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ASSIGNMENT
NICMAR / CODE OFFICE
1. Name
-2. Reg. No.
-3. Course No. - NCP 27
4. Course Title - Construction Quality Management 5. Assignment No. - Two
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 rain water seepage so that the overall quality standard and image of company is raised.
Purpose
The purpose of this document i.e. Quality Assurance Plan is to establish work methodology for Quality Control and Material engineering for Construction of High Rise Building in Mumbai for very rich personalities from industry and film world.
The procedure will outline the methods that will be used in line with the National Building Codes, Local building codes Specifications for Building works and the Technical Specifications as per the requirements of the Engineer or his representatives.
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The methodology also defines the standards of workmanship and requirements for materials necessary for the work.
Scope
This procedure is applicable to all engineers, workmen, supervisors, inspectors and quality control personnel engaged in the works for the Construction of High rise residential apartments in Mumbai. It intends to correlate and control the tasks pertaining to Quality Control and Materials testing in compliance with the requirements. patience
Quality management System
Quality management system refers to all plans, processes and activities that are developed to achieve the intended degree of conformance in the design and execution of any project. The QMS concept focuses attention of the following specific aspects of construction processes.
1. Construction is a one time activity. It affords no second chance of modification, repair or rejection once the construction work is completed. There is no scope for catching the defects after the construction is over. Therefore quality consciousness, skill and workers are essential in achieving quality. Training, motivation and commitment are the primary requirement of quality construction.
2. With the increase in complexity and the size of construction operations, the responsibility for ensuring quality has gradually shifted from the worker to supervisor of inspection and later to the quality control department. This
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3. trend has to be reversed if quality is the goal. Responsibility to ensure quality has to be shifted back to the worker at site and his supervisor.
4. It is a well known fact that the quality cannot be constructed. It has to be designed into a project system. QMS therefore starts from the design stage itself. Quality of design is the difference between various design of the project for achieving the same end use and the most optimal design finally selected. Thus economy, quality and safety are very closely interlinked in construction process.
5. Quality is expensive. Quality decisions are based on trade-offs between cost of construction and the benefits derived from the operations of facility. Once the decision is taken, it has to be backed by appropriate staff strength, infrastructure and support services. The management must therefore be committed to quality, participate in all measures developed to achieve it and lend support to QMS personnel.
6. QMS is the responsibility of the project authority. The owner or his representative formulates the policy, determines the scope of quality planning and management establishes the relationship between the various participating organizations and delegates responsibility and authority to them so that the quality objectives set by the owner are achieved.
Quality Control:
Quality control refers to the technical processes that gather, examine, analyse and report the projects progress and conformance with the performance requirements. QC mainly relates to four basic functions:
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1. Setting up of standards and specifications.
2. Evaluating materials, processes and outputs through appropriate tests, inspection etc.
3. Appraising failures to these standards and acting when standards are not being adhered to.
4. Planning improvements in the standards and specifications.
Quality Control norms, techniques and procedures:
Inspection:Once quality standards and other things are laid out inspection becomes a routine matter. In any quality control programme actual inspection and measurement is an undetachable factor, which is to be planned at properly to meet with the overall objective of the quality control. Various stages of inspection should be determined . Some of such stages could be following.
i. Material inspection at suppliers end. ii. Material inspection at the stage of receipt. iii. Material inspection at the stage of issue.
iv. Inspection of the process at the time of initial setting of machine/equipment.
v. Inspection of trial run batch.
vi. Inspection while the execution is in progress. vii. Inspection of the finished process.
viii. Inspection before erection and commissioning. ix. Inspection of commissioning.
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x. Inspection of machines and equipment commissioned.
Having decided various stages of inspection and various quality characteristics to be inspected it is also important to decide who will inspect, when the inspection will be carried out, how many units will be inspected, instruments to be used required approval for acceptance.
While planning such inspection activities it is also important to decide what information is to be given to the inspector at the time of inspection. Some of the basic information required is design specifications, product specification, quality characteristics, quality standards and tolerances available and the detailed inspection procedures.
For total quality control the following six phases are necessary (6Cs)
i. Comprehension - What is quality. It should be definable and measureable.
ii. Commitment - Clarity of concept and policies organizations for it. iii. Competence - Develop methods test procedures to evaluate quality understand the price conformance to quality.
iv. Communication - Create awareness, resolve conflicts, coordinate activities,
v. Correction - Solve problems for non conformance. They may be due
to lack of attention rather than lack of knowledge or lack of facilities.
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exposure to sustained programme.
Quality control standards and specifications
The quality of construction depends upon right material 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 the data analysis is done by experts in office.
Specifications:
The project authorities prepare the process of working out specifications of various facilities where concrete will be used. However, the standards and specifications for concrete and its various ingredients are universally standardized and they are required to be in conformity with same. Indian standards IS for concrete and its 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 specifications.
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
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results are compared with the prescribed standards and specifications and judgements 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 need 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 known only when the final product is tested. In such situation the testing of final product is important.
Statistical Quality Control:
Total quality management addresses organizational quality from managerial and philosophical viewpoint. TQM focuses on customer driven quality standards, managerial leadership, continuous improvement, quality identified problems at the source and quality made everyone’s responsibility. However, talking about solving quality problems is not enough. We need specific tools that helps us make the right quality decision. These tools comes from the area of statistics and are used to help identify quality problems in the production process as well as in product itself.
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Statistical quality control is the term used to describe the set of statistical tools used by quality professionals. Statistical quality control can be devided into three broad categories.
Descriptive Statistics:
Are used to describe quality characteristics and relationships. Included are statistics such as the mean, standard deviation, the range and a measure of distribution of data.
