project review presentation (2)
TRANSCRIPT
Project informationS# Info Details
1 Project Name MULTI CROP BREEDING STATION
2 Site Location
Chandipa Village,
Shankarapally Mandal,
Hyderabad.
3 Owner/Client
BAYER BIO SCIENCES PVT.LTD,
Ohris Tech Park,
Plot No 13, Survey No P64/2,
Software Unit Layout, Madharpur,
Hyderabad-500081.
4 Consultant
M/s TEBODIN CONSULTANTS & ENGINEERS INDIA PVT.LTD,
2nd Floor, BNT Towers No 126,
Nelson Manickem Road, Chennai-600029,
Tamillnadu, India.
Tel : +91 44 434 03 200
Fax: +91 44 434 03 210.
www.Tebodin.com
5 Contractor
M/s CONSOLIDATED CONSTUCTION CONSORTIUM LTD,
# 5, 2nd Link Street C.I.T Colony, Mylapore ,
Chennai – 600004,
Tamillnadu, India.
Tel : 044 23454500 (100 Lines)
Email : [email protected]
Project Details
• Office & Lab Building = 2074.40 SQM
• Storage & Processing Lab = 2050.40 SQM
• Green House = 6558.35 SQM
• Canteen Building = 559.68 SQM
• Tool Shed Building = 1110.10 SQM
• Threshing & Drying Floor = 541.31 SQM
• Workers facility & First Aid = 240.19 SQM
• Security Building = 67.42 SQM
• Electrical Sub Station = 220.00 SQM
• Parking Shelter = 462.30 SQM
• Rain water Harvesting Pond = 2641.30 SQM
• Water tank & Pump House = 135.78 SQM
• STP = 109.00 SQM
• Diesel Tank = 140.57 SQM
• Site Grading = 378.00 SQM
• Connecting Corridor = 91.16 SQM
• Internal Paved Road = 0.65 KM
• Compound Wall = 1.67 KM
Agenda
• HSE Status with statics
• Quality Assurance & Control in project
• Review of site progress
• Review of total scope & deviations
• Construction Schedule & progress
• Review of Critical construction activities
• Value addition in construction review
• Review of procurement & Value addition( Mr. Angala)
HSE Status with statics
HSE :
• The site Safety team implemented standard safety practices during the execution :
• Conducting of induction trainings, daily/weekly toolbox trainings, first aid trainings,risk
assessments, permit systems(cold & hot works at elevation, excavations)
• The main document systems followed to prevent the incidents are, JSA, FON’s, NCR’s& Near
miss reports.
• The Safety team conducting motivational programs to workers to improve safety more awareness
& be cultured Safety trainings like Use of PPE, Heat Stress Training, Waste management, etc. by
the experts from Tebodin & Bayer to Cccl staff & workers, prior to start of a new activity to
avoid, incidents & accidents which helps in getting safe man hours.
13798
57356
7481281133
97733
246
488
834 826
1113
0
20000
40000
60000
80000
100000
120000
0
200
400
600
800
1000
1200
Mar-12 Apr-12 May-12 Jun-12 Jul-12
Mar-12 Apr-12 May-12 Jun-12 Jul-12
Manhours 13798 57356 74812 81133 97733
Total Number of Training 246 488 834 826 1113
Manhours Total Number of Training
MANHOURS VS TOTAL NUMBER OF TRAINING
13798
57356
74812
81133
97733
0
20000
40000
60000
80000
100000
120000
0
50
100
150
200
250
Mar-12 Apr-12 May-12 Jun-12 Jul-12
Mar-12 Apr-12 May-12 Jun-12 Jul-12
Manhours 13798 57356 74812 81133 97733
Safety Induction to New workmen
91 154 88 179 236
Manhours Safety Induction to New workmen
MANHOURS VS SAFETY INDUCTION TO NEW WORKMEN
HSE Monthly training indicator
HSE Status & statistics
• Till August 28th Safety team has given following trainings to CCCL staff & labors –
• Induction Training – 921 Labours in 167 days
• Tool Box Talk – 5010 Labours in 167 Sessions
• Job Specific Trainings for CCCL staff – 595 Staff members in 22 Sessions
• First Aid Training – 7 Stewards & Engg –Training course
26 trainings for onsite Supervisors
• CCCL was found inadequate in HSE documentation at the beginning, but after proper training by
Tebodin & Bayer, documentation has been improved
• CCCL has arranged Doctor’s weekly visit for labors & their families staying in labour camp
• The up coming challenges are hot works at elevation in PEB, erection of Roof trusses, sheeting
works,pumps with motors & handling of machine tools.
