1 - Company Profile

Tel: (974) 4490 3836 Fax: (974) 4490 3835 P.O. Box: 50311, Doha, State of Qatar E-mail:[email protected], Web: www.dohaprecast.com

Company Profile

Company Profile

Introduction:

Doha Precast Factory (DPF) established in Qatar 2008 located in Mesaieed Industrial City about 30KM from Doha.

The Factory meant to produce reinforced Concrete Pipes and fittings in low head and gravity flow systems. The present concrete pipes produce in the DPF design utilizing EPDM gasket , and T- Locking system PVC, H.D.P.E. and GRP lining and externally coated by coal tar epoxy (optional). It’s especially developed for drainage pipe installed in the generally corrosive soils and ground water of Qatar and G.C.C. coastal areas. The production range is from 200mm to 3000mm Internal Diameter. The pipe design to be withstand against external load and to suit client specifications and site requirements.

Doha Precast Factory is Producing Precast Manhole Elements as Benching, shaft and cover Slab with complete facilities to produce all types and sizes of Precast Manholes.

Standards and Quality Assurance:

All products are manufactured in accordance with relevant standard mainly ASTM C 76M and related standard of ASTM pertain to reinforced concrete pipes and raw materials, BS 5911 P: 1 2000 and, BSEN 1916 and related standard of BS for reinforcement concrete pipe and raw material, with considering BS 5911 P: 100 and P:120, which are clearly defines all the performance tests necessary to ensure that the product will perform satisfactorily in service and be durable for long period.

The Doha Precast Factory is certified international Quality system as ISO 9001:2008 Quality Management Systems, ISO 14001:2004 Environmental Management Systems and OHSAS 18001:2007 Occupational Health and Safety Management systems. Doha Precast Ensure about not only quality of Product, but also it will ensure about the Safety and Environmental aspects.

The Doha Precast Factory is certified for Storm Sewer and Culvert pipe and Manholes Plant by American Concrete Pipe Association- QCast and Certified by BSI for KITE Mark, Concrete pipes and Fittings, unreinforced, steel fiber and reinforced and fiber- cement products – pressure pipes and joints. While we believe that this certification scheme gives added assurance that the products fully comply through third party scheme of supervision administrated by the quality assurance services. In addition to monitoring all aspects of quality control procedure from receipt of raw materials through the production, inspection and testing stages to the efficient loading and transportation of products to site.

Technology:

Doha Precast Factory is equipped with latest modern technology to meet with our client’s satisfaction by producing consistent and high quality products meeting the latest international standards.

Following technology suppliers are utilized in Doha Precast Factory:

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Pipe Casting Machine –M/s PEDERSHAAP - Denmark

Laboratory Equipments – M/s ELE - England

Pipe Cutting & Milling Machine –M/s KOLB - Germany

Automatic Coating Machine –M/s GRACO - USA

Fork Lifts –M/s KALMAR - Sweden

Steel Cage Machine –M/s MBK - Germany

Concrete Batching Plant – M/s IMER – Italy

SKAKO- Denmark

EOT Crane–M/s DEMAG - Germany

Hydrostatic Testing Machine –M/s MESSMANN - Germany

Pipe Crushing Machine- M/s PEDERSHAAP - Denmark

Internal Lining:

Doha Precast Factory can produce reinforced concrete pipe lined with H.D.P.E., P.V.C. or G. R. P. (optional)

The pipe will be 360º lined to protect the internal service and against chemical attack from liquids conveyed. During the fabrication process of the pipe the sheet lining is placed around the core, so the concrete is casted around the ribs or the anchor if we use G.R.P. liner once the concrete is set, the lining is locked mechanically to the pipe interior and can tolerate large movements at the joints without losing its physical integrity, while the continuity of the lining is assured by welding or laminating each individual pipe joint to the next.

The quality control programme of Doha Precast Factory shows how we can test any welded joint to ensure that the welding processes fulfilled the requirements.

Reinforcement:

Reinforcement cage required for the reinforced concrete pipes are produced from cold drawn steel wire to meet with BS and ASTM related standards. On automatic welding machine (MBK- Germany). As the cage revolves, steel wire is wind in spiral around longitudinal bars and automatically welded at each contacts point till the required length of cage completed.

Water Protection Coating

Doha Precast Factory has a facility to coat the service of reinforced concrete pipe with coal tar epoxy coating with normally applied to thickness of between 200 to 1000 micron by either Graco machine technology or brush to protect the exterior of the pipe from attack by potentially destructive soil chemicals. The coating can tolerate soil stresses and pipe deflections without cracking or disbanding. Also Doha Precast Factory’s laboratory is furnished with all required test equipments to control thickness and bonding criteria of coating.

