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1. Course no PGPPM 23

2. Module M 56

3. Course Title Construction quality, safety andenvironment

4. Candidate Name G.S.VINOD VASAN5. Reg. No. 211-03-31-9250-21336. Assignment No. 17. Date of Dispatch8. Last date of receipt 28 February 2012

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ASSIGNMENT

You have been selected as a project manager for a prestigious high rise building in Mumbai

which will be housing very rich personalities from industry and film world.

Your company management has asked you to formalize Quality management system (QMS)

for interior finishes, plumbing and prevention of rainwater seepage so that the overall quality

standard and image of the company is raised.

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QUALITY POLICY STATEMENT:

To consistently meet and strive to exceed the agreed requirements of our clients in the most cost

effective manner by providing a high standard of Management, Technical expertise, Workmanship

and timely completion of the project.

This will be achieved by employing highly professional people with drive and determination to work

as a team with our Clients, Architects, Consultants subcontractors and Suppliers in a non-

adversarial manner. It is our commitment to maintain a management system which reflects the way

our business works, our clients needs and the requirements of the international standard for

Quality systems ISO 9001:1994

QUALITY MANAGEMENT SYSTEM

An established system of Management of Quality is followed aiming to achieve the following

Establishing an international standard of procurement and work practices. Resolving specific problem areas covering technical, product or system issues Investigating new methods of work and ideas. Innovation in the existing procedures and practices Continuous Improvement

This is achieved by proper planning, monitoring, control and co-ordination of the following

Design Intent Documentation Subcontractor Selection Contract Project Program Procurement Strategies Construction and Review of Methodologies

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DESIGN

Programs and Manage the flow of Design information plan the project and oversee the work ofthe subcontracts so that the project is completed in accordance with the drawings, specifications,

program, safety and cost plan.

Systematically assess proposed design, drawings and specifications for practicability,Buildability, program effect, coordination, potential Quality and value for money and make

appropriate recommendations to the Designers.

DOCUMENTATION

All pertinent incoming/ out going documents for the project will be controlled in accordancewith the Document control procedure, which will ensure their effective recording and review. It

will also provide for the subsequent controlled distribution of Documents and Destruction or

removal of obsolete documents

The Document control procedure will identify all requirements for long term storage,maintenance and retrieval of archive records including defect liability period (DLP).

Ensuring the subcontractor to maintain records and detail it in their Quality Plan and submit tocontractors/Consultants for inspection and approval as and when required.

Generating handover documentation, performance histories, performance reviews and testingand commissioning reports during handover phase.

SUB-CONTRACTORS

All subcontractors are thoroughly reviewed in terms of Quality, Buildability and performanceduring the bid process and during project mobilization. Continuing reviews are undertaken at

regular contract progress meetings with all relevant parties.

All changes and addition to subcontracts are reviewed on receipt to ensure that the requirementsare adequately defined and will be able to be met by the subcontractor appointed.

All the guarantees, warranties and performance parameter setout in the specifications/agreedwith the clients and consultants are forming part of subcontracts to ensure that the set out

standards are met.

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PROJECT PROGRAMME

Requirements to Client

A detailed contract programme shall be prepared and monitored on a weekly basis and reportedto client as and when required. A target schedule shall be prepared by the planning engineer and

issued to the package managers package wise for monitoring on a weekly basis.

Progress photographs shall be taken and issued to client. Reasons for the slippage in the activities shall be documented; the mitigation strategy for the

same shall be agreed by the team.

Delay trackers shall be maintained and reasons for the delay shall be documented.

Requirements from Subcontractors

Subcontractors to submit a master Programme for the entire scope of works as outlined in thecontract and adopt the same as a base Programme after the approval

The programme shall be updated on a weekly basis and submitted. Subcontractors to submit weekly/ Bi-weekly programs, which will be matched with the baseline

and will be closely monitored.

PROCUREMENT

Goods and services will be procured from acceptable services and conformance to thespecifications. The selection of such sources will be by short listing based on the analysis of

Pre- Qualification Questionnaire from the following,

- Procurement database- Client standing lists- Architects/Consultants- Design team Input- Project Team recommendations- Enquiries from Trade Sub-Contractors

A thorough Technical Bid Analysis (TBA) would be carried out to ensure all the specificationsare well understood by the subcontractors before they are awarded the subcontract

The appointed Subcontractors/Suppliers will be required to provide appropriate Qualitydocuments with the means to confirm the Quality is being competently addressed and

implemented at all levels.

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Subcontracts and purchase orders will contain all relevant information and are reviewed prior toissue.

