Gharpure Engineering & Construction (P) Ltd.

1st AUDIT COMPLAINCE DATE : 12.12.11 to 14.12.11

Name of Client: NMMC Name of Auditor:INDIAN REGISTER OF SHIPPING (IRS) Name of work : Under the integrated Development of sewerage system in Navi Mumbai municipal corporation area ( Underground sewerage system for NMMC) Providing of sewer network & improvement of sewage system in Turbhe & Vashi ward Constructing, Erecting and Commissioning of Sewage Treatment Plant of avg. advance technology including operation and Maintenance for 3 years at Sector 20, Sanpada, Navi Mumbai.
The above documents were seen for the period of 20.08.2009 to 31.05.2010

1st AUDIT COMPLAINCE

SR NO. 6.0

OBSERVATION RAISED BY IRS

COMPLAINCE

REMARK

CIVIL WORK
Methodology & Quality Assurance Plan: I. It is stated by the contractor that tender conditions do not specify preparation of methodology for the work, hence methodology is not prepared. II. It is suggested that contractor shall prepare a methodology for each and every item of the BOQ to know how the items will be executed by means of methodology of the sequence etc. III. It is obligatory on the part of contractor to prepare QAP within 14 days from commencement of work and as such QAP is prepared by the contractor but not approved by PMC / NMMC. IV. It is further noticed that many points are not being complied as stated in the QAP prepared by the contractor though it is claimed that QAP is prepared for their own guidance. Control of Data and Documentation: Methodology attached. (Pg No. 1)

Methodology attached. (Pg No. 1) PMC APPROVED COPY ATTACHED

Methodology attached. (Pg No. 1)

7.0

a) Base Documents:
i) ii) iii) iv) v)

Tender copy Vol. I & II Work Order copy STP billing break up (Approved) Correspondence file Daily progress reports

Already shown at the audit time. Already shown at the audit time. Already shown at the audit time. Already shown at the audit time. Already shown at the audit time.

b) Technical Documents: A. STP

i) Concrete consumption registerDay to day concrete consumption of various grades of concrete is maintained in register. ii) Soil investigation report-Soil investigation was carried out by M/s. Geotechnical Solutions in November 2009 & December 2009. & soil investigation reports along with bore samples are available at site iii) Cube testing registerCube test register is maintained at site.

Already shown at the audit time.

Already shown at the audit time. Already shown at the audit time.

Already shown at the

audit time. iv) Reinforcement steel challan file Already shown at the is maintained at site . audit time. v) Compaction test record compaction test record is Already shown at the maintained layerwise. audit time. vi) R.C.C. Pipe File- R.C.C Pipe invoice along with manufacturers test Already shown at the record is maintained audit time. vii) Batch record file Date wise concrete batch record is maintained Already shown at the audit time. viii) Mix design file RMC concrete was procured from Lafarge, Ultratech, and RMC India. Mix design from Lafarge, Ultratech, and RMC India was approved by PMC M/s. Tandon & Associates. NOTED. ix) Level Register: - level record should be documented in level register to verify on going work as per drawing at any stage of construction. Site instruction book is maintained & photo x) Instruction book- Instruction copy are attached book should be maintained at herewith Pg. No. 5 site to record suggestions of senior officers visit / their Drawing file available at observations of ongoing works & site. NMMC approval compliances of the same. work is under progress. xi) Drawing file- Various Drawing files are maintained as per various units of sewage treatment plant. All drawings prepared by M/S S. N. Gharpure Engg. & const. pvt. Ltd. & checked for dimension & levels by SFC Environmental Technologies Pvt. Ltd (Technology provider from Austria for SNG) & Only RCC proof checked by IIT p for Noted. approval of Consultant (Tandon & assoc.) stamped by PMC, the approval from NMMC shall be suitably furnished.