Statistical Process Control:
Involves inspecting a random sample of the output from a process and deciding whether the process is producing products with characteristics that fall within a predetermined range. SPC answer the questions whether the process is functioning properly or not.
Acceptance Sampling:
Is the process of randomly inspecting a sample of goods and deciding whether to accept the entire lot based on the results. Acceptance sampling determines whether a batch of goods should be accepted or rejected.
Quality Assurance:
Quality assurance refers to the managerial processes which determine the organizations design, objectives and resources, the project team, funding agencies, performance standards and feedback on the project performance, appropriate
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actions to deal with deviations and all steps necessary for promoting quality awareness at all levels and in all parts of the project organizations.
A typical quality assurance programme addresses itself to the following.
1. Organization structure of the project team and quality assurance department.
2. Responsibilities and powers of the various personnel involved. 3. Identification of the coordinating personnel.
4. Quality and its programmes. 5. Quality education and awareness, 6. Quality circles.
7. Training.
8. Setting up of MIS for quality.
9. Resolution of technical differences and disputes.
10. Preparation of quality assurance manuals and their checklist. 11. Vendor survey procedures.
12. Vendor surveillance procedure
Quality assurance provides protection against quality problems through early warnings of trouble ahead. Such early warnings play an important role in the prevention of both internal and external problems. The assurance is provided from objective evidence but the type of evidence differs widely according to persons requiring the assurance and nature of product.
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It need not be emphasized that quality assurance is an essential prerequisite of all construction projects. Over years the accent on quality has graduated progressively from simple Inspection to quality control to quality assurance and to quality management. Whereas the limitations of inspections are quite
obvious, a quality control system includes testing of raw materials at selection and processing stage, testing at various stages of production, acceptance and feedback.
Management responsibilities:
Management Commitment:Top management comprises of CEO, MD, all Directors, all VPs, and Functional Heads of various departments at Head Office. The leadership (including In-charges / Managers / Heads) hold key positions at HO, and Project sites in a matrix organizational structure. Management has appointed a Management Representative and a Quality Management Cell for effective implementation and monitoring of QMS throughout organization. Management Reviews are planned at various levels for effective monitoring of QMS.
Evidence of top management commitment to development and implementation of the quality management system with a view to continually improve its effectiveness through the following manner:
-a) Communicating throughout the organization the importance of meeting customer as well as statutory and regulatory requirements.
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Work places and is understood by all employees by discussions, training and providing printed pocket cards, which are carried by employees.
c) Quality objectives for the company are established & displayed at all site locations and work places. Quality objectives are also defined for each major & critical process at Head Office level.
d) Management Review process is established and the frequency for this review is half yearly.
e) Availability of resources for implementing Quality Management System is ensured through proper planning and logistics.
Customer Focus:
Responsibility: Primary – Project In Charge; Secondary – All Section Heads
Processes are established for customer communication on suggestions for improvements, information on status of project and direct meetings. Areas of dissatisfaction / improvements, if any, are discussed at
various levels and informed to project site and corrective actions taken based on above inputs.
Record the Customer complaint and acknowledge the receipt of the same within 3 working days.
Discuss the Customer complaint
Examine root causes.
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Review procedure and reformulate prevention of repetitive complaint.
Reply to Customer complaints with action plan and target dates for achieving the same.
Communicate to customer on action taken on complaint.
Receive information about direct customer satisfaction from MIOF.
Prepare action plan on area of dissatisfaction with the consultation of all sections
Improve performance on area of dissatisfaction.
Quality Policy:
Top management has articulated “Quality Policy”
Shows commitment to comply with the requirements and continually improve the effectiveness of the Quality Management System
Provides a framework for establishing and reviewing quality objectives Communicated and understood within the organization
The policy is communicated to all by displaying at strategic locations and through Quality manual, which is being distributed to all
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sections and intend being circulated to all employees of company.
References
Document Reference No.
1. Specifications for High rise building National building by National Building codes & Mumbai Mahanagar Regional Development authority (MMRDA) building by laws
2. Technical Specifications for residential building 3. Quality Control Inspection Plan Appendix II 4. Quality records – Checklists Appendix III 5. Quality records – Format for Internal
tests
Appendix IV 6. Calibration Schedule Appendix V 7. Relevant NBC, Neuferts, IS codes & Time saver standards
Methodology:
Identification of source for raw materials.
The identification for source for raw materials will be on the basis of proximity from the location of work, conformance of quality of material in accordance with requirement for the project and commercial viability.
For manufactured products, vendors are to be got approved from the engineer.
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Different mix designs for various grades of concrete works for High Rise Building (Frame structures) & foundations construction are to be developed at the Site Laboratory through trials. On identification and successful trial in conformity to the requirements, the details are to be supplied for adoption in construction works after due approval from the Engineer or his representative.
Quality control in Construction.
The Supervisors for Construction work will be assisted with testing equipment for monitoring of gradation, slump, temperature and for sampling / spot test of materials as and when required.
Control / checks / monitoring of levels, dimensions, profile during and after construction activities, will be done by construction engineers / survey engineers. QC Engineers will be assigned to the Building work and Road work as and when required by the Materials Engineer of The Contractors. They will assist the respective building / Road sectional In-charges / Engineers / Supervisors for collecting test samples, performing field tests as required. Whenever required, material samples will be drawn for spot testing or tests at the site laboratory in accordance with Documents.
Conformance of Post Construction checks will be done by the respective Engineers of building and road engineer.