Necessary inspection/test shall be conducted on purchased equipment/specialized items at thesuppliers or Subcontractors premises including access for the Clients representative/ architects

and Consultants if required, to ensure the right material/product usage.

CONSTRUCTION

Methods of monitoring the activities of Subcontractors will include, but not limited to, the

following

Management of the subcontractors process in accordance with the contract and Head Contractto avoid the rework caused due to not understanding the design. This is made clear through to

the subcontractor by asking them to submit method statements, which will be reviewed and

approved, before they procure and execute the works.

Auditing subcontractors Quality Management Systems and their implementation. Involvingsubcontractors quality dept. and senior management personnel

Review and approval of method statements and monitoring their implementation Witnessing activities, inspections and tests Surveillance and site inspection Checklists Mock up and Approval. Material Inspection and Testing ( MTR) Corrective Action Requests (CAR) Control of Non-conforming Products Review of records and Data. Closeout Procedures DLP Quality audit from BLL HO

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Management of the Subcontractors process in accordance with the subcontract and Head Contract

The subcontract will be ensured to be followed by contractors in its full spirit and

contents. This will be monitored by means of progress meetings. All changes will be

reviewed on receipt to ensure that the requirements are adequately defined and executable.

All these are properly documented and will be ensured executed by means of Progress

Certificates and Change management procedure as agreed between Client, Contractor,

Architects and Consultants.

Auditing Contractor and Subcontractors Quality Management Systems and theirimplementation.

The Construction manager (head of QA/QC) will be in-charge of arranging audits of

all activities to ensure compliance with the operating procedures. He will carry these out by

periodical audits in accordance with the checklists /records/MTRs as set out in this

documents. The audit program will cover the following categories of audits.

Internal Audits of Contractor Site and HO External Audits of suppliers and Subcontractors where appropriate by package managers Audits of Contractor by Architects and Consultants on behalf of clients. All quality audits whether internal or external, will be carried out in accordance with the

quality system auditing procedures. These procedures will also cover the distribution or

reports and method of follow up and close out of findings

A summary of visits and audit and comments of auditing personnel shall be issued

monthly, attached as part of PCG report. Findings and discussions of PCG shall be

implemented and used for closeout and regularly issued in the next PCG.

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Review and Approval of Method Statements and monitoring their implementation.

Subcontractors will be instructed to submit a ten point Method Statement prior to the

commencement of any work in which they need to describe point to point the system and

procedures followed by the contractor in purview of Quality, Safety, Documentation while

executing the work. These method statements will be analyzed and approval will be given

under three heads

A- Approved for constructionB- Approved with suggestionsC- Rejected

If the Status of approval is B or C the contractor has to re-submit the document and

get the approval prior to work.

Witnessing activities, inspections and tests

Subcontractor shall give sufficient intimation for witnessing inspection and testing

and will provide the details of the tests need to be conducted and observations to be made.

However contractor will provide sufficient guidelines for ensuring proper Inspection and

tests and will also have an overall supervision of works to ensure the utmost Quality of

works.

Package managers on the guidelines set in this manual do inspection and testing of

the materials on day-to-day basis.

The broad guidelines have been already agreed in the consultants meetings, they

shall be used to update existing or develop the MTRs and Checklist.

Surveillance and site inspection

Contractor engineers will have a thorough surveillance and regular site inspections to ensure

that subcontractors are performing to the required standards so as to deliver a high Quality

product as per the contract, Specifications and Client Expectations.

Checklists

Contractor has got a vast range of checklist to cater to almost all works and practices

in the industry. Further customized checklist will be prepared based on the broad heads

agreed between consultants and Contractor

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Mock up and Approval

Contractor will submit samples of materials and Mockups prior to start of any work

thro Mockup-flow chart Subcontractor will be instructed to submit samples of materials

and Mock up of works prior to the start of any work . The same will be got approved from,

client/ consultant to ensure utmost justification to their expectations.

Corrective Action Requests (CAR)

Incase of the works getting done which is not conforming to the method statements

resulting in faulty works/unacceptable quality, BLL will raise corrective action request on

the subcontractor asking for the review of works with reference to the methods agreed.

In case of methods agreed does not result in final expected product, Contractor will

raise the CAR on subcontractor asking for a discussion/ to find the causes and involve the

entire project team to review the revised method statements addressing all the root causes

for the failure. The package managers are asked to make closeout reports for the CARs,

which will be sent.

Control of Non-conforming Products ( NCR)

Subcontractors will be asked to identify non-conforming work by means of physical

identification or quarantine. The subcontractor will be issued with, or be required to issue, a

non-conformance report and required to state what action will be taken to correct non

conforming work and prevent its recurrence.

Review of records and Data.