NIL

NIL NIL NIL NIL

xii) The contractor has furnished us the list of associated consultants viz. C-Tech Technology Consultant, BEP consultant GA & RCC consultant, Sewer Network Consultant, Geo technical consultant, Electrical & Instrumentation Consultant. However RCC proof checking & RFI attached. (Pg. No. 6a, BEP approval is done by IIT & 6b) rest of the works are handled by sole agencies as mentioned above without the requirement of further checking. xiii) Stage passing particularly strata approval record for footing by PMC is not reflected in RFI. The RFI only mentions the item of work e.g. PCC, plinth beam or any other foundation but does not throw light on strata approval. Shuttering/reinforcement checked/approved etc. The general remark of inspection passed is ticked in the RFI which in fact should have been more elaborate taking into the account above aspects of importance. B . UGD Under mentioned documents were found maintained at site. a. Approved General master plan/cross section b. Challans along with MTCs for pipes/materials c. Level register d. Cube test register e. Approval/testing of pipes record f. Bill record g. Source approval record Remark: in addition to above some records not available during audit are as follows. i) approved hydro test record ii) approval for bitumen macadam Plants and Equipments deployed at site:

OK.

Already shown at the audit time. Already shown at the audit time. Already shown at the audit time. Already shown at the audit time. Already shown at the audit time.

XEROX ATTACHED. (Pg. No 8) XEROX ATTACHED. (Pg. No 9)

8.0

The site laboratory following equipments -

has

the
Already shown at the audit time. Already shown at the audit time. Already shown at the audit time. Already shown at the audit time. NIL NIL NIL NIL

1. Cube moulds (150mmx150mmx150mm)-40 nos. 2. CTM of capacity 1000KN 3. Sieves-1 set 4. Core cutter 5. Oven 6. weighing Balance of capacity 10Kg. 7. Slump cone-3 nos.

Remark: Quality control lab has been established at site. All necessary equipments were available at site. However valid calibration of Cube moulds Sieves, Slump cone, etc was not available. Only Calibration of CTM on 27-4-10 by Allied services & core cutter on 13-5-10 by Technical & scientific sales were available. 9.0

Now SIEVE CALIBRATION is done at site & certificates are attached. (Pg. No. 22)

Testing and Quality Control materials & Products: A. Soil investigation

of
Already shown at the audit time. NIL

a. M/S Geotechnical Solutions conducted geotechnical investigation and submitted report No.IZ/GECL/SPD/STP/G-775B dtd.15th Nov.2009. For this purpose BH 1 to BH 7 =seven bore holes were executed for ascertaining the sub profiles & BH 8 was made in the location of pump house. Since structure of SBR is located within the existing maturation ponds (lagoons) column footings at the weathered rock level are recommended for supporting major units.

b. The execution of exploratory bore holes Already shown at the & the laboratory investigation were audit time. carried out by M/s. DBM Geotechnics & construction. Pvt. Ltd.The observations by the consultants are as under: The ground water table recorded during exploratory drilling of holes was + 4.5 m RL. Since the ponds were almost full during investigation & the shallow ground water table during investigation is expected to be due to the pond. The surrounding areas are at lower level & the actual ground water table should be much below +4.5m RL. The trial pit excavation made up to the weathered rock recorded water at +1.5m RL. The shallow ground water table is expected to be due to the rains at the time of investigation, hence the ground water table at +2.00m RL(about 2.2m below FGL) may be used in the design of foundation & different structures. c. The chemical analysis of Soil & ground water: The sulphates & chloride values are higher than the allowable limits up to which special precautions for foundation concrete are not required. Precaution for safe guarding the concrete & steel from the chemical attack shall be taken in the construction. However no special consideration appears to have been

NIL

NIL Photographs are attached. (Pg. No. )

done.

Since the invert level of the basin is +4.175 m RL the C-tech basin is proposed to be supported on column footings while the bed is designed as suspended slab. The recommended foundations level for the footings is +0.8m RL & SBC recommended is 40T/m2. The column height up to the base slab may be of 2.2m & no intermediate tie for columns necessary. d. Plate load tests are conducted for foundation & the results show. i. Ultimate bearing capacity as 136.96 T/m2 & safe BC 46.65 T/m2 as with FOS- 3 So recommended SBC is 45 T/m2 at a depth of 3m. ii. For C-tech Basin No.2 & 4 Ultimate BC observed 154.08 T/m2 with SBC as 51.36 T/m2 with FOS-3. So SBC recommended is 45 T/m2 iii. 2nd Plate load test shows Ultimate BC as 136.96 T/m2 & SBC as 40 T/m2 with FOS 3. iv. For Blower room -Ultimate BC observed 154.08 T/m2 SBC as 51.36 T/m2 e. For staff Quarter the soil testing is done through Oriental Consulting Engg. Also for all above tests the SBC is recommended as 7 T/m2 at a depth of 4m below EGL. B. Observation on Concrete record of STP a) Observation on Mix Design:Suppliers Name Ultratech MC(India) Godrej b) Physical & chemical tests records in independent lab for RMC suppliers: Supplier's Name Ultratech RMC India Remark :

NIL Already shown at the audit time.