Marble /Granite tiling work in floors
1. Marble /Granite shall be of approved quality in terms of source, thickness, colour, texture, etc.
2. Sizes of marble blocks, slabs & Tiles shall be as per Approved Drawings & specification.
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3. Only slabs and tiles shall be machine cut & factory made. The following tolerances shall be applied(As per CPWD Specification) in the dimensions of blocks, slabs & tiles.
Dimension Blocks Slabs Tiles
Length + 2% + 2% + 3%
Width + 2% + 2% + 3%
Thickness + 2% + 3% + 1%
4. Before starting of work the samples shall be approved by Client. Requirement for physical properties shall be as per CPWD Specifications as follows:
Characteristics Requirements Method of Test
1. Moisture absorption after 24 hours immersion in cold water
Maxm. 0.4% by weight
IS: 1124
2. Hardness Minimum 3 Mhors scale
3. Specific Gravity Minimum 2.5 IS: 1124
5. Each stone shall be cut to required size and chisel dressed on all bed and joints.
6. The mortar shall be as specified. All stones shall be wetted before placing in position. These shall then be floated on mortar and bedded properly in position with wooden mallets.
7. Stones shall be laid in regular courses of not less than 15 cm in height and shall be of the same height unless otherwise noted.
8. The depth of the joints 6 mm from face shall be uniform and as fine as possible but shall not be more than 1.5 mm thick.
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9. The curing shall be done for a period of at least 7 days. After curing it shall be rubbed with carborandum stone of different grades numbers 60,120 & 320 in succession and cleaned & washed with a solution of oxalic acid.
10. Sample size & criteria of conformity shall be as follows( As per CPWD Specifications ): Nos. of blocks/slabs/tiles in lot Nos. of blocks/slabs/tiles to be selected in sample Permissible number of defects Sub-sample size in number Upto 25 3 0 2 26 to 100 5 0 2 101 to 200 8 0 3 201 to 500 13 0 4 501 to 1000 20 1 5
Ceramic / Glazed tile flooring
Tiles shall be of approved make, size, colour & thickness.
1. Sample approvals shall be taken before start of work from client.
2. The length of all four sides shall be measured correct to 0.1 mm and average length and breadth shall not vary more than +/- 0.8 mm from specified dimensions. The tolerance for thickness shall be up to +/- 0.4 mm.
3. Base concrete (RCC slab) shall be cleaned, wetted & mopped. Bedding of cement mortar (1:3) shall be laid with average thickness 10 mm while thickness under any portion of the tiles shall not be less than 5 mm.
4. Over mortar bedding neat grey cement slurry of required consistency shall be applied @3.3 kg/m2 over an area to cover 20 tiles.
5. Tiles shall be soaked in water, washed clean and shall be fixed in this grout with gentle tapping with wooden mallet.
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6. Surface of flooring during laying shall be frequently checked with a straight edge about 2 mm long so as to obtain true surface with required slope.
Brick Work
1. The bricks shall be of class 7.5 & of non-modular type.
Bond: Generally English bond shall be followed wherever applicable, toothing and closure shall be provided.
2. Following tests shall be performed. a) Efflorescence.
b) Crushing strength. c) Water Absorption. d) Dimension Check.
3. Frequency of tests/sampling shall be 20 bricks chosen randomly for every 1 lac Bricks for each brand.
No. of Bricks in the lot
For characteristic specified for individual bricks
For dimensional characteristic of group of 20 bricks No. of bricks to be chosen No. of bricks to be selected Permissible no of defective in the sample 2001-10000 20 1 40 10001-35000 32 2 60 35001-50000 50 3 80
Lot size Sampling size for compressive strength, water absorption & efflorescence
Permissible No. of defective for efflorescence
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2001-10000 5 0
10001-35000 10 0
35001-50000 15 1
5. The mortar of brickwork shall be 1:6(1cement:6coarse sand).
6. Bricks shall be soaked in water before use for a period for the water to just penetrate the whole depth of brick.
7. Half or cut bricks shall not be used except as closures where necessary. 8. Suitable measuring boxes shall be made for measuring sand to prepare the
mortar.
9. While laying the brickwork the frog should be face up. The joints shall be racked to an average depth of 10 mm. When plaster or pointing to be done the joints should be streaked flush.
10. Curing shall be done for atleast seven days or as per specification.
Plumbing and sanitation
1. All water supply/plumbing installation work to be done by licensed plumbers.
2. All fittings/fixtures and accessories shall be of approved brands only. Prior approval of samples of all fittings & fixtures shall be taken from client. 3. All materials of pipes (CI, GI, Glazed stoneware, etc) shall be of approved
brands only. Prior approval of samples of all Piping materials & accessories shall be taken from Client.
4. Unless otherwise specified shop drawings shall be prepared for various activities and approval of same shall be taken from Client.
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5. No cross connections with waterlines of wholesome water and wastewater pipelines shall be done.
External drainage
1. All line out of layout designed for pipelines, manhole and inspection chambers shall be marked on the ground.
2. The trenches for underground drainage shall be excavated as per design depth and grade.
3. The required bed of slope shall be provided as per drawing in the pipeline to create required velocity.
4. For joints in the pipeline the caulking material shall be of specified quality and the same shall be executed as per drawing. Socket ends of all the pipes shall face uphill.
5. Sufficient spun yarn shall be forced into the socket and required depth should be available for filling the caulking material. If the caulking material is lead then it shall be poured in one action and when the lead is thoroughly fluid.
