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NATIONAL HIGHWAYS AUTHORITY OF INDIA
PROJECT TITLE: Consultancy Services for Quality System Audit of NHAL
Projects,
AUDIT COMPLETION REPORT
(AUDIT CYCLE NO.11)
AUDITEE: Mls. PFC - FPI~ FTE (JV)
(Choose cera.
‘Add alee. VoOoOo 8
Executive summary
4, Introduction
2. The Lucknow Muzaffarpur National Highways Project .......
3. Background of Packages
4. Planning for Quality System Audit .
5. On-Site Audit
5.1 Opening Meeting
5.2Closing Meeting
6. Details of Non ~ Conformities closed
7. Details of Non — Conformities not closed ..
8. Declaration
Quality Index
4. Introduction
2. Quality Index
Annexure — I On site Audit report
Annexure — Il Follow up Audit Opening Meeting Attendance.
Annexure ~ III Corrective Action Report
Annexure — IV Evidence for NCR Closure
Annexure — IV Quality index
. Page No. 1-1
Page No. 1-1
Page No. 1-6
Page No. 6-6
Page No. 6-6
Page No. 6-8
Page No. 8-8
Page No. 8-12
Page No. 12-12
Page No. 12-12
Page No. 13-14
Page No.14- 14
Page No. 15-43
Page No. 44-44
Page No. 45-45
Page No. 1-12
Page No. 1-4 EXECUTIVE SUMMARY
4. INTRODUCTION
India has embarked on a 10 years highway transportation improvement program as &
part ofthe national policy to globalize its economy. National Highway comprises about 2
% of total road length in the country and carries over 40 % of total traffic across the
length and breadth of the country.
National Highways Authority of India was constituted by an act of Parliament, the
National Highway Authority of India Act, 1988. It is responsible for the development,
maintenance and management of National Highways. The Authority became operational
in February 1995, National Highway Authority of india (NHAN) in mandated to implement
National Highways Development Project (NHDP), which is India’s largest ever highways
improvement project formulated to equip India with world ~ class roads having
uninterrupted traffic flow. The NHDP is a major initiative for capacity ‘enhancement of
National Highways wich includes four / six laning of around 13,146 Km road length at
total cost of approximately Rs. 54,000 crores.
2. The Lucknow Muzaffarpur National Highways Project (LMNHP) :
‘The Lucknow = Muzaffarpur National highway Project (LMNHP) is @ part of the East
‘West corridor from Porbandar to Silchar. The LMNHP evisions improvement (four laning)
of the section of NH — 28 between Lucknow and Muzaffarpur. NH ~ 28 originates t
Lucknow the capital Gy of Uttar Pradesh passing through important towns has a total
renath of about 628 Kr. The Highway links important centers tke Ayodhye, Gorakhpur,
Kushi Nagar, Gopalgan), Muzaffarpur and ends at Barauni, an industrial town in Bihar.
3. Background of packages
3.1 Package 7
“The project package LMNHP-VII begins at km.279.800,where Gorakhpur bypass meets
with the existing alignment of NH-28 and ends at km.319.600 at Kasiya Township. The
total length of the package is 40 km. It is under the region of Gorakhpur, Kushinager and
Deotia Districts of Uttar Pradesh. The terrain of the project stretch is flat and falls under
typical flood prone Zone of north-eastem part of Uttar Pradesh. YvouoIVOoO SS
3.2 Package Kms
Contract Packages in Gorakpur -
Gopaiganj section C-lIVS of Lucknow Muzaffarpur *
under NHAI phase-III Program of East-West corridor development,
Contact
: Name of the
Packa
ackages Packages Chainage Length inkm | oor tactor
Calis (Gorakhpur | Vil Kim.279.800 to | 40.000 | NCC-VEEQV)
Gopalganj km 319.800
section)Km.279,800 to
402.000 of NH-28
3.3 PROJECT DATA
1. Project name
2. Lenght of Project
3.Contract/Phase
4, Name of Contractor
5. Name of Sub- Contractor
6. Contract Commencement Date
7. Original Completion Dats
4-Laning from Km 279,800 to Km 319.800 of
Gorakhpur- Gopalganj Section of NH-28 in UP.
India.
40 Kms
: Contract Package No-LMNHP-EW-II(WB) -7
: Mis NCC-VEE(JV)
1 13-Dec-2008
8. Likely/Expected Completion Date : -
9, Name of Supervision Consultant :
10. No. of Structures
PFC, FP(I) & FEEDBACK JV
New Replacement a
ti
Type of Structure Fin new lane In existing lane Exiting
Major Bridge 3 Q 3
Minor Bridge 13 8 3 Vou o
Sour Asia
‘Slab Culvert 29 3 29
Hume Pipe Culvert | 26 18 26
Box Culvert 4 1 4
Under PASS 6 0
RE-Wall 43520 Sqm
11, Underpasses and Flyovers on the following: Nil
Locations have been provided as additional works
12. Major Towns Enroute 7 dagdishpur (Km.281.70),Sonbarsa
(Km.284.90),Sukrauli
(Km.202.30),Hata
(Km.301.2),Kushinagar (km.316.50)
& Kasia (km.319.10)
3.4 Package 8
The Project Package LMNHP — VIII begins at km.319.800, just after Kasia and
terminates at km 360.915 of NH - 28 (UP — Bihar Border). The total length of the
Package is 41.116 km. and it falls under Kushinagar District of Uttar Pradesh. The
Project stretch runs through flat terrain and falls under typical flood prone zone of north
eastern part of Uttar Pradesh.
3.6 Package Kms
Contract Packages in Gorakhpur - Gopalganj section C-lI/5 of Lucknow Muzaffarpur
under NHAI Phase — Ill Programme of East ~ West corridor development.
Contract ; Name of the
Package i No. | Shainage Length inkm | Contractor
cls
(Gorakhpur
Gopalganj SIMPLEX
section) Km, 319.800 to i
vill kmaeoes | (ahtts eee
Km. 279.800 to .
402.000 of NH ~
28 )
}
2Y
SO 5;
3.6 PROJECT DATA:
4. Project Name
2. Length of Project
3. Contract / Phase
4, Name of Contractor
5, Name of Sub — Contractor
6. Contract Commencement Date
7. Original Completion Date
8, Likely / Expected Completion Dat
9, Name of Supervision Consultant =
10. No. of Structures :
4 laining from km.319.800 to Km
360.915 of Gorakhpur to Gopalgan Section of
NH - 28 in UP, India, civil Contract Package
No. LMNHP = EWI (WB), Package ~ 8
41.115 Km.
Package - 8
Ms, Simplex Infrastructure Ltd.,
08/12/2005
07/12/2008
PFC, FP (|) & FEEDBACK JV
‘Type of Structure
Existing
Major Bridge
Minor Bridge
Toll Plaza
Rest Area
Hume Pipe Culverts
Box Culverts
Slab Culverts:
fafa) 8] >| 2] 5) 5
‘Underpass
2
8
0
0
36
13
Ey
0
411, Flyover / Underpasses on the following
Locations have been provided as additional works: =
12, Major Town Enroute
13. Rivers Enroute
14, Any other
15. No of Old Bridges to be rehabilitated
under running contract
Permawalia (Km 326.100),
Jokawa (Km.330.840), Fazilnagar
(Km. 334.500), Patherwa (Km.
339.500) Tamkuhe (Km. 347.500)
Ghaghi River (Km. 327.890),
Jharthi River (Km. 345.880) ODO S IF
~ UID
5
37
3.8
39
South Asa
() Major Bridge 2 1No.
Gi) Minor Bridge > 2Nos.
Package 9
‘The Project package LMNHP-IX starts at km 360.015 (U.P-Bihar border) and terminates
at km 402.000 of NH-28 (Near Devapur ) in Bihar. The length of the package is 47.085
km, which falls under Gopaiganj district of Bihar .The project stretch runs thorough flat
terrain and falls under typical flood prone Zone of north-western part of Binar. The land
use is primarily agriclturel, The Most prominent topographical features include
numerous minor drainage rivulets with a major watercourse being the Gandak River.
River Gandak runs parallel to project Road Stretch on the north side,
Package KMS
Sallent features of the Contract Packages from Gorakhpur to Gopalganj section of NH-
28 Lucknow - Muzaffarpur under NHAI Phase-lIl Program of East-West corridor
development.
Contract
; Length | Contract Name of the
Package Packsge Chainage | (Km) Valuers) | C
Gorakhpur | 1X Km.300.015 | 41.085 | 357,14,59,137 | WS
Gopalganj to Progressive
section Km.402.000 Construction
Km.279.800 Ltd.
to 402.000
of NH-28
Package-LMNHP-EW-II (WB)-09
Project Title Four Laining trom Km 360+915 fo 402.000 of Gorakhpur to
Gopalganj Section of NH-28 in Bihar, Civil package No.
LMNHP-EW-II (WB)-09.
Client Employer | Chairman, National highways Authority of India | 9 Oo
VU 2
“>
Soun Asis
Engineer/Consultant
(i) Pell Frischman Consultant Pvt.Ltd London UK
(2) Pell FrischmanPrabhu (India)Pvt Ltd, Mumbai, India.