MIX DESIGN COPY ATTACHED. (Pg. No. )

CHEMICAL & PHYSICAL TEST COPY ATTACHED. (Pg. No.) Already shown at the audit time. NIL Already shown at the audit time. NIL Already shown at the audit time.

1. RMC concrete was procured from Lafarge , Ultratech, RMC India & mix design from Lafarge ,Ultratech, RMC India was approved by PMC M/s. Tandon & Associates. 2. Mix design from Lafarge & trial mix record of Ultratech, RMC India, Godrej was available during audit & following are the observation

3. Trial mix test sheet and cube test results attached with the mix design from Lafarge. 4. Physical properties & chemical test reports for Fine and coarse aggregate, cement, admixture and water are attached with only mix design report from Lafarge. 5. Physical & chemical test records of ingredients of concrete from RMC suppliers viz. Ultratech , RMC India are not available with trial mix records to ascertain the requirements as per IS 10262. 6. Combined gradation of ingredient of concrete as per IS 10262 has not been enclosed with mix design. 7. Concrete mix design is not approved by NMMC officials.

NIL

Already shown at the audit time.

NIL

Attached. No 41)

( Pg. NIL

NIL Attached. (Pg. No. 32 to 40)

Mix design copies of various grade M20 to M35, all RMC suppliers copies are submitted to NMMC for approval.

NIL

c)

Concrete Test Remark: i. Frequency of concrete cube test for all grades maintained as per IS 456:2000. ii. Independent lab tests were not carried out. iii. Standard deviation was not computed on site.

Already shown at the audit time. Independent test has been carried out in PWD for M20, M30, M35 grade & Photo copies are attached. (Pg. No. 7) Standard deviation is now computed. Standard Deviation found 2.27 (i.e good quality) Photo copy attached. (Pg. No. 7)

NIL

d)

Verification of concrete records: following concrete work quality records & its correlation has been verified . For M25 22-4-10 Blower foundation For M35 23-3-10 REMARK

Sr.No. Details of record 1 date of concrete

structure name

C-tech footing

3 4 5 6 7

level record RMC supplier batch slip time of concreting approved drawing

not available Lafarge available 19:25 to 00.25 available

not available Godrej available 13.30 to 14.45 available

Level record is being traced & will be submitted in next audit.

8 9

RFI BBS

not available available

not available available

M35 AVAILABLE M25 RFI HAS BEEN MISPLACED

10 11 12

theoretical quantity actual quantity slump record

not mentioned 42 cu.m. available

not mentioned 18 cu.m. available

Now theoretical quantities are calculated & mentioned in concrete pour card.

13 14

cube taken cube results 7 days in N/mm2 28 days in N/mm2

12

12

Frequency of casting cubes are now followed as per IS per 456:2000.

20.52 31.4

30.44 & 30.73 42.29

e)

Concrete batch record

i. Concrete batch slips of Lafarge, Ultratech, RMC India, and Godrej have been reviewed & it is observed that slump record at plant is not mentioned on batch slips. Slump record is maintained in concrete register at site. Water added at the time of concrete batch as per mix design record. However slump record in batch slip is not mentioned. Noted. NIL

ii.

Epoxy application record:

Records of epoxy application on concrete structure such as challans and thickness check are not available during audit. Epoxy challan are now available at site with MTC.

D.

Backfilling:
Records of backfilling work for concrete structures such as challans, consumption register and thickness check are not available during audit.

E.