6. C.I. vent pipe shall be provided at the head of drain and cowl is provided at the top.
Stoneware pipes
1. Pipes shall be inspected and cracked or chipped pipes shall be rejected in the work. Pipes shall be thoroughly checked and cleaned before laying. 2. The minimum dia of the pipes for outside drainage shall not be less than that
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3. The pipe trench for laying the pipes shall be of sufficient width to have easy jointing and caulking activity. The required gully traps and manholes shall be provided at the pipe junction as per drawing.
4. Testing for water tightness shall be done as required in the Specification.
5. Sufficient time shall be allowed for the joints to set and then trenches filled, watered and compacted.
Sanitary and plumbing- CI pipes
1. The pipes shall be checked for specified quality and its water tightness. 2. The pipes shall be laid in position with the socket ends facing uphill
irrespective of the direction of flow.
3. The caulking material shall be as specified. In case of lead caulking for spigot and socket joints sufficient yarn shall be forced into the socket to have the required depth for lead for filling.
4. After completion of pipes laying in each section, water tightness shall be tested before covering with soil.
5. Unless otherwise specified, Non-return valves or check valves shall be used of brass, duly chromium polished and provided on ascending part of the main to check the return flow.
G.I. Pipes and fittings
1. Pipes laid under ground shall be atleast 0.5m below G.L. or as specified on grads as specified.
2. Pipes before laying shall be checked for visible damage (broken edges, cracking or spalling of pipes) if any. If detected the defective pipes shall be rejected.
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3. After laying pipes same shall be tested under water pressure at least 100 lbs per sq. inch unless otherwise specified or mentioned.
4. Joints shall be filled with cement or any other specified material with proper caulking finishing etc.
5. Pipe work shall be laid in such a way that it is accessible for inspection, replacement & repairs (as far as not to be buried in walls and solid floors).
6. Service pipe or supply pipe shall be connected directly to W.C. All such suppliers should be connected from cisterns which shall be supplied from storage tank.
Plastering work
1. Loose mortar if any is sticked with wall shall be brushed out.
2. Any hole filling or repairs shall be completed prior to the plastering work. 3. The wall surface shall be thoroughly washed with water, cleaned and kept
wet before plastering is commenced.
4. 12 mm thick, 150mm x 150 mm square gauges shall be applied horizontally and vertically, at not more than 2.0 metre interval.
5. 1st or the undercoat coat of 12 mm plaster shall be applied in 1:5, cement: sand ratio by volume only.
6. Proper line and level with true surface shall be provided for this coat.
7. The surface shall be roughened and furrowed 2 mm deep with scratching tool / broom to form keys for the finishing coat.
8. The curing shall be continued till Finish Coat is applied.
9. The Finish coat shall be applied after the under coat is sufficiently set, but not dried and in any case within 48 hrs.
10. Sand for the second coat of plaster shall be sieved with 3.0 mm sieve. 11. The mortar for 2nd coat shall be in 1:2 cement: sand ratio by volume.
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12. The 2nd or the finish coat shall be struck uniformly over the first coat and firmly pressed and levelled by using a 3.0 to 4.0 mts. Long aluminum batten.
13. All the edges, angles, arises and junctions shall be vertical and horizontal. 14. When the work is suspended at the end of the day, the plaster shall be left,
cut clean to the to line both horizontally and vertically. When plastering is to be resumed, the edge of the old work shall be scraped, cleaned and wetted with water before plaster is applied to the adjacent areas.
15. The surface shall than be firmly trowelled and sponge floated to remove excess moisture and bring the sand to the surface. The surface thus prepared shall be uniformly roughened for texture.
16. The surface of plaster shall be kept wet for at least 7 days and shall be protected from the sun (covering it by suitable method).
Health, Safety and Environment
The working areas will be suitably barricaded as and when required. Proper sign boards / signages shall be erected to caution / inform the surrounding people. Personal protective equipment relevant to the nature of work will be used for the Project. Personnel handling admixtures or other chemicals will use appropriate protective equipment recommended by the manufacturer. Persons handling nuclear gauges / instruments shall wear special protective attires as recommended by the manufacturer.
Care shall be taken during dismantling the structures against fall of materials from top. All excavation shall be provided with slope or bench.
All electrical and mechanical equipment and installations shall be periodically inspected for safety and necessary maintenance work carried out.
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Care shall be taken:
(i) to reduce generation of dust during operation,
(ii) against pollution of water source due to construction operation (iii) against undue cutting of greenery / plants and trees.
Appendix I
Management of QC / Materials System – Flowchart.
Page 23 of 55 Project In-Charge Material Engineer QC Engineer Central Laboratory QC Engineer Field Laboratory QC QC QC Engineer Field Laboratory QC QC
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks Concrete Works material and field control
1 Petro graphic examination of Coarse and fine aggregate Cl.1007, Cl. 1008 Sample from source of
coarse and fine aggregate i.e quarry , river bed from where rock / boulders, sand are to be collected. External IS 2386 Pt 8 Initially 1 set of 3 specimens for each source of supply, subsequentl y when warranted by change of source / quality.
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks 2 Alkali Aggregate reactivity Cl.1007, Cl. 1008 Crushed sample from proposed source of
coarse and fine aggregate i.e quarry , river bed from where rock / boulders, sand are to be collected.
External Material shall be Innocuous IS 2386 Pt 7 Initially 1 set of 3 specimens for each source of supply, subsequentl y when warranted by change of source / quality.
