test shall be carried out at specified frequency. Plate load tests shall be carried out if specified. Necessary records of tests shall be maintained. 3.56 Road crust shall be construction as specified in design / drawing as per relevant specifications. 3.57 testing. 3.58 3.59 Road work shall be recorded in checklist for construction of road (QC-02-16) The completed road shall handed over the statutory bodies / client after inspection. F) External Electrification 3.60 Layout drawing shall be got-approved from the statutory bodies like electricity board etc. 3.61 3.62 3.63 3.64 The electrical materials shall be procured as per the scope of work involved. The electrical sub-stations shall be constructed as per the approved drawings. Necessary RCC hume pies shall be laid at the crossings. The necessary charges shall be paid to statutory bodies for external electrification including street lights. Asphalting Required layers of finishing coats such as BBM/DBM/BM/AC/Seal coat etc. shall be laid as per design/ drawing & relevant specifications with necessary
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3.65
The actual work of laying the cables and energizing the substation shall be done by the statutory bodies like MSEB, BSES etc. or otherwise departmentally through licensed electrical agencies.
3.66
Safety installations like lightening arrestors, aviation lights and earthings etc. shall be provided as applicable. Testing and commissioning to be f\done after completion of work.
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Standard deviation
1.0 SCOPE : Standard deviation calculations are used to analyse the concrete strength & decide about its acceptability 2.0 REFERENCES : IS 456- 2000
3.0 procedure 4.1 A random sampling procedure shall be adopted for every grade of concrete separately to ensure that each concrete batch is reasonably tested i.e. the sampling should be spread over entire period of concreting. 4.2 The test strength of the sample shall be the average of strength of three specimen. The individual variation should not be more than + -15% of the average. The result having individual variation more than 15% shall be discarded. 4.3 The total number of test results required to constitute an acceptable record for calculation of standard deviation shall not be less than 30. 4.4 after every change of mix design or once in 3 months, calculation of standard deviation shall be brought upto date. 4.5 Data shall be collected & recorded for at least 30 test specimens. Let the test strengths of n specimens be XI. X2, X3 .. Xn. 4.6 Mean value of strength shall be calculated as X = X1 +X2+X3 + ---------+XN n n = no. of test samples
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4.7 for each test strength, deviation from mean strength shall be calculated as
4.8 square of deviations
shall be calculated as
4.9 Summation
of all values of
shall be worked out.
4.10 Standard deviation (S) shall be calculated as
4.11 The concrete shall be accepted for the compressive strength requirement if the 28 days strength is equal to or more than specified characteristic value. If the strength is less than the specified characteristic value, acceptance criteria observed
as specified under cl.no 4.12 shall be applied 4.12 The concrete shall be deemed to comply the strength requirement as hence acceptable, if Specified Grade M 20 or Above Mean of the Group of 4 Non-Overlapping Consecutive Test Results in N/mm2 fck + 0.825 * established standard deviation (Rounded off to nearest 0.5 N/mm2) OR fck + 4 N/mm2, whichever is grater Individual Test Results in N/mm2 fck 4 N/mm2
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CHECKLIST FOR SEWERAGE NETWORK Project : ______________________________________________ Location : _____________________________________________ Sr. Particulars No. Date : Remarks
(Accepted / Not accepted Corrections / Rejected /Not Applicable etc.)
1 2
Detailed line out as per layout plan. excavation / sufficient width w.r.t. diameter and invert level. Cleaning trench bottom P.C.C. leveling course of specified grade / precast concrete bed block or required dimensions. Lying SWG / RCC pipe of required dia. Line (alignment) & level of pipes. jointing with spun yarn soaked in cement slurry. finishing joints with cement mortar 1:1 curing of joints Hydraulic testing concrete encasing, if required. Back filling in layers along with compaction Approved By
3 4
5 6 7 8 9 10 11 12
checked By
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CHECKLIST FOR SEWERAGE Project : ______________________________________________ Location : _____________________________________________ Sr. Particulars No. Date : Remarks
(Accepted / Not accepted Corrections / Rejected /Not Applicable etc.)
A) 1. 2. 3. 4. 5. 6.
SUBGRADE PREPARATION : Line out as per demarcation plan. Cutting / filling to required level as per drawing. Filling in layers of specified thickness along with compaction Cutting and compaction of base with roller. Provision of pipes at various crossings for services as per drawings Testing of sub-base compaction by proctor Test / CBR test.
checked By B) FIRST LAYER (SUBBASE) 1. 2. 3. Size of metal / compaction Murum / crushed stone dust for filling interstices Rolling
Approved By
Checked By C) BASE COURSE & WEARING COURSE. as per specification drawing.
Approved By
Checked By
Approved By
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CHECKLIST FOR SEWERAGE Project : ______________________________________________ Location : _____________________________________________ Sr. No. Particulars Remarks (Accepted / Not accepted Corrections / Rejected /Not Applicable etc.) 1 2 3 4 5 6 7 8 Detailed line out as per layout plan. excavation / sufficient width Cleaning trench bottom Leveling PCC of required grade SAmooth finish plaster on internal face curing for 3 days approval of statutory body A.C. pipes for weep holes Date :
checked By
Approved By
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CHECKLIST FOR GRANULAR SUB BASE (GSB) AND WET MIX MACADAM (WMM) Date : Name of Project Location : __________________________________ : __________________________________
Ref. Drawing No. : __________________________________ Specification Sr. Particulars No. A. 1. 2. 3. 4. B 1 2. 3. 4. GSB Checking of sub grade top up to required standard and level Material laying and spreading. Compaction Field dry density ( FDD) WMM Checking of GSB top up to required standards and levels Material laying and Spreading Compaction. Field dry density ( FDD )
Remarks (Accepted / Not Accepted Corrections / Rejected / Not Applicable etc)
Checked by
Approved by
CHECKLIST FOR EARTH WORK AND SUB GRADE
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Date : Name of Project Location : __________________________________ : __________________________________
Ref. Drawing No. : __________________________________ Specification Sr. Particulars No. 1 2. 3. 4. 5. 6. 7. 8. Line out as per demarcation plant Clearing and grubbing. Levels Original ground level test Cutting. Base Rolling. Filling in layers up to embankment top Sub grade in layers with CBR and field density.
Remarks (Accepted / Not Accepted Corrections / Rejected / Not Applicable etc)
Checked by
Approved by
CHECKLIST FOR BATHROOM / TOILET WATERPROOFING Date : Name of Project : __________________________________
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Location Sr. No. 1 2. 3. 4. 5. 6. 7. 8. 9. : __________________________________ Particulars Remarks (Accepted / Not Accepted Corrections / Rejected / Not Applicable etc)
Cleaning the surface and removing loose material, if any. Pressure grouting, wherever necessary Fixing Nahani / P/S/ traps at required location Sealing of joints. First coat plaster 300mm above floor Testing (by flood test). Brickbat coba with waterproofing powder. Final coat. Testing
Checked by
Approved by
CHECKLIST FOR TERRACE WATERPROOFING Date : Name of Project Location Sr. No. : __________________________________ : __________________________________ Particulars Remarks (Accepted / Not Accepted Corrections / Rejected /
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Not Applicable etc) A) CEMENT BASED WATERPROOFING :
1 2. 3. 4 5 6. 7 8 9 10
Completion of plaster for parapet, slab columns etc. 300mm Confirmation of fan hooks and electrical conduits Cleaning, dusting and patch work. Removing loose material Cement grouting if necessary. Fixing of water spout / Rain water down take pipes Identifying rider lines and valley lines and fixing line dori to indicate slope to lay bricks / brickbats. Well burnt quality bricks / brickbats. Prior soaking wetting of bricks Mix proportion of bedding mortar as per specification using measuring box. Thickensss of mortar Joints not more than 25mm
Checked by B) After completion work : 1 2. 3. 4 5. 6 7.
Approved by
Smoothness / Finishing Thread line marking / proper filling of tile joints. Slope towards spout / down take pipe and disposal of water Spout mouth finishing Galatha and joint bet waterproofing and plaster Curing by ponding water for seven days. Testing by flooding.
Checked by
Approved by
CHECKLIST FOR SAFETY PRECAUTIONS Date : Name of Project Location Sr. No. 1 : __________________________________ : __________________________________ Particulars Shoes / gumboots are worn by concerned workers? Remarks (Yes / No. / Not Applicable etc.)
