QS435-48 GFRC Completion Pack Review Surveillance Report Rev 1

QUALITY
Surveillance Report
Contract Number: C435 Location: Farringdon
Contractor Name: Bam Ferrovial Kier (BFK)
Main Activity: GFRC Completion Pack Review Date of Surveillance: 28th Feb 2020
Document Number: C435-XRL-O4-RGN-CR001-50054 Surveillance Number: QS435-48
Surveillance by: Asif Babar Attendees: Desk Top Review
Main Controlling Document(s):
Works Information Volume 2B CRL1-XRL-V3-XWI-CR001-50035 (V2)

Architectural Specification C100-ATK-N2-RSP-CR002-00001 Rev 12 Clause JH40.2300
EXECUTIVE SUMMARY
At the request of Chief Engineers Group (CEG) Architectural Lead, a desktop Surveillance was undertaken at
C435 Farringdon to check on the compliance of Glass Fibre Reinforced Concrete (GFRC) and Stainless Steel
(S/S) support framework ‘Completion Packages’, mainly Installation. The GFRC Cladding and S/S support
framework has been installed on the Platforms and in the Tunnels.
The Contractors Architectural designer is Atkins. SORBA is completing the F2 detailed design and drawing
development. The steel is fabricated at JVB (Holland) and the GFRC panels are manufactured at Concrete
Valley (Holland); both are part of SORBA, the onsite installation is also being carried out by SORBA.
The surveillance focused mainly the provided scope mentioned in this report. All comments regarding
omissions and discrepancies are noted in detail within this report.
Prepared By: Asif Babar Approved by: Peter Andrews Date: 06th March 20
Distribution:
Neil Young, Colin Brown, Chris Binns, Chris Sexton, Lee John Allen, Chris Titterton, Stuart
Westgate, Piotr Swieboda, Julian Robinson, Soji Abass, Mike Twiddy, Chris Goatman.
Transmittal to BFK by Project Manager
© Crossrail Limited CRL RESTRICTED

Template Number: CRL1-XRL-O4-ZTM-CR001-50011 Rev 3.0
Surveillance Report C435-XRL-O4-RGN-CR001-50054
REPORT
The scope of this desk top surveillance is to check as follows:
1. ITP for fabrication at Code 1

2. ITP for installation at Code 1
3. JH40.2200
a. Samples acceptance by the CRL Lead Architect

b. Prototype inspection and acceptance record with acceptance by the CRL Lead
Architect
c. Bench Mark installation record – signed Code 1 by the CRL Lead Architect
4. JH40.2300
a. Test Reports
i. Impact
ii. Fire performance
iii. Fixings
iv. Materials testing (including witnessing by CRL Field Engineering in accordance
with the ITP)
v. Blast
5. Material Compliance Records
6. Construction installation records.
7. Proof Load Testing Records
8. O&M manual
Controlling Documentation
C100 Architectural Common Components Design Stage F1 Specification C100-ATK-N2-RSP-CR002-

00001 (Rev 12) Clause JH40.2300
Glass Fibre Reinforced Concrete Panels at Platform Levels at Level -6 and in Escalator Shafts ES1
(Escalators 4, 5, 6) and ES2 (Escalators 10,11): C435-BFK-A-CER-M123-50017 Rev 1.0
ETH Architectural Works - Glass Fibre Reinforced Concrete Panels at Level 0, -3 and Escalators 7, 8,
9: C435-BFK-A-CER-M123-50072 Rev 1.0
Page 2 of 10
Summary of CRL Comments:
The following are the comments of this surveillance:
C1: Soft Body Impact Testing of GRC Panels C435-BFK-Y-CER-M123-50002 Rev 1.0 Code1.
Unable to find this technical report for Soft Body Impact Testing in the package listing C435-BFK-A-CER-
M123-50017 and C435-BFK-A-CER-M123-50072. Please note impact testing is a review point for CRL as
per the approved ITP C435-BFK-C-ITP-M-123-50263 Rev 2.0.
Fire Test Report (Sorba) C435-BFK-Y-RGN-M123-51001 Rev 2.0 Code1