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks 3 Specific Gravity of aggregates Cl.1007, Cl.1008
-do- Site lab - IS 2386 Pt
3 Initially 1 set of 3 specimens for each source of supply, subsequentl y when warranted by change of source / quality otherwise on monthly basis. 4 Water absorption of coarse and fine aggregates Cl.1007, Cl.1008
-do- Site lab - IS 2386 Pt
3 Initially 1 set of 3 specimens for each source of supply.
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks Subsequentl y, one test for coarse aggregate and two tests for fine aggregate per day. 5 Deleterious material for aggregate. Cl.1007, Cl.1008 -do- External IS 2386 Pt 2 Initially 1 set of 3 specimens for each source of supply, subsequentl y when warranted by change Coarse aggregate Coal = / < 1% Clay lump = / < 1% Finer than 75µ= / < 3% Total = / < 5%
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks of source / quality Fine aggregate Coal = / < 1% Clay lump = / < 1% Finer than 75µ= / < 3% Shale: = / < 1% Total = / < 5% 6 Soundness (5 cycles) of coarse aggregate
Cl. 1007 -do- External Sodium
Sulphate = / < 12% Magnesium Sulphate = / < 18% IS 2386 Pt 5 Initially 1 set of 3 specimens for each source of supply, In case for aggreg ate water absorpt
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks subsequentl y when warranted by change of source / quality. ion exceed s 2% Soundness (5 cycles) of fine aggregate Sodium Sulphate = / < 10% Magnesium Sulphate = / < 15%
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks 7 LA abrasion value of coarse aggregate
Cl. 1007 -do Site lab a) = / < 50%
for concrete b) for concrete wearing coat = / < 30% IS 2386 Pt 4 Initially 1 set of 3 specimens for each source of supply, subsequentl y when warranted by change of source / quality otherwise on monthly basis.
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks 8 Aggregate impact value of coarse aggregate
Cl. 1007 -do Site lab a) = / < 45%
for concrete b) for concrete wearing coat = / < 30% IS 2386 Pt 4 -do-9 Flakiness Index for coarse aggregate Cl. 1007 Crushed aggregate from crusher or any other proposed source. Site lab = / < 35% IS 2386, Pt 1 Initially 1 set of 3 specimens for each source of supply, subsequentl y when 10 Aggregate crushing value Cl.1007 Crushed aggregate from crusher or any other proposed source External / Site lab. a) = / < 45% for concrete b) = / < 30% for concrete IS 2386, Pt 4 Initially at time of approval of source.
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks wearing coat. 11 Gradation coarse aggregate Table 900-6 Crushed aggregate from proposed source. Subsequently from stock pile at site. Site lab. - IS 2386, Pt.1 Initially before mix design for approval of source. Subsequentl y, one test for every day’s work of each fraction of coarse aggregate. 12 Gradation fine aggregate Table 900-6 Fine aggregate from proposed source.
Site lab. F.M. of sand shall not be >2 and < 3.5-IS 2386, Pt.1 Initially before mix design for approval of source. Subsequentl Fine aggreg ate confor ming to
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks Subsequently from stock pile at site. y, one test for every day’s work of each fraction of coarse aggregate. zone 1V as per table-4 of IS383 shall not be used for reinfor ced concret e. 13 Gradation of all –in – aggregate Blended aggregate
Site lab. As per IS 383 table -5 IS 2386, Pt.1 Initially during mix design. Subsequentl y one test for every
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks day’s work. 14 Workability of fresh concrete ( slump test) Table 900-6 At concrete batching plant and site of construction. At plant site and field As per table 1700 -4
IS 516 One test per each vehicle, both at concrete batching plant and site of pouring at start of work. Subsequentl y as required. Values stated in table 1700 – 4 are not for pumpa ble concret e. For pumpa ble concret e min. slump require ment is around 120 mm.Fo
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks r Transit Mixer minimu m slump is 50 mm 15 Strength of concrete Cl.1716. 2.3
Cube test Site lab. As per
Cl.1716.2.5 IS 516 As per frequency of collection of samples. 16 Cement ( OPC 53 grade ) Cl.1006 At manufacturer’s plant. Atmanufacture r’s lab. -do-As per IS 12269 >225 m2/kg As per IS 12269 MTC for every batch of cement Excepti ng bridge, Cement of other 1.Fineness
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks At site At site -do-At site At site At site <10 <0.8 grades also can be used as approv ed by the Engine er or his represe ntative. 2.Soundness (i)Lechatlier method (ii)Autoclave method 3. Standard Consistency -4.Temp.durin g testing 27 degree Celcius 5.Initial & Final Setting time >30 min,< 600 min. 6.Compressiv e Strength >27MPa at 3 days Chemical Requirement s External As per IS 12269 As per IS 12269 Frequency for External test:
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks >0.8<1.02 >0.66 <3.0 <6.0 <3.0 <4.0 Not specified <0.1 Not specified 1 test in 6 Months MTC for every batch of cement 1.Lime Saturation Factor 2.Alumina iron Ratio 3.Insoluble residue 4.Magnesia 5.Sulphuric Anhydride 6.Total loss on Ignition 7.Total alkalis as Na2o 8.Total chlorides 9.Tricalcium Aluminate
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks 17 Concrete admixture Cl.1012 & IS:9103 At manufacturer’s Plant At manufacture r’s Lab. <0.2%* > 3%* ± 1* >1%* within 2%* *All based on the value declared by the manufacturer. IS 6925 As per IS 9103 MTC for Each lot/sampling from every consignmen t Unifor mity test from externa l test house @ 1 test / 7000 Lts. Accept able limits 1.Chloride content 2.Dry Material content 3.pH value 4.Ash content 5.Relative density