HSE Status & statistics
• Incident statistics –
• Major/Minor accident – 0 No.
• First Aid – 1 No.
• Near Miss – 3 Nos.
• Other site observations –
• Unsafe Act – 23 Nos.
• Unsafe conditions – 37 Nos.
• Housekeeping & Hygienic condition at site is improved since last 2-3 weeks &
maintained with good practices
Construction Management team by implementing good safety
practices able to achieve 0.423 million safe working Man-hours
Quality Assurance & Control in project
QA /QC in project
The following tests conducted during execution of the project till date are
- Soil compaction test, sieve analysis, cube compressive strength of concrete & blocks, water
absorption tests in site lab set up by Cccl.
Apart from the manufacturers test certificates, the other tests conducted as per the quality
plans by the third party are –
- Drinking water & construction purpose water
- Physical & chemical properties of Reinforcement steel & cement
Solid & Hollow blocks, River sand, Crusher sand
- Grading of GSB for Internal & Access road
- CBR values for soil & GSB
Quality Assurance & Control in project
Tebodin conducted quality trainings for Cccl Engineers :
• Raw materials of concrete,
• Grading of aggregates,
• Batching of materials,
• Properties of concrete,
• Formworks/shuttering,
• Concreting in high temperatures,
• Quality management system & Procedure of Block works/plastering till date.
Regarding in execution of quality works at site the Construction management
team tried to control maximum quality in all respects.
But still some quality problems are exposed when we started and finishing item of
works, that can be rectified/covered up in finishing works.
Quality Management Systems
• An organization will benefit from establishing an effective quality management system
(QMS).
• The cornerstone of a quality organization is the concept of the customer and
supplier working together for their mutual benefit.
• A QMS can be defined as:
• “A set of coordinated activities to direct and control an organization in order to
• continually improve the effectiveness and efficiency of its performance.”
• These activities interact and are affected by being in the system, so the isolation
and study of each one in detail will not necessarily lead to an understanding of the
system as a whole.
• The main thrust of a QMS is in defining the processes, which will result in the
production of quality products and services, rather than in detecting defective
products or services after they have been produced.
Quality Management Plans
• QMS is the management & control system document having three elements
• Quality Assurance plans
• Quality Control process & its implementation
• Quality Audit system of tracking & documentation
• QMS cannot be developed in totality at the inception. It has to undergo various
stages of development such as design, procurement of materials, construction,
inspection, erection & commissioning.
• Stages of QMS are:
• Planning -- Owner formulates/develops QA policy & plan
• Engineering – Consultant develops design QA program & that of prospective
• Vendors & Contractors
• Procurement – Suppliers develop & submit their QA programs/QC methods
• Construction – Contractor develop & submit their QA program/QC methods
• Inspection -- The testing agencies develop their QA programs
Review of site progress
The present up to date physical progress is as follows :
• Office building roof slab at 9.300 level casted & head room columns are in
progress
• Connecting corridor fabrication of truss work is in progress
• Storage head room slab shuttering completed, reinforcement work is in progress
• Canteen at 8.500 level slab shuttering is in progress
• Green house back filling & plinth beam reinforcement work is in progress
• Tool shed PEB structure shop drawings submitted for approval & preparation
work for plinth beam is in progress
• Workers facility roof beam is in progress & fabrication of roof truss is in progress.
• Water tank grid slab completed & PO issued to vendor for supply & placing of
GRP tank
• Septic tanks top slab casted, curing is in progress
• STP/WTP work
Review of site progress
• Electrical substation trench wall concrete & Block work is in progress
• Parking shelter fabrication of roof truss is in progress
• Security building plastering is in progress
• Compound wall fencing pole work is started
• External services crossing works of water supply, sewage, storm water crossings
is in progress, Electrical, Rain water & Fire fighting crossings work yet to start
• Internal roads one layer of GSB completed & kerbstone laying is started
• Access road WMM layer is completed, BT work will be taken up after rainy season
• Diesel storage yard, Metering yard & crop drying platform yet to be started.