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2 Safety helmets/ safety belts worn by workers working at site & at higher level ? Safety goggles / hand shields / welding helmets / leather gloves worn by workers doing welding work? Openings, corners & edges are guarded with barriers? Availability of first aid boxes at different sections is checked? Expiry dates of medicines available in first aid boxes are checked? Does any workman happen to ride on the bucket / component which is being lifted? All electrical cables are laid underground or overhead on wooden poles? ( Except temporary lines ) Live joints / cable joints are insulated / protected by insulation taps or chamber? Warning signs as DANGER-440 VOLTS, NO SMOKING & other safety slogans are displayed? Fire extinguishers & sand buckets are available at the point of storage where inflammable materials are stored? Whether children are observed very near construction work? Whether diversion boards are displayed at required locations? Whether cautionary sign and boards are displayed at required locations? Approved by
3 4 5. 6 7 8. 9 10 11 12 13 14
Checked by
Title: Procedure for Planning and construction process at Site 1.0 PURPOSE: To ensure that construction process is planned & carried out under controlled conditions. 2.0 SCOPE: Applicable for construction activity at site.
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3.0 * 5.1 INPUT Following are considered as inputs to this procedure. PROCEDURE
Inputs details with format no. A- Tender Document B- Green Schedule (CR-01-09) C- Working Drawing D- Raw materials E- plant & Machinery F- Manpower
Received from Contracts Sr. C.E. / C.E. D & D H.O. / Client / consultants / Equipment manufactures Suppliers / client self / rental / lease Self
Above inputs when received, verified & reviewed for adequacy & filed in respective 5.2 files & registers.
PROCESS / OPERATION Process IS identified and carried out as per flow chart given in this procedure.
5.2.1
After award of project a P.M. / site Incharge is appointed & site staff is nominated by concerned CEO, PM prepares an site organization chart which includes nomination of safety officer & Q.A. engr. Processes are planned & carried out under following controlled conditions.
5.2.2
Planning On the basis of requirement for material, staff, labour, plant & machinery for ssite, mobilization of site officers & other utilities are planned & established.
5.2.3 5.2.4
A detailed Bar chart / Pert chart is prepared for the project to demonstrate activity plan & actual activity done. Cash flow till completion is prepared Site layout plan is prepared on the frawing received from D & D (H.O.) / client which shall demonstrate temporary structures (i.e. offices) including service lines.
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5.2.5 Material requirement For entire project material requirement is planned on the basis of tender document. Material requirement is worked out as per the bar chart& communicated to M.P.P. dept. thorugh by referring G.S. 5.2.6 Staff & Labour requirement For entire project Staff requirements and Labour requirements are planned on the basis of tender documents and worked out as per the bar chart. 5.2.7 Plant & Machinery Plant & machinery required at site as planned by taking into account activities, completion period and communicated to CEO. 5.2.8 a) i) ii) iii) Execution Construction process are carried out under following controlled conditions Information that describes products characteristics are available in the form of Working drawings Tender documents or specification Approved samples
b) c)
The construction process is carried out as per relevant work instruction The construction process of infrastructure projects viz. concrete roads, bituminous roads, bridges & other structures are carried out as per work instructions
d)
The receipt of drawings at site is recorded in drawing receipt & issue register The excavation upto the required depth as per structural drawing / contract specification and the depth is recorded in Register for works up
e)
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to plinth including excavation If SBC of strata available is required, PM / Client shall be consulted as required. f) Precasting of structural components is done, as applicable as per checklist for precasting and details are recorded in Register for precast components g) h) The Plant & Machinery required for construction is available & maintained at site, the same is covered under preventive maintenance schedule Monitoring & measuring devices are covered under valid calibration / verification & are in use. i) Monitoring & measurement during the process of construction is implemented as per procedure No. QC-02. j) Overall planning and monthly targets given by PM/site incharge are recorded in Engineers Diary with assessments details for all working days of a month. k) Safety precautions during construction are dealt with as per work instruction. Safety officer monitors the implementation through checklist for safety precautions once in a fortnight. l) Final release of product for further construction process or delivery / handing over to customer is carried out only after inspection / testing as per specification / drawings records of such release are maintained. less than the
m)
Approval of mix design shall be obtained from PM with the trial mix design results.
n)
All concreting work shall be recorded in Register for concreting work
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For particular process as specified in contract like waterproofing aluminium work landscaping work, China Mosaic work etc. sub-contract work shall be carried out. 5.3 5.4.1 5.4.2 MONITORING, MEASUREMENT, ANALYSIS AND CONTROL Department quality objectives are monitored on monthly basis. Following data is analysed once in 3 months 1. Bar chart & actual activities carried out at site are monitored on day to day basis & bar chart is reviewed once in a quarter based on achievement. 2. 3. wherever required P.M. shall review customer requirement & prepare sketches for miscellaneous construction work. Monthly review is conducted by Client to monitor the progress of the activities at site. The review is carried out with the concerned Engr. & section 4. I/c. details of decision taken, action planned & the responsibilities are recorded in monthly review minutes. Rejection / rework are dealt with as per sections 8.3 of QM & analysed by P.M. & analysis is submitted to management for review. 5.4.3 CUSTOMER FEED BACK Customer feedback is obtained. Whatever feedbacks are received are analysed quarterly & reported to management once in six months for review. 5.4.4 CUSTOMERS COMPLAINTS Customer complaints received in writing or verbally during construction process & after handing over are recorded in customer complaints register.
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5.4.4.1. P.M./Site incharge nominates Engr. / sup. As a customer service in charge who attends the customer complaints by arranging resources from same or other site. 5.4.4.2. Action taken against customer complaints is recorded in the customer complaints register & status of completion is evidenced. 5.4.4.3. Customer complain are analysed by P.M./site Incharge once in six months &v reported to management review.
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1.0
PURPOSE :
To ensure that incoming material is monitored measured and only conforming material is released for further processing.
2.0
SCOPE :
Applicable for monitoring and measurement of incoming materials.
3.0 3.1 *
PROCEDURE INPUT Following are considered as inputs to this procedure. Inputs details with format no. A- quality Assurance plan B- IS Codes C- MORT&H D- Contract Documents E- Material samples F- Incoming Materials Received from D&D BIS & MR Ministry Of Road Transport & Highways Client Suppler, Client Supplier, client
Above inputs when received, are scrutinized and reviewed for adequacy and then field / recorded /stored in respective files / registers / designed area. 5.2 PROCESS / OPERATION Process IS identified and carried out as per flow chart given in this procedure. 5.2.1 Incoming material sample is received duly identified along with necessary documents from store I/c.
5.2.2
Incoming material is inspected as per quality assurance, plan Pos, IS codes, IRC codes, MORT&H, tender specification and customer-approved samples.
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5.2.3 Inspection results giving the details of what characteristics has been inspected and actual readings/values are recorded in monitoring and measurement of incoming materials register
5.2.4
In case of machinery maintenance spares, the same are inspected as per procedure for machinery maintenance by PM and his representative at site. Product/Process nonconformity If nonconformity is found at any inspection stage, the same is dealt as per procedure documented in section 8.3 of quality manual.
5.3 OUTPUT Following are considered as outputs of this process carried out by the QA department. Type of output with format No. Monitoring & measurement Sent to / Forwarded to of retained at site
incoming materials register Above outputs are revi9ewed and approved for adequacy and correctness prior to sending /forwarding to other user depts., who considered as internal customers. 5.4 MONITORING, MEASUREMENT, ANALYSIS AND CONTROL 5.4.1 Departmental months. 5.4.2 5.4.3 Material reconciliations is carried out on regular basis. Following monitoring activities are carried out to control the process/ operation. quality objectives are monitored on monthly basis and
achievements are recorded and submitted to management for review once 6
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A. It is ensured that the instruments / equipments used for monitoring and management of incoming material are within the valid calibration. Process flow chart for monitoring and measurement of incoming material.
Input
Input
Input
Material specificatio n as per contract
Receive Sample & lots of incoming
Inspect Material as Per PO, QAP, IS, IRC, MORT & H
Reject
Quality, Plans, IS, MORT&H, IRC

