SETSCO Services Pte Ltd Form.

Ref: SS/QA-5
Weekly Inspection Report
Date 01/06/13-
07/06/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, For LTA Contract C9309
DTL2 and NSLE at ACPM Factory, Pontian, Johor

A. Highlights of Inspection and Safety Observations

1. Production Related

(i) Mainline Sleepers:

A total of 656 nos. mainline sleepers - monoblock type 1 were produced, while a total of
576 nos. mainline sleepers - monoblock type 1 were delivered to ALSTOM (C910) track
work in Singapore for the period 01/06/13 to 07/06/13. Detailed breakdown of the
production of mainline sleepers are as presented in table 1 and 2.

(ii) Turnout bearers:

A total of 102 nos. bearers were produced, while no bearers were delivered to ALSTOM
(C910) track work in Singapore for the period 01/06/13 to 07/06/13. Detailed
breakdown of the production of bearers is presented in table 3.

(iii) Depot Ballasted Sleepers:

No depot ballasted sleepers were produced and delivered to ALSTOM (C910) track
work in Singapore for the period 01/06/13 to 07/06/13. Detailed breakdown of the
production of depot ballasted sleepers is presented in table 4.

(iv) Guard Rail Sleepers:

As informed by ACPM/ALSTOM, production of guard rail sleepers was stopped on the
06/12/12 as the required quantity had been achieved. Detailed breakdown of the guard
rail sleepers production and delivery as at 07/12/12 is presented in table 5.

(v) Summary of the recorded cube test results for mainline sleepers, turnout bearers, depot
ballasted sleepers and guard rail sleepers for the period 01/06/13 to 07/06/13 are as
presented below:

Age at Test (days) Average cube compressive strength (N/mm2) - Remarks

Range
Mainline Turnout Depot Guard
Sleepers Bearers Ballasted Rail
Sleepers Sleepers
1 day
40.5 - 42.5 41.0 - 42.0 - - min 30N/mm2
(for transfer age)
7 days 50.5 - 53.0 51.0 - 54.0 - - -
14 days - 57.5 - 65.0 - - -
21 days - 62.0 - 67.0 - - -
28 days 70.5 - 74.5 73.0 - 75.5 - - min 60N/mm2

Reported by SETSCO’s Inspector: Zainal Sariman Vetted by QA Engineer: Tan HK

SETSCO Services Pte Ltd Form. Ref: SS/QA-5
Weekly Inspection Report
Date 01/06/13-
07/06/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, For LTA Contract C9309
DTL2 and NSLE at ACPM Factory, Pontian, Johor

(vi) Summary of the recorded rejected mainline sleepers, turnout bearers, depot ballasted
sleepers and guard rail sleepers for the period 01/06/13 to 07/06/13 are as presented
below:

Type of sleepers Nos of sleepers rejected with cause (s) for rejection
a b c d e f g h
Mainline Sleepers - 1 0 0 0 0 0 0 0
Monoblock Type 1
Mainline Sleepers - 0 0 0 0 0 0 0 0
Single block Type 1
Mainline Sleepers - 0 0 0 0 0 0 0 0
Monoblock Type 2
Mainline Sleepers - 0 0 0 0 0 0 0 0
Single block Type 2
Turnout Bearers 0 0 0 0 0 0 0 0
Depot Ballasted 0 0 0 0 0 0 0 0
Sleepers
Guard Rail Sleepers 0 0 0 0 0 0 0 0
Notes: “a” – shoulder height out of tolerances; “b” – chipped off;
“c” – honeycombing; “d” - misaligned insert; “e” – outer-outer Go/NoGo;
“f” – rail seat Go/NoGo; “g”- dimensional check; “h” – others

(vii) QC testing such as Go-NoGo gauge tests and surface checks for mainline sleepers and
turnout bearers (performed by Alstom) are on-going.

