63645995-PGPM-23

1Course Name Module 56/ PGPPM

2 Candidate Name Anil Kumar B R

3 Course Title Construction Quality, Safety & Environment

4 Reg. No. 211-01-31-9055-2122

5 Assignment No. PGPM-23

6 Date of Dispatch 06.06.2012

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 client’s 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

DESIGN

Programme and Manage the flow of Design information plan the project and oversee the work of the 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 accordance with 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 to

contractors/Consultants for inspection and approval as and when required.

Generating handover documentation, performance histories, performance reviews and testing and commissioning

reports during handover phase.

SUBCONTRACTOR SELECTION

All Subcontractors are thoroughly analyzed before recommending for bidding by means of Pre- Qualification

Questionnaire and a well laid system of analyzing it through well defined and customized parameters, based on their

Quality and Safety policy, systems and procedures, experience in similar works and our experience of the previous

projects with the subcontractor.

The Architect and consultants furnish the recommended list of vendors.

SUB-CONTRACTORS

All subcontractors are thoroughly reviewed in terms of Quality, Buildability and performance during 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 requirements are adequately

defined and will be able to be met by the subcontractor appointed.

All the guarantees, warranties and performance parameter setout in the specifications/agreed with the clients and

consultants are forming part of subcontracts to ensure that the set out standards are met.

PROGRAMME

Requirements to Client

A detailed contract programme shall be prepared and monitored on a weekly basis and reported to client as and

when required. A target schedule shall be prepared by the planning engineer and issued to the package manager’s

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

Subcontractor’s to submit a master Programme for the entire scope of works as outlined in the contract 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 the specifications. 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 specifications are well understood

by the subcontractors before they are awarded the subcontract

The appointed Subcontractors/Suppliers will be required to provide appropriate Quality documents with the means

to confirm the Quality is being competently addressed and implemented at all levels.

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

Necessary inspection/test shall be conducted on purchased equipment/specialized items at the suppliers or

Subcontractor’s premises including access for the Client’s 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 subcontractor’s process in accordance with the contract and Head Contract to 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 subcontractor’s Quality Management Systems and their implementation. Involving subcontractors 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

Management of the Subcontractor’s 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 Subcontractor’s Quality Management Systems and their implementation.

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.

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 construction

B- Approved with suggestions

C- 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

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.

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 and checklists shall be

prepared.

2. Contractual close-out: Ensuring obligations in head contracts are closed out and corresponding close-out

of subcontracts package-wise and all their accounts settled

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

4. Design close-out: Furnishing of As-built documentation from subcontractor to Contractor, 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 be intimated 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.

QUALITY REQUIREMENTS FOR TRADE SUB-CONTRACTORS

SUB-CONTRACTORS QUALITY PLAN

The following points are minimum procedures the sub contractors should comply with,

1. Use of the Contractors own checklists previously approved and Contractor checklist spot-checked.

2. Visual inspection.

3. The sub-contractor shall deliver as part of his submission a project specific PQP which will be reviewed

during the selection process.

4. The PQP shall cover the works of the sub-contractor plus any of his subcontractor’s petty contractors.

5. Contractor’s representatives or other members of the design team will spot-check the works and sign the

relevant records to confirm what has been spot-checked, however the responsibility for ensuring the works

are to specification will remain with the subcontractor. Contractor will request the Architects and

Consultants to cross check, Spot check the works, usually any new job before starting, an approval is

sought by Contractor to check quality by consultants for their design intent and a certification will be

requested, the same will become part of quality audit, which shall be submitted to client during the close-

out process.

6. Should major or repeat non-conformity be identified by Contractor a Corrective Action Request (CAR)

will be issued. The subcontractor will be required to close out the CAR within the prescribed period.

7. Should the subcontractor fail to effectively implement the agreed then Contractor will take whatever action

is necessary to regain control of the works and/or standard of workmanship of the product all at the

subcontractor’s expense.

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.

SpecificationThe 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 aggregates – coarse 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 supplier’s 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. Some intermediate process may not be having tests and they cannot be tested and the inadequacies if any can know only when the final product is tested. In such situation the 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.

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 and send them to seniors

in the department.7. Prepare daily report of inspection on the prescribed forms and send to seniors in the department.8. Check to ensure that QA manual for workers and supervisors are available at hand at workstations 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 specifications and 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 conform to IS

specifications.11. Investigate the case where the test results of input materials are satisfactory but that of in process 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.

Concreting- Making and transportation

Ingredients of Concrete

Cement Use of appropriate grade of cement as recommended by the consultant and confirming to IS 456:2000 Manufactures test certificate should accompany each consignment and cement should be consumed within one

month of manufacturing date. Cement should be properly stored in stacks not more than ten bags, clear from the walls by 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 maximum size of 20mm and down.

It should be obtained from crushed granite, trap, and basalt quarry. it should be chemically 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 should not 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.