The records and Data generated in the due course of project will be analyzed using

Statistical Techniques and forms the base of a continuous improvement process.

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Close Out Procedures.

Project Finalization Plan shall be prepared integrated in to the program and implemented thro

checklists for the following areas.

1. Technical Close-out :(This shall be done package-wise and detailed program andchecklists shall be prepared.

2. Contractual close-out: Ensuring obligations in head contracts are closed out andcorresponding close-out of subcontracts package-wise and all their accounts settled

3. Establishment of Handover procedure for subcontractors to Contractor and Contractor toClients

4. Design close-out: Furnishing of As-built documentation from subcontractor toContractor, Contractor to clients and Consultants to Clients

5. Handing over to the Operation and Maintenance Team

For achieving all the above five points a project finalization meeting shall be conducted to

define the team, roles and responsibility

Defect liability Period

Contractor shall serve DLP as per the conditions of contract,

Contractor shall inform all the list of all vendors with a name of contact person,addresses and any other form of communications available with the vendor for

establishing the long-term service set up and contact during the DLP. Also Contractor

will identify the contact during the DLP who shall be informed by the client in case of

any support required from the vendors.

Incase, vendor fails to address the issue to the satisfaction of the client, Contractor beintimated by the client. Contractor on advise from the client shall initiate a process of

addressing the defect/operational issues during DL period, shall coordinate with the

vendors and consultants (if required) to arrive at the required action plan to be carried

out by the vendor.

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QUALITY CONTROL STANDARDS AND SPECIFICATIONS:

The quality of construction depends upon right materials used, the correct methods followed and

produce end product of acceptable performance. Quality control attempts to ensure just that much.

The means of quality control are tests, inspection, supervision and analysis of data etc. Quality tests

are conducted in laboratories and inspection and supervision are carried out on the site and experts

in office do the data analysis.

Specification

The project authorities prepare the process of working out specification of various facilities

where concrete will be used. However, the standards and specifications for concrete and its various

ingredients are universally standardised and they are required to be in conformity with it. Indian

Standards IS for concrete and it basic ingredients viz cement aggregatescoarse and fine, water

admixtures and various aspects of concreting, its placement and final acceptance should be as per IS

specification.

Tests

Tests are used to determine the various properties of the materials, which help in their

selection as well as for ascertaining the quality of final product. The test results are compared with

the prescribed standards and specifications and judgments are arrived at. Proper methods of

sampling, prescribed procedures of testing, well qualified and trained personnel for testing work

and properly equipped laboratories are necessary.

What to Test

The manufactured goods such as cement and steel carry their suppliers warrantee but this does

not mean that they are not to be tested. In case of materials like aggregate and water the properties

may vary widely over time and space and proper selection has to done to meet the engineering

requirements. The raw materials are processed to obtain the final product. The processing needs to

be tested and supervised carefully. Testing of final product is important. This helps to ascertain:

i. Conformity to specificationii. Validity of design assumptioniii. Need of modification due to any erroriv. Comparative position of work at different sites.

The data analysis and interpretation becomes meaningful only if observations are adequate

and frequencies are numerous in relation to the volume and importance of work.

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INSPECTION

Inspection is the act of physical verification of the subject work on the site and under normal

day-to-day working conditions. The inspection for quality is done by quality control Inspectors who

are posted at all active sites and who should be persons at deputy engineer and above levels. They

are a member of the quality control team and unrelated to the production process directly.

1. The duties of quality control inspectors are as under:2. Check that the input materials brought at site are as per specifications.3. Check that the working is proceeding in accordance with the specifications and bring the

substandard work to notice of concerned authorities.

4.

Inspect personally and regularly the work in progress at sites.5. Review the previous days "Daily QC" reports filed by the Field Quality Control units

and convey immediately to the concerned site incharge and any adverse results and

recommendation for rectification.

6. Verify that the results of the tests received from labs have been duly attended to andsend them to seniors in the department.

7. Prepare daily report of inspection on the prescribed forms and send to seniors in thedepartment.

8. Check to ensure that QA manual for workers and supervisors are available at hand atworkstations that they are not in torn stage, that they are easily accessible and that they

are being referred to.

9. Check to ensure that copies of contract conditions particularly regarding specificationsand related matters are available at site offices and are being referred to.

10.Check that all equipments plants are in proper working condition and that they conformto IS specifications.

11.Investigate the case where the test results of input materials are satisfactory but that of inprocess stage are not, or there is a discrepancy in test results during in process and end

product stage and find out the causes of mishap.

12.Investigate the human factor and machine condition/capability more particularly.