4.0 6.1 6.1.1
Record inspection results in register
Output QC-01-R-01
CONTINUAL IMPROVEMENT Continue improvement activities are carried out and records are maintained. Achievements/improvements are reported to management for review.
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QUALITY PLAN Date : Name of Project Location Sr. No. 1 a) b) Soundness i) By Auto-clave OR ii) By LeChatliers Sub lot Upto 100T - 2 sub lots 101 T to 200T 3 sub lots 201 T to300T 4 Sub lots 301T to 500T -5 sub lots 500T to 1000T-6 sub lots 1000T to2000T-7 sub lots Gross Sample From 2% sub lot bags or Minimum 5 bags. : __________________________________ : __________________________________ Description/ Characteristic Physical tests Qty. to be checked Lot Frequency of Check Not more than 50 MT Acceptance Criteria Tolerance Ref. Doc Not more than 10% (When tested on IS test Sieve No.9) The expansion shall be not more than 0.8% The Exapnsion shall be not more than 10mm Not less than 30 min Not more than 600 min Not less than 230 Kg/cm2 Not less than 330 Kg/cm2 Not less than 430 Kg/cm2 Vicat needle Penetrate to a pt.5 to 7mm from bottom of Vicat mould IS:3535 IS:8112 Table PM/QA Engr. IS:4301 (Part 6) PM/QA Engr. IS:4031 (Part 5) Responsibilit y PM/QA Engr. Checking Method IS: 4031 Remarks
PM/QA Engr,
IS:4031 (Part I)
From approve d Test House
c)
Setting time i) initial setting time ii) Final Setting time Compressive strength i) 3 days ii) 7 days
D)
e)
iii) 28 days Consistency
Chemical Tests
Vicat needle Penetrate to a pt.5 to 7mmm from bottom of Vicat mould PM/QA Engr
PM/QA Engr.
IS:4031 (Part 4)
Manufacturer Certificate
Approved by
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QUALITY PLAN Material-Reinforcement Steel-Deformed Steel Bars (Fe 415 Grade) Sr. Description/ Qty .to Frequency Acceptance Responsibility No. Characteristic be of check criteria Checked Tolerance Ref. Doc. 1. Nominal 1 Once in IS::1786, .QA Engr. sizes/mass Sample six month CI.No.5.1, 1 sample 5.2,6.1,6.2,2.2, for 10T for Table 1,Table2 each dia received from each supplier. For bar Dia, Above 16 mm to 10 mm & less 2. Tensile Strength 1 Sample __ _____ 10% more than Proof stress but not 485 N/mm2 (IS:;1786, table 3) No transverse crack is seen in the bent portion No frature in the bent portion. Q.A. Engr. Code No.QP-04 Checking Remarks Method IS:1786 CI.No.8, 8.5
CI.No.5.3, 6.2.3 IS:2062, CI.No. 6 IS:1608 IS:2062, CI.No.7.3. 2 7.3.2, 8.5 8 IS:1599 IS:1786 CI.No.8.3, 8.5, 8.0 IS:1786 CI.No.8.4, 8.4.1, 8.5, 8.0
Approved Test House.
3.
Bend Test
1 Sample 1 Sample
__ _____
Q.A. Engr.
Approved Test House. Approved Test House
4.
Rebend Test
__ _____
Q.A. Engr.
Approved by:
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QUALITY PLAN Material Stone Metal ( Coarse Aggregate ) Code No. QP 06 Sr. Description/ Qty. to Frequency Acceptance Responsibility No. Characteristic be of cheque criteria checked Tolerance Ref. Doc (E) Soundness From gross sample a For coarse QAE mentioned in A select aggregate sample as per IS : 12% when 2386 (Part V ) clause tested with No.42 sodium sulphate - 18% when tested with magneseum sulphate 25% for each index Checking method IS: 2386 (Part IV) Remarks
Required when 1. Source of aggregate 2. change of source
(F)
Flackiness & elongation index
IS :2386 (Part-I) once in sixh months
QAE
IS:2396
(G) (H)
Alkali aggregate reactivity Mechanical Properties 1. Aggregate impact value
IS:2430, 2386 (PartI to VIII)
IS :2386 (VIII)
QAE
IS:2386 (PartVII)
Required when 1.soure of aggregate 2. chage of source -
Once in six months
2. Aggregate crushing value
Once for source
Aggregate impact value shall not exceed 45% by weight for aggregates used for concrete other than wearing surface IS:383 Cl. No. 3.4 Aggregate crushing value shall not exceed 45% by
QAE
IS:2286 (partIV)
QAE
IS :2386 (PartIV)
To be done at the source when source is
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weight for concrete other than wearing surface IS: 383 Cl.No.3.2 The abrasion value of aggregate using los angles machine for aggregates line concrete used other the wearing surfaces shall not exceed 50% IS:383, Clause 3.3 changed
3. Aggregate Abrasion value
Once in six months
QAE
IS:2386 (PartIV)
Approved Test House.
Approved by:
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QUALITY PLAN Material Stone Metal ( Coarse Aggregate ) Code No. QP 06 Sr. Description/ Qty. to be Frequency Acceptance Responsibility No. Characteristic checked of cheque criteria Tolerance Ref. Doc (A) Specific gravity Table 1-ISOnce in PM/QAE 2430 three months Lot size No. of sub (m3) lots 101-500 3 501 1500 5 1501-5000 7 Each sub-lot shall have a gross sample of weight depending upon maximum size of aggregate Weight of gorss sample Max. Minimum Nominal weieht of size of Gross Aggregte sample (mm) (kg) 9.50 10 10.00 10 12.50 15 13.20 15 16.00 20 19.00 25 20.00 25 25.00 50 At least 10 increament of a suitable weight eash not less than 1 kg shall be taken for one gross sample Checking method IS:2386 (Part3) Remarks
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(B) Water absorption Weekly Rock type Absorption percent 0.1-03 0.2.0.15 0.06 QAE IS : 2386 (PARTIII) Clause 3.0 Approved test House Oven is used to measure moisture content QAE IS : 2386 (PARTIII) Clase 2.0 Approved Test House
Basalt granite lime stone Bulk density Once in three months weekly Weekly
(D)
Miositure content
QAE
Approved by:
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QUALITY PLAN Material Stone Metal ( Coarse Aggregate ) Sr. Description/ Qty. to be No. Characteristic checked (D) Specific gravity Table 1-IS2430 Frequency of cheque Acceptance criteria Tolerance Ref. Doc Responsibility Checking method IS:2386 (Part3) Remarks
Once in three months Lot size (m3) No. of sub lots 101-500 3 501 1500 5 1501-5000 7 Each sub-lot shall have a gross sample of weight depending upon maximum size of aggregate Weight of gorss sample Max. Nominal Minimum size of weieht of Aggregte Gross (mm) sample (kg) 9.50 10 10.00 10 12.50 15 13.20 15 16.00 20 19.00 25 20.00 25 25.00 50 At least 10 increament of a suitable weight eash not less than 1 kg shall be taken for one gross sample Weekly Basalt granite lime stone
PM/QAE
(E)
Water absorption
Rock type Absorption percent 0.1-03 0.2.0.15 0.06 -
QAE
IS : 2386 (PART-III) Clase 2.0
Approved Test House
(F)
Bulk density
(F)
Moisture content
Once in three months weekly Weekly
QAE
QAE
IS : 2386 (PART-III) Clause 3.0 Oven drying method--
Approved test House
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QUALITY PLAN Material Stone Metal ( Coarse Aggregate ) Sr. No. 1 Description/ Characteristic Dimensions a) Width & Height b) Thickenss Qty. to be checked Lot size (nos) 26 to 50 51 to 100 101 to 150 151 to 300 301 to 500 501 & above Lot size (Nos.) 26 to 50 51 to 100 101 to 150 151 to 300 301 to 500 5001 & above Lot size (nos) 26 to 50 51 to 100 101 to 150 151 to 300 301 to 500 5001 & above Frequency of cheque Sample size (nos) 8 13 20 32 50 80 Sample size (Nos) 1 2 2 3 4 5 Sample size (Nos) 5 8 13 20 32 50 Acceptance criteria Tolerance Ref. Doc 5mm 1.0mm Responsibility Checking method IS 4020 (Part2) Remarks
QA Engr.
2)
Knife test
Only the knife width should peel off nothing extra (Minimum pass excellent standard)
QA Engr.
IS 4020 (Part 15)
Approved Test House
3)
Moisture content 1) 50mm above thk 2) Less than 50mm thk
QA Engr.
IS 1003 (Part I)
Approved Test House
Approved by :
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QUALITY PLAN Sr. No. 1. 2. Material Concrete Description/ Qty. to Characteristic be checked pH Value Sulphate Content Chloride Content 2 lit. (IS:3025 Part 1) 2 lit. (IS:3025 Part 1) 2 lit. (IS:3025 Part 1) Frequenc y of check Monthly Monthly Acceptance criteria Tolerance Ref. Doc. Not less than 6 (IS:456) 400 mg/1 (IS:456) 2000 mg/1 for concrete not containing embedded steel. 500mg/1 for R.C.C. work Responsibili ty QA Engr. QA Engr. Checkin g Method IS:3025 (Part 23) IS:3025 (Part 24) IS:3025 (Part 32) Alternatively Test can be done by ion exchange method. Remarks
3.
Monthly
QA Engr.
Approved by: QUALITY PLAN
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Sr. No. A. 1. 2. Material Concrete Description/ Qty. to be Characteristic checked Fresh Concrete Workability Compressive Strength 7 days 28 days Frequency of check Acceptance criteria Tolerance Ref. Doc. As required by Mix Design. As per Grade of concrete IS:456
Responsibili ty
Checkin g Method IS:1199 IS:1199 IS:516 IS:1199
Remarks
Not less than 0.02 m3 Concrete Quantity m3 1-5 6-15 16-30 31-50 51 & above
_ No. of Sample 1 2 3 4 4 + one Addl. Sample for every addl. 50 m3
QA Engr./ Site Engr. QA Engr./ Site Engr..
3 months
1 set for substructure/ Bldg. 1 set for per 4 floor/Bldg.
IS:456
QA Engr./ Site Engr.
IS:516 IS:1199
B.
Hardened Concrete Ultrasonic test Only in case of doubt or as per contract requireme nts. Actual concrete strength shall be verified as per previously calibrate graph of pulse velocity Aginst Stength of concrete.
1.
QA. Engr./ Site incharge
IS:1331 1
Approved by:
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QUALITY PLAN Sr. No. 1. Material Bricks (Burnt clay) Description/ Qty. to be Frequenc Characteristi checked y c of check Compressive Strength Lot Size (Nos) 2001 to 10000 10001 to 35000 35001 to 50000 _________ Sample Size (Nos) 10 15 Acceptance criteria Tolerance Ref. Doc. As specified (Class of brick) Responsibili ty Code No. QP-10 Checkin Remarks g Method IS:3495 (Part 1)
QA Engr
2.
Water Absorption
_______ _
Not more than 20% up to class 125 and 15% for higher class by wt. After immersion in cold water for 24 hours (IS:1077)
QA Engr./
IS:3495 (Part 2)
(IS:5454)
Approved by
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QUALITY PLAN Sr. No. 1. Material Timber Description/ Qty. to be Characteristi checked c Determinatio n of moisture content Lot Size (Nos) 2001 to 10000 10001 to 35000 35001 to 50000 Frequenc y of check Lot Size (Nos) 10 15 Acceptance criteria Tolerance Ref. Doc. Not more Than 12% Responsibili ty Checkin g Method IS:1003 (Part 1) Remarks
Vol 2/8/2 QA Engr
QUALITY PLAN
155