(viii) Track gauge assembly checks, pull-out test and rail seat (+) positive moment test for
the 43rd & 44th batch of mainline sleepers - monoblock type 1 were carried out on the
03/06/13 & 05/06/13 respectively. All test results are satisfactory.

(ix) As informed by ACPM, casting of turnout bearers for NSLE & BTW had reached the
required quantity (last cast on the 03/06/13). While, casting of turnout bearers-depot
had resumed on the 05/06/13.

(x) A total of 7000pcs anchor bolt inserts (for depot ballasted sleepers) arrived at ACPM on
the 06/06/13.

(xi) Setsco QA Engineer visited ACPM factory for routine inspection on sleepers
production on the 06/06/13.

Reported by SETSCO’s Inspector: Zainal Sariman Vetted by QA Engineer: Tan HK

SETSCO Services Pte Ltd Form. Ref: SS/QA-5
Weekly Inspection Report
Date 01/06/13-
07/06/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, For LTA Contract C9309
DTL2 and NSLE at ACPM Factory, Pontian, Johor

2. Safety Issues
No major breach of safety.

B. Issued/Closed out NCN with reasons by Setsco Inspector or advice given

Nil.

C. NCR with corrective action raised/closed out by ACPM

Nil.

D. Others
Nil.

Reported by SETSCO’s Inspector: Zainal Sariman Vetted by QA Engineer: Tan HK

 SETSCO Services Pte Ltd Form. Ref: SS/QA-5
Weekly Inspection Report
Date 01/06/13-
07/06/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, For LTA Contract C9309
DTL2 and NSLE at ACPM Factory, Pontian, Johor

Table 1:

Weekly Production & Delivery

Mainline Sleepers - Monoblock Type 1

Date Day Produced Unchecked Quarantined Rejected Accepted Delivered

01/06/13 Saturday 0 - - 0 0 0
02/06/13 Sunday 0 - - 0 0 0
03/06/13 Monday 164 - - 0 164 96
04/06/13 Tuesday 164 - - 0 164 96
05/06/13 Wednesday 164 - - 0 164 192
06/06/13 Thursday 164 - - 0 164 192
07/06/13 Friday 0 - - 1 163 0

This Week Total 656 - - 1 819 576

Cumulative Total (Since

28/09/10) 33940 164 6 603 33167 *28551

Total Nos Required - - - - - -

Mainline Sleepers - Single block Type 1

Date Day Produced Unchecked Quarantined Rejected Accepted Delivered

01/06/13 Saturday 0 - - 0 0 0
02/06/13 Sunday 0 - - 0 0 0
03/06/13 Monday 0 - - 0 0 0
04/06/13 Tuesday 0 - - 0 0 0
05/06/13 Wednesday 0 - - 0 0 0
06/06/13 Thursday 0 - - 0 0 0
07/06/13 Friday 0 - - 0 0 0

This Week Total 0 - - 0 0 0

Cumulative Total (since

18/12/10) 496 0 0 50 446 399

Total Nos Required 700 - - - - -

Note: “*” - Inclusive of 7500 nos. required for DTL 1.

Reported by SETSCO’s Inspector: Zainal Sariman Vetted by QA Engineer: Tan HK

 SETSCO Services Pte Ltd Form. Ref: SS/QA-5
Weekly Inspection Report
Date 01/06/13-
07/06/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, For LTA Contract C9309
DTL2 and NSLE at ACPM Factory, Pontian, Johor

Table 2:

Weekly Production & Delivery

Mainline Sleepers - Monoblock Type 2

Date Day Produced Unchecked Quarantined Rejected Accepted Delivered

01/06/13 Saturday 0 - - 0 0 0
02/06/13 Sunday 0 - - 0 0 0
03/06/13 Monday 0 - - 0 0 0
04/06/13 Tuesday 0 - - 0 0 0
05/06/13 Wednesday 0 - - 0 0 0
06/06/13 Thursday 0 - - 0 0 0
07/06/13 Friday 0 - - 0 0 0