• Rain water harvesting pond location is proposed to be shifted with scope of work
• Surface water pond & farm roads will be taken up after rainy season
Total scope & deviations
S.No Description of Works Tender Rate ( INR) Negotiated Rate (INR) Savings/Extra (INR) Remarks
1 CIVIL & Access road works 20,41,78,770 18,57,23,860 1,84,54,910
2 PEB Works 74,10,991 71,17,855 2,93,136
3 Electrical works 6,12,47,323 4,94,31,454 1,18,15,869
For Buildings/units 2,61,04,344 2,61,04,344
Sub station 3,51,42,979 1,10,95,452 2,40,47,527
a LT panel 1,25,27,253 1,09,63,736 15,63,517
b HT Panel Works 11,65,539 13,85,433 -2,19,894
c Transformer Works - 33 kv 56,32,770 23,59,804 32,72,966
d DGs 86,18,137 86,18,137 - Negotiations yet to be done
EX-ITM IT - Data & Voice 27,60,291
4 Mechanical works 1,47,97,324 1,45,25,026 2,72,298
a STP Works 12,78,827 14,38,483 -1,59,656
b Diesel storage yard 35,04,825 30,72,871 4,31,954
c Fire fighting services 58,37,666 58,37,666 - Negotiations yet to be done
d Other Mechanical works 41,76,006 41,76,006 -
5 HVAC & Cold Room Works 5,69,52,066 4,79,27,588 90,24,477
TOTAL COST OF THE PROJECT IN INR 34,45,86,474 30,74,86,075 3,71,00,399
Total scope & deviations
Sl No Code DescriptionAmount As Per
BE In INRTender(INR)
Revised Budget
as per Execution
(INR)
Saving (BE &
Plan)(INR)
Excess(BE &
Plan)(INR)
(I) CIVIL, STRUCTURAL AND ARCHITECTURAL
A BUILDINGS
1 101 Office & Lab Building 4,76,19,936 4,15,94,785 3,91,24,270 84,95,666
2 201 Storage and Processing building 3,60,34,001 3,40,49,858 3,04,86,403 55,47,598
Connecting Corridor between Building-1 & Building -2. 7,35,301 3,67,247 3,57,433 3,77,868
3 301 Green House 1,28,80,324 2,36,00,839 2,55,47,114 1,26,66,790
4 401 Canteen & Recreation 1,71,09,143 1,20,93,273 1,10,18,154 60,90,989
5 501 Workers Facility 30,54,312 41,70,744 39,57,928 9,03,616
6 601 Tool Shed including PEB 1,17,10,708 56,83,476 64,05,306 53,05,402
7 701 Security Building 16,12,994 17,28,717 18,07,535 1,94,541
8 801 Electrical Sub Station 27,70,775 40,48,921 35,05,014 7,34,239
9 061 Pump House and GRP Tank 31,56,476 33,48,474 34,05,813 2,49,337
SUB TOTAL AMOUNT FOR BUILDINGS- A 13,66,83,970 13,06,86,334 12,56,14,971 2,58,17,522 1,47,48,523
Total scope & deviations
Sl
NoCode Description
Amount As Per
BE In INRTender(INR)
Revised
Budget as per
Execution
(INR)
Saving (BE
&
Plan)(INR)
Excess(BE
&
Plan)(INR)
(I) CIVIL, STRUCTURAL AND ARCHITECTURAL
B EXTERNAL WORKS
10 Site Grading and Dismantling of Existing Structure 20,00,000 60,22,141 24,14,085 4,14,085
11 011 Parking Shelter 16,91,385 37,08,278 36,93,821 20,02,436
12 021 Crop Dyring Platform 5,00,366 5,55,880 5,97,688 97,322
13 External Water Supply System including Irrigation Pipe Line 15,00,000 20,19,691 27,97,224 12,97,224
14External Drainage System (Septic Tank and Collection tank STP civil
Structures)10,00,000 26,12,118 46,75,065 36,75,065
15 031Rain water Harvesting system Including collection pipe line network and
Pond42,06,544 71,57,422 71,32,194 29,25,650
16 002 Surface Water collection Pond 30,35,854 30,35,854 30,35,854
17 041 Fencing and Main Gate 48,89,470 55,96,809 60,70,973 11,81,503