Sr. No. Material Tiles-Ceramic Description/ Qty. to be Characteristi checked c Dimensions Frequenc y of check Acceptance criteria Tolerance Ref. Doc. IS:44571982 IS:44571982 Responsibili ty Checkin g Method IS:1363 0 (Part 1) IS:1363 0 (Part 2) Approved Test House Approved Test House Remarks
1.
IS:13711-Table 1
QA Engr
2.
Water Absorption
IS:13711- Table 1
QA Engr.
3.
Crazing resistance
IS:13711 Table 1 IS:44571982
QA. Engr. IS:1363 0 (Part 9)
QUALITY PLAN
156

Material Natural Stones:Marble, Granite, Kotah, Shahabad, Tandur & Caddapah Sr. No. 1. Description/ Characteristi c Dimensions Qty. to be checked 25% Frequenc y of check As and when received _______ _ _______ _ 100% Damages, if any _______ _ Acceptance criteria Tolerance Ref. Doc. As per requirement + 50mm Uniform As per requirement + 3mm Acceptabilit y Discretion of QA Engr. Responsibili ty Checkin g Method Visual Inspecti on ______ _ Remarks
QA/Site Engr. ________
2. 3.
Color /Shade Thickness
________ ________
________ ______ _ ________ ______ _
4.
Approved by:
QUALITY PLAN
157

Material Tiles Ceramic Sr. Description Qty. to be No. characteristics checked 1 2 3 4 5. Dimensions Water Absorption Crazing resistance Modules of rupture Scratch hardness (Mohs scale ) Frequency of check Acceptance criteria tolerance Ref. Doc. As specified Max. 6% Post 500 M2 of tile are for each brand , size & colur shade (Ref. IS 13711) No cracks Min 22 N/mm2 Min 6 Responsibility Checking method IS : 13630 (PART 1) IS : 13630 (PART 2) IS : 13630 (PART 9 ) IS : 13630 (PART 9 ) IS : 13630 (PART 9 ) remark s
QA Engr. QA Engr. QA Engr. QA Engr. QA Engr.
Approv ed test House Approv ed test House Approv ed test House Approv ed test House
Approved by
158

QUALITY PLAN Material Concrete Admixure Sr. Description Qty. to be No. characteristics checked 1 Sp. Gravity 2 litr. For 1 set of tests Frequency of check As per IS : 9103 Per batch of Manfr Acceptance criteria tolerance Ref. Doc. As per IS:9103 Responsibility Checking method IS 9103 remark s Mnfr. Test Report s for each batch
QA Engr. / Site Engr.
1 3 4 5
Ph value Chloride content Sulphate content Silid content
_ do _
QUALITY PLAN Material Structure concrete Sr. Description Qty. to be No. characteristics checked Frequency of check Acceptance criteria tolerance Responsibility Checking method remark s
159

1 Non destractive tests 5% of total structural compone nts As required Ref. Doc. IS 13111(P1) PM/QAE APPROVE D
160

RECORD FORMATES
MONITORING AND MEASURMENT OF INCOMING MATERIALS REGISTER Sr. Date No. Material Description Quantity Received Inspection Results Remarks Signature of QA Engr. & Date
161

3.0
SAFETY POLICY
The protection of our staff, workers, our environment and the community are fundamental values in our business.
162

Everybody in our organization shall contribute to achieve best precautions in respect of safety aspect by conducting trainings, awareness programmes, safety drills and implementing instructions in this Safety Plan. We have to ensure that specialized agencies appointed by us shall also have to maintain same work culture for implementation of safety measures.
Chief Executive officer
163

4.0 EARTH WORK FOR BUILDING & ROADS WITH PLANT & MACHINERY 1) Drivers, operators of plant and machinery shall be knowledgeable, experienced, competent, who can read and write and must be above 18 years. Only authorized drivers and operators shall be allowed to operate plant and machinery. Preventive maintenance schedules shall be strictly adered to ensure that all plant and machinery are systematically inspected, serviced, repaired and maintained as necessary. Prior to commencement of earth works, overhead and underground electrical cables and other pipelines shall be identified and precautions shall be taken to prevent damage to these services. Non-essential personnel shall be kept well away from the area of operation and trained signal man shall be provided wherever necessary. Site speed limit of 20 Km/hr. for all vehicles shall be strictly enforced. Plant accessories & spares shall be kept at defined place. Moving vehicle shall be fitted with proper rear view mirror and reversing alarms. Do not reverse the vehicles without directions from cleaner. Employees and workmen working in the vicinity of earth moving operations shall wear safety helmets, safety footwears, eye-glasses if required. Drivers shall not remain on a vehicle being loaded unless a suitable overhead protective canopy is provided. Personnel should stand at a safer distance from loading operations. Sleeping / resting under or rear side of vehicle like Tippers, Hyvas, Hydra, Tractors, etc. shall be strictly prohibited. No unauthorized person should be allowed to enter in drivers cabin. Do no park vehicles on a slope for push starting, if battery is weak. All vehicles must have self-starter. No workman shall be allowed to sit / ride on stationery or moving tower crane, mobile crane etc. No. passengers are allowed in operators cabin. Walky talky shall be provided, if required for better communication between crane operator and lifting gang. Inspection of wire-rope of cranes shall be carried out by Mech. l/c once in a quarter. Operating any machine beyond its design limits can damage the machine & it can cause very serious accidents. Do not overload any machine. The engine of any machine has exposed rotating parts. Do not engine cover while the engine is running. All other guards & protective devices must be in place while operating any machine. While using excavator, because of long boom & dipper arm, one must be very careful when slewing. Operator should not slew quickly and strike the dipper arm against any obstacle. Operator should not wear loose clothing as it can catch in moving parts of machine and cause serious accidents.
2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18)
164