Fire test is a witness point for CRL as per the approved ITP C435-BFK-C-ITP-M-123-50263 Rev 2.0.
Testing and Fixing deliverable document C435-BFK-Y-RGN-M123-51002 Rev 1.0 Test report: pull out test
on cast-in brackets of GFRC panels. This document appears as obsolete on eB. The testing of fixing is a
witness point for CRL. As per the approved ITP.
C2: The check sheets are missing Smoke screen and protection of works with Corex checks as per ITP
deliverables.
C3: O&M manual: Wall Cladding System at Farringdon Station C435-BFK-K2-OMT03-M123-50004 Rev
2.0 is obsolete on eB.
CRL Surveillance Comments
Page 3 of 10
REF REQUIREMENT CRL SURVEILLANCE COMMENTS C
Check ITP for Fabrication is at The status of the following ITPs was checked on
1 Code1 eB to see if they are Code1:
C435 - ITP for Manufacturing of GFRC - Concrete

Valley Factory: C435-BFK-A-ITP-M123-50001
Rev 1.0 Code1 (Ref: Glass Fibre Reinforced
Concrete Panels at Platform Levels at Level -6
and in Escalator Shafts ES1 (Escalators 4, 5, 6)
and ES2 (Escalators 10,11): C435-BFK-A-CER-
M123-50017 Rev 1.0)
C435 – ITP for Production & Assembly Subframe

C435-BFK-C-ITP-M123-50264 Rev 1.0 Code 1
(Ref: Glass Fibre Reinforced Concrete Panels at
Platform Levels at Level -6 and in Escalator
Shafts ES1 (Escalators 4, 5, 6) and ES2
(Escalators 10,11): C435-BFK-A-CER-M123-
50017 Rev 1.0)
2 Check ITP for Installation is at C435- ITP for Installation of GFRC Panels C435-
Code 1 BFK-A-ITP-M123-50002 Rev 3.0 Code1
50017 Rev 1.0)
3 JH40.2200 Ref: Glass Fibre Reinforced Concrete Panels
at Platform Levels at Level -6 and in Escalator
a. Samples acceptance by CRL Shafts ES1 (Escalators 4, 5, 6) and ES2
b. Prototype inspection and 50017 Rev 1.0
acceptance record with
acceptance by the CRL Materials Compliance Record - GFRC - Typical
Section C435-BFK-A-LRC-M123-50176 Rev 1.0
c. Bench Mark installation record Code1 by CRL FE
– signed Code 1 by the CRL
Materials Compliance Record - GFRC - Typical
Junction C435-BFK-C4-LRC-M123-50506 Rev
2.0 Code1 by CRL FE
Materials Compliance Record - GFRC - Cross

Passage C435-BFK-A-LRC-M123-50174 Rev 1.0
Code1 by CRL FE
Materials Compliance Record - GFRC - Escalator

shaft C435-BFK-A-LRC-M123-50197 Rev 1.0
Code1 by CRL FE
Page 4 of 10
Materials Compliance Record - GFRC - Lower

concourse C435-BFK-A-LRC-M123-50196 Rev
1.0 Code1 by CRL FE
Materials Compliance Record - Prototype

Approval – GFRC- Sorba C435-BFK-A-LRC-
M123-50018 Rev 2.0 Signed by CRL PFE
Ref: ETH Architectural Works - Glass Fibre

Reinforced Concrete Panels at Level 0, -3 and
Escalators 7, 8, 9: C435-BFK-A-CER-M123-
50072 Rev 1.0
Benchmark Approval - Horizontal Cavity Closure

C435-BFK-C-LRC-M123-50965 Rev 1.0 Code1
by CRL FE
Benchmark/Sample/Prototype - ETH GRFC

Cladding Panels Benchmark C435-BFK-C-LRC-
M123-50971 Rev 1.0 Code1 CRL FE
JH40.2300
Soft Body Impact Testing of GRC Panels C435- C1
a. Check Test records for BFK-Y-CER-M123-50002 Rev 1.0 Code1.
i. Impact Unable to find this technical report for Soft Body
ii. Fire performance Impact Testing in the package listing C435-BFK-
iii. Fixings A-CER-M123-50017 and C435-BFK-A-CER-
iv. Materials testing (including M123-50072. Please note impact testing is a
witnessing by CRL Field review point for CRL as per the approved ITP
Engineering in accordance with C435-BFK-C-ITP-M-123-50263 Rev 2.0.
4 the ITP)
Fire Test Report (Sorba) C435-BFK-Y-RGN-
M123-51001 Rev 2.0 Code1 C1
Fire test is a witness point for CRL as per the
approved ITP C435-BFK-C-ITP-M-123-50263
Rev 2.0.
Testing and Fixing deliverable document C435-