Rock anchoring:
PULL OUT test conducted for SPS SH-1, Wet well. Drawing no. SNG/NMMC/SAN/RCC/32(RO). Total 101 nos. (32 mm dia rock anchors having 18T tension capacity) for wet well. Rock anchors of 32 dia. are spaced 1250mm x 1250mm & 985mm x 1250mm in a 14000mm internal dia. of well. Note on the above drawing states that grouting to be done with MC-Expacrete as per manufacturers instruction. However record was not shown & whether pressure grouting or gravity flow grouting was resorted to, not mentioned on the drawing. As per drawing note During construction floatation of structure due to sub soil water logging of site shall be prevented & stable equilibrium of the structure shall be ensured & in detail of anchor the test to be conducted for tension is 18 tones without specifying no. of bars to be subjected to tests. Only 4 bars (Anchor bars No.44, 55 & 73, 84) as above drg. tested with RFI dtd.28-4-10 in the presence of PMC, NMMC. Each anchor bar is tested for 27KN load. However no instruction of actual no. of testing to be done is specified anywhere. Only 4 bars tested out of 101 anchor i.e. 4% approx. testing which should have been at least 30%. Further the report (4.9.3) states that the backfilling between the wet well wall and the rock cutting can be done using lean concrete containing fly ash and cement so that the lateral pressure on the wall is limited to the water pressure. This could not Already shown at the audit time. NIL

Challan and MTC is attached. Pg. No

NIL Already shown at the audit time.

Designer has made all consideration for lateral pressure on wall, so there is no any requirement.

be ascertained.

F. Reinforcement steel Reinforcement steel records up to 31-5-10

Dia. of steel in mm 8 10 Received in lots 8 6 Total Qty. in MT. 52.49 All ITCs from structwel are available 53.33 One lot failed in yield stress & returned vide challan no. 468 dtd. 16-4-10 12 9 114.87 all passed & Thane TMT(old) failed in yield stress TC-31343-44 dtd.25-3-10 TMX 4076/dtd.14.3.10, 3 204.98 specimen tested 112.39 From Thane TMT(in Structwel) & TCR lab. Only one lot tested three specimen from Thane TMT 2 20.08 Lots not tested (Structwel Lab.) 4.98 3 specimen tested in Structwel lab.& results found OK Remark

16 20

10 13

25 32

3 1

The ITC from TCR engg. services Pvt. Ltd. for the test conducted on 10 mm dia. failed in 0.2% proof stress value. Value of 389.35N/mm2 tested on 11-1-10 without Ref. no. but only AF 7138. 16 mm dia. steel tested on 02-0210 in TCR engg. Services lab. Shows yield stress value as 433,423 & 415 and are borderline cases for Fe 415 grade. However the UTS values are 569.87, 560.47 & 554.18 N/mm2 & hence allowable. 12mm steel tested on 05-2-10 in TCR Lab. shows Yield stress value of three specimen show 417.53, 388.97, 377.81

Already shown at the audit time.

NIL

All failed reinforcement are removed from site as per mentioned reference of PMC & NMMC Instruction.

NIL

N/mm2. less than the required min. of 415 N/mm2 & it is written on test report 12mm dia. failed in Tensile strength & contractor has been instructed to remove the steel from STP site by PMC. Removed from site vide challan 468 dtd 16.4.2010.. 10mm dia. steel tested by structwel lab. on 05-4-10 vide report no. R&DLAB/2010/SAN0560709/0066. The values of 0.2% proof stress are 383.90, 382.61, 381.17 N/mm2 showing consistent low values than the required 415 N/mm2 minimum. Remark in steel testing register maintained at site shows the material is rejected & removed from site with all 3 signatures of Contractor, PMC & NMMC. Also for 12mm dia. in the same report values are 411.83 N/mm2, 410.51 N/mm2, and 400.85 N/mm2 showing low results (border line) for Thane Fe415 old. However this test results do not find mention in the register. The UTS values for these are 564.80, 569.69, 559.52 N/mm2 & are acceptable. 3 specimen of each dia. of bars are tested in independent lab. either Structwel or TCR lab. or CIDCO material Testing Lab. & the results of 0.2% proof stress are generally in order. Only in case of 10mm, 12mm dia. steel, some lots are failed in yield stress & removed from site vide challan 468 dtd. 164-10 of M/S Gharpure engg. & const. pvt. Ltd. In case of 16mm dia. steel lot received from Sumeet steel dtd. 22-1-10 Qty. 9.53 MT (Gurdian steel Pvt. Ltd. secondary manufacturer) failed in Phosphorous content being 0.093%0.06 max.. The steel register mentions a remark rejected & removed from site with signatures of contractor, PMC, NMMC. 10.
Contractual Aspects: I. Tender document is made available during the audit. II. Bar chart planning is prepared by

NIL All failed reinforcement are removed from site as per mentioned reference of PMC & NMMC Instruction.