(8) Feedback Ventures Pvt Ltd, New Dethi,India (JV)
Site Office /
Pell Frischman Consultants in joint venture with |
FrischmanPrabhu (India)&Feedback ventures Pvt Ltd.
LMNHP-EW-I(WB)-9 Four Laining from Gorakhpur to
Gopalgani.
Office of Team Leader
Contractor
Naar Custom all Jaath_Tieaha_Paet.Kasin Dictt.|
PROGRESSIVE CONSTRUCTION Ltd,18 KOLKATA LANE
ROSE AVENUE
NEW DELHI-110002, PHONE-011-2322251 1-12-12-14
Project office
PROGRESSIVE CONSTRUCTION Lid, NEAR FC] GODOWN
(CH:394+400
NEAR KOINI VILLAGE,GOPALGANJ,BIHAR-641428
‘The cumulative physical Progress of works of last three months is as follows:
‘Month ] Package 7 Package & Package 9
June's | 33.46% 25.06% 20.01% |
Julyos | 33.52% 25.28% 20.03%
‘Augustos Bas 2035%
Planning for Quality System Audit:
With reference to Letter No. 11018/28/2006/PQ dated 09.07.2008 regarding Quality
System of Aut of National Highway projects scheduled during August - October, 2008,
the audit of this Consultancy was planned from 13.09.2008 to 18.09.2008.
On site Audit:
Opening Meeting:
Opening meeting was conducted on 13.09.2008 at Project Director Office, PIU
Gorakhpur. The opening meeting was chaired by Project Director and all others present
of Supervision Consultancy with Material Engineers of consultant
were Team Leader
and contractor.
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5.1.3
Soutn Asia
During the opening meeting the entire process of audit has been explained by Team
leader of Audit team and submitted the Audit plan to Project Director. The audit plan
‘submitted is attached herewith
The following tests were witnessed during the audit period.
Package 7:
> Coarse aggregate sample of 10mm and 20mm collected from stack yard and
witnessed gradation test (individual and combined) and Aggregate Impact value test
conducted and results found within limits.
> Concrete cubes of structure at 294.100 km (deck slab) and 298.100km (Abutment
final lift) tested and the results are satisfactory.
> Soil sample of barrow area No. 53 collected and tested for OMC and Maximum dry
density and compared with the approved test results and found satisfactory.
> Field density test for WMM 1* layer between chainage 200.060km to 290.230km
conducted and results found satisfactory. Gradation of the same sample collected also is
with in specified limits.
> DBM cores were collected between chainage 289.860km to 289.980 km and checked
thickness, density, bitumen content and gradation after extraction and results found
satisfactory.
> Roughness index test of DBM 2 layer between chainages 317.268 to 217.70 and
317,900 to 318.450km and found with in limits but on higher side.
Package 8
> DBM cores were collected between chainage 322.880km to 323.800 km and checked
thickness & density and results found satisfactory.
> Roughness index test of DBM 2” layer between chainages 320.580 to 322.600 L's
and R/s_and found with in limits.
Package 9
> Coarse aggregate sample of 10mm and 20mm collected from stack yard and
witnessed gradation test , Flakiness and elongation and Aggregate Impact value test
conducted and results found within limits. woo UVOUBU oOo Ss
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52
53
64
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> DBM cores were collected between chainage 372.289km to 372.381km and checked
thickness, density, bitumen content and gradation after extraction and results found
satisfactory
» Birla OPC 43 grade cement of 28" week tested for consistency, setting time and
fineness and results are satisfactory.
Closing Meeting:
Closing meeting was conducted on 18.09.2008 at Project Director Office, PIU
Gorakhpur. The closing meeting was chaired Project Director, PIU Gorakhpur, and also
present were Team leader of Supervision Consultancy end the Audit team.
‘During the closing meeting the Team feader of audit team discussed regarding all the
NCR findings and explained the procedure of root cause analysis and corrective action
process. The audit NCR's are handed over to DGM and the same are attached herewith.
The on-site audit report is attached as Annexure - 4
Follow up Audit:
Foilow up audit was conducted from 17.09.09 to 18.09.09. Auditor involved in follow up
audit is Mr. K, Guruprasad. The attendance is attached as Annexure — 2.
The follow up audit was conducted to verify the Corrective action report submitted for the
NCR's issued during the on-site audit vide letter No. 11025/1/2006/GKP/QA-SA/5499
DT: 08/14/2008. The Action taken report is attached as Annexure — 3.
During the Onsite Audit total of 07 NCR's were issued and based upon the Corrective
‘Action received 6 NCR's closed and 1 NCR's are still open. The details of closure of
NCR's are as follows:
Details of Non-conformities closed:
Non-Conformity: System of periodic review of concrete mix designs based on
compressive strength achieved and evidence of calculation of standard deviation and
following of acceptance criteria is not evident.
‘Standard: IS: 456 : 2000
Evidence:
4. As per approved mix design the 28 days compressive strength achieved during
trial mix was 48.6 N/mm? where as the strength achieved during production is verifying
between 31.1 to 42.03 N/mm* OOS
OO 0
62
2. The individual cube strengths of concrete used for casting of slab in the wall (L/S) at
3204400 on ‘09/05/08 are recorded
a8(33.3,30.2,35.6)(35.8,29.8,30.7)(35.6,31.8,27.1)(80.4,34.7,28.4)(31.1,30.0,33.8)
Nimm? and average strengths are 33.3,32.10,31,50,31.17, 31.63 Nimm etc. Material
engineer approved the strengths of individual cubes of 27.1 and 28.4 based on column
3 of table 11 of 1S:456:2000 individual cube strengths shall not be less than fck-
3Nimm? but not considered column 2 of table to satisfy the average strength
requirements ie., fck+0.85 times standard deviation or fek+3Nimm”.
Root Cause Analysis:
4. Concrete mix design based on current margin as per table 1700-5 at MORTH & H
specification. Review of concrete mix design based on standard deviation is job of
contractor as per sub ~ clause of MORT &H 1704.01(!). We would like to state that
compressive strength of concrete cubes achieved is more than characteristic strength.
Also please find enclosed here sheets of standard deviation & moving average of each
grade of concrete.
2 Compressive strength of cubes is accepted as per MORT &H specification
clause no: 1716.2.5 (Acceptance Criteria).
Corrective Action of the CSC:
Compressive strength of cubes is accepted as per MORT &H specification clause no:
1716.2.5 (Acceptance Criteria), Project Supervision Consultant accepted to follow 1S 456
for further Concrete mix designs.
‘Auditor Comments: The Compressive Strength of the cubes is complying with regard
to Characteristic Compressive Strength of Concrete as per MORT &H. Also checked the
standard deviation and found satisfactory. Hence the NCR is closed.
Non-Conformity: System for Mobilization! Deployment and replacement of Key
Professionals as required by Contract Agreement was found ineffective.
Evidence: RE for package-8 was not mobilized till date.
Corrective action of CSC.
Four proposals for replacement of RE for package LMNHP-8 was submitted for
approval - No response from NHA! (neither approved nor reject.) 9
63
6.4
South Asia
Auditor Comments: RE for package 8 has been depioyed from 05.01.09. The evidence
of deployment is attached as Annexure - 4 pages 1 to'3. Hence the NCR Is closed.
Non-Conformity: System of checking and timely approval of RFI's not evident.
Evidence: RFI No: RW 10228 to RW 10243 submitted by contractor to consultant on
12/09/08 at 4:40PM for inspection on 13/09/08. But not a single RFI is attended by
consultant representative on 19/09/08. All tests were conducted by contractors
representative till date the RFI's are either approved or rejected.
‘System of checking and timely approval of RFI s not evident.
Corrective action of CSC.
Tests witnessed, RFI action delayed due to holidays of contractor.
Auditor Comments: The RFl's are attended and the same were reviewed during the
follow up audit. Hence the NCR is closed.
Non-Conformity: System of approval for casting of working pile after test pile testing &
acceptance and routine testing of working piles is not evident.
Standard: 1S : 2911 Part IV
Evidence :
4. Test plles was casted at structure No, 337/1 but no test was performed on test pile but
approval for casting of working piles given.
2. Evidence of routine testing of working piles of structure No 348/3 is not traceable.
‘Comments / Compliance.
1. Please find enclosed here with Test pile report performed on 14/10/06. Please refer
to R.F.l No B.R 925 & The conceming report was submitted on 18/10/06 by letter Ref
No. 02/ up road/Engg/001/vol-4 / 0402 which is attached as enclosure for your ready
reference.
Also , load test on working pile was performed on 15/03/07. Please refer R.F.| No BR.
2256 and the report submitted on 21/03/07 vide letter no.02/UP ROAD / ENGG / 001 /
VOL-5 / 0640 both of which are enclosed. Therefore it is evident that Initial load test was
carried out on 14/10/08 and working pile load test was carried out on 15/03/07.