C1
BFK-Y-RGN-M123-51002 Rev 1.0 Test report:
pull out test on cast-in brackets of GFRC panels.
This document appears as obsolete on eB. The
testing of fixing is a witness point for CRL. As per
the approved ITP.
(Ref: Inspection and Test Plan - Manufacturing of
GFRC - Concrete Valley Factory C435-BFK-C-
ITP-M123-50263 Rev 2.0)
Materials Compliance Record - GFRC – Fixings
C435-BFK-Y-LRC-M123-50006 Rev 3.0 Code1
5
Material Compliance Records a. C435-Materials Compliance Record - GFRC
Page 5 of 10
cladding panels C435-BFK-Y-LRC-M123-

a. GFRC mix 50001 (Rev 4.0) Code1
b. Stainless steel structure (Ref: Glass Fibre Reinforced Concrete Panels
c. Bolts at Platform Levels at Level -6 and in Escalator
d. Acoustic material Shafts ES1 (Escalators 4, 5, 6) and ES2
e. Gasket (Escalators 10,11): C435-BFK-A-CER-M123-
f. Anti-graffiti treatment 50017 Rev 1.0)
b. C435- Materials Compliance Record - GFRC-
Stainless Steel C435-BFK-Y-LRC-M123-
50007 Rev 3.0 Code1
(Ref: Glass Fibre Reinforced Concrete Panels
50017 Rev 1.0)
c. C435- Materials Compliance Record - GFRC

– Fixings C435-BFK-Y-LRC-M123-50006 Rev
3.0
50017 Rev 1.0)
d. C435-Materials Compliance Record - GFRC -

Acoustic Insulation C435-BFK-Y-LRC-M123-
50002 Rev 5.0 Code1.
The current MCR is at Rev 5.0 instead of Rev
4.0 as shown in the package listing
50017 Rev 1.0)
e. C435-Materials Compliance Record – Gasket

C435-BFK-Y-LRC-M123-50008 Rev 3.0
Code1
The current MCR is at Rev 3.0 instead of Rev
2.0 as shown in the package listing
50017 Rev 1.0)
f. C435- Materials Compliance Record - GFRC-

Anti-Graffiti Coating Rev 1.0 Code1
50017 Rev 1.0)
Page 6 of 10
Sorba installation check sheets are available on C2

eB in the Inspection and Test Records/Reports -
Construction installation records. GFRC Installation – Platform Tunnel East &
Platform Tunnel West C435-BFK-C4-LRC-M123-
50561 Rev 1.0.
The check sheets are missing Smoke screen and
protection of works with Corex checks as per ITP
deliverables.
6 Platform Levels at Level -6 and in Escalator
50017 Rev 1.0)
Sorba installation check sheets are available on

C2
GFRC Installation – Cross Passages, Concourses
and Lift Passage 1 C435-BFK-C4-LRC-M123-
50562 Rev 1.0.
The check sheets are missing Smoke screen
installation check as per ITP deliverables.
50017 Rev 1.0)

GFRC Installation – Escalators ES1 and ES2
C435-BFK-C4-LRC-M123-50563 Rev 1.0.
50017 Rev 1.0)

eB in Inspection and Test Records/Reports -
GFRC Installation – ETH level -3, 0 and
Escalators 7,8,9 C435-BFK-C4-LRC-M123-50564
Rev 1.0.
(Ref: ETH Architectural Works - Internal Cladding
GFRC SORBA: C435-BFK-A-CER-M123-50072
Rev 1.0)
Proof Load Testing Records Ref: Glass Fibre Reinforced Concrete Panels
7
50017 Rev 1.0
Page 7 of 10
Proof Load Testing Records are available in the

ITP records – Installation of GFRC Panels
(*50017/50561).
Ref: ETH Architectural Works - Internal

Cladding GFRC SORBA: C435-BFK-A-CER-
M123-50072 Rev 1.0
Proof Load Testing Records are available in the