Admixtures

Use of admixtures/additives must be done only after obtaining clearance from technical

consultants. Accelerators, plasticizers, retarders, integral water proofing compound are the additives

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 ½ the coarse aggregate followed by ½ the fine aggregate. Above this the

entire quantity of cement should be spread. Then ½ 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 is about 15-20 revolutions per minute.

If plasticizer is used one litre of water must be held back. Add requisite quantity of 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.

GRADE Characteristic strength after 7 days (n/mm2)

Characteristic strength after 28 days (n/mm2)

Minimum cement content per cum

M10 7 10 220kgsM15 10 15 280kgsM20 13.5 20 320kgsM25 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 of segregation,

remix the concrete before placing. Concrete by vision must be homogeneous in colour, well graded, fluffy and it should form a

shape of ball when rounded in the hands.

Batching plant mix (RMC)

Preference for RMC concrete from reputed companies possessing automated batching 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 cum every ten to fifteen minutes.

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

Concrete should be received with a delivery challan and data cycle sheet showing grade, quantity, water cement ratio, slump, cement content, time of manufacturing, dosage of additive added, weight of various ingredients of concrete.

Go through the data cycle sheet before accepting the concrete, and get yourself confirmed 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 bend is put. Reduce the length of pipe to the minimum to reduce frictional losses and excessive strain on the

pump. The pipeline should be independently supported on vertical segment and not on the shuttering.

The vibrations due to pumping should not affect or displace shuttering works. Pump rich slurry (one bag) before pumping concrete to lubricate the inner surface of pipes. In case of intermittent supply keep the current transit mixer unloading in progress 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 the pipeline after the

days work is over. Due to negligence somebody could get hurt. Employ professional hands for connecting pipeline. They will do a neater and faster job without

any safety problems. Leave the pipeline, under the pomp and adjacent areas clean of concrete dumping after the work

is completed.

PLACING AND COMPACTION

Do not use chutes longer than 4.sm or inclined at more than 45 to horizontal to pour concrete. Place cement concrete to the required depth and vibrate it until entrapped air inside 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 old observe 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 of the 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 the leveling 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 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 water standing for 7 days a

stretch.

In case ponding is not possible, cover it with hessain cloth and keep it moist through 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 the close 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 to be conducted.

Cube results of RMC supplier for same batch can be tested.

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 plumber’s 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 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 onResting 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 ears100 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 kg100 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.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 inside16. 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 been made 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 ring true 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. Minor damage shall be made good by painting over with hot tar or preferably bitumen. But if 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 work which 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 inspected and 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 IRONGlazedware 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: 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 PIPES—Cast 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 OBSTRUCTION —The 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 RECORDS—Complete records shall be kept of all tests carried out on sewers and drains both during construction and after being put into service.

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 Foundation

Concreting- 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

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 Inspection

Point Wiring ( Installation Inspection)

Sockets and Switches ( Material Inspection)

Transformer ( Installation Inspection)

Transformer ( Material Inspection)

AIR CONDITIONING

Material Inspection

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

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.AlignmentPlumb & LevelCondition of form work surfaceProps and BracingsRelease agent / shuttering oil

2. REINFORCEMENT :Bar Bending Schedule approvedCheck for location of service conduitsExtra reinforcement around openings insertsReinforcement check against BBS Ref Drawing NoAnchorages and lap length Cover block in placeLinks, stirrups, spacersRebars cleanStarter bars for column

3. CONCRETE :Availability of materials/EquipmentsMix No. of cubes/Slump takenKickersCuringVisual inspection after deshuttering

4. SAFETYPPEAccessHousekeepingWalk way provided

CHECKLIST FOR CEMENT

MATERIAL: CEMENTAM

PM

Sl. No.

Description Date Signature Remarks

1 Make of Cement

2. Date of Manufacture

3. Date of receipt on site

4. Storage5. Test certificate6. Check Grade 43/537. Certificate from external agency8. Fineness9. Initial setting time10. Final setting time11. Compressive strength12. Soundness13. Specific gravity14. Any further checks

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 beadsi. 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 / glass 10 Check for sealing of gaps

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 manufacturer’s 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.

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

CHECKLIST FOR FIRE FIGHTING SYSTEM – COMMISSIONING

LOCATION:

Sl. No.

Description Date Signature Remarks

1 Equipment and location2 Drawing no./Rev.3 Equipment as per spec/Drg.4 Pipes & fittings as per spec.5 Proper sizes used.6 Welding joints proper7 Bolted /threaded joints proper8 Depth of laying of U/G pipe9 Concrete pedestal provided10 Insulation provided11 Hydro test done12 Holiday test done13 Openings in wall closed14 Posts height as per drg.15 Hose box height as per drg.16 Commissioning test report available17 Commissioning test report available18 Proper colour code used19 Pipe line flushed & cleaned

11 Safety:1 PPE

2 Access3 Barricade / Hazard tape

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.

Bibliography:

Nicmar lesson books. Quality manuals of construction.