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Concreting- Making and transportation

Ingredients of Concrete

Cement

Use of appropriate grade of cement as recommended by the consultant and confirming to IS456:2000

Manufactures test certificate should accompany each consignment and cement should beconsumed within one month of manufacturing date.

Cement should be properly stored in stacks not more than ten bags, clear from the wallsby one meter and protected at all time from moisture. However do not wrap the bag with

polythene sheets as sweating may occur.

Identify each lot of cement and follow a FIFO (first in first out) method of issue of bags. Each consignment of cement should be tested in house for consistency, setting time, and

strength.

Aggregate for concrete

For RCC works coarse aggregates confirming to IS 383 and IS 2386 having maximumsize of 20mm and down.

It should be obtained from crushed granite, trap, and basalt quarry. it should bechemically inert , rounded or angular in shape and free from dust, foreign matter and not

thin ,porous ,laminated or flaky.

Fine aggregate shall be gritty sand with FM range between 2.6 to 3.2, silt content shouldnot be more than 5% and there should be no traces of salt. Aggregates with specific

gravity less than 2.6 should not be used.

If dirty wash the sand before use. Sand should be clear of organic materials

Water

Water must be clean, fresh and free from oil, alkali, acid and organic matter. Potable water is considered good for concreting and curing. IS 456:2000 gives permissible limits of solids.

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Admixtures

Use of admixtures/additives must be done only after obtaining clearance fromtechnical consultants.

Accelerators, plasticizers, retarders, integral water proofing compound are theadditives commonly used.

Expiry date of the chemical must be checked before use.

Mixing of concrete

In-situ mixing

Ensure adequate stock of all ingredients of concrete Use calibrated farma for measurement or in case of weigh batching, use a weigh

batcher machine.

Charge the rotating drum with 25% of required water to rotate 3-4 times. Generally 20-25 litres of water is recommended to one bag of cement. The water

cement ratio is kept to 0.4 0.5. The moisture content of aggregates should be

checked at frequent intervals.

Load the hopper with the coarse aggregate followed by the fine aggregate.Above this the entire quantity of cement should be spread. Then the quantity

of fine aggregate followed by balance coarse aggregate should be loaded. This

type of sandwiching is done to avoid the spillage of cement while discharging

into the drum. Immediately after loading the drum balance quantity of water is

added.

The drum should be rotated for at least 1.5-2 minutes. The rotation of drum isabout 15-20 revolutions per minute.

If plasticizer is used one litre of water must be held back. Add requisite quantityof plasticizer to water and mix it thoroughly. This mixture is poured into the

drum after the drum has rotated for about one minute. The drum must be rotated

for atleast one minute after adding the plasticizer mixture to ensure proper

dispersion.

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GRADE Characteristic

strength after 7 days

(n/mm2)

Characteristic

strength after 28

days (n/mm2)

Minimum cement

content per cum

M10 7 10 220kgs

M15 10 15 280kgs

M20 13.5 20 320kgs

M25 17 25 360kgs

No grade below M20 shall be used for RCC works. Concrete must be placed in position and compacted within half an hour of

mixing of the same.

Always keep a supervisor on the mixer to monitor the works. Use large band lies, wheelbarrows, and hoist machine to expedite

transporting process. Wet the surface of the carrier to avoid moisture loss due

to adsorption.

Be careful to avoid segregation and wastage during transportation. In case ofsegregation, remix the concrete before placing.

Concrete by vision must be homogeneous in colour, well graded, fluffy and itshould form a shape of ball when rounded in the hands.

Batching plant mix (RMC)

Preference for RMC concrete from reputed companies possessing automatedbatching plant, at least 30 cum per hour capacity supported by adequate number

of transit mixers.

The logistics should be worked out so as to receive atleast one load of 6 cumevery ten to fifteen minutes.

Check the empty transit mixer for preset concrete in the drum. Preset quantityaffects the quantum of concrete received.

Concrete should be received with a delivery challan and data cycle sheetshowing grade, quantity, water cement ratio, slump, cement content, time of

manufacturing, dosage of additive added, weight of various ingredients of

concrete.

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Go through the data cycle sheet before accepting the concrete, and get yourselfconfirmed whether the weights of the ingredients as per the data cycle sheet is

similar to the one in the design mix report prepared for the project. This is very

essential because, the RMC shall be accepted for the work only based on this

validation.

Do not accept concrete after 3 hours of mixing. Do not recharge the concrete by adding additive, water, cement without prior

permission from the project in-charge.

Slump recommended for RMC mix is 100mm to 125mm Place the concrete pump on horizontal, hard even surface and keep the approach

area free of materials to facilitate easy maneuverability of transit mixers. The

approach should not slope towards t5he concrete pump.

The horizontal section of pipe should be at least 7 meters before the vertical bendis put.