ITP records – Installation of GFRC Panels
(*50072/50564).
8 O+M manual Operations and Maintenance - Wall Cladding C3

System at Farringdon Station C435-BFK-K2-
OMT03-M123-50004 Rev 2.0 is obsolete on eB.
Rev 1.0)
Ref: Glass Fibre Reinforced Concrete Panels at

50017 Rev 1.0
Rev 1.0)
Material Compliance Records Materials Compliance Record - GFRC cladding
panels C435-BFK-Y-LRC-M123-50001 Rev 4.0
Code 1
Materials Compliance Record - GFRC - Acoustic
Insulation C435-BFK-Y-LRC-M123-50002 Rev
5.0 Code1. (Document superseded by Rev 5
instead of Rev 4.0 as per package listing: C435-
BFK-A-CER-M123-50017)
Materials Compliance Record - GFRC-Anti-Graffiti

Coating C435-BFK-Y-LRC-M123-50003 Rev1.0
Code1
9
Materials Compliance Record - GFRC - Hilti HKD
– S C435-BFK-Y-LRC-M123-50004 Rev 4.0
Code1
Materials Compliance Record - GFRC - Monet

Blind Rivet C435-BFK-Y-LRC-M123-50005 Rev
2.0 Code1

Materials Compliance Record - GFRC- Stainless
Page 8 of 10
Steel C435-BFK-Y-LRC-M123-50007 Rev 3.0

Code1
Materials Compliance Record – Gasket C435-

BFK-Y-LRC-M123-50008 Rev 3.0 Code1
(Document superseded by Rev 3 instead of Rev 2
as per package listing: C435-BFK-A-CER-M123-
50017)
Materials Compliance Record - GFRC – Lanyard

Materials Compliance Record - GFRC – Panel

Restrictor C435-BFK-Y-LRC-M123-50010 Rev
2.0 Code1
Materials Compliance Record - GFRC – Piano

Hinge C435-BFK-Y-LRC-M123-50011 Rev 1.0
Code1
Materials Compliance Record - GFRC – Quarter

turn lock C435-BFK-Y-LRC-M123-50012 Code
5.0 Code1
Materials Compliance Record - GFRC – Welding

Consumables C435-BFK-Y-LRC-M123-50013
Rev 1.0 Code1
Materials Compliance Record - Electric isolation

Materials Compliance Record - GFRC – Spring

for Installing Insulation C435-BFK-A-LRC-M123-
50012 Rev 2.0 Code1
Materials Compliance Record - GFRC – Gas

Spring C435-BFK-A-LRC-M123-50013 Rev 1.0
Code1
Materials Compliance Record - GFRC – Cavity

Barrier C435-BFK-A-LRC-M123-50014 Rev 1.0
Code1
Materials Compliance Record - GFRC – Smoke

Barrier C435-BFK-A-LRC-M123-50015 Rev 6.0
Code1

Cavity Barrier C435-BFK-A-LRC-M123-50049
Rev 1.0 Code1
Materials Compliance Record - GFRC – Grout

C435-BFK-A-LRC-M123-50119 Rev 1.0 Code1
Page 9 of 10
Materials Compliance Record - GFRC - Rockwool

FirePro Glue C435-BFK-A-LRC-M123-50166 rev
2.0 Code1
Materials Compliance Record - GFRC - Rockwool

SP Firestop Bracket C435-BFK-A-LRC-M123-
50167 Rev 3.0 Code1 (Document superseded by
Rev 3 instead of Rev 2 as per package listing:
C435-BFK-A-CER-M123-50017)
Materials Compliance Record - GFRC – Repair

C435-BFK-A-LRC-M123-50168 Rev 1.0 Code1
Materials Compliance Record - Asset Tags C435-

BFK-X-LRC-M123-56164 Code1
Materials Compliance Record - Inox-Color Grade

304 Stainless Steel Panels C435-BFK-A-LRC-
M123-50056 Rev 3.0 Code1
Materials Compliance Record - Cavity Closures

C435-BFK-X-LRC-M123-56040 Rev 1.0 Code1
Materials Compliance Record - Hollo-Bolt HB 12-