5.0 EXCAVATION
1) Boards indicating private properties shall be available. Trespassers shall not be allowed. Necessary safety precautions shall be ensured for visitiors. 2) Services drawings shall be used to determine cable / pipeline route. 3) Detailed study to be undertaken if excavation work is to be carried out adjacent to existing and / or temporary foundation / buildings. Temporary shoring or strutting of structure shall be carried out prior to the commencement of excavation in order to prevent collapse. 4) Pipe work / cables exposed by excavation shall be supported. 5) Earthwork excavation shall be carried out by stepwise cutting / Trapezoidal shape cutting. Straight cutting shall be avoided. 6) During rainy season, plastic sheet shall be covered over the peripheral area of deep excavation. De-watering shall be carried out immediately. 7) Stops / Barriers shall be provided, where necessary at excavation edges in order to prevent driving in to them. 8) Fencing shall be provided to total boundary area of site there is a heavy rush of outsiders. 9) Barricades shall be erected around excavation pits / areas. Also it should be erected around the excavated area sufficiently away from the outside edge of foundation. Ladders shall be provided as a means of access to excavated pits. 10) Adequate means of access ladders in to excavation shall be provided. 11) Heavy equipment shall be kept sufficiently away from the excavation trench. 12) Equipment used to backfill excavation shall be maintained in the safe condition. 13) Equipment shall be operated by licensed, experienced & authorized operator. 14) Unauthorized personnel should not allowed where the back filling of excavation is in progress. 15) A survey of the area shall be carried out to assess risks to any adjacent structures and / or utilities that may exist. Operators shall be briefed on any identified potential hazards. 16) Material like drums, steel, shuttering etc. should be carried through bucket of excavator. 17) Electrical panel cables, welding machine and other equipment should be protected from rain by covering plastic sheets.
165

6.0 ROCK BREAKING
1) Services drawings shall be studied to determine cable / pipe line routes. 2) Temporary supporting of existing foundations / building shall be carried out prior to commencement of work. 3) Personnel carrying out work shall wear safety helmet, safety footwear, eye protection and hearing protection. 4) Equipments / compressors used for the operation should be maintained in a safe location. 5) If blasting is to be done, only controlled blasting shall be allowed Personnel shall not be allowed near the area where blasting operation is carried out. 6) Experienced personnel shall be engaged in the job.
166

7.0 SITE TRANSPORT
1) Site conditions shall be taken into account in the selection of the equipment or vehicle. Drivers shall be aware of the limitations of their machines and safe operating procedures. 2) Vehicles shall be maintained in good condition. Periodic servicing of vehicles shall be carried out in accordance with the manufactures instructions. 3) Speed limits of 20 KM/hr. shall be established and strictly followed. 4) Driving license and medical fitness of drivers shall be ensured. After crossing the age of 35 years, the eyesight shall be examined and certified after every year. 5) Drivers shall be instructed not to leave the vehicle with their engine running. Whenever driver leaves the vehicle, he must look the operators cabin properly. 6) Drivers shall be instructed not to carry unauthorized passengers. 7) Safe working shall be planned in order to reduce the possibility of personnel being struck by reversing vehicles by provision of separate man for giving directions from behind or fitting of reversing alarm to vehicle. 8) Labours shall not be transported by open vehicles. 9) Vehicles shall not be overloaded by any materials. 10) Dumpers shall not be allowed to travel with the body in raised position unless inching forward to discharge the load. 11) Tyre rotation shall be carried out regularly as per the preventive maintenance schedule, so as to improve tyre life. Tyre pressure must be checked as per P. M. interval. 12) Proper approaches for vehicle movements shall be ensured around the site. Approach roads shall be fairly leveled and compacted to avoid skidding of vehicles.
167

8.0 MATERIAL HANDLING
1) Valid test certificates of wire rope sling, chain pulley block, wire ropes, pulley, etc. shall be maintained. 2) Supervision shall assess weight, center of gravity and determine the number of persons required carrying out the work safely. He should not overload any machine. 3) Personnel shall be trained in manual handling techniques. 4) Personnel engaged in material handling shall wear safety footwear and helmet with necessary PPE. 5) Good housekeeping measures shall be enforced in order to prevent slips, trips and falls during material handling 6) Construction materials shall not be stacked on the floors more than the allowable loads and shall be stacked in safe manner. 7) Material shall be stored in designated areas. 8) Trained, experienced signalman / supervisor shall be engaged for handling erection components. 9) Stacking of material shall be done in such a way to ensure that easy movement of workmen and vehicles along the rods. Also care shall be taken to avoid fall of material due to improper stacking. 10) Workers should use the mask while loading / unloading cement bags. 11) The approach roads to the building or to the site shall be free from all obstructions like steel rods, protruding nails, steel pieces etc. lying on the ground. 12) Nails and nut-bolts should be always stored & shifted in wooden boxes and should not kept loosely on the ground or floor. Nails, nut-bolts, washers, cut pieces of binding wire should be removed and kept in boxes immediately after deshuttering. 13) There should be different color boxes for nut-bolts, washers, nails, binding wire etc. for easy identification. 14) Use of handgloves is essential while handling wire-rope slings. 15) Supervisor and operator must ensure that all overload relays & limit switch of material handling equipment like tower crane, mobile crane are in perfect working condition. 16) Wire rope sling of proper capacity to be used for loading and unloading work.
168

9.0 STEEL HANDLING AND FIXING
1) 2) 3) 4) 5) 6)
Personnel to wear suitable footwear, safety helmet at all the time. Safety belt to wear while working at height. Hand gloves shall be worn by workers while handling / shifting steel. Suitable equipment is to be used to lift the steelwork. Steel shall be stored in designated areas on wooden chavis / sleepers. Good housekeeping standards shall be maintained in steel yard in order to prevent slips, trips and falls. 7) Experienced and trained persons shall be engaged with adequate supervision. 8) Re-bar shall be lifted safely in to the work area using lifting equipment or manually. 9) Re-bar off cuts / wires shall be removed in order to alleviate slips, trips and falls. 10) Steel fixers shall use proper tools in order to assist in bar bending type activates. 11) Talks shall be conducted emphasizing the hazards involved in bar bending and handling steel re-bar (sharp edges). 12) Exposed vertical bars, if observed shall be bent, covered or protected by some other means. 13) Stacking of fabricated bars shall be done at designated areas. 14) Proper capacity wire rope shall be used while handling the material with cranes. 15) The stack of steel or shuttering should be fully vertical and firmly supported by strongly vertical steel or timber. 16) Before start of erection work, methodology to be decided and necessary approval shall be taken from consultant / client.
169

10.0 HANDLING OF TIMBER AND SHUTTERING
1) Personnel to wear suitable foot wear, safety helmet and safety belt while handling timber and shuttering plates. 2) Timber shall be de-nailed in order to prevent puncture &* wounds. 3) Timber shall be stored in designated areas away from office and other buildings. 4) Good standards of house keeping shall be maintained in order to prevent slips, trips and falls. 5) Personnel shall be instructed on the safe operation of mechanical / electrical equipment. 6) It shall be ensured that shuttering shall take the load of poured concrete. Deshuttering shall be done strictly as per IS 456:2000. 7) Access for personnel to carry out work on shuttering to be planned. Safe means of access to be provided at all time in order to prevent risk of falls from height. 8) Suitable and sufficient cranes shall be provided in order to alleviate manual handling of shuttering and associated components. Manual handling procedure to be developed and implemented. 9) Handling of shuttering material by crane is to be controlled by experienced operators and where necessary, with the help of signalman. Considerations of high wind conditions and associated risks are to be recognized. 10) Hand and power tools to be properly maintained. Defective tools shall not be used. 11) Dangerous moving parts of machinery shall be guarded. 12) Fire protection equipments to be kept near timber stacking area. 13) Care should be taken to remove the nailed plywood or timber pieces in surrounding area & approach roads. 14) Rusted material shall be painted periodically.
170