18 004Internal Road ( Interlocking tiles paved road and Crop Field Roads and
lined drains) 1,28,00,243 2,24,76,995 2,08,90,985 80,90,742
19 051 Diesel Tank Yard Civil Works 3,06,812 4,01,147 4,01,147
20 Additional Bore Wells 8,00,000 7,29,171 12,15,285 4,15,285
21 003 Land Scaping 20,00,000 10,78,435 10,78,435 9,21,565
SUB TOTAL AMOUNT FOR EXTERNAL WORKS- B 3,13,88,008 5,52,99,607 5,40,02,756 9,21,565 2,35,36,312
TOTAL AMOUNT FOR CIVIL, STRUCTURAL AND
ARCHITECTURAL16,80,71,978 18,59,85,941 17,96,17,726 2,67,39,087 3,82,84,835
Total scope & deviations
Sl
NoCode Description
Amount As Per
BE In INRTender(INR)
Revised
Budget as per
Execution
(INR)
Saving (BE
&
Plan)(INR)
Excess(BE &
Plan)(INR)
D ELECTRICAL
i) Lighting and Power 4,35,20,245 6,12,47,323 4,94,31,454 59,11,209
TOTAL AMOUNT FOR ELECTRICAL 4,35,20,245 6,12,47,323 4,94,31,454 59,11,209
ii) FIRE ALARM SYSTEM 27,00,462 27,00,462
iii) ACCESS CONTROL CCTV SYSTEM 27,51,490 27,51,490
iv) AUDIO, VIDEO, PUBLIC ADDRESS, DATA VOICE AND COMPUTER & SYSTEM 61,00,895 27,60,291 33,40,604
v) UPS & SERVER STABILIZER 77,27,500 77,27,500
E AUTOMATIC WEATHER STATION 5,65,000 5,65,000
F HVAC 3,94,07,780 5,69,52,066 4,79,27,588 85,19,808
G MECHANICAL WORKS 51,57,040 1,47,97,324 1,45,25,026 93,67,986
PEB WORKS 74,10,991 71,17,855 71,17,855
H ACCESS ROAD 50,00,000 60,32,850 61,06,134 11,06,134
I FURNITURE FOR OFFICE, STORAGE, CANTEEN & SECURITY BUILDING 85,30,600 85,30,600
J GREEN HOUSE BY BOSMAN 13,00,40,600 18,89,89,200 5,89,48,600
K LAB EQUIPMENTS 3,00,00,000 3,00,00,000
L DEMARCATION OF CROP FIELD 5,24,970 5,24,970
M TEMPLE 2,00,000 2,00,000
Aluminium composite panel including shades for Office and Lab, Storage and Canteen 1,21,59,979
TOTAL 44,97,73,590 34,45,86,474 54,94,75,297 3,00,79,691 12,97,81,397
70,00,000 70,00,000
PROVISION FOR CONSTRUCTION MANAGEMENT SERVICES 1,75,00,000 1,75,00,000
PERMISSIONS & STATUTORY APPROVALS 50,00,000 50,00,000
GRAND TOTAL AMOUNT 47,92,73,590 34,45,86,474 57,89,75,297 3,00,79,691 12,97,81,397
Grand Total in Indian Rupees 47,92,73,590 34,45,86,474 57,89,75,297 3,00,79,691 12,97,81,397
Grand Total in Euro 73,73,440 53,01,330 89,07,312 4,62,764 19,96,637
Deviations - Building Wise
S.No DESCRIPTION BOQ IN INR ACTUAL IN INR
DIFFERENCE
IN INR SAVING IN INR EXTRA IN INR REMARKS
1 LAB & OFFICE BUILDING 4,44,99,743 3,72,63,339 72,36,404 1,05,60,417 33,24,013
2 CONNECTING CORRIDOR 3,49,779 3,40,432 9,347 1,02,824 93,477
3 STORAGE BUILDING 3,72,81,195 2,90,36,329 82,44,866 1,02,22,109 19,77,243
4 GREEN HOUSE 2,24,78,274 2,43,31,975 -18,53,701 56,22,437 74,76,138
5 CANTEEN BUILDING 1,33,65,351 1,04,94,080 28,71,271 40,21,308 11,50,037
6 WORKERS FACILITY BUILDING 39,72,364 37,69,671 2,02,693 6,84,824 4,82,131
7 TOOL SHED BUILDING 54,13,144 61,00,640 -6,87,496 3,44,881 10,32,377
8 SECURITY BUILDING 16,46,491 17,21,560 -75,069 1,94,305 2,69,374
9 SUBSTATION BUILDING 38,56,336 33,38,299 5,18,037 12,06,232 6,88,195
10 PUMP HOUSE AND WATER TANK 31,89,205 32,43,817 -54,612 2,22,521 2,77,133
11 PARKING SHELTER 35,31,895 35,18,126 13,769 12,90,937 12,77,168