Other major manufactured products
1. Reinforceme nt steel bar Cl.1009. 3 At manufacturer’s plant At manufactu rer’s lab Fe 415 Grade IS 228, IS 1608, IS 1559, IS 1786 MTC for every batch of A) Chemical test A) Chemical test
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks At Site. External reinforceme nt steel. Frequency: 1 test in 500 MT Carbon = / < 0.30+.02 % Sulphur = / < 0.06 + 0.005 % Phosphorus = / < 0.06 + 0.005 % B) Physical test B) Physical test 0.2% proof stress 415 N / sqmm. Elongation 14.5 %
Bend test Satisfactory
2 RCC Hume pipe At manufacturer’s plant At manufactu rer’s lab As per IS 458 – for NP4 class pipe. IS 458 MTC for each Lot. 3 Structural steel sections and plates Cl.1009. 6 At manufacturer’s plant At manufactu rer’s lab. As per 2062 , GR –A, B or C as IS 228, IS 1608
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Appendix II Quality Control Inspection Plan ( QCIP)
Sl. NO Test Required Test Ref. Sampling Ref & Process Test Location Acceptance Criteria Test As per Test Frequency Remar ks applicable 4 Hot dip Galvanised steel for soil
Cl.4.1.1 of appendix -1 At manufacturer’s plant At manufactu rer’s lab / lab. of specialise d agency. Steel soil reinforcement -a) shape & form a) strips, grids, sheets As per designed dimension To be checked at random b) Physical and mechanical properties b) BS EN 10025 or equivalent of IS 2062 IS 228, IS 1608, is1559 b) test result for each lot of material c) Galvanisation thickness c) as per specification of specialised agency. IS 4826 c) – do
-Registration no. MATERIAL NAME OF THE TEST FIELD/
LABORATORY TEST MIN. QUANTITY OF MATERIAL REQUIRED FREQUENCY OF TEST/ SAMPLING Brick / Tile bricks/ Concrete block a) Efflorescence b) Water absorption c) Compressive Strength
d) Tolerance (Size & shape) Field Laboratory Laboratory Field As desired by the Engineer -50,000 nos. as required by the Engineer.
20 bricks chosen at random for every 100,000 bricks for each brick field.
Timber a) Moisture content (Oven drying method) b) Species Laboratory Field 1 Cum As reqd. by the Engineer.
From each fresh lot or each 10 cum material one sample.
Flush shutters/ Plywood
a) Test for end immersion
b) Test for glue adhesion
c) Test for adhesion of
Laboratory Laboratory Laboratory 11 Shutters As reqd. by the Engineer 6 nos. – 0 to 65 13 nos. 66 to 110 20 nos. 111 to 180 32 nos. 181 to 300
-Registration no. MATERIAL NAME OF THE TEST FIELD/
LABORATORY TEST MIN. QUANTITY OF MATERIAL REQUIRED FREQUENCY OF TEST/ SAMPLING Hardening compound - do - do -Precast Terrazzo Tiles
a) Shape & Dimension b) Transverse strength c) Resistance to wear d) Water absorption do do do do do do do do -12 nos./2000 nos. 6 nos./2000 nos. 6 nos./2000 nos. 8 nos./2000 nos. Glazed tiles a) Water absorption
b) Impact test do do -3000 nos. As decided by the Engineer. * * Granite marble Hardness test - do - - do - *
Fire Doors Fire test - do - Specified fire rated. 1 Door
Steel doors a) Thickness of steel b) Sheets Field/Lab. do -As specified. do -1 Door Aluminium a) Composition of Alumn. Alloy b) Powder coating Laboratory Field As per BIS. 65 microns. 1 Sample
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WATER PROOFING
Waterproofing of Raft and Retaining Walls
Waterproofing of Raft and Retaining walls by external tanking (including grouting of Concrete)
External tanking (including grouting of concrete) of basement, trenches, etc. shall be carried out using an approved acrylic chemical waterproofing compound, in stages given below :
Stage 1:
After the lean concrete has been laid to receive the RCC raft, a 345 mm thick brick toe wall in Cement Mortar 1:6 shall be constructed, on the perimeter of the area to be water proofed. The height of this wall shall be equal to the thickness of the RCC Raft. The brick toe wall shall be paid separately under the item of Brick work.
Stage 2: Base
The external tanking treatment shall be carried out for the base raft over the lean concrete in the following sequence.
a) A layer of cement slurry mixed with the acrylic waterproofing compound shall be spread over the lean concrete.
b) In each layer where acrylic waterproofing compound is to be used it shall be mixed in the ratio of 400 gms per 50 kg. Of cement unless specified otherwise.
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c) Thereafter a 25mm thick (minimum) bedding layer of cement mortar 1:3 (one part cement: three parts course sand) mixed with acrylic waterproofing compound shall be laid.
d) Curing shall be done by spraying water for 7 days.
e) A layer of Kota stone slabs of approximately 600 x 600mm and having minimum thickness of 20mm shall be laid. The joints between the stones shall be 6mm. After laying the joints shall be raked and sealed with cement mixed with acrylic waterproofing compound (in the ratio 1:1).
f) A layer of cement mortar 1:4 (one part cement : four parts coarse sand) mixed with acrylic waterproofing compound shall be laid and finished smooth.
g) Curing shall be done by spraying water for 7 days.
h) The waterproofing shall be turned up along the brick wall on the perimeter of the basement raft. The work shall be carried out as described under walls.
NB : The above specification shall also be followed for the roof of basement.
Stage 3 : Grouting of Concrete Raft
Placing and prefixing of 15mm M.S. nozzles of length 0.5D where D is the depth of the raft shall be done on the construction joints and pour strips. The spacing of the nozzles shall be 1 m apart in both directions in the raft to
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enable grouting to be done. The pipes shall project 50mm above the top of the raft and shall be plugged using M.S. caps.