11.0 CONCRETE POURS
1) Personnel placing concrete shall wear suitable gloves & Gumboots with necessary PPE. 2) Plant and machinery used during concreting shall be operated by trained and authorized personnel under close supervision. 3) Un-authorised personnel shall be prohibited near concreting activities. 4) Access shall be restricted by providing portable boards to maintain safe place of work. 5) For hacking, suitable goggles shall be provided to workers before hacking work is started. Is shall be ensured that the platform (on the ground or on the floor) is safe on which worker stands for hacking. 6) While slab concreting is carried out by pump, it shall be ensured that more concrete is not pumped at a time. For better communication, walky talky shall be preferred, if required.
171

12.0 BRICK MASONRY, UCR AND PLASTER WOPRKS
1) Plywood/ planks form of height 1m should be firmly fixed covering the opening of duct or shaft to avoid falling. 2) Personnel engaged in the work shall wear suitable gloves and footwear with necessary PPE. 3) Plant and equipment used during transportation of material shall be operated by trained and authorized personnel under close supervision. 4) Un-authorised person shall be prohibited to enter in areas where work is carried out at heights. 5) Wherever required platforms / scaffolds shall be used for the work. 6) Safe means of access / egress shall be provided and maintained for the personnel carrying out the erection of scaffolding and the personnel working on them. 7) Suitable and sufficient material shall be made available to erect the scaffolding properly. 8) Safety belt should be worn and tied on scaffold while working at height. 9) Scaffolding shall be provided with adequate ties / supports in order to prevent collapse. 10) Lifting cage / cradle for carrying concrete blocks and material should be of sound construction, strong enough to carry the load and suitable for the work in hand. 11) Cage should be constructed in such a way that no material shall fall while carrying / traveling. 12) Nobody shall be allowed to work under the load or in the crane coverage area. 13) No workman shall be allowed to ride on the bucket / components which are being lifted.
172

13.0 WORKING AT HEIGHT
High structures refer to any permanent or temporary structure above ground structures used by personnel for any purpose during the course of construction works. 1) In order to minimize exposure to risk, the minimum practical number of persons shall be assigned to the job. 2) The operations above ground level shall be carried out in such a way that non involved personnel, in the vicinity of the activity, are not at risk. 3) All personnel working at height shall use the appropriate personal protective equipment (PPE). 4) Means of access to elevated areas shall be of an approved type, of sound construction, suitable for the purpose and shall be used in a safe manner. 5) Safety belt shall be provided, worn and properly secured in all work situations where there are chances of falling from height. 6) All accesses shall be kept clear. 7) Before work commences, the supervisor in charge of the work shall ensure that all personnel have been provided with the required personal protection. 8) Electrical, pneumatic and hydraulic tools shall not be pulled forcefully by their power lines. 9) All lifting operations shall be controlled by supervisor (signal man) who shall ensure that safe lifting practices are used at all times. 10) During lifting operations, no person shall be positioned beneath the load, hoist or jib. Similarly load shall not be slewed over the heads of personnel. 11) Where practicable personnel shall not be allowed to work direcly below the overhead work positions of other persons. Where this is unavoidable, suitable precautions shall be taken. 12) Tools, equipment shall not left laying around the structures. They shall be kept in such a location that they do not represent a tripping hazard and cannot fall or be knocked from the higher elevation. 13) Where there is a risk to fall through the openings, high visibility warning tapes and notice boards shall be provided. Also safety tape shall be provided around the building on each floor along the periphery. 14) Safety nets shall be provided wherever necessary.
173

14.0 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) WELDING Electrician shall inspect the correctness of technical requirement of welding machine when it arrived at site. Welders shall be provided with and wear welding gloves, helmets, shoes and welding goggles with correct fitter. Inflammable materials shall be removed from areas where welding is to be undertaken. Welding cables and cable joints shall be maintained in good conditions. Earthing clamps shall be firmly connected to the metal on which welding is taken place. Conditioned welding machines shall be used and experienced welders shall perform the welding. Welding and pieces/left out welding rods shall be collected and stocked at designated areas. In case of coated electrodes, welding slag shall be removed when it becomes cold. First aid box shall be made available in fabrication section. Welding spatter shall be removed. Necessary welding tests for welders to be conducted for welders qualification. Identification cards shall be issued to welders, so that we can check the welding work carried out by particular welder.
174

15.0 1) 2) 3) 4) 5) 6) 7) 8) USE OF HAZARDOUS SUBSTANCES Personnel shall be instructed to take appropriate precautions to protect their health from the hazard. Hazardous substances shall be segregated and stored in safe manner. Personnel engaged in the work shall wear suitable gloves and footwear with necessary PPE. Fire fighting equipments such as extinguishers shall be kept near the storage of inflammable materials. Proper ventilation shall be ensured where hazardous substances are stored. Drums containing liquid, which is dangerous to health, shall be stacked separately and away from the operational area. Gas cylinders shall be carried in handcarts. Rolling of gas cylinder on ground/road shall not be allowed. It shall be ensured that gas Cylinder regulators are leak poof. If any leakage is found then it has to be repaired immediately.
175

16.0 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) 17) 18) 19) 20) 21) 22) 23) SCAFOLDING The ground on which the scaffolding is erected should be thoroughly leveled & compacted. It should be tied at every floor. Standard size of base plates shall be ensured irrespective of the foundation surface. Scaffold erection to be undertaken by experienced personnel working under close supervision. Care should be taken for the excavation near by. Safe means of access / ladder to be provided and maintained for the personnel carrying out the erection work. The vertical Height between ladder access platforms shall not exceed 9 meters in one stage. Ladders shall be constructed, tied off and supported properly. Ladders shall be properly tied throughout the vertical height of scaffold as it progresses. Temporary railing by rope or pipe shall be carried out on the scaffolding platform where persons are working. Scaffolds shall be used for the purpose to which they have been erected. They shall not be overloaded under any circumstances. Suitable and sufficient material shall be available in order for the scaffold to be erected properly. The spacing between standards is determined by the intended use of scaffolding. Use of safety belts shall be ensured. Scaffolding shall be provided with adequate ties / supports in order to prevent collapse. Effective actions shall be taken by supervisions in order to ensure that scaffolding defects are rectified immediately. The pins used in the props for the adjustment of height should be of uniform diameter for all the props & minimum possible length. PVC bushes should be fixed on both the ends of the pin to aoid injury to head or eyes while operations. Personnel working on scaffolds shall be instructed not to interfere or alter and existing scaffold. Any person on top of scaffolding must make sure at first that the scaffolding is properly secured by bracings and is safe. Any plank put on the scaffolding for bridging the gap must be tied properly to the pipe to avoid tilting of planks. Scaffold materials shall be strictly prohibited. Surplus boards and fitting shall be removed from platform as the work progresses and at the end of day. It is primary responsibility of the concerned Engineers / Supervisors to see that proper and effective scaffolding are arranged.
176

17.0 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) ELECTRICAL SAFETY Electrical work shall be carried out by trained and experienced electricians. These personnel shall understand the hazards, which may arise during work, and precautions, which are required to be taken. Working on live conductors or on electrical equipment shall be carried out only under appropriate work procedures. Jointing of cables should be done with proper lugs and joints shall be covered with insulating tape. Safe means of access shall be provided for electrician required to work at height. Insulated tools shall be used in order to carry out electrical work. Cable shall be laid in such a way that it shall not cause slips, trips and falls. Cables shall be provided underground or overhead to avoid damage wherever possible. Temporary electrical light points / fixtures shall be fixed on wooden posts. Special attention shall be given for proper earthing of cable and equipment. Earth leakage circuit breakers (ELCB) shall be used for electrical installation / equipment. Cabling shall be done by using cables of suitable size and rating. Protective gloves shall be used in electrical operations involving high voltage (440V). Earthling shall be fitted to all distribution boards and metal support frames. Colour coding shall be used to easy identification of electricians. Workers should not be allowed to take electrical connection in hut on his own but only authorized electrician should provide the connection with prior approval of Site l/c. The same shall be checked periodically.
177