Reduce the length of pipe to the minimum to reduce frictional losses andexcessive strain on the pump.

The pipeline should be independently supported on vertical segment and not onthe shuttering. The vibrations due to pumping should not affect or displace

shuttering works.

Pump rich slurry (one bag) before pumping concrete to lubricate the innersurface of pipes.

In case of intermittent supply keep the current transit mixer unloading inprogress until the next mixer arrivers at site. This avoids choking of pipeline due

to non-pumping for long duration. Avoid reverse stroke to clear a choke. The

fluid gets flushed out and the problem gets compounded.

Do not bend the flexible end pipe by more than 135 degrees while concreting. In constricted areas do not unload directly from the pipe. Use bandly and mumty

to shift and place concrete in such areas.

Be excessively careful while passing the ball while clearing the concrete in thepipeline after the days work is over. Due to negligence somebody could get hurt.

Employ professional hands for connecting pipeline. They will do a neater andfaster job without any safety problems.

Leave the pipeline, under the pomp and adjacent areas clean of concrete dumping

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after the work is completed.

PLACING AND COMPACTION

Do not use chutes longer than 4.sm or inclined at more than 45 to horizontal topour concrete.

Place cement concrete to the required depth and vibrate it until entrapped airinside concrete is released.

Pour concrete into beams and then over the slab portion. Bond new concrete to previously poured concrete. If the previous pour was less than 4 hours prior, the laitance film and porous

layer shall be removed from the surface of previous pour.

If the previous pour was more than 4 hours prior but less than 30 days oldobserve the above process and expose aggregate with wire mesh and wash with

clean water.

If the joint is more than a month old use bonding agents as per specification ofthe manufacturer.

If the beam more than 500mm deep, concrete it in layers. Columns, beam, slab level of concrete top should be pre-marked before start of

concreting works.

Check the slab level during concreting with line dori method and also theleveling instrument.

Use appropriate needles for vibration depending on the aggregate size,reinforcement spacing and element to concrete. For big footings use 60m needle,

for slabs use 40mm needle and for starters and precast lintels use 25mm needle.

Vibrators should operate for a speed not less than 10,000 rpm. Ensure that just

adequate vibration is only done. Over vibration is very bad.

Use wooden runner to ram so as to form slurry on top of the concrete surface. Clean the shuttering works of all spilled concrete immediately after concreting. Leave vertical construction joints after consultation with the structural engineer. Match the vibrators, masons to the rate of concreting. All surfaces of shuttering shall be moistened before placing of concrete to reduce

water loss due to absorption.

Slab should be sprayed with water after covering with hessain cloth 3 hours after

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concreting, i.e. initial setting is over and ensure that hessain cloth will remain

wet till ponding of water.

Pond water to a depth of 25mm using bunds the next day and keep waterstanding for 7 days a stretch.

In case ponding is not possible, cover it with hessain cloth and keep it moistthrough out.

Do not ignore curing of slab to facilitate marking of columns for the upper slab. The beam bottoms should be cleaned using high-pressure cleaners.

Testing of concrete

Slump test

Conduct slump cone test, one during the start, one at midday and one towards theclose of days work.

Again any load on suspect can be tested on case-to-case basis.

Cube test

The sample is made at the point of discharge of mixture. Take 3 samples after 7 days and 3 samples after 28 days. The test frequency shall be in accordance with IS 456-2000. For concrete manufactured at site, there must be representative samples for

the days work and for different elements like footing, slab, column, wall.

In case of cube failure, the element to be identified and nondestructive test tobe conducted. Cube results of RMC supplier for same batch can be tested.

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QUALITY CONTROL IN SERVICES:

PLUMBING OPERATIONS

Most of the plumbing failures like water closets urinal sinks washbasins taps etc. are manufactured

units. If care is taken to obtain these items from repeated manufacturers, much of these trouble

faced later can be avoided. Plumbing problems do not usually arise out of fault in the components

used but it is their faulty installation, which cause trouble. A plumbers skill includes an ever-

widening knowledge of different types of metals and Fittings in the market.

There is a tendency on the part of plumber workman to do a shoddy job, as plumbing is time-

consuming job. Short cuts in labour are employed by workman and most of the job is covered by

flouring or concrete. As bulk of the job is hidden it is difficult to list out the quality of work. It is

only when leakages appear attention is drawn towards the installation and by that time it is too late.

WATER SUPPLY

In India major piping material is galvanised iron although plastics have started making in roads.