2. Please find enclosed herewith RFI No. BR 2497 on 16/04/07 and its concerning
report through letter NO. 02/UP ROAD / ENGG / 001 / VOL-§ 0686 dated 25.04.07 for
routine testing of working piles of structure no. 348/3. 20
SGC SCSCIS
65
66
South Asie
Auditor Comments: Initial Pile load Test was witnessed by CSC and approved,
‘subsequently Routine Piles also tested and found satisfactory. These documents were
shown during the on-site audit. The RFI’s of the testing are attached as page no. 4, § of
Annexure -4. Hence the NCR is closed.
Non-Conformity: No documented procedure for contro! of issue drawings.
Evidence: There is no control of issue of working drawings and retrieval of obsolete
drawings,
No documented procedures for control of issue drawings.
Corrective action of CSC.
The drawings are issued vide reference letter maintained in dispatched register.
Auditor Comments: Now the Register is being maintained and the Issue and revision
status of Drawings are maintained. Hence the NCR Is closed.
Non-Conformity: System of calibration of plant and equipment as per frequency is not
evident.
Evidence:
1. Batching plant calibrated on 18/02/08 and next due was on 18/08/08.
2. WMM plant calibrated on 16/02/08 and due was on 14/02/08. RFI issued 28/08/08
No.MS/366 for calibration of WMM plant and batching plant, but calibration was not
done and RFI not approved. But from 18/08/08 concrete and WMM production was
done without calibration,
3. Calibration by contractor for WMM plant on 13/09/08 but not witnessed by CSC.
Calibration done by contractor for RMM used with Oven (Rotak model 220/230V) on
02/06/08 but Oven was not calibrated.
Comments / Compliance.
41. No such frequency of calibration is mentioned in MORT &H section 1700,but we had
conducted calibration on 22/09/2008.sheet enclosed for your reference.
2. WMM Plant calibrated on 15/02/2008 & on calibration sheet it is mentioned next due
date of calibration is 14/02/2009 enclosed for your ready reference.
3. Calibration of WMM plant is due on 14/02/2009 as mentioned earlier. The calibration
of WMM plant done on 13/09/2008 was contractor internal calibration check. No RF! 8.0
Sout Ata
for such activity was submitted to us. Rotak modal 220/230V Oven is provided with
regulator and thermometer, which is calibrated on 16/04/2008 by independent
agency whose sheet is attached for your reference.
Auditor Comments: The Calibration was delayed for WMM & Batching plant due to
plants was water logged. Now the frequency for calibration of plant & machinery is,
maintained. For details see the page no. 6-12 of Annexure-4. Hence the NCR Is
closed,
Details of Non-conformities not closed till the end of follow up audit.
Non-Conformity: System of control on the checking of output from the batching plant
and Hot Mix plant is not evident.
Evidence: The Hot Mix plant and Batching plant of package-7 is not provided with
printout facility to check the batch production with respective JMF & mix design.
System of control on checking of output
Corrective action of CSC,
Register maintained at batching plant and hot mix plant,
Auditor Comments: Now the Register is maintaining for Hot Mix Plant &
Batching Plant based on the Display given by machina, But individual quantities of the
batch are not recorded to know the variation, Printout facility is not working till date,
Hence the NCR is open.
Declaration:
All the documents listed in the List of Documents reviewed sheet attached in On-site
Audit Report pertaining to that specific project are available at site.
Team Leader
war 490 SSC OO5
CUS
1.0
Index
Introduction:
Quality Index is derived from IRC - SP ~ 67 - 2000 - Which states
“For each of the important item of work, certain attributes are listed which contribute or
affect the work Quality of that item. Individual scores are then assigned to each of the
attributes on a scale of 0 to 5 depending on observations and scrutiny of that attribute of
that site. The sum total of the scores of all attributes for particular item divided by
maximum score achievable is termed as Quality index of that item." (Referred in Page
No. 102)
Considering the Agreement condition, statutory requirements and the documentation
Tequirements 20 attributes are listed which contributes or affect the Quality System.
‘These 20 attributes are sub — divided into 3 categories with certain weightage
Attributes category
A-with 50 % weightage
B — with 30 % weightage
C-with 20 % weightage
Each attributes under category ‘A’ carries a weightage of ‘10°
Each attributes under category ‘B’ carries a weightage of ‘6°
Each attributes under category ‘C’ carries a weightage of '2'
individuat source are assigned to each of these attributes on a points scale of 0 to 5
depending on performance standards as per Quality System requirements.
Total score of an individual attribute is the product of weightage of that attribute and the
Point score allotted against the respective attribute,
‘Maximum score achieved will be product of total weightage i.e. ‘100 and maximum
Points for each attribute i.e. ‘5’. This shali be equal to ‘S00.
The ratio of sum total of the all attributes for the particular audit cycle over maximum
Score and appropriately converted to a scale of 0-10 is termed as quality index for that
audit cycle.
Pare 3
o
20
Sout ia
Based on the Total Obtained Score, The Quality index will be measured on the scale of
0-10. This scale measure will be up to two decimal points.
Quality Index:
Based on the on-site quality system audit followed by follow up audit, the Quality Index
for this audit cycle is worked out and the working of the quality index is attached as
Annexure ~ 5,
The quality index obtained for this audit cycle on scale of 0-10 is 7.1 I
o
a
3
x
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<
No, o CHS (Gorakhpur | VIP ‘Km.279.800 to | 49.000 NCC-VEE(Y) ) Gopalgan} km 319.800 ) section)Km.279.800 to D 402.000 of NH-28 5 | o 2.1.2 PROJECT DATA 1. Project name 2 4rLaning from Km 279.800 to km 319.800 of ) Gorakhpur- Gopalganj Section of NH-28 in UP. India, 3) 2, Lenght of Project 7 40 Kms ) 3.Contract/Phase : Contract Package No-LMNHP-EW-II{WB) -7 o 4, Name of Contractor 1 M/SNCC-VEEUV) 5 5. Name of Sub- Contractor poe > 6. Contract Commencement Date: 14-Dec-2005 d 7. Original Completion Date : 13-Dec-2008 ) ikely/Expected Completion Date: - : 9, Name of Supervision Consultant + PFC, FP(I) & FEEDBACK JV ) 10, No, of Structures ) [New [ Replacement Type of Stru Exist > a Ete Innew lane In existing lane re ; Major 3 0 3 i Minor Bridge B 8 B Slab Culvert 29. 3 29 Hume Pipe Culvert _| 26 18 26 ) Box Culvert 1 1 i Under PASS _ Bre fo RE-Wall 43520 Sam ) 5 9 Qo LL Underpasses and Flyoverson the following : Nil : Locations have been provided as additional works ) 12, Major Towns Enroute Jagdishpur (Km,281.70),Sonbarsa ‘ (m.284.90} Sukroull (Kr.292.30) Hata o (Km.301.2),kushinagar (km.316.50) & y Kasia hm.319.10) ) ) 22 Package 8 9 ‘The Project Package LMNHP — Vill begins at km.319.800, just after Kasie and terminates at km 360.915 ; of NH ~ 28 (UP — Bihar Border). The total length of the Package is 41.115 km. and it falls under Kushinagar District of Uttar Pradesh, The Project stretch runs through flat terrain and falls under typical Fo} flood prone zone of north eastern part of Uttar Pradesh. y 2.2.1 Package kms ) Contract Packages in Gorakhpur — Gopalganj section C-11/5 of Lucknow Muzaffarpur under NHAL Phiase— : I Programme of East - West corridor development. ) ) te Contract Package Name of the age ho, Chainage Lengthinkm | Co ractor ) 4 CANS (Gorakhpur o Gopalganj ) section) SIMPLEX é vil Kon, 318-600 *0) aaa35 Infrastructure ) km. 279.800 to km 360.915 Ltd, | 402.000 of NH ~ } 28 2.2.2 PROJECT DATA: 12. Project Name 2. Length of Project 4 laining from km.319.800 to Km 360.915 of Gorakhpur to Gopalganj Section of NH ~ 28 In