18.0 1) 2) 3) NIGHT WORKING When occasions occur that require working at night, the Site l/c, Safety officer, Concerned l/c shall ensure that all necessary precautions are in place. Flashing lights and adequate lighting shall be made available at all work locations. Cables installed for the purpose of temporary lighting shall be routed to ensure that they do not present a trip hazard or other obstructions. They should be sufficiently buried in the ground or laid on the poles at sufficient height. The junctions and switch boxes should be away from the road & building and should be protected against rain. They should be operated by authorized electricians only. All points of exits, pathways shall be illuminated. Availability of election shall be ensured during night working.
4) 5)
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19.0 PERSONAL PROTECTIVE EQUIPMENT (PPE)
Personal protective equipment (PPE) is defined as equipment designed to worn or held by individuals to protect themselves against work related hazards, which may endanger their health and safety. 1) 2) 3) 4) 5) 6) The risk posed in any particular work activity shall be assessed, and adequate PPE selected accordingly. The safety helmets and safety shoes shall be used in addition to above all other PPE wherever necessary. Safety goggles and ear protection shall be used in addition to above all other PPE wherever necessary. Safety belts shall be provided, worned and properly secured in all work situations where there are chances of falling. Clothing of the workers / Supervisors / Engineers should not be loose fitting to avoid mishaps. It is the responsibility of concerned Engineer / Supervisor, safety engineer to ensure that workers wear safety belts wherever necessary with all other PPE before start of work.
179

20.0 PERSONAL PROTECTIVE EQUIPMENT
1. Head Protection All Employees, visitors and vendors shall wear a hard hat in designated areas. The hat shall be worn properly. The only exception will be welders whose hats ay have to be reverse to accommodate welding shields. 2. Eye & Face Protection Eye injuries are the most frequent type of injuries, which can be prevented by wearing proper eye protection. Employee shall ware approved safety glasses in designated area. 3. Hearing Protection All employees exposed to noise in excess of 85 dB (A) in an eight hour day shall wear hearing protective devices. This could include situations where equipment such as jackhammers, saws, drills, grinders, sandblasting operation etc 4. Clothing Employees must were clothing suitable for the work they are performing color scheme to be followed as per company regulations. 5. Feet Protection All employees shall wear safety shoe/boot as per recommended practices of the company. 6. Hand protection Gloves should be worn when handling objects or substances that could cut, tear, burn or other wise injure the hands, employees using gloves should inspect them for defects prior to each use. 7. Safety Belt, Body harness, Lifeline Safety belts/ harnesses and lifelines shall be used when other safeguards such as guardrails, planking, and scaffolding cannot be provided. Ensure safety lines member capable of substantiating. The safe guard shall be secured to a structural member capable of sustaining the force imposed if you were to fall protection device that the Shock loaded must be removed from services and destroyed immediately
180

20.0 FIRE
This is an oxidation reaction releasing heat and flame. Classification of Fire a) Class A Fire : Fire involving solid combustible materials of organic nature such as wood, paper, rubber, plastic where the cooling effect of water is essential for extinction of fires. Fire involving inflammable liquids or liquefiable solids or the like where a blanketing effect is essential. Fire involving inflammable gases under pressure including liquefied gases, where it is necessary to inhibit the burning gas at fast rate with an insert gas, powder or vaporizing liquid to extinguish. Fire involving combustible metals, when the burning metal are reactive to water and water containing agent and in certain cases a Carbon dioxide, Halogenated hydro carbon and ordinary dry powders. This fire requires special media and techniques to extinguish
b) c)
Class B Fire Class CFire
: :
d)
Class DFire
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20.0 FIRE
1) 2) 3) 4) 5)
In case of fire, preventive measures shall be ensured at site and at labour camp. All fire doors / Shutters, passages and exit doors shall be kept unobstructed. Good Housekeeping shall be maintained through out the construction activity. Main electrical equipment shall be switched off when not in use. Fire extinguisher shall be provided at prominent locations, which can be used in case of fire and training shall be given for the use of fire extinguishers. 6) In addition, sand and water buckets shall also be provided at prominent location. 7) If the fire is out of control, the intimation shall be given to fire brigade to avoid further risk.
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20.0 TYPE OF EXTINGUISHER
Sr.No . 1 2 3 4 5 6 7 8
Type of extinguisher Soda acid type fire extinguisher (IS 934,IS5506) Water type fire extinguisher (Gas Cartridge, IS 940) Water type fire extinguisher (stored pressure) IS 6234 Chemical foam type fire extinguisher IIS 933, IS 55047, IS 10474 Mechanical foam type fire extinguisher (IS 10204) Dry powder type , fire extinguisher (IS 2171, IS 106587) Dry Powder type fire extinguisher IS 11833 Co2 type fire extinguisher IS 2818, IS 8149
Type of fire A S S NS NS NS NS NS NS B NS NS S S S S NS S C NS NS NS NS NS NS NS S D NS NS NS NS NS NS S NS
N. B (S = Suitable, N.S. = Not Suitable)
183

21.0 DIESEL STORAGE
1) Petrol / diesel and inflammable materials like paint / varnishes shall be stored separately from each other with all safety precautions. 2) Temporary shade shall be provided for the storage. 3) Fire extinguisher shall be provided at prominent locations, which can be used in case of fire and training shall be given for the use of fire extinguishers. 4) In addition, sand buckets shall also be provided at storage area. 5) No smoking sign shall be displayed near the storage area. 6) Mobile phones should not be used near storage area. 7) No welding activity should be carried out near fuel storage area.
184

22.0 CONSTRUCTION OF ROADS
1) 2) 3) 4) 5) 6)
Barrication shall be erected around excavation pits / areas. Heavy equipment shall be kept sufficiently away from the excavation trench. Personnel to weaar suitable footwear, safety helmet at all time. Safety belt to wear while working at height. Scaffolding shall be provided with adequate ties / supports to prevent collapse. It the prime responsibility of Engineers and Supervisors to ensure safety of scaffolding. 7) Diversion boards shall be displayed at required locations to maintain the existing traffic flow smoothly. 8) Cautionary signs and boards shall be displayed at required locations. 9) Mask shall be used by persons working near the Crushers and Quarries where there is a generation of dust. 10) At night, adequate lighting shall be provided at road diversion and also at work places. 11) Erosion of banks of river or creeks due to flow of water shall be anticipated, while using areas on the banks.
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24.0 LABOUR CAMP
1) Temporary accommodations shall be provided to workforce as per the requirement. 2) Subcontractors including their subcontractors are fully responsible for ensuring that the arrangements provided shall be maintained. 3) Domestic waste from the camp shall be stored in predetermined collection points prior to their removal and disposal. 4) Use of heaters shall not be allowed for cooking in labour huts. 5) House keeping shall be prime important in the camp and shall be maintained at all time. 6) First aid box shall be made available at security gate & at convenient place, with all medicines, band- aids etc. and they should be easily accessible. 7) Expiry dates of medicines shall be checked frequently by safety officer. 8) Drinking water and service water shall be supplied as appropriate. Drinking water shall be properly covered and extracted with special device. 9) Creche shall be provided for the children staying in camp along with caretaker. 10) Fire extinguisher shall be provided at priminent locations, which can be used in case of fire. 11) Centralized illumination shall be provided. 12) If there is fire, the nearest fire extinguisher can be used to put out the fire. In addition, sand buckets shall be provided as per the requirement. 13) Toilet facility shall be provided at camp. 14) No Alcohol policy shall be strictly followed. 15) Emergency vehicle shall be made available at site.
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30.0 FIRST AID MEASURES
1. First Aid Training To render skilled assistance in the cases of accident / injury, site administration shall arrange to provide first aid training to the employees. 2. First Aid Box. First aid box shall contain all required medicine and emergency medicine for the treatment of injured as mentioned in contract labour and abolition act 1948 3. DOS AND DONTS FOR FIRST AID DOS Do the first thing first quickly quietly and calmly. Stop servere bleeding, if any. Administer artificial respiration if required and continue it till the doctor arrives. Treat for shocks Boost up the morale of the victim to lessen his anxiety Arrange for immediate treatment for qualified doctor.
DONTS Avoid crowding around the victim. Unless REUIRED DO NOT REMOVE CLOTHS. Dont try to achieve too much Dont soak the victim to wake him up.
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CHECK LIST FOR SAFETY PRECAUTIONS
Project :_______________________________________ Date:___________ Location :______________________________________
Sr. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Particulars Shoes / gumboots are worn by concerned works? Safety helmets / safety belts worn by workers working at site & at higher level? Safety goggles / hand shields/ welding helmets/ leather gloves worn by workers doing welding work? Openings, corners & edges are guarded with barriers? Availability of first aid boxes at different sections is checked? Expiry dates of medicines available in first aid boxes are checked? Does any workman happen to ride on the bucket/ component which is being lifted? All electrical cables are laid underground or overhead on wooden poles? (Except temporary lines) Live Joints / cable joints are insulated/ protected by insulation taps or chamber? Warning signs as Danger -440 VOLTS, NO SMOKING & other safety slogans are displayed?
Remarks (Yes /No/Not applicable etc)
188