12 CROP DRYING PLATFORM 5,29,440 5,69,259 -39,819 39,819
13 RAINWATER HARVESTING POND 68,16,982 67,92,954 24,028 1,89,764 1,65,736
14 COMPOUND WALL 53,30,599 57,82,209 -4,51,610 1,05,624 5,57,234
15 INTERNAL ROADS 2,14,07,885 1,98,97,313 15,10,572 32,77,784 17,67,212
16 SURFACE POND 28,91,455 28,91,455
17 DIESEL TANK 2,92,219 3,82,067 -89,848 89,848
18 SITE GRATING & DISMANTLING 57,35,700 22,99,260 34,36,440 34,36,440
19 EXTERNAL WATER SUPPLY 19,23,625 26,64,175 -7,40,550 3,53,550 10,94,100
20 EXTERNAL DRAINAGE 24,87,874 44,52,697 -19,64,823 51,500 20,16,323
21 BORE WELL 6,94,488 11,57,480 -4,62,992 4,62,992
22 LANDSCAPPING 10,27,140 10,27,140
23 ACCESS ROAD WORKS 57,45,900 58,15,698 -69,798 25,831 95,629
Total Summary in INR 19,44,67,084 17,68,89,975 1,75,77,109 4,19,13,288 2,43,36,179
ADD SERVICE TAX(4.994%) IN INR 96,14,453 87,45,440 8,69,012 20,72,193 12,03,181
GRAND TOTAL IN INR 20,40,81,537 18,56,35,415 1,84,46,121 4,39,85,481 2,55,39,360
Deviations - Item Wise
SNO DESCRIPTION Total As Per Item(INR) Remarks
Deviation Saving Extra Spend
1 Excavation 34,52,032 34,52,032
2 Hard Rock -8,23,899 8,23,899
3 Backfilling -available earth -12,349 12,349
4 Backfilling -Supply -18,91,715 18,91,715
5 River Sand 43,55,920 43,55,920
6 PCC 5,68,416 5,68,416
7 Plum Concrete -5,05,203 5,05,203
8 Form Work -1,72,978 1,72,978
9 M25 RCC 73,52,934 73,52,934
10 Reinforcement Steel -11,29,391 11,29,391
11 Structural Steel 2,83,168 2,83,168
12 Structural Steel + Roofing -28,193 28,193
13 Sub base Filling - with GSB -7,87,041 7,87,041
14 Masonry - Hollow Block 6,76,638 6,76,638
15 Masonry - Solid Block -27,23,144 27,23,144
16 plaster in all levels 4,25,826 4,25,826
17 Flooring 71,556 71,556
18 Eurocon Tiles (Exterior & Interior) -2,07,562 2,07,562
19 Granolithac Flooring -3,62,751 3,62,751
20 Joinery 10,55,308 10,55,308
21 Joinery Extra item ( Swing , Puf Doors) -1,31,083 1,31,083
22 SS door with Single / Double leaf with 2 Hr. Fire Rating -2,30,306 2,30,306
23 SS Swing Door (D06) -2,71,588 2,71,588
24 Painting 1,36,437 1,36,437
25 Painting Exra Item -1,66,250 1,66,250
26 Extra Item (Aluminium Composite panel ) 1,15,81,594 1,15,81,594
27 Extra for Galvanized Bolts -4,79,406 4,79,406
28 Interlocking Paver Tiles -72,947 72,947
29 PCC precast concrete kerbing blocks 9,69,919 9,69,919
30 Surface Drain Channel -37,024 37,024
31 Cutting & Disposint of Trees -30,630 -30,630
32 SUB TOTAL 2,08,96,918 3,09,29,748 1,00,32,830
33 External Drainage works -20,71,333 20,71,333
34 Bore Well -4,62,992 4,62,992
Total IN INR 3,09,29,748 1,25,67,155
S-Curve (Planned v/s Actual)
25.8
11.0
22
37
57
72
82
91
100
25.0
10.0
1822
38
0
20
40
60
80
100
120
Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12 Oct-12 Nov-12 Dec-12
Planned
Achieved
Progress Construction Schedule
Construction Schedule:-
• As per schedule up to date we are lagging by18% due to following concerns
• Office building delayed due to the decision taking regarding drainage system of first floor
• Storage roof slab taken some time casting due to, we spent some time on HVAC for technical
clarification/ joint negotiation to get some financial gain.