UP, India, civil Contract Package No. LMINHP ~ EW =I (NB), Package ~ 8 42.115 km. we a Ooo 3. Contract / Phase 4, Name of Contractor 5. Name af Sub ~ Contractor Package -8 M/s. Simplex infrastructure Ltd., 6. Contract Commencement Date 98/12/2005 7. Original Completion Date : 07/12/2008 8. Likely / Expected Completion Date > 9..Name of Supervision Consultant —:—_~PFC, FP |) & FEEDBACK 10. No. of Structures : [Type of Structure New Existing Major Bridge 2 2 Minor Bridge = 3 Toll Piara 1 o Rest Area 2 0 Hurie Pipe Culverts 36 35 Box Culverts 3 B STab Culverts 3i a Underpass 5 0 11. Flyover / Underpasses on the following. Locations have been provided as additional works: - 12. Major Town Enroute 13, Rivers Enroute, 14. Any other 15. No of Old Bridges to be rehabilitated under running contract (i) Major Bridge (ii) Minor Bridge 20 Permawalia (km 326.100), Jokawa (Km.330.840), FaziInagar (Km. 334,500), Patherwa (Km, 339.500) Tamkuhe (Km. 347.500) Ghaghi River (Km. 327.890}, Jharthi River (Km. 345.580) No. 2Nos. d 9 9 9 y ) oO d 9 9 23 Package “The Project package LMNHP-IX starts at km 360.915 (U.P-Bihar border) and terminates at km 402.000 of NNH-28 (Near Devapur ) in Bihar. The length of the package is 41.085 km. which falis under Gopalgenj district of Bihar .The project stretch runs thorough flat terrain and fells under typical flood prone Zone ‘of north-western part of Bihar. The land use is primarily agricultural. The Most prominent topographical features include numerous minor drainage rivulets with a major watercourse being the Gandak River. River Gandak runs parallel to project Road Stretch on the north side, 23.1 Package KMS Silent features of the Contract Packages from Gorakhpur to Gopalgenj section of NH-28 Lucknow - ‘Muzaffarpur under NHAI Phase-Ilt Program of East-West corridor development. | Contract Contract Name of the Package | Package No. | Shainage Length (Km) Value (Rs) Contractor | | Gorakhpur ~ | 1x km.360.915 | 41.085 357,14,59,137 | M/S Gopalganj to Progressive section Km.402.000 Construction ‘Km.279,800 Ltd. to 402.000 of NH-28 2.4 Packege-LMNHP-EW-ll (WB)-08 Project Title Four Laining from Km 360+515 to 402.000 of Gorakhpur to Gopaiganj Section of NH-28 in Bihar, Civil package No. LMNHP-EW- 1 (we)-09. Client / Employer I Chairman, National highways Authority of India. 9 O86 SOS Sou én | Engineer/Consultant [~~ (1) Pell Frischman Consultant Pvt ltdLondon,UK (2) Pell FrischmanPrabhu {India)Pvt Ltd, Mumbei, india. (3) Feedback Ventures Pvt Ltd, New Delhindia (/V) Site Office Pell Frischman Consultants in joint venture with FrischmanPrabhu {India)& Feedback ventures Pvt Ltd, LMNHP-EW-II(WB)-3 Four Laining from Gorakhpur to Gopalganj. Office of Team Leader Near Custom, office, Gopalgarh Tiraha Post-Kasia, Distt-Kushinagar (UP) TelFax-05564-252910 Contractor PROGRESSIVE CONSTRUCTION Ltd, KOLKATA LANE ROSE AVENUE NEW DELHI-110002, PHONE-011-28222511-12-12-14 Project office PROGRESSIVE CONSTRUCTION Ltd, NEAR FCI GODOWN cH:394+400 NEAR KOINI VILLAGE, GOPALGAN),BIHAR-841428 ‘The curnulative physical Progress of works of last three months is as follows: Month | Package 7 Package 8 Package 9 June’08 | 33.46% 25.06% 20.0156 July's 23.52% 26.25% 20.08% ‘August 08 27.33% 20.35% 3.0 Planning for Quality System Audit: With reference to Letter No, 11018/28/2006/PQ dated 02.07.3008 regarding Quelity System of Audit of National Highway projects scheduled during August ~ October, 2008, the audit of this Consultancy was planned from 13.09.2008 to 18.09,2008. 3.1 Onsite Audit: 3.1.1 Opening Meeting: Opening meeting was conducted on 13.09.2008 at Project Director Office, PIU Gorekhpur, The ‘opening meeting was chaired by Project Director and all others present were Team Leader of Supervision Consultancy with Material Engineers of consultant and contractor. The list of opening meeting participants is attached herewith. a 22 @o20 QL Oo 2 During the opening meeting the éntire process of audit has been explained by Team leader of Audit ‘eam and submitted the Audit plan to Project Director. The aueit plan submited ie attached herewith ‘The following tests were witnessed during the audit period, 3 L2 Package 7: > Coarse aggregate sample of 1mm and 20mm collected from stack yard and witnessed gradation test (individual and combined) and Aggregate Impact value test conducted and results found within limite Reports attached as annexure 4. > Concrete cubes of structure at 294.100 km (deck slab) and 298. 100km (Abutment final lift) tested and ‘the results are satisfactory. Reports attached as annexure 2 > Soil sample of barrow area No, 53 collected and tested for OMC and Maximum dry density and Compared with the approved test results and found satisfactory. Reports attached as annexure 3 > Field density test for WIM 2" layer between chainage 290.050km to 290.220km conducted ard results found satisfactory. Gradation of the same sample collected also is with in specified limits. Reports attached as annexure 4 > DBM cores were collected between chainage 288.860km to 289,980 km and checked thickness, ensity bituren content and gradation after extrection and resus found satisfoctory. Reports attached asznnexure 5 ® Roughness index test of DBM 2" tayer between chainages 317.268 to 217.780 and 317.900 to 318.450km and found with in limits but on higher side. Reports attached as annexure 6 3.1.3 Package 8 > DBM cores were collected between chainage 322.880km to 322.800 km and checked thickness & density and results found satisfactory. Reports attached as annexure 7 > Roughness index test of DBM 2 layer between chainages 320.580 to 322.600 L/s and R/s and found with in limits. Reports attached as annexure & 3.1.4 Package 9 > Coarse aggregate sample of 10mm and 20mm collected from stack yard and witnessed gradation test , Flakiness and elongation and Aggregate Impact value test conducted and results found within fimits, Reports attached as annexure 9, > DBM cores were collected between chainage 372.293km to 372.391km and checked thickness, density, bitumen content and gradation after extraction and results found satisfactory. Reports attached asannexure 10 > Birla OPC 43 grade cement of 28" week tested for consistency, setting time and fineness and results factory. Reports attached as annexure 14 3.2 Closing Meeting: Closing meeting wes conducted on 18.09.2008 at Project Director Office, PIU Gorakhpur. The closing meeting was chaired Project Director, PIU Gorakhpur, and also present were Team leader of Supervision Consultancy and the Audit team. The list of closing meeting participants is attached herewith, During the closing meeting the Tezm leader of ausit team ciscussed regarding all the NCR findings and explained the procedure of root cause analysis and corrective action process. The audit NCR's are handed over to DGM and the same are attached herewith, oe 4 OmOnEe) List of Audit Participants Opening Meeting Audit cycle no. 1} Suh Aa waleglee Type of Audit Quality System Audit (Audit period 43.09.10% & IF.09 08 Company Mpc. Rul Sripdasen Coratid No. [Name [Designation Signature 1 R-P SiH PD, PIU GaP Ria ME, Pky? bos F -Thnag z Krisko Purr tL o7sds Aly ME pact she & nook ey its “Da, ~o& EC e+] Bioyapear Ks Pannal Se~ oka = | Ae Amsare BCE Pre @ | vtec sere tema PEG 6 [MA Shel De RZ Cntr. | | Ip | B.S. iRinRb « Qt Raineer Ne Lk Wann ete Secrenra Core | me — Per F 12] Su i ral DN Chausty { CPHy PR 25 Page tof? QO F Oo a oO Audit Plan Stage 1 Audit 4 Audit eycle no.14 y a Type of audit Quality System Audit ~) | | Standard! Date of issue: ‘Audit period on site 73,00,2008 to 16 09.2008. }. |€ompany/ Client: iia, Pell Fiischmann Consultants L1g,, Ui in JV with Frisehmann Prabhu (1p Feedback Ventures Pvt Ltd.. ). [Street 7P.0- box Kasi Post code / City ") [Audit responsible: Team Leader [Lead audtorAuditer: Ta ea et Leader, We NS Anja, i. K Gurpredad