Pipes are jointed either by threading or by welding. During erection trash and debris should be kept

out of pipefittings and fixture. Care should be taken to prevent animals from entering into piping

system. The support of piping is critical for both successful operation of the system as well as for

the safety of the structure. The basic source of stability support is the anchorage of the support. All

pipes are to be tested to 50-kg/cin2 and pipe network tested for 10 kg/cm2 before putting them into

operation. For water supply galvanized pipes are available in three grades, which are banded with

distinguishing colours of paint. It is advisable to get pipe from repeated manufacturers only. Great

care has to be taken for jointing these pipes which is done by cutting threads and using sockets.

Workmen have a tendency to do a shoddy job. Plumber white lead (safeda) should be used while

making joints.

In water supply installation fitments are provided in the form of ball valves, globe valves, gate

valves and water taps. Ball valves are available in two types; high pressure valves used in water

mains having a pressure of 1.75 kg/cm sq. Low pressure valves have domains having pressure tube

1.5 kg/cm sq and 3.5 kg/cm sq. Every bit or stage tap should be tested on an internal hydraulic

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pressure of 20 kg/cm sq and pressure maintained for at least 2 minutes during which it will not

sweat or leak. The length of the spindle lead should be such that when the washer plate is resting on

Resting without a washer the length of the thread equals to not less than their fourth of the external

diameter of the threaded portion of the spindle. Globe valves are used for throttling. Valves are

rated according to pressure. This should be checked to ensure that valves of the proper strength of

materials are used.

SANITARY FITTINGS

For sanitary Fittings there are two types of pipes available; one is the sand cost view pipe

confirming to IS 1759 and the other one is spun cost iron pipe conferring to IS 3989. The weight of

the pipe should be checked. For sand cost iron pipes the weights for 1.8-meter length should be as

under:

75 mm dia, weight 16.52 kg excluding ears

100 mm dia, weight 21.67 kg excluding ears

For spun cast iron pipe the weight per 1.75-meter length should be as under:

75 mm dia 12.2 kg

100 mm dia 18.4 kg

In these, tolerance upto 10% may be allowed while jointing the pipe the interior of socket and the

exterior of spigot end should be thoroughly cleaned and dried. The spigot end should be inserted

into the socket right upto the back of the socket and carefully centered by 2 to 3 taps of treated spun

yarn twisted into coils of uniform thickness well caulked with the back of the socket. Lead is to be

poured later and well caulked for a tight fit. Vitreous china sanitary fittings are classified as first

category, commercial and off grade. Standard firm mark the class of fittings and mention whether it

conforms to IS specification. The wrapping paper is different for first class and different for

commercial fittings. Off grade fittings should be avoided at all costs.

Work basis can have tolerances up to 4mm or less. All internal angles should be cleanable and all

flat ruins should slope towards the bowl.

For water closet the test of performance is that six pieces of usual toilet papers of 150 x 115 mm

should get flushed three times out of four. When flushed there should be no smudge left. In case of

flushing cistern the chain should be capable of holding 50 kg load without any distortion. It is better

to insist on ISI mark cistern. For pipes the test is by a hammer and when striking it should emit

clear ringing sound.

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Floor traps should be checked for water set

1. Pipes - check for size, strength and quality2. Check valves and fittings for conformity to specification and pressure3. Check for jointing4. Check for hydraulic pressure and test for leakage5. Pipe installation should be approachable for maintenance6. Sanitary fixtures must be checked for dimension makes finish and ISI grade marking7. HCI pipe for dimension weight make finish and whether coated with anticorrosive paint8. Class of GI pipe size and made9. Water supply fittings weight makes finish and ISI mark10.Lead connection pipes and plastic connection pipes for weight size and ISI marks11.Flushing cistern whether it has ISI marks12.Sizes of brackets for wash basins sinks and flushing cisterns13.Ms clamps for fixing HCI pipes, their size and mode of fixture in cement blocks14.Quality and quantity of lead in joints15.Water tanks - thickness of sheets size of tank size of various fittings, whether tanks are

painted with priming red lead cost outside and two costs of bitumen paints inside

16.Manhole covers road gully gratings weights size, make and finish17.Home pipe class make decision and finish18.Testing of system and general quality of lines levels etc.19.Stoneware pipe makes dimension glazing and finish.

INSPECTION AND TESTING

All sanitary appliances and fitments shall be carefully examined for defects before they are installed

and also on the completion of the work.

Pipes are liable to get damaged in transit and, notwithstanding tests that may have beenmade before dispatch, each pipe shall be carefully examined on arrival on the site.

Preferably, each pipe shall be rung with a hammer or mallet and those that do not ringtrue and clear shall be rejected. Sound pipes shall be carefully stored to prevent damage.

Any defective pipes shall be segregated, marked in a conspicuous manner and their use in

the works prevented.

