Civil Quality Issues

1. Few locations the cable entry from the exterior into the prefab structure is not
well silicon sealed.
2. Honeycombing in Columns observed (cavities within Coarse aggregate in
concrete, external surface not finished). This is mostly due to improper
consolidations (even distribution of concrete within mold / formwork).
Locations of deep honeycombing must be treated with expansion grout
injection. Other locations of external rough surface shall be plastered well with
CM 1:4 mix to outer surface smooth finished with cement grout.
3. Most of the sites have mud deposited over the peripheral PCC which have
resulted in growth of vegetation over. In some sites PCC laid are of not good
quality, similar situations should be cleared manually, surface cleaned with
pressure washer and fresh layer of PCC along the full width (not Individual
patching).
4. In few Pre-Aggregation POP locations, the dimensions of columns were observed
to be not matching with approved layout provided for inspection. If any revised
layout is available kindly provide the copy of the same.
5. Exposed PU on POP's back side roof panel, leads to disintegration of PU little by
little by exposing to rain and sunlight. Also, currently it's aesthetically not pleasing
as it forms a blackish color. Recommended to provide flashing as suitable.
6. In POP shelter, base plate should be welded thoroughly, not tack welding being
followed at present. All sites.
7. Trees with long branches / trees (or branches) that cause challenges and
situated near to shelter premise should be cut as it causes shredding of leaves,
water accumulation or falling of branches etc. At least 10% of all sites across
Kerala have this problem.
8. It has been observed that rusting in Base Plate is very common across site, also
occasionally at cable tray, ceiling. Should be painted or galvanized as per need.
9. In between base plate and column gap, Expansive cement should be used
instead of cement as former is more reachable. Suggestion: FOSROC GP2
10. Peripheral 1.2 M PCC should be minimum 2.5cm above finished ground level.
Under current situation, due to water runoff, soil gets accumulated at PCC and
cause vegetation. Suggestion.

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11. Manhole for cable loop should be 5 cm above finished ground level as to
prevent from runoff water and soil. Suggestion.
12. All Earth Chambers in a site should be on same level.
13. Still no approved structural drawing submitted for extra structural support of Core
POP's Battery section. Pending.
14. Revised approved drawing for Aggregation, Pre-Aggregation & Spur is pending,
but it's been observed that revised drawing is used for latest construction.
15. Frequency of testing should be update in SOP regarding PU Density Test & Paint
Thickness Test. Currently only one test conducted the same for 110 Nos of POPs.
Frequency of test for PU density and Paint thickness should be updated.
Currently, it is not being maintained. Include PMA representatives for testing.
16. Concrete Cube test frequency should be updated, currently it's not maintaining
even though there are different vendors working in different districts. Include PMA
representative presence to testing cube in approved lab.
17. Release an approved brand list for civil works (raw materials) for Steel and
Cement.
18. Release an approved design mix or nominal mix for M20 & M25 mix for site record
and uniformity among vendors.
19. It's been noticed that in all sites Hand mixing of concrete were followed even
though in drawing machine mix was preferred. Need approval for the same for
records.

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