Qvally ) Motem Avaitors ane Mi, Senjay Genju Bdge Engine ‘Audit language(s) [English — 5 Audit plan released: Date aajerlaons Signature Lead Auditor ) ‘Ausit plan changed: Dato 12 |o5 |2e06 Signature Lead Aucitor__<> ) Date Time Event Heeded documents for Audit Persons / ‘Auditors: ) “departments | Schedule FETA TOSOAM | Vericaion ofthe aio |= Maragerien Marval Hesicent 130M | ofthe organization TMatageRyacsurance Pen. |Engieer(PSC) |Auibor) ) regerding { Preject supersion Gime -Paccage [Auitor2 aerEE jement system | Consul! Agearent ? autor ) Maree aten |=Gontrector Quy Audios i + Project Review Gurance Plen ) » Processes and = PSC Organization with suthority 2 Ineracions ang. mparsiie aCLONE ape | ent soresrendence ; Sues Si ree eatenens. | + Iniemal audits ‘agpromd OC Pah ) + Performance date = Test reports & MTC's. Tnerne: Aut Repors . TNs deta + = Corrective Actions record, TBrevertwe aalon rece. , Tgortite [buneh . ‘200M | 2) Tea TE TE -Canrata aiy Resrane Fan. TLaboriony/ Se 1 2.0080 io [ofthe organization "SreReainthog stron. |e viet (Aug Soopw |regereng "Ekisaton reports Peerage? ior ‘© Projeci Review = Site Order book 7 ‘Auditor + roe eed | Approved QC Pin ferees ‘ | interactions ~ Test reports & MTC's. Inleractors ment |- Ewen besk down repens + Plantend Eavpment |” Eguipment eal tine rat bb inspection T'gafely BEnvironmenial , + Penommance data | Menegement Pier re : z 2 _| i Hamnerdendotbayt t my nota 8. 89501 an page tote - 26 i ‘Audit Plan Stage 1 Audit ‘Audit eycie no.14 Vo OS d vate | Time Event Havana Gocumante Tor AuBie | Persons / ‘Auditors: 5 sgepaniments |_Schedule Jay [roan [veteation ofthe sysiem Sean Cai Rares an [Se Rust ) [ ssoent feineeanton SRhent correspondence ST | Autor2 regereing ~ pproves metnas statements autor3 Ber nent ayeiom |-Appreved GC ASN pucteré ) waragomert=vse™ | “Consutant een (epee » eevee | festeepete Sr ) Rica Resna | teenal Aug Repon interactions TGR dota | + Opjecves ofthe ~Sotrective Actions werd ) Pitesti 7 Preventive ection records. «eta audits ~ Serety 8 Eevironmentah ) 2 Taare 1eain_|Maneperen PO 730 PH tanh , bean 92 ST [Weniicaan oF he svsie™ —appraved matrod Seen [auaratony | Ste [RIOR een | of the organization ~ Airoved Werk instocons ever [assten ) regarding ~ Baye rete Suman once ver \austors SATUS entaytem | -Aporved ispesten Toe Pee sustors 5 anagemer sem |" Consutant revi pone | ame en (TPO : + ProeetRevs .|-irtemal ag Repo | > interactions TNCRs deal | e Oajoctves of he ~ Sorectve Actions reco" organization 1 Breventive action rates ‘organi oats Soaty& Environmensel pedetmanee 38 Management Pin Hatin ane ond ot Bay 2 15.08.08 | 10.30AM "Jerification of ne sysiem™ THanagement Manual. "Resisent SPO sore [ofthe organzsten THe aT ualty Assurance Plot Resreor(PS0) | Audion! regarding “project supenaion Eanes accepe [Austor2 SATED nent system | Coneutart Aareenere 9 Austor3 Socarentstion Contractor Gualty = Vauaions + Project Review Saesorance Plan {> > Projet Revie | Pac orgenaasen sutnoiy / interactions aha. responsviles | "eee rine |-Sienhcarmg es a : i organization Cirgve meted staterents _ | = infernal aude “Aparese 3 me «eet evi 290 \ riormance Cote “Test reports & MTC TYpterna Avat Reports TNers dota. “Gorreeine Ac 7 Serentve acon recor BERIT | Cun \ 2.90PM Paget of Audit Plan Stage 1 Audit Audit cycle n0.11 Time Event Needed documenis for Audit) Persons? | Auditors “departments | Schedule Verticaion ofthe sysiam | - Contactar Gusliy Assurzice Plan [Laboratory Sits 2.0naNeto| ofthe owentzatin “Approved method Stare: ice veh ‘SaneM. | regarding + | Elibratonrepats Paves ) + ProjectReview ” |: Site order ook 2 * Processasena | Approved aG-Pan At ) interactions “Testrepons & Mi. + Pantand Equipment |= quant bresk dou epors es | S Onete aewice””” |-Equpment dea me mpore ) | ovoticn 2 Sate Benuronmerte + Perornence data | Management Pan 9 ) 1 Return snd end of Dey ) ‘16.00.08 | 8. 304M to [Verification of the sysiem | Contractor Quality Assurance Plan, | Sle nepection ~ [Audion 1.30 PM | of the organization + Client correspondence | Peckage-2 Auditor-2 ) Tegerding “approved mated Sisoments, sors * Management system | Approved OC Pan, asiont Goeumantaton’ | -Coneuiant review pots ) + ProectRevew | Testropors & Mite. 2 Processes end |lniemal Aut Reports d interactions: = NCR's details, + Ojeciwr ere | Barwa clonseco sees Preventive ecton eco ; eerste EH aco aces {Pertormance vate _| Managemen Pian ) Taw Tone lo 2.004 ) 2.00 PM | Vertcaton of he sysiem | -Menagernent HaRIal Rendert 1©8002M oftne orpanzaton Project Guelty Assurance Pian, | Engineer (PSC) | auditors regarding = Project supervision Office «Package | Auditor? + Management system | Consultant Agreement § Authors Socumenistin | -Centacior Qectty Auctions ; + Projet Review ‘surance Pan, + Processes end [-P8C Orgenizetion wth author : interecions ang responsbillies ) «© Objectives ofthe | - Client correspondence srgenization “Aeproved method Slatments + Inert avets oproved 0 Flan 7 avai ensullant review ep0 beatitls " + Test reports & MTC's. Tiniemafauelt epens CNGR eats, | et “Cortetive Actons record j ieee {Preventive acon reeore. if | Roturn and ond of Dey na 07 radon ae: one. 4 7 Page 3of4 TH? Audit Plan Stage 4 Audit Audit cycie no.11 Date [Time Event Needed documents for Audit | Persons] | Auditors aw reter “departments | Schedule ; 75 ito | Vericetion of tie system —|~ Contractor Gually Assurance Plan. | Laboretoy Sis | Audion ) 4.30PM | ofthe orgenzation Approved meinod Sisemenis. [Otrce yah [auctor ‘egerding: | -Aperoved ac Pian: Package-@ | Ausior3 ) ‘+ Management system’ | -Consultent review reports. Auciors ocumentation ~Test reparis & MiTC's, ) + Project Review + Envronmentat Wanegement Pian + Processes and interactions ) + Objectives of the organization ) + niernal audits | + Performance data | 1 T SOPH TS Laneh > 2.00PM ) 2.00PM is | Verification ofthe eyslem | - Wanagersent Manvel [Team Leader Audi Team 5.30 PM | ofthe orpanization. = Projeci Guaity Aseurance Pian. fice Fegarcing: = Projet supenision ) + Management system | Consultant Agreement, documentalion |= Contractor Quatiy + Project Review Assurance Pian. ) + Processes and =PSC Organization with euhosty Interactions +] and. responsibiltes, + Objectives ofthe |-Client eomespondence Senaeatoe | Approved method Steméns, ) + Internal audits Approved QC Pian. 2 Pertormanes data | Consultant review reports Test feporis & NC's + Internei Audit Reporis, NCR's details | Corrective Actions record ) = Preventive action records Return and end of Bay > FTBBROET BOOART “Bua Notes and NOR Preparation a 5 42.000, 72 308M ; | Closing meeting at PO, Gorakhpur, Offce a. en 0 ein enc. wer 2g Pagedos4 Tov? 3M YJooOVgo IS List of Audit Participants Closing Audit cycle no. 11 Meeting Type of Audit Quality System Audit ‘Audit period 13.09.08 +p 18.09.08 Company Pre -E pg—FTE (Sv) No. [Name Designation [Signature \ Rup. Searga. PD, Piu Gey ia 2. | Mukesh shayma, Manager Creei)| s Aa)" b | Arishna Murer’ | pe CPG) | yg A & Vomit pum va Rood ers) Newker L | vs Thana ap (yee £ |i.a. Shot, a aes 21s? Page tof "30 vos y ‘Tv Set Asi 305 & S08, Navkelan Compl» SD.RtaieSeondnebas S00 08 Te -e40HSH2INtSoineT2. “HERE SETERETS » SOTESOT «Fax: 1 4DEERTIET2 Enel Hyaeabatgcsucin Ref: P1826721/L/180908 Dt. 18" September 2008 To Mr. R.P.Singh, Project Director, NHAI, PIU = Gorakhpur. Dear Sir, Sub; Submission of NCR Report of On site Quality System Audit - Reg, We thank for the kind courtesy extended for the audit team, With reference to the captioned subject please find enclosed herewith the NCR report of the on site Quality System Audit conducted rom 13/09/08 to 18/09/08, We request you're good selves to kindly send us the Corrective action report within 30 days from this date as so to enable us to plan for the follow-up audit to close the NCR's issued. Yours faithfully For TOV SUD South Asia Pvt. Ltd., Mw Manofar Team Leader CC to: Project Director, Muzafarpur. {TGV SOD Seu po Po. 