Cast iron pipes shall be carefully examined for damage to the protective coating. Minordamage shall be made good by painting over with hot tar or preferably bitumen. But if

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major defects in coating exist, the pipes shall not be used unless recoated.

Each pipe shall be carefully re-examined for soundness before laying. Close inspection shall be maintained at every stage in the work, particularly as to the

adequacy of timber supports used in excavation and the care and thoroughness exercised

in Filling.

Careful note shall be kept of the condition of any sewer, manhole or other existing workwhich may be uncovered and any defects evident shall be pointed out immediately to the

Authority.

No work shall be covered over or surrounded with concrete until it has been inspectedand approved by the Authority.

Testing

Comprehensive tests of all appliances shall be made by simulating conditions of use. Overflow

shall be examined for obstructions.

SMOKE TEST

All soil pipes, waste pipes, and vent pipes and all other pipes when above ground shall be approved

gastight by a smoke test conducted under a pressure of 25 mm of water and maintained for 15min

after all trap seals have been filled with water. The smoke is produced by burning only waste or

tarpaper or similar material in the combustion chamber of a smoke machine. Chemical smokes are

not satisfactory.

WATER TEST FOR PIPES OTHER THAN CAST IRON

Glazedware and concrete pipes shall be subjected to a test pressure of at least 1.5m head of water at

the highest point of the section under test. The tolerance figure of 2 litres/cm of diameter/km may

be allowed during a period of ten minutes. The test shall be carried out by suitably plugging the low

end of the drain and the ends of connections, if any, and filling the system with water. A knuckle

bend shall be temporarily jointed in at the top end and a sufficient length of the vertical pipe jointed

to it so as to provide the required test head, or the top end may be plugged with a connection to a

hose ending in a funnel which could be raised or lowered till the required head is obtained and

Fixed suitably for observation.

Subsidence of the test water may be due to one or more of the following causes:

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Absorption by pipes and joints: Sweating of pipes or joints: Cleavage at joints or from defective pipes: Trapped air.

Allowance shall be made for (a) by adding water until absorption has ceased after which the test

proper should commence. Any leakage will be visible and the defective part of the work should be

cut out and made good. A slight amount of sweating which is uniform may be overlooked, but

excessive sweating from a particular pipe or joint shall be watched for and taken as indicating a

defect to be made good. This test will not be applicable to sanitary pipe work above ground level.

FOR CAST IRON PIPESCast iron sewers and drains shall be tested as for glazedware and

concrete pipes. The drain plug shall be suitably strutted to prevent their being forced out of the pipe

during the test.

TESTS FOR STRAIGHTNESS AND OBSTRUCTIONThe following tests shall be carried out

by inserting at the high end of the sewer or drain a smooth ball of a diameter 3mm less than the pipe

bore. In the absence of obstruction, such as yarn or mortar projecting through the joints, the ball

should roll down the invert of the pipe, and emerge at the lower end and by means of a mirror at

one end of the line and lamp at the other. If the pipeline is straight, the full circle of light may be

observed. If the pipeline is not straight, this will be apparent. The mirror will also indicate

obstruction in the barrel.

TEST RECORDSComplete records shall be kept of all tests carried out on sewers and drains

both during construction and after being put into service.

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CHECKLISTS.

Following checklists shall be prepared based on the project progress and the requirements. As the

project progresses the following list shall be revised as and when required by the project team in

concept with the project manager concept (Specimen checklist attached).

CIVIL WORKS

Excavation, Back filling and Compaction (a) Shallow (b) Deep

Anti-termite treatment

Laying PCC in FoundationConcreting- For Foundation, Columns, Beams, Slabs, Lintels, Retaining walls

Pre-casting- Lintels and Curbs

Stone Cladding-

Water Proofing

Block work/Brick works

Stone Masonry

Internal / External Plastering

IPS Flooring

Rough in Sanitary works

Tiling and Dadoing

FINSIHES WORKS

Doors

Windows

Flooring

Ceiling- Gypsum, Modular

Furniture

Painting

Plumbing Fixtures and Granite Counters

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EXTERNAL WORKS

Site Grading

Roads

Parking

Drains

Walkways and Pathways

Curbs

External Signage

ELECTRICAL

Race ways

Lighting inspection

Cable trays ( Installation Inspection)

Cable trays ( Material Inspection)

Earthing Pits

Junction Box ( Installation Inspection)

Junction Box (Material inspection)

Lighting (Material / Installation Inspection)

LT cables ( Installation Inspection)

LT cables ( Material Inspection)

MV/LT Panel (Installation Inspection)

MV/LT Panel (Material Inspection)

PDB/LDB Material Inspection

PDB/LDB Installation InspectionPoint Wiring ( Installation Inspection)

Sockets and Switches ( Material Inspection)

Transformer ( Installation Inspection)

Transformer ( Material Inspection)

AIR CONDITIONING

Material Inspection

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Installation Inspection

Commissioning

PLUMBING AND SANITARY

Equipment

Piping

Panels

Performance tests

FIRE DETECTION AND FIRE FIGHTING SYSTEM

Material Inspection

Installation inspection

Commissioning

GENERAL

Welding Inspection

Final Check and take Over

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SAMPLE FORMATS

CHECKLIST FOR CONCRETING

LOCATION:

AM

PM

Sl.