1 C435-BFK-C-LRC-M123-50913 Rev 1.0 Code1
Materials Compliance Record - Mapei Mapesil LM

C435-BFK-C-LRC-M123-51167 Rev 1.0 Code1
Notes
Quality surveillance in the context of this report is defined as a check of compliance of selected aspects of the work in
accordance with package listings, ITP and specifications. It does not certify the work; this remains the responsibility of the
organisation as defined by contract.
Quality surveillance has taken place of a sample of activities completed or in progress. As this surveillance was carried out on
a sample basis, non-conformances may exist that were undetected as part of this process. The documents above have not
been reviewed in details surveillance has been carried out as per the provided scope only.
Page 10 of 10

QS435-48 GFRC Completion Pack Review Surveillance Report Rev 1

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

QS435-48 GFRC Completion Pack Review Surveillance Report Rev 1

Uploaded by

Copyright:

Available Formats

QUALITY

Contractor Name: Bam Ferrovial Kier (BFK)

Document Number: C435-XRL-O4-RGN-CR001-50054 Surveillance Number: QS435-48

Surveillance by: Asif Babar Attendees: Desk Top Review

Main Controlling Document(s):

Works Information Volume 2B CRL1-XRL-V3-XWI-CR001-50035 (V2)

Transmittal to BFK by Project Manager

© Crossrail Limited CRL RESTRICTED

1. ITP for fabrication at Code 1

a. Samples acceptance by the CRL Lead Architect

5. Material Compliance Records

6. Construction installation records.

7. Proof Load Testing Records

C100 Architectural Common Components Design Stage F1 Specification C100-ATK-N2-RSP-CR002-

Summary of CRL Comments:

The following are the comments of this surveillance:

Fire Test Report (Sorba) C435-BFK-Y-RGN-M123-51001 Rev 2.0 Code1

CRL Surveillance Comments

REF REQUIREMENT CRL SURVEILLANCE COMMENTS C

C435 - ITP for Manufacturing of GFRC - Concrete

C435 – ITP for Production & Assembly Subframe

Materials Compliance Record - GFRC - Cross

Materials Compliance Record - GFRC - Escalator

REF REQUIREMENT CRL SURVEILLANCE COMMENTS C

Materials Compliance Record - GFRC - Lower

Materials Compliance Record - Prototype

Ref: ETH Architectural Works - Glass Fibre

Benchmark Approval - Horizontal Cavity Closure

Benchmark/Sample/Prototype - ETH GRFC

Testing and Fixing deliverable document C435-

REF REQUIREMENT CRL SURVEILLANCE COMMENTS C

cladding panels C435-BFK-Y-LRC-M123-

c. C435- Materials Compliance Record - GFRC

d. C435-Materials Compliance Record - GFRC -

e. C435-Materials Compliance Record – Gasket

f. C435- Materials Compliance Record - GFRC-

REF REQUIREMENT CRL SURVEILLANCE COMMENTS C

Sorba installation check sheets are available on C2

Sorba installation check sheets are available on

Sorba installation check sheets are available on C2

Sorba installation check sheets are available on C2

REF REQUIREMENT CRL SURVEILLANCE COMMENTS C

Proof Load Testing Records are available in the

Ref: ETH Architectural Works - Internal

Proof Load Testing Records are available in the

8 O+M manual Operations and Maintenance - Wall Cladding C3

Ref: Glass Fibre Reinforced Concrete Panels at

Materials Compliance Record - GFRC-Anti-Graffiti

Materials Compliance Record - GFRC - Monet

Materials Compliance Record - GFRC – Fixings

Materials Compliance Record - GFRC- Stainless

REF REQUIREMENT CRL SURVEILLANCE COMMENTS C

Steel C435-BFK-Y-LRC-M123-50007 Rev 3.0

Materials Compliance Record – Gasket C435-

Materials Compliance Record - GFRC – Lanyard

Materials Compliance Record - GFRC – Panel

Materials Compliance Record - GFRC – Piano

Materials Compliance Record - GFRC – Quarter

Materials Compliance Record - GFRC – Welding

Materials Compliance Record - Electric isolation

Materials Compliance Record - GFRC – Spring

Materials Compliance Record - GFRC – Gas

Materials Compliance Record - GFRC – Cavity

Materials Compliance Record - GFRC – Smoke