The RCC shall be cast after placement of the nozzles as required.
After the concrete of raft has attained proper maturity the injection of cement mixed with non-shrink polymeric grouting compound through the nozzles under maximum pressure of 2.5 kg/sqcm. By hand/air/electric/pump shall be carried out.
The nozzles shall be sealed after injection operation is over with a cementations rendering with quick setting admixture of CICO make or approved equivalent.
The above specification shall also be followed for the roof of basement if required.
Waterproofing of other areas (roofs, terraces, water tanks, toilets, floor slabs, etc.)
Scope of Work
The work shall include waterproofing for the building roofs, terraces, water tanks, toilets, floor slabs, walls, planters, chajjas, sills and any other areas and at any other locations and situations as directed by the Engineer, in accordance with the design, shapes, thickness, details, all as shown on the “Good for Construction” drawings or as specified or as directed by the Engineer complete in all respects to give the quality of finished work as desired by and to the entire satisfaction of the Engineer.
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The work shall be carried out by an experienced specialist sub-contractor who shall be appointed only after prior approval of the Engineer.
Materials Tapecrete
An acrylic based polymer modified cementations composite coating system manufactured by FRC Composites India Ltd. Or approved equivalent.
Waterproofing – General
The waterproofing treatment shall be done on smooth plastered surfaces. Portland ordinary cement shall be used for the plastering on the concrete screed on roofs. The plastered areas shall be cured for a minimum of 7 (seven) days. Curing shall be done by keeping wet gunny or burlap or ponding water.
The surface shall be allowed to dry for about 4 to 6 weeks, after the curing period is over.
The surface on which waterproofing is to be done shall be bone dry, free of all dust, loose material, laitance etc. A surface dry area shall not be construed as being totally (bone) dry.
The Contractor shall ensure that everything where the waterproofing is worked around or into are fixed (e.g. rainwater downtakes, etc.) in position and all pre-waterproofing application work by the other Contractors is complete.
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Waterproofing to Toilets, Kitchens etc.
Waterproofing treatment to floor slabs and walls, chhajjas, roof projections, toilets, kitchens etc. in the building shall be done as described below.
A priming coat shall be applied over the complete area to be waterproofed. The primer shall be made of net grey cement mixed with an integral waterproofing compound in the proportion as recommended by the manufacturer.
Thereafter two coats of “Tapercrete” mixed with cement in the proportion 1:2 (1 kg Tapercrete : 2 kg of cement) shall be applied.
All the joints of pipes, edges, corners, openings shall be sealed with epoxy putty. As refer above.
Waterproofing and Testing
The treated area (flat and horizontal only) shall be tested by allowing water to stand on the treated areas to a depth of 150mm for a minimum period of 72 hours.
The treated area (flat and horizontal) shall have a continuous slope towards the rainwater outlets and no water shall pond anywhere on the surface.
The roofs shall be water-tight and shall be tested on completion by flooding the roof with water to a minimum depth of 25mm fir 24 hrs. Where it is impracticable, because of roof falls or otherwise, to contain a 25mm depth of water, the roof shall have water applied by a continuous hose of sprinkler system to provide a sheet flow of water over the entire area of the roof for not less than 6 hrs. In either case the roof shall be considered satisfactory if
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no leaks or damp patches show on the soffit. Should the structure not satisfy either of these tests, then after completion of the remedial work, it should be retested in accordance with this clause. The roof insulation and covering should be completed as soon as possible after satisfactory testing.
Inspection, testing and controlling of Non
conforming product
:Inspection & Testing:
Plan the characteristics of the raw material, process and
product to be checked, frequency of check, method of check, sampling size
Plan stages of customer verification as per contract agreement. Conduct inspection & tests as per plan and keep
relevant records to demonstrate the conformance.
Check the results against planned requirements. Improve methodology or process and take necessary corrective action where planned results are not achieved
Get approval of the competent authority and or the customer for acceptable minor deviations from the planned arrangements.
Registration no. Control of Non-Conforming Product
Identify Non-conforming product / service found through Customer complaints, Audits and Inspections
Prepare action plan to remove the non-conformity.
By rectification /reworks/corrective action, By alternative use, By degrading or By scraping.
Implement corrective action to eliminate the root cause of the non-conformity.
Officers & their qualifications: 1. Project manager
Qualification: Should be Graduate with additional qualification of masters in Project management from a reputed institute.
Experience: Should have minimum 20 years exp. Out of which Last five should have worked in similar capacity with lots of impetus on quality control and assurance.
2. Senior Engineer (QA/QC) Civil
Qualification: Should be Graduate with additional qualification of masters in Project management from a reputed institute. Should be well versed with quality control measures especially for civil as well interiors and water proofing
Experience: Should have minimum 15 years exp. Out of which Last ten should have worked in similar capacity monitoring and controlling quality.
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3. Engineer Civil Execution
Qualification: Should be Graduate from a reputed institute
Experience: Should have minimum 10-12 years exp. Out of which five years should have worked in similar capacity in execution of such prestigious high-rise building.
4. Engineer (QA/QC) Plumbing and sanitary
Qualification: Should be Graduate with from a reputed institute. Should be well versed with quality control measures especially plumbing and sanitary
Experience: Should have minimum 15 years exp. Out of which last ten should have worked in similar capacity monitoring and controlling quality.
5. Junior Engineer (QA/QC) Civil
Qualification: Should be Graduate/Diploma from a reputed institute. Should be well versed with quality control measures especially for civil as well interiors and water proofing
Experience: Should have minimum 8-10 years exp. Out of which last five should have worked in similar capacity monitoring and
controlling quality.