No

Description Date Sign Remarks

FORM WORK :

1. Form work drawing checked

for size and details including

services.

Alignment

Plumb & Level

Condition of form work

surface

Props and Bracings

Release agent / shuttering oil

2. REINFORCEMENT :

Bar Bending Schedule

approved

Check for location of service

conduits

Extra reinforcement around

openings inserts

Reinforcement check against

BBS

Ref Drawing No

Anchorages and lap length

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Cover block in place

Links, stirrups, spacers

Rebars clean

Starter bars for column3. CONCRETE :

Availability of

materials/Equipments

Mix

No. of cubes/Slump taken

Kickers

CuringVisual inspection after

deshuttering

4. SAFETY

PPE

Access

Housekeeping

Walk way provided

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CHECKLIST FOR CEMENT

MATERIAL:CEMENT

AM

PM

Sl.

No.

Description Date Signature Remarks

1Make of Cement

2. Date of Manufacture

3. Date of receipt on site

4. Storage

5. Test certificate

6. Check Grade 43/53

7. Certificate from external

agency

8. Fineness

9. Initial setting time

10. Final setting time

11. Compressive strength

12. Soundness

13. Specific gravity

14. Any further checks

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CHECKLIST FOR FIXING ALUMINIUM DOORS

Location:

Sl.

No.

Description Date Signature Remarks

1 Is approved method statement

available?

2 Is sample approved?

3 Check for grouting of vertical

members of the door frames into the

floor.

4 Check for plumb for the door frames

with reference to masonry opening.

5 Check for fastening of door frames to

walls by screws?

6 Check for the provision and proper

functioning of the following:

a. Joints cleatsb. Pivotsc. Door closersd. Floor springse. Boltsf. Locksg. Weather strippingh.

Glazing beads

i. EPDM rubber gasketsj. Others

7 Final check for paint, surface finish,

glazing.

8 Check for overall satisfactory

functioning of aluminium door.

9 Check for protection of frame / glass10 Check for sealing of gaps

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CHECKLIST FOR PLASTIC EMULSION PAINT

Location:

Sl.

No.

Description Date Signature Remarks

1 Is method statement approved?

2 Surface to be painted is clean

and free from dead mortar, dirt,

dust, grease etc.

3 Application of mist coat (Putty)

4 Check for suitability, stability

and safety of scaffolding.

5 Check for mixing of paint with

water. Is it as per

manufacturers specification?

6 Check for proper covering of

floor surface protection to other

finishes.

7 Check for number of coats and

thickness.

8 Check for surface finish and

shade of paint as per approval.

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CHECKLIST FOR PLUMBING WORK

Location:

Sl.

No.

Description Date Signature Remarks

1 Check for completion of chasing

2 Check for alignment, level of

pipeline

3 Check for fixing and clamping

arrangement

4 Check for leakage test

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CHECKLIST FOR FIRE FIGHTING SYSTEMCOMMISSIONING

LOCATION:

Sl.

No.

Description Date Signature Remarks

1 Equipment and location

2 Drawing no./Rev.

3 Equipment as per spec/Drg.

4 Pipes & fittings as per spec.

5 Proper sizes used.

6 Welding joints proper

7 Bolted /threaded joints proper

8 Depth of laying of U/G pipe

9 Concrete pedestal provided

10 Insulation provided

11 Hydro test done

12 Holiday test done

13 Openings in wall closed

14 Posts height as per drg.

15 Hose box height as per drg.

16 Commissioning test report

available

17 Commissioning test report

available18 Proper colour code used

19 Pipe line flushed & cleaned

11 Safety:

1PPE

2 Access

3 Barricade / Hazard tape

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Organizational structure for flow of command for quality control

Quality Assurance Organization Unit at Site

Conclusions:

Quality cannot exist in isolation. It is apparent from the above that the concept of

quality should be the over all determinant in any construction process as opposed to

being a mere system of post construction checks and balances or error rectification.

Quality is best maintained if it is incorporated from the inception stages itself.