CHECK LIST FOR SAFETY PRECAUTIONS
Project :_______________________________________ Date:___________ Location :______________________________________
Sr. No. 11. 12. 13. 14
Particulars Fire extinguisher & sand buckets are available at the point of storage where inflammable materials are stored? Whether children are observed very near construction work? Whether diversion boards are displayed at required locations? Whether cautionary signs and boards are displayed at required locations? Safety officer
Remarks (Yes /No/Not applicable etc)
189

TREATED EFFLUENT TEST REPORT SR. No. i) ii) iii) Biochemical Oxygen Demand (as BODS) Total Suspended Solids COD Permanent Pollutants Value Treated As per effluent norms 5 or less mg/1 10 or less mg/1 Less than or equal to iv) v) pH Oil and Grease 50 mg/1 7-9 Less than or equal to vi) Ammonical Nitrogen 5 mg/1 Less than or equal to vii) Nitrate Nitrogen 2 mg/1 Less than or equal to viii) Total Phosphorous 10 mg/1 Less than or equal to ix) Focal coliforms 2 mg/1 Less than or equal to 100 nos. / 100 ml STAFF ENGAGED ON OPERATION AND MAINTENANCE WORK Remarks
190

Position / Designation Manager Supervisor / Degree or diploma in civil / mechanical electrical engineering of equivalent Year 10 Nature Construction operation maintenance infrastructure project. in Preferable water public / and of Minimum Qualification Minimum Experience
supply / sewerage Pump Operator / ITI certificate in trade of mechanic / electrical wireman trade 5 system . Workshop Pumping electrical Fitter / Plumber ITI certificate or 5 installation. Workshop / water supply or sewerage installation / stations
Electrification
treatment plants /
equivalent / License in plumbing
The positions and designation of key staff in this list are indicative and for guidance only. The Tenderer shall propose the position, designation, number and other specifications of the key staff it considers essential to perform the functions in this work.
191

ATTACHMENT 1 DAILY SUMMARY OF OPERATION AT PUMPING STATION Date : __________________ Pumps Set Hours of No. operation Wet well level in meter Energy Consumption Initial Final Total reading reading consumption Time power failure Diesel consumption of DG Set
192

ATTACHMENT 2 DAILY SUMMARY OF OPERATION OF EQUIPMENTS Date : _______________ Diffuser Se Hours t N o. of operati on Other Equipments Descripti Hours on of Operati on Emergency Consumption Initial Final Total readi ng readi ng consumpt ion Tim e pow er failur e Diesel consumpti on of DG Set
193

ATTACHMENT 3 SEWAGE QUALITY MONITORING AT SEWAGE TREATMENT PLANT Date: ________________ S r. N o. Loca tion of sam ple Colle ction Anal ysis Rep ort Para meter Val ue Para meter Val ue Date and Time of Influent Effluent Effluent Standard Para Val meter ue Rem ark
TREATED EFFLUENT TEST REPORT SR. No. Permanent Pollutants Value Treated As per Remarks
194

effluent i) Biochemical Oxygen Demand (as BODS) norms 5 or less mg/1 ii) iii) Total Suspended Solids COD 10 or less mg/1 Less than or equal to iv) v) pH Oil and Grease 50 mg/1 7-9 Less than or equal to vi) Ammonical Nitrogen 5 mg/1 Less than or equal to vii) Nitrate Nitrogen 2 mg/1 Less than or equal to viii) Total Phosphorous 10 mg/1 Less than or equal to ix) Focal coliforms 2 mg/1 Less than or equal to 100 nos. / 100 ml
STAFF ENGAGED ON OPERATION AND MAINTENANCE WORK Position / Designation Manager / Degree or diploma in civil Year 10 Nature Construction / Minimum Qualification Minimum Experience
195

Supervisor / mechanical electrical operation maintenance infrastructure project. in Preferable water public and of engineering of equivalent
supply / sewerage Pump Operator / ITI certificate in trade of mechanic / electrical wireman trade 5 system . Workshop Pumping electrical Fitter / Plumber ITI certificate or 5 installation. Workshop / water supply or sewerage installation / stations
Electrification
treatment plants /
equivalent / License in plumbing
The positions and designation of key staff in this list are indicative and for guidance only. The Tenderer shall propose the position, designation, number and other specifications of the key staff it considers essential to perform the functions in this work.
196

ATTACHMENT 1 DAILY SUMMARY OF OPERATION AT PUMPING STATION Date : __________________ Pumps Set Hours of No. operation Wet well level in meter Energy Consumption Initial Final Total reading reading consumption Time power failure Diesel consumption of DG Set
197

ATTACHMENT 2 DAILY SUMMARY OF OPERATION OF EQUIPMENTS Date : _______________ Diffuser Se Hours t N o. of operati on Other Equipments Descripti Hours on of Operati on Emergency Consumption Initial Final Total readi ng readi ng consumpt ion Tim e pow er failur e Diesel consumpti on of DG Set
198

ATTACHMENT 3 SEWAGE QUALITY MONITORING AT SEWAGE TREATMENT PLANT Date: ________________ S r. N o. Loca tion of sam ple Colle ction Anal ysis Rep ort Para meter Val ue Para meter Val ue Date and Time of Influent Effluent Effluent Standard Para Val meter ue Rem ark
199

200

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Gharpure Engineering & Constructions (P) Ltd.

50 MLD STP AT KALAMBOLI QUALITY MANUAL

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

MCC & Control Room ,.,Tool Room , 1 No work shop 1 No 1 No

Gharpure Engineering & Constructions (P) Ltd.

Ashutosh Awasthi Chief Executive officer

Suresh N. Gharpure Managing Director

Gharpure Engineering & Constructions (P) Ltd.

GHARPURE ENGINEERING & CONSTRUCTIONS (P) LTD.

MR. SHRIRAM N. GHARPURE DIRECTOR

MR.SURESH N. GHARPURE MANAGING DIRECTOR

ACCOUNT OFFICER PURCHASE MANAGER ADMINISTRATIVE OFFICER

TECHNICAL SUPPORT QUALITY CONTROL

TENDERING&MARKETING PROGRESS MONITORING

SR. ENGINEER JR. ENGINEER

SR. ENGINEER JR. ENGINEER

PROJECT DIVISION EXICUTION PROJECT MANAGER

SUPPORTING STAFF RESIDENT ENGINEER

JR. ENGINEERS SUPERVISORS

Gharpure Engineering & Constructions (P) Ltd.

PR O JEC T M A NAG E M E NT STR U C TU R E

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

Scope of the Quality Management System:

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

2.4.2 Quality Management System Planning

Gharpure Engineering & Constructions (P) Ltd.

Responsibility, Authority and Communication

2.5.1 Responsibility and Authority

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

2.6.2 Review Input

Management Review Inputs

Gharpure Engineering & Constructions (P) Ltd.

2.6.3 Review Output Management review output consists of the following:

Resource Management Provision of Resources

Gharpure Engineering & Constructions (P) Ltd.

3.2.1 Competence, awareness and training

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

4.2.2 Review of requirements related to product

Gharpure Engineering & Constructions (P) Ltd.

4.3.1 Design and Development Planning

Gharpure Engineering & Constructions (P) Ltd.

Design and Development Output

Gharpure Engineering & Constructions (P) Ltd.

Design and Development verification:

Design and Development validation

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.

Tags/Labels Not applicable

Storage Protection per On wooden As instructions or as reapers/bins

Project Code Manual

The stock Ledger for raw materials is maintained.

Gharpure Engineering & Constructions (P) Ltd.

Gharpure Engineering & Constructions (P) Ltd.