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Civil Contract Package No.: LMNHP - EW -II (WB) Package 7,8 & 9 Dear Sir, Quality audit- NCR report & our compliances Please refer 1o your letter no. 1301 1/6/2005/GKP/PFCFPI-FTE/5285 dated 18.09.08 regarding NCR - report of site quality system audit, please find enclosed herewith report of compliances/comments on NCR pointed out by M/s TUV-SUD South Asia Pvt. Ltd (audit period from 13.09.08 to 18.09.08). wn a Hi ti Sl. Evaluation Description Corrective action of CSC Pe No. oe 7 NCI System of periodie | Please see page 1 t0 29 4 review of concrete mix design &. 2. [NCha2 Deployment and |4 proposals for replacement of RE for bd} Teplacement of key | package LMNHP-8 was submitted for & professionals Approval — No response from NHAL = (neither approved nor reject). 0 3. [NCIS System of control on [Register mainiained at batching plant and on checking of cutput | hot mix plant. ib = PNCH ‘System of checking | Please see reply from page 3010 32 and timely approval of ie RFls not evident i s NCi-4 System of approval | Please see reply from page 33 10 67 [le for casting of working - pile = 6 [NCEE No documented The drawings are issued vide reference letter | oO procedures for maintained in dispatched register, & control of issue L drawings e 7 [NCIS System of calibration | Please see reply from page 68 to 65 iS of plant and | oe equipment % a tw ls Frishmann Prabhu (oda) Pvt id Pall Frischmann Consultants Lt, Feedback Ventures Pt Li, S ‘315,Bakjoind Wad, New Prsoadov Red, 5 Manchester Gquae, Forbes Hose, 7,L8C, y ‘Prebhadavi, Mumbai 400 025, INDIA. ‘London WIA TAU Panchs!veel Park, Nee Delhi110017, INDIA. 1 hy Tek 022-560 3801 Fax 072-5660 3602 Te 4 (01207486 3681 Fax 46 (0207487 4183 Tet O11-2605766, 6406767 Fax O11-26¢0417B6765 £ ooh * e G4 feamoate MELE 4g “ i ceiceaaecneouee eeeena ae Bi eign F te = PELL FRISCHMANN CONSULTANTS F2=DBACKS = in Joint Venture with VENTURES Frischmann Prabhu (India) & Feedback Ventures Pvt. Lid, Waloy Noon hazy L ) Evaluation Description Correciive action of CSC . Tnperfections Comective action of the company RFls are continuously | The contactor submitted RFI based on the raised and rejected for | next day planning, The contractor was the same work | unable to execute the planned works which, without giving | was not ready for inspection. Such cases it reasons for rejection | was returned to the contractor as there was no action required from CSC, 9.__~| Methodology for piles Please see brief report fom page no. 86 to 109. 10 | Methodology for raft Please see brief report from page no. 110 to foundation 113. TL, | Mix design Slump measurement | The concrete slump measured for checking timing of workability at site; however approval of concrete is based on cube compressive 4 strength test results. Alertness: Roughness control: Thanks very much for your concern on control roughness, it shal! be complied. ; Check list: For structure works it is being complied and for road works it is monitored vide RFis such as f level records and field density test result in case of approval. cad Thanking you. Yours faithfully, For PRC-FPI-FTE (JV) io) ‘> > 2 ( eee eA Team Leader ) Enclosures: A comprehensive report attached herewith Fascias Paavo Pi cel Finan Gonsizi Feedback Vor Pet Fae age, Now PratnecerRoxs, SMart Sav, Fedak Howe, 7, LSC Pranecon None 40025/hoKLeron Wie sb Pore Pa Now Dis 07 NA Tet 022-5660 2901 Fax: 022-5860 3602 Tok v4 (}20 7486 3861 Fan: o44 (01207487 4159 Te:O11-26495768, ZSSTET Fax: Dtt-264DAtTEISTOS ot 47 a). ~ = be ke BR B » nr ae > Corrective Action Report on NCR report of on quality system audit for Project Package LMNHP ~ I (W.B) ~ 08 from 13-09-2008 to 18-09-2008 NC1-1 at page 1 of 8 1. Your comment as per approved mix design the 28 days compressive strength achieved during trail mix was 48.6 Nimm2. Where as the strength achieved uring production is verifying between 31.1 to 42.03 Nim? Comment / Compliance Concrete mix design based an current margin as per table 1700-5 at MORTH&H Specification, Review of concrete mix design based on stance? deviation is job of Contractor as per sub-clause of MORT@H 1704,2 |i), We would like to state that compressive strength of concrete cubes achieved is more than characteristic strength, Also please find enclosed herewith sheets of standard deviation & Moving Average of each grade of concrete, NCI ~1 at page 2 of 8 The individual cube strength of concrete used for cating of slab in the wall (L/S) at 320+400 on 09/05/08 are recorded as (33.3,30.2,35.6)(35.8,29,830.7)(35.6,31.8,2 1)(80.4,34.7.28.4)(31. 1,30.0,33.8) Nim Comment/Compliance Compressive strength of cubes are accepted as per MORT&H specification clause no: 1716.2.5 (Acceptance Criteria) 4E.6 Qo ray | BITTE CECH I terre eres Ee ra o& = & Reference: NC2-1 NCR: System of checking and timely approval of RFI’s not evident. Evidence: RFI No. RW 10228 to RW 10243 submitted by contractor to consultant on 12/09/08 at 4.40 pm for inspection on 13/09/08. But not a single RFI is attended by consultant representative on 13/09/08. ‘All tests were conducted by contractor’ representative till date the RFI's are either approval or rejected. pleen pe trchod Lae s © pr RE s epproml THEE EECTTI CTs PECEENTT IT ITY a eeu Id RFINo. | Item of work inspected Action RW 10228 | Providing and laying of Bituminous | Tests witnessed, prime coat RF action delayed due to holidays of contractor. RW 10229 Laying of median kerb at service road | Cubes casting carried out RFI approval : after confirmation of 28 days cube test results, RW 10230 | Level checking and FDT of GSB1_| Gradation, FDT and level towards median checked, Sheets enclosed, 4 RFI approval delayed due to holidays for contractor. RW 10031 | Level checking and FDT of subgrade | Level and FDT checked. Sheets top at widening portion enclosed, RFI approval delayed due to holidays for contractor, RW 10232 | Level checking and FDT of subgrade | Level checking and FDT of top at widening portion subgrade top at widening portion RFI approval delayed due to holidays for contractor. RW 10233 | Level checking and FDT of GSB] Gradation, FDT and level towards widening portion checked, Sheets enclosed. RFI approval delayed due to holidays for contractor. RW 10234_| FDT of WMMI (PCO) layer The stretch not ready for FDT, rolling still in progress. RFl action delayed due to holidays for contractor. RW 10235 | Providing and laying of Bituminous | Tests witnessed, prime coat ’ RFI action delayed due to holidays of contractor, RW 10236 | FDT of WMM1I(PCO) layer ‘The stretch not ready for FOT, rolling still in progress. RFI action delayed due to holidays for contractor. RW 10237 | Excavation of trench upto subgrade | Excavation upto subgrade top » | top towards median cartied out RFI action delayed due to holidays for contractor RW 10238 | Level checking and FDT of GSB top | Gradation, FDT and level at service road checked, Sheets enclosed. RFI approval delayed due to é holidays for contractor. RW 10239 | Level checking and FDT of GSBTat | Gradation, FDT and level Main Carrlageway checked, Sheets enclosed. RFI approval delayed due to holidays for contractor. tf tte COMPETE TCIM ALLELE ogy CETTE al oe & a ¥ RW 10240 Providing and laying of WMM top layer at service road The work not done by the contractor due to paver breakdown RFI action delayed due to holidays for contractor [Rwiosa7 Providing and laying of WMM I layer at service road The work not done by the contractor due to paver breakdown RF] action delayed due to holidays for contractor RW 10242 Tevel checking and FDT of GSBI towards widening portion Gradation, FDT and level checked, Sheets enclosed. RFI approval delayed due to holidays for contractor. iy” o € were er SIUCT tdd errr FRM we & in a d Corrective action report on NCR of on site quality system audit for Project package LMNHP-II (W.B) from 13/09/08 to 18/09/08 NCI-4 at page 4 of 8 1) Asitis remarked that Test piles was casted at structure No 337/1 but no test was pesformed on test pile but approval for casting of working piles given. Comment/Compliance Please find enclosed here with Test pile report performed on 14/10/06, Please refer to RFI No BR 925 & the concerning report was submitted on 18/10/06 by letter Ref No: 02/UPROAD/ENGG/001/VOL-4/0402 which is attached as enclosure for your ready reference. ‘Also, load test on working pile was performed on 15/03/07 .Please refer R.F.1 No.BR 2255 and the report submitied on 21/03/07 vide letter no: 02/UPROAD/ENGG/001/VOL-5/0640 boti of which ere enclosed. Therefore it is evident that Initial load test was carried out on 14/10/06 and working pile load test was cartied out on 15/03/07. 