6. Junior Engineer Execution Civil
Qualification: Should be Graduate/Diploma from a reputed institute. Experience: Should have minimum 8-10 years exp. Out of which last five should have worked in similar capacity monitoring and
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7. Store keeper
Qualification: Should be Graduate from a reputed institute. Should be versed with latest material management procedures.
Experience: Should have minimum 5-7 years exp. Out of which last three should have worked in similar capacity monitoring and
controlling quality.
8. Junior Store keeper
Qualification: Should be Graduate/under graduate from a reputed institute. Should be versed with latest material management procedures.
Experience: Should have minimum 5 years exp. Out of which last three should have worked in similar capacity monitoring and controlling quality.
Functions and Responsibilities: (1) Project manager
Functions & responsibilities: Should be responsible for overall quality control and assurance as well as for execution. Should have overall control and command over all implementation of quality control measures and will have checks for its outcome.
(2) Senior Engineer (QA/QC) Civil
Functions & responsibilities: Should be responsible for overall quality control and assurance. Should have overall control and command over all implementation of quality control measures and will have checks for its outcome.
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(3) Engineer Civil Execution
Functions & responsibilities: Should be responsible for overall quality while execution. Should help and co operate with QA/QC team to improve overall quality.
(4) Engineer (QA/QC) Plumbing and sanitary
Functions & responsibilities: Should be responsible for overall quality control and assurance for all plumbing and sanitary works. Should have control over all implementation of quality control measures for sanitary & plumbing and will have checks for its outcome.
(5) Junior Engineer (QA/QC) Civil
Functions & responsibilities: Should assist in implementing quality control and assurance procedure. Should supervise implementation of quality control measures and will monitor for its outcome.
Monitoring and controlling quality.
(6) Junior Engineer Execution Civil
Functions & responsibilities: Should assist and supervise work with an eye for quality control and assurance procedure.
(7) Store keeper
Functions & responsibilities: Should be responsible in implementing quality control and assurance procedure for all materials brought at site using latest material management procedures.
Should supervise implementation of quality control measures and will monitor for its outcome.
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(8) Junior Store keeper
Functions & responsibilities: Should assist in implementing quality control and assurance procedure for all materials brought at site using latest material management procedures.
Should assist &supervise implementation of quality control measures and will monitor for its outcome.
Reporting to Whom
Project Manager___________ Managing Director
Senior Engineer (QA/QC) Civil________ Project Manager Engineer (QA/QC) Plumbing and sanitary _______ Senior
Engineer (QA/QC) Civil
Engineer Civil Execution ____________ Project Manager Junior Engineer (QA/QC) _________ Senior Engineer
(QA/QC) Civil
Junior Engineer Execution Civil ________ Engineer Civil Execution
Store keeper _____________ Senior Engineer (QA/QC) Civil Junior Store keeper ___________ Store keeper
Compliance work with regulations and bylaws
The Contractor shall conform in all aspects with:
(a) the provision of any enactment in India as applicable from time to time
(b) the regulations or bye-laws of any local body and utilities.
(c) The Contractor shall be bound to give all notices required by statute, regulations or by-laws, as aforesaid and to pay all fees and bills payable in respect thereof. The Contractor will arrange necessary clearances and Approvals before the Work is taken up.
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Ignorance of Rules, Regulations and Bylaws shall not constitute a basis for any claim at any stage of work
Compliance with Contractor’s Request for Details
i. The Contractor shall give written notice to the Engineer whenever progress of the Works is likely to be delayed or disrupted unless any further Drawing, where the Special Conditions of Contract provide for such Drawings to be prepared by the Engineer, or order, including a direction, instruction or Approval is issued by the Engineer within a reasonable time. The notice shall include details of the Drawing or order required and of why and by when it is
ii. required and of any delay or disruption likely to be suffered if this issue is delayed.
iii. The Engineer shall furnish with reasonable promptness, on receipt of request from the Contractor, additional instructions by means of Drawings or otherwise necessary for the proper execution of the Works or any part thereof. All such Drawings and instructions shall be consistent with the Contract documents and reasonably inferable therefrom. The Engineer may ask the Contractor for alternative proposals or clarifications or additional data or any other detail in respect Contractors request, if any.
If, due to any failure or inability of the Engineer to issue within a reasonable time any Drawing or order requested by the Contractor as stated above, the Contractor suffers delay and / or incurs additional costs, the Engineer shall take such delay into account while determining any extension of time to which the Contractor would be entitled under.
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Suitable incentives are given to the contractor on successfully, timely & within the quoted rates (i.e with variations) completion of work for critical activities.
Delays
Failure or delay by the Employer or the Engineer, to hand over to the Contractor the Site necessary for execution of Works, or any part of the Works, or to give necessary notice to commence the Works, or to provide necessary Drawings or instructions or clarifications or to supply any material, plant or machinery, which under the Contract, is the responsibility of the Employer, shall in no way affect or vitiate the Contract or alter the character thereof; or entitle the Contractor to damages or compensation thereof but in any such case, the Engineer shall extend the time period for the completion of the Contract, as in his opinion is / are reasonable.
In case of delay on the part of the Contractor, the Contractor shall be liable to pay liquidated damages in addition to any other compensation for the damages suffered by the Employer. This is without prejudice to the right of the Employer to rescind the Contract.
Bibliography/ Readings:
Material from NICMAR Internet
Quality control manuals of DLF Metro & Delhi Metro. CPWD Specifications, National Building Codes.