• Canteen & workers facility buildings is delayed due crop field area where part of foundations
work is not being carried out, but it can be completed in time.
• Tool shed & STP is delayed in vendor finalization & issuing of POs, but it can be completed in
time only
• watertank,septictank,substation,& security building is as per schedule.
• Diesel yard, Metering yard, & drying crop platform is getting delayed due to area clearance from
forest department.
• Parking shelter is delayed due to the introduction of new columns in the cantilever portion area
• Compound wall fencing is delayed due to procurement of materials, but it can be completed by
attacking from two more corners as it is a scattered work.
• Internal roads second layer of GSB is delayed due to finalization of type of storm water drain &
will be taken up after cross drainage works.
• Access road GSB/WMM works is completed during monsoon as it was planned earlier before
monsoon.
Critical construction activities
The main Critical activities are :
• Office & Storage buildings may be delayed due to HVAC & Cold rooms work
• Infrastructure works with External services is getting delayed due to the submission &
approval of shop drawings
• Compound wall is delayed due to procurement of materials as the supplier taken more time in
delivery, but it can be completed within time as the work is scattered can be taken up from two
more corners.
• The delay in getting tree cutting permission from concern forest department is affecting badly
for start of construction of HSD Tank, Electrical metering room & HT yard, Crop drying
platform, part of green house
Project Upcoming Challenges :
• Procurement activity for Lift, DG, STP, HSD, Data & Voice, Office & Lab Furniture, Lab Equipment,
etc.
• On time delivery of all materials (especially MEP & PEB) at site to catch-up delay of procurement of
about almost 3 months against originally planned
• Construction of all activities at all structures parallel to each other to catch-up earlier delay as all
activities are becoming critical
• Quality work of foundation construction (Precision in foundation bolt fixing) for Green Houses
• Infrastructure works/External services works have not started in full swing is a big challenge to
complete with internal works of all structures
• Field Area roads, irrigation system & electrical works will be also a challenge to work parallel.
Approved Construction drawings are yet to be finalized as early as Tebodin office
• R A bill payments from Bayer to Cccl is badly affected the cash flow of the contractor & it is started
showing effect on the progress
• Cutting of trees along the compound wall is another big challenge to take up the work of field roads.
• A revised resource planning with rigorous follow-up on resources & manpower is essential to
make the things possible from impossible
Critical construction activities
Value addition in construction review
• Cccl as a general contractor didn’t had the expert is in safety & quality execution. Tebodin with
construction team implemented high standards of good standard construction practices.
• Cccl intended to complete their work for the Business perspective where as Tebodin Construction
team works towards the achievement of providing technical services for the end users.
• Tebodin conducted quality awareness trainings to Cccl staff which will help in improvements in
implementing the system of quality & also technically benefitted individually.
• Cccl doesn’t have technical experts in MEP works which affects the project progress, Tebodin
construction team technical support improved the situation.
• In spite of full Tebodin’s cooperation & support Cccl failed to achieve required progress during peak
period
• Further to improve the situation & to catch up the delay following actions were implemented recently
• BTS CM implemented some construction management practices as mentioned below which were
used effectively in earlier projects to catch-up the schedule which was delayed by 19% during first
week of Aug’12 –
• BTS & Tebodin decided to have site round with CCCL PM at site for quality as well as progress
discussion at individual building ongoing activity
• BTS implemented the status update meetings with CCCL to update & follow-up with contractor in
procurement & delivery of material of upcoming activities
• BTS CM trained discipline engineers to carry out good construction management practices to
catch-up the activities & avoid delay