2) Asitis remarked that evidence of routine testing of working piles of structures no. 348/3 is not traceable. Comments / Compliance Please find enclosed herewith RFI No. BR, 2497 on 16/04/07 and its concerning report through letter no, 02/UPROADG/ENGG/001/Vol-5/0686 dated 25.04.07 for routine testing of working piles of structure no. 348/3. Re a Field Engineer Bridge Engineer Team Leader . 52 EEE | CITY ¥ eT Tver Fh Orde PRTT J Th NCI = at page 5 of 8 i) Batching Plant calibrated on 18/02/2008 and next due on 18/68/2008. Comment/Compliance: No such frequency of calibration is mentioned in MORT&H Section 1700, but we had. conducted calibration on 22/09/2008. Sheet enclosed for your reference, ii) WMM Plant calibrated on 15/02/2008 & due was on 14/02/2008, RFT issued 28/08/2008. No MS-368 for calibration of WMM plant & Batching Plant but calibration has not done & RFI not approved. Comment/Compliance: WMM Plant Calibrated on 15/02/2008 & on calibration sheet it is mentioned next due date of calibration is 14/02/2009 enclosed for your ready reference. iit) Calibration by contractor for WMM plant on 13/09/2008 but not witnessed by (st PSC. Calibration done by contractor for RMIM used with Oven (Rotak model220/230V) on 02/06/2008 but Oven was not calibrated. Comment/Compliance: Calitretion of WMM plant is due on. 14/02/2009 as mhentioned earlier. The calibration of WMM plant done on 13/09/2008 was contractor internal calibration check, No RFI for such activity was submitted to us. Rotait mode! 220/230 Oven is provided with regulétor and thermometer to check the calibration instantly, We also check the Oven with digital Thermometer, which is calibrated on 16/04/2008 by independent Agency whose sheet is attached for your reference. seC Material Engineer Tear Leader LMNHP PKG - 08 LMNHP PKG - 08 band am i oa < . 25 FECEINE GB GEE % Ie | Corrective action report on NCR of on site quality system audit for Project package LMNHP-I (W.B) from 13/09/08 to 18/09/08 Imperfection /Alertness As per your comments on pége 6 of 8 1. Bore log of different strata encountered during bore drilling is not maintained, Comments / compliance We bad performed confirmatory bore test for each pile bridge locations. As for your reference soil exploration for 337/1 i.e. 336+777.640 was conducted on 08.04.06 with reference to RFI no. BR0048 and the report is also attached for your ready reference, 2. There is no testing of Bentonite Comments/compliance Testing of Bentonite was done by third party. Copy of test certificate is attached for your ready reference 3. The Density of Bentonite at the bottom is not checked at all before concreting Comments/compliance Density of Bentonite suspension was frequently tested.at site during piling and just before concreting. 4, No test reports of Bentonite slurry density check available. Comments/compliances Please see attached third party test report for your ready reference or Field Engineer Bridge Engineer Team Leader Annexure — IV Evidences for NCR Closure > oO: a : x es ) “L. FRIBEE MSULTANTS FEEDBACK. a Joint Ventui'e wit aiNTURES chinann Prabhu (frets) a Feedhek Ventures Pvt: Ltd Wokin Sxfactustue: t a # WSCIINB43/09 = Dates. 27.01.2008 * 9 : : ) 9 2 Kin: 360.915 of Gorakhpur to Gopalganj Section of NH ~ ) ‘oi LMNHP=EW- Il (WB) Packege 8 ) Dene sir, oad : 9 “EW (WB)-8 ) Lesa approved for-the - post of’ Resident Engineer ja’ place of A00202/C Ti Teeh-HULMNHP-SC-I dated 05.01.2008, s ; .sreement, Mr. V.K. Shrivastava had been originally’aporoved for L LANE: "BWCWB)S. Due nav ‘placed in LMNHP-EW(WB}7 for ) PXEW(WB)-7.at the time of hi placement. Be Sh y lon sil in process of egeutibrandét removed for inajor stretches (ebout,- ‘ able site possession, and considering to.work load in LMNHP-EW ) wes vecant for the past 36 months. It is necessary to place wey <2 ; would place this approved Resident Engineer in LMNHP-EW (WB). hrivastava Residint Enginece (placed in LMNHE-EW-(WB)-7) lef, the-project at the crucial > ‘aployment without prior notice to Team Leader, and proper hand over. ; VAG, Sheivastava, for black listfor placement of any capeeity in future ). Thesking yoo, | ‘Yours faithfully, “Hou PPO-RPLPTE (IV) Prabhu (0) Mumbai eniures, New Delhi a Foodback Ventures Prt Li FesdbeckHass,7, 5.0, oe Parcishol Prk, New Dei-10 01 INDIA, ia Kind atin: Wy Puonuichothamnin Oe HR pps {Pro vac constr GRA Fai 25003607 psc fn 268 8 “BeGitd 6, feeet0, er, we RePet10 078 B58 8, Sector-10, Owatka, Nev: Daihi11007 M/s PFC-FPL-FTE (iV), HE Feedback House, 7. s Panchsheel Park, New Delhi 140 017, Kind Atin: Shri Vijey'kemar : : Replacement of ‘Key. Pi | ypervislon. Consultancy. Conliact LMNHP-SC-Il-on NH-28: in eplacement of: CVs = feg. 26.11.2008 vie Which replacement Cvs oF MreAlok lace of Shri VK. Abrivastava for position of Resident.Enginger ‘Shrisnil_ Kumar Singh. in, place .of Shri N.P. Singh fol-posHiionsof-Bridgs Engi “forwarded 1o NHAT. In-ti : ot Shri Alok Kumar Singh in ‘place of “Sil V.K. yastava ‘or this position. of Resident Engineer for this vision consultancy packcige ire. LMNHP-EW-II[WB)-SC Nits Rersiy opproved. You are requested to mabilize ihe obove Key. personnel lo project site. immediajely. with. information to Ihis*effice. 48. © ©¥ of Shit acill Kumar, Singh is. plOeeoF Shi'N.P. singh’ pesition of Bridge" Engineer, ing. retuned Rerewith 3 (Pradeep Mudgal) Manager (EW-Iil)” |_—d ly, Taangarejan “time Schedule for Professional s “SGP TOR): Namo of the Statt Herish Wahi I T |S $ Pandit , lool k k Parmar (Ret) IVikes Kumar-Stivastava.. lo Sivenande “MAN Appa :|Borra Tataiah Material Engineer - JAM Puranik lakes Raman |Promod'Kumar Rathi _fAnjani Kumar Pkg? <|Mano} Kumar Giri» ‘Highway. cur |Highway.cum Pavement Er ois ening fom Km. 319.800'to 360.915 of Gorakhpur Gopalganj Section of NH-28,U.2 Package- LMNHP-8 Consultant:-PFC-FPI-FTE (JV) : REQUEST FOR INSPECTION/QUALITY TEST PALES Inspection:-Date A MMAL2K, Time: LO.0n.Aw : CONTRACTOR M/s Simplex Infrastructures Limited fons BBY7e From B26 FTE Kt 0: ger stvortar aye ee es ie Veto Jota jent - NHAI S STRUCTURE COMPONENT: 1ch Sketch) oe : position: de _eesice ie haw : Time: fer PH” ; oN ONSTRUCTION SUPERVISION CONSULTANT Cc For PFC-FPI-FTE (JV) 7 [Received by: | Date: Time: \Construction Supervision ee era! Vat ) Qnittal. Ph Loud we ex pl 4 ‘ ch! arches: 225 Readang of bent. 3) pass ey me Yo he sab ( at d ¥4 (ATELY a mended for Se Date: ibe let ‘(Residont Engineer/Team Leads) __ ee out laning from Km. 319.800 to 360.915 of Gorakhpur Gopalganj Section of NH-28,U.P. Package~LMNHP-8 Consultant:-PFC-FPI-FTE (JV) REQUEST FOR INSPECTION/QUALITY TEST Inspection: Date LOH 2. Time: l:28,4.PR. - 2255 =, CONTRACTOR M/s°Simplex Infrastructures Limited Location: 33%) 926 +2902 From: : To - | en cel Tong pcebion | Approved of Reith Teap— 3.0.0 tein No:- STRUCTURE COMPONENT. < (Altech Sketch) ‘, : : may Submitted By ‘gs i : Postion