Already shown at the audit time.

NIL

III. IV.

the contractor but not approved by PMC / NMMC. The time extension is approved three times.

Now Bar Chart planning prepared & approved by PMC. Photo copy are attached herewith. NIL Noted. Noted. NIL

Excess and saving statement is prepared. V. There is no variation in contract up to 31.05.2010. VI. It is stated by the contractor that no weekly / monthly progress is being submitted. however it is stated by the contractor that PMC is submitting MPR based on the information and facts. VII. As per contract condition contractor can work is two shifts. VIII. RFI is being maintained for each and every activity duly signed by contractor, PMC and NMMC engineer. IX. Work order book is not maintained by the contractor though obligatory to maintain as per contract conditions. X. PMC had some format for issuing necessary instructions to the contractor whenever solicited but there is no trace of compliances for the instructions given by PMC engineer. XI. QAP and safety manual is not approved by PMC and NMMC. XII. Till period of 31.05.2010. Contractor has claimed two R.A. Bills and mobilization advance payment. No claims were made towards price escalation.

NIL

NIL NIL

Work order book is mentioned & attached herewith. As per instruction given by PMC, necessary action was taken and complained on work order instruction book itself only.

NIL

11

SAFETY MEASURES: I. Necessary NOC is taken from the Police Authority for partly diversion of traffic etc. NOC was valid up to 31.05.2011 II. CAR and W.C. are valid policy are in force since commencement of the work and both are valid up to 20.08.2012 and 20.08.2011 respectively. III. Contractor is having a labour Licence no DC / THA / KLA / 057 / 057/55 dated 18.12. 2009 is valid up to 31.12.2011. IV. It is obligatory on the part of contractor to submit and get approval of safety manual from PMC / NMMC V. Contractor has prepared a safety manual in general but same is not approved by PMC / NNMC.

Noted.

NIL

Noted.

NIL

NIL Noted.

Noted.

NIL

NIL Noted.

VI. Good record is being maintained by the contractor for all aspects of the HSE except scaffolding procedure and is made available for the inspection. VII. Contractor has appointed qualified safety officer in HSE and fire. VIII. Interaction with safety officer is done. IX. Some photos were given by the contractor for the period up to 31.05.2011. many photos reveal that no PPEs were used by workmen.

Noted.

NIL

Noted. Noted. PPEs are now provided to workers during excavation photo proofs are attached.

NIL NIL

NIL

MECHANICAL WORKS
1)

Mechanical works:
1) BEP(BASIC ENGINEERING PACKAGE) seen approved by IIT. 2) Process &.Instrumentation. Diagram seen approved by IIT 3) Hydraulic calculation for pump station/velocity calculation for pipe lines approved by IIT. Following machinery details checked for the period 21ST 2009 TO 31ST MAY 2010. from inward register and found following in consistencies A) Decantor :i. Make : Alfa laval ii. Qty : 3 Nos iii. Model : Aldec45 1) Performance test report seen but no particular identification on report is observed thereby traceability can not be found 2) No approved/verified signature on any report of MTC of TPI 3) ( Tandon & Associates) 4) As per release note, Noise level/Capacity to be checked at site however no report seen for the same. 5) No motor certificates available. B) Agitator Make : Fibre & Fibre products Qty : 2 Nos Motor: 1.5 Hp Sr no :2744699/7055473 Gear box : A-237 1) All certificates seen but no signature of TPI on any certificates showing verification.( Tandon & Associates) C) Submersible pump Make : Aqua machinery Qty : 15 Nos Model/Sr no :2033DM 080:-18571 TO 18577-7 NOS ANS 1023 SXM-004 :- 18582 TO 18585-4 NOS 1527 DL 010 :- 18578 TO 18581-4 NOS 1) Performance test/curve test report not available for Model no 2033 DM 088 -6 nos,1527 DL 010- 3NOS & ANS 1023 SXM 004- 3NOS 2) All other releated documents found in order but no signature verifying the documents by TPI(Tandon & Associates) ALREADY SHOWN ON AUDIT DATE ALREADY SHOWN ON AUDIT DATE ALREADY SHOWN ON AUDIT DATE NIL NIL NIL