This Week Total 0 - - 0 0 0

Cumulative Total (Since

18/12/10) 6120 0 0 87 6033 5612

Total Nos Required 5912 - - - - -

Mainline Sleepers - Single block Type 2

Date Day Produced Unchecked Quarantined Rejected Accepted Delivered

01/06/13 Saturday 0 - - 0 0 0
02/06/13 Sunday 0 - - 0 0 0
03/06/13 Monday 0 - - 0 0 0
04/06/13 Tuesday 0 - - 0 0 0
05/06/13 Wednesday 0 - - 0 0 0
06/06/13 Thursday 0 - - 0 0 0
07/06/13 Friday 0 - - 0 0 0

This Week Total 0 - - 0 0 0

Cumulative Total (since

18/12/10) 448 0 0 42 406 385

Total Nos Required 320 - - - - -

Reported by SETSCO’s Inspector: Zainal Sariman Vetted by QA Engineer: Tan HK

 SETSCO Services Pte Ltd Form. Ref: SS/QA-5
Weekly Inspection Report
Date 01/06/13-
07/06/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, For LTA Contract C9309
DTL2 and NSLE at ACPM Factory, Pontian, Johor

Table 3:

Weekly Production & Delivery

Bearers

Date Day Produced Unchecked Quarantined Rejected Accepted Delivered

01/06/13 Saturday 25 - - 0 35 0
02/06/13 Sunday 0 - - 0 0 0
03/06/13 Monday 15 - - 0 34 0
04/06/13 Tuesday 0 - - 0 25 0
05/06/13 Wednesday 27 - - 0 15 0
06/06/13 Thursday 0 - - 0 0 0
07/06/13 Friday 35 - - 0 27 0
This Week Total 102 - - 0 136 0
Cumulative Total (Since
19/07/11) 4780 35 11 83 4651 *3870
Total Nos Required - - - - - -
Note: “*” - Inclusive of 71 nos. bearers selected for 3 rd party testing at DNV and mockup test
(integrated test).

Table 4:

Weekly Production & Delivery

Depot Ballasted Sleepers

Date Day Produced Unchecked Quarantined Rejected Accepted Delivered

01/06/13 Saturday 0 - - 0 0 0
02/06/13 Sunday 0 - - 0 0 0
03/06/13 Monday 0 - - 0 0 0
04/06/13 Tuesday 0 - - 0 0 0
05/06/13 Wednesday 0 - - 0 0 0
06/06/13 Thursday 0 - - 0 0 0
07/06/13 Friday 0 - - 0 0 0
This Week Total 0 - - 0 0 0
Cumulative Total (Since
24/10/11) 19092 0 0 161 18931 *18632
Total Nos Required - - - - - -
Note: “*” - Inclusive of 24 nos. depot ballasted sleepers (prototype) selected for 3 rd party testing
at DNV.

Reported by SETSCO’s Inspector: Zainal Sariman Vetted by QA Engineer: Tan HK

 SETSCO Services Pte Ltd Form. Ref: SS/QA-5
Weekly Inspection Report
Date 01/06/13-
07/06/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, For LTA Contract C9309
DTL2 and NSLE at ACPM Factory, Pontian, Johor

Table 5:

Weekly Production & Delivery

Guard Rail Sleepers

Date Day Produced Unchecked Quarantined Rejected Accepted Delivered

01/06/13 Saturday 0 - - 0 0 0
02/06/13 Sunday 0 - - 0 0 0
03/06/13 Monday 0 - - 0 0 0
04/06/13 Tuesday 0 - - 0 0 0
05/06/13 Wednesday 0 - - 0 0 0
06/06/13 Thursday 0 - - 0 0 0
07/06/13 Friday 0 - - 0 0 0
This Week Total 0 - - 0 0 0
Cumulative Total (Since
12/09/12) 440 0 0 6 434 416
Total Nos Required - - - - - -

Reported by SETSCO’s Inspector: Zainal Sariman Vetted by QA Engineer: Tan HK