ge flees ead 2 Dee: 14/a/o¥. ; Tim: 9.00.) mp CONSTRUCTION SUPERVISION CONSULTANT * For PFC-FPI-FTE (JV) ment PileRestini Auk comivonted db 1:50 AM On isfox|oy oma complied ok 2:20 7M ew 16/03/07. j Recommended for approval eee ~ re ye sl : _ |[Sianed by: ner hed = Date:_16 S10) ena \ (Bridge Engined:/Highway-cur Pavement EngineeriGurvey EncinesiiMiaterial Engineer fal |APPROVED/NOT APPROVED EE * ‘i “ 4 i APPROVED Signed by: ates, z (Resident Engineer/Team Leader)» 4-Laning from Km-319.800 to Km-360.915 of Gorakhpur-Gopalganj Section of NH-28 in UP, India Civil Contract Package No:-LMNHP-EW-II(WB)-8 EMPLOYER National Highways Authority of India ENGINEER : PFC, FP(|) & Feedback JV. CONTRACTOR : Simplex Infrastructures Ltd. Calibration of Wet Mix Plan Location : MAIN CAMP (324+000 L/S) Date of calibration: 06/05/2009 ‘Next Calibration Date : When Required. vo Plant Capacity: 160TPH Total capacity of the plant i +160 TPH So per min capecity : 160160 = 2.67TAmin Belt Length 230m i Time required for one revolution of belt 1: 24See. ‘Therefore in 60sec belt can run + GO1X60Y24 = 75.25 Pecrunning Meir (m) weight of Mate, :2.61/75.25 = 0,035487-35.48 ke. So for 120 TPH required rm weight of Material - (35.48K120/160) = 26.61 ke As per Design Mix (WMM -01) 40mm 20mm 1omm | Stone Dust vee @in-1) @in-2) @n-3) | @m-4) Ratio 35% 19% 1% a Reqd. Qty. for 120TPH in ke. /im 931 ~5.06 452 ~ 72 foe : adel Lat\Technician ician Material Engineer Material Engineer RE/TL For Contractor # Engineer For Contractor 6 For Engineer For Engineer 7 rage £0r 2 Q / 9 : o Calibration detai dg Ee ~ SL | Gate opening | We of Material | Theoretical We ) Feeder No. Ta PemnS | per meter Belt for120TPH f Remarks No.| inmm 5 (gms.) (gms.) Bin-3ie Lt 25 1350 9 ion 2 40 3050 4520 3 70 5585 Yd aes 1 40 1917 fee ee ee 70 4510 5066 D 3 90 6393 - 5 : i 10 6573 ) fu eae 2 130 8561 9310 3 180 10540 | ae i 30 3008 ) Bin-4ie, 34 50 5125 7720 A Stone Dust |} eH = 5 7 As per trial: i ) For 120TPH required speed for each Bin . a oO 40mm Gate opening : 151mm. : 20mm Gate opening 76 mii 10mm . Gate opening 58° mm #2 3 Dust Gate opening 61 mm fer Oo ) i ) ) j » 7 * - = = ee . oo yee tee » © Lalf Technician 19> Material Engineer Material Engineer” RET For Contractor Fef Engineer For Capactor For Enginesr For Engineer 9 yor 4-Laning from Km-319,800 to Km-360.915 of Gorskhpur-Gopalgan Section of NH-28 in UP, India, 9 Civil Contaret Package No:-LMNEP-EW-Il(WB)-8 i EMPLOYER + National Highways Authority of India. ENGINEER : PFC,FP() & Feedback JV. ‘VGONTRACTOR — : Simplex Infrastructures Lic. ) 9 CALIBRATION CHART OF BATCHING PLANT FOR AGGREGATE GAUGE Calibration date : 04.05.08 Next Calibration Date : When Required - DIAL GAUGE READING Load TRIAL! Load TRIAL 1 Applied Applied 7 (kg) | load |Unioading| Average | Variation | (kg) Load [Unloading] Average | Variation 40 0 0 o ° 800 Bot 800 800.5 4 {80 50 50 50. 0 850 850 854 850.5 D4 “(200_] 100 99 99.5 1 909 201 900 200.5 oA iso_| 150 +51 150.6 07 950 951 oe 950 02 200_| 200 204 200.5 05 1000 1001 +001 4001 00 1 250 250 248) 249.5 o4 1050 1051 1050 [os | ‘300 300 3200.5 300.25 20.2 1100 1104 1102 1401.6 0.4 )_350 350, 350 350 0.0 1180 4162 1151 1181.5 on 400. | 400 404 400.5. 03 4200 1204 +200_| 12005 ot 5.450_| 454 449, 450 4 1250 1251 4250_|. 1250.8 ot s00_| - s00 490 498.5, 2 1300 1300 ‘so1_| 19005 | -01 550} 550 554 550.5, 02 41350 1352 1350 1351 os J y 00_| - 600 599 598.5 02 4400 1400 4aor_| 1400.5 | 0.4 y 650 | 650 652 651 23 4450 1464 1454 1451 20 ‘709_| 700 oz 7ot 03 tso0__| 1601 | 1500 | 15005 | 01 1750 752 752 752 0.0 | keémarks o a+ one 7 CBntractor's fSirocoigve ; erp EE resensive \ me eas Prada Designation & (aly “Fe ha + 2ésignation Date AL | yee G | oF s cel :-LMNEP-EW-II(WB)-8 7 4-Laning from Km-319.800 to Km-360.915 of Gorakhpur-Gopalganj Section of NH-28 in UP, India. Civil Contarct Package Ni EMPLOYER: + National Highways Authority of incia. : ENGINEER PFC,FP(|) & Feedback JV. 5 D CONTRACTOR : Simplex Infrastructures Ltd 9 7 5 CALIBRATION CHART OF BATCHING PL) R CEMENT GAUGE “) Calibration date 04.08.09 Next Calibration Date : When Re d Load DIAL GAUGE READING ) eae Loadirig Unloading Average Variation 5 0.00 0.00 0.00 0.00 0.00 20.00 20.00 20.00 20.00 0.00 ? 40.00 40.00 40.00 40.00 0.00 ) 60.00 80.50 60.50 60.60 0.90 ) 80.00 80.50 80.00 80.25 062 ) 100.00 100.10 99.50 29.80 0.60 7 120.00 120.60 420.50 t 420.50 0.00 140.00 140.50 140.50) : 140.50 ee > [460.00 16060 760.00 i 160.25. ot ) 180.00 180.00 180.00 | 180.00 0.00 ) 200.00 200.50 200.50 200.50 0.00 [220.00 220.50 220.00 220.25 0.23 ) L240.00 240.50 240.00 240.25 0.24 260.00 260.00 260.10 280.05 0.04 ) ° | 280.00 280.00 281.00 280.50 0.36 ) 300.00 301,00 301.00 301.00 0.00 er) 321.00 321.00 321.00 0.00 ) [340.00 340.50 347.00 340.75. “0.15 , | 360.00 361.00 361.00 361.00 0.00 380,00 380.50 381 380.75 0.13 400.00 401.00 401.00 401.00 a OB>— Contractor's Representative » Name Manish rods Designation 1 pa Affog tsb ena er AE ont Name 5 (3 ~Gtte Designation Cats Calan Date Aes a ) Y EMPLOYER ao + National Highways Authority of India. ENGINEER 1 PFC,FP(I) & Feedback JV. CONTRACTOR Simplex Infrastructures Ltd. 4-Laning from Krn-319.800 to Ken-360,915 of Gorakhpur-Gopalganj Section of NH-28 in UP, Indi. ‘Civil Contarct Package No:-LMNHP-EW-II(WB)-8 CALIBRATION CHART OF BATCHING PLANT FOR WATER METER Calibration date : 04.05.09 Next Calibration Date : When Required SLNO. Meter Reading (itrstkgs.) } Wator Measured (Itrs/Kgs.) Variation 1 ° 2 0 2 40 10 o 3 20 20 0.0 i 4 30 30 00 5 40 40.0 00 6 50 50.0 00 _| 7 60 60.0 20 é 70 70.0 0.0) @ 80 800 0.0) 10 20 89.5 06 a 100 00.0 0.0 12 70 110.0 0.0 3 120 520.6 04 . 14 730 730.0 00 15 140 140.0 0.0) 16 450) 1606 03 7 160 160.0 0.0 18 170 470.0 0.0 19 780 180.0 0.0 20 7190 790.0 0.0 24 200) 200.5 03 22 20 2105 “02 23 220 221.0 “05 24 230 230.5 02 25 240, 240.5 -02, 26 250 250.5 0.2 27 260 2605 0.2 28 270 Wo 0.4 28 280 280.0 0.0 30 290) 230.0 0.0 34 300) 300.0 09 feo SS — Contracjér's eregeneine Name Cy Manisa $i 2g pret lest eng EE eave Name Sle. BWR Designation (als “~“pecky ~ Date atdaw . 5 sry 4-Laning from Kmm-319,800 to Kmr-360.915 of Gorakhpur-Gopalganj Section of NE-28 in UP, India. ns Civil Contaret Package No:-LMNHP-EW-II(WB)-8 )/ EMPLOYER: Netone! Highways Autos of ini ENGINEER : PEO.FP\I) & Feedback JV, 6 CONTRACTOR: Simplex Infrastructures Le 9 CALIBRATION CHART OF BATCHING PLANT FOR ADDITIVES Calibration Date : 04.05.09 Next Calfretion Date : When Required 9 bariat Loading (gms) | Unloading (ams) Average Variation ) o 0 ° ° ° ) 4 500 500 500 500 ° ) 400 4000 1000 1000 0 > Oo] 1500 1500 1500 1500 6 1 | ) t i 2000 | 2001 2000 2000.5 0.08 i) ) 2500 2500, 2500 2500 ° Qo 3000 3000 3000 3000 ° 2) Q 3500 3500 3501 3500.5 008 ef 4000 4000 4000 4000 0 : Remarks: | oe— Contracte{'s Representative Name Maamist SPrds, Designation LT 1 Date 4404 dec At ena EE ema Name Sp SUA Designation ys dee ALTOS: . ! SAI KRISHNA AGENCY 1. No. 21-10-37, “Salkrishna’, I Line, Sri Nagar Colony, Near Satyanarayana Puram fly Quaniss, Vil, Te 1 'AYAWADA: 1 i: ‘ ; | TEST CERTIFICATE ' ou 7 | Gistomer M/S SIMPLEX INFRASTRUCTURES LID. | [Site office GORAKHPUR UP >», [ie of he nsiaent OVEN 250LTR i Identification No SIL-MC -GKP-O-1 Instrument used for calibration Glass Thermometer } | Environment conditions “| TEMPERATURE - 25 +/-2 DEGREE CEChg | HUMIDITY -50+/-10%. 7 Confirmation standard 1S.1248-1971 a Oo Check report 3) > Due date of calibration 24.09.09 a oo NOTE: I yPRE oO Cc ‘The above-mentioned Oven has been checked and is found to be as per the accoriland > | 18. 1248-1971 ¢ D ‘NOTE: — ‘The equipment used for the calibration has been calibrated by M/S BAGSON O CALIBRATION LAB PVT LTD, Vide their Gertificate NO. BC/25828/2007,Dt:) FOR SAI KRISHNA AGENCY Authorised Distributor for= Mrepemon 12 > I wo = 3 x a c ¢ You might also like