XEROX ATTACHED

Noise Record note is kept in file (XEROX ATTACHED)

ALREADY SHOWN ON AUDIT DATE

NIL

PERFORMANCE TEST/CURVE TEST REPORT FOR MODEL NO.2033 DM 080-6 NOS 1520 DL 010-3 NOS & ANS 1023 SXM 004-3NOS-MADE AVAILABLE & PUT IN FILE

D) Submersible pump Make: Kishore Qty : 4 Nos Model/Sr no :KDS 70LD 200:-83809 TO 83810-2 NOS KDS 75LD 200:-83811 TO 83812-2 NOS 1) Performance test/curve test report verified & found in order for following Model KDS 70LD 200:83809 TO 83810-2 NOS KDS 75LD 200:-83811 TO 83812-2 NOS 2) All other releated documents found in order but no signature verifying the documents by TPI(Tandon & Associates ) E) Motor pump Make : Jyoti Ltd Qty : 3 Nos 1) All other releated documents found in order but no signature verifying the documents by TPI(Tandon & Associates ) & Mainly no entry in inward register. F) Inward register has detail of following motor pump but no certificates available. a) Make : W R Talwalkar Qty : 1 Nos Sr no :146.08.09045 Mechanical fine bar b) Make : Jash eng Qty : 2 Nos Model screen ZA-1135-900 6MM 2) All other releated documents found in order but no signature verifying the documents by TPI(Tandon & Associates ) & Mainly no entry in inward register. 3) Data sheet/QAP verified & found ok.

SHOWN & PUT IN FILE

SIGNED BY TPI (TONDON & ASSOCIATE) ENTRY IN INWARD REGISTER MADE

NOTED & WILL BE SUBMITTED IN NEXT 4TH AUDIT

4)

5)

G).Ductile Iron PIPES----------------------XEROX ATTACHED------Make. Lanco Size/ Qty . 500 dia(K9) x 810.50 Mtrs Challan no 18491 Received in mtrs 111MTRS Size 500 Dia x K9

18490 18533 18534 18538 18562

108.50MTRS 161.50MTRS 157MTRS 105.50MTRS 167MTRS

500 Dia x K9 500 Dia x K9 500 Dia x K9 500 Dia x K9 500 Dia x K9

Above Details checked & found in order but no signature verfying the documents by TPI(Tandon & Associates)

ELECTRICAL WORKS
12 Electrical Observations Document referred:-Tender no. 1. Following Quality control documents are not available. a). Drawing register: To know the approval status and the number of copies issued for site activities b) Non-Conformity reports/Conformity records not available. 2. Category for the inspection of various PMC & NMMC electrical items eg. Transformer, INSPECTED Switchgear, Motor etc. indicated in the tender as A, B and C. But the Scope of inspection under specific category is not mentioned, same to be produced. Following Electrical items received at site during the period 21.08.2009 to 31.05.2010 as mentioned in their inward material register. a) Transformer (11KV/433V)Joint Inspection report of kirloskar, XEROX ATTACHED Tendon & associates and NMMC was available where as approved Data Sheet/QAP were not available in the project file. As per tender type test certificate of transformer having similar construction and design required where as same was not available in project file. b) LT cable :- Approved data sheet and manufacturer test certificates were not available in the project file c) Control panel ,PLC panel and

switches:No supporting documents are available in the project file d) HT panel: - Joint Inspection report of ABB, Tendon & associates and NMMC was available. Approved QAP/data sheet was not available in the project file. e) Ultrasonic flow transmitter:Approved data sheet was available. Calibration reports and manufacturer test certificates were not available in the project file

PROJECT MANAGER GHARPURE ENGG. & CONST. PVT LTD

PROJECT MANAGER TONDON & ASSOCIATES

JUNIOR ENGG. NMMC