Product Dimension

Doha Precast Factory producing standard and jacking pipe with 2m,2.5m,and 3m lengths and from 200 to 3000 mm ID. All acceptable limits as dimensions are mentioned in Quality Manual of DPF and ASTM / BS Standards. Moreover, Doha Precast Factory has very high technology to produce any length to meet the site requirements.

The KOLB cutting and milling machine is sophisticated to do these activities with very high performance and accuracy.

Materials:

Doha Precast Factory committed to use very high quality materials such as cement, full crushed gabbro aggregate, sweet water and additives in the manufacturing product, which are constantly monitored at each work to ensure compliance with relevant standards the process of producing a dense high strength concrete involves electronic monitoring to control water content and patch weighing the mixing of material.

Quality Control:

Doha Precast Factory offer superior quality concrete pipe products and services to our customers. We established Quality Control and Research Department staffed with qualified and experienced personnel and equipped with modern measuring and testing devices. The function of Quality Control and Research Department is to ensure that Doha Precast Factory products are manufactured in full compliances to the project specification, specified national standard, approved project quality assurance and Quality Control Programme of Doha Precast Factory.

Doha Precast Factory Quality Control and Research Departments are supported by Group Engineering Department consisting of experienced and professional engineers dedicated to support and upgrade the quality standard, when required.

Besides our internal quality an audit, Doha Precast Factory is audited annually by Bureau Veritas and American Concrete Pipe Association for Q-Cast and BSI for Kite mark, this will keep us alert to maintain and improve our quality product and to add more reinforcement to our strong platform.

Handling, Storage and Transportation :

Each shipment of pipes is loaded, should be blocked and securely fasten to avoid damages during transportation.

Unloading of the pipes should be controlled by the customer representative at the site, following Doha Precast Factory’s instruction.

Care should be taken to avoid damages especially the spigots and sockets.

Use appropriate lifting equipments for the offloading.

Nylon slings are recommended to be used for offloading and should be used around the pipe and never through it.

Stacks pipes on even ground on timber to protect mainly their sockets and spigots. The pipe bottom must be securely chocked at both ends using suitable timber wedges.

Rubber gasket should be kept clean away from oil, grease, excessive heat and out of the direct rays of the sun.

Installation procedure could be found in the Doha Precast Factory’s technical submittal.

For the Technical and structure details and specification will be presented with Technical submittal as per project specification or Clients requirements


Process Flow Chart

DOHA PRECAST FACTORY مصنع الدوحة للقوالب الخرسانية IMS –001

Process Flow Chart APPENDIX 2

Rev. No. 01

Date: 15-10-2012

Production Planning (GM, QA/QC , PE)

Material Purchasing (SK & Ph)

Human Resource (GM & Administrator)

Equipment & Resources (Maint. Eng.)

Quality Control (QA/QC Department)

Designing (If Required) (QA/QC Department)

Cost Analysis ( GM, PE, QA/QC)

Production (PE /PS)

Finished Product Checking & Identification (marking)

(QA/AC & YS)

Storing & Delivery (D.C. & YS)

Estimating material (PE)

Order Confirmation (GM & Client)

Concrete Mix (Plant Operator)

Steel cage (Cage machine Operator)

Finishing &Curing (PS & Mason)

Coating (Optional) (Coating Machine Operator)

Repairing & Finishing (YS)

Liner preparation (Optional) (liner welder)

Invoicing (SK)

Accounting (Accountant/Co-ordinator)

Verification of orders (GM)

Client Acceptance / Customer Feed Back

Pipe Production (Machine Operator)

Reporting to Client

Coordination & Document Control (Document Controller & IT service)

Maintenance and Calibration (QA/QC & Maint. Eng.)

GM -General manager QA/QC -QA/QC manager PE -Production Engineer PS -Production Supervisor SK -Store Keeper Ph -Purchaser YS -Yard Supervisor DC -Delivery Clerk

Customer Inquiry / Order (Client/Customer)

Visual and Dimensional Checking (QA/QC)

Third Party Interested

-MIC/QP

Client / Customer

Legal Requirements

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HSE Aspects - Health & Safety - Environmental

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Organization Chart

DOHA PRECAST FACTORY ORGANIZATION CHART

APPENDIX 1

Production Supervisor 1-Mofiziudin 2-Mohd Ayup

Production Foreman 1-LambertoTomayo 2- Wassim Mauuad 3-Fathy

Prod. Asst. Foreman 2-Shabir Ahmed-DC DP

Finance and Administration Manager (To be appointed)

Sales Staff (Rep. GM)

QA/QC Manager (MR) S. Rajarethinam

Maintenance Engineer 1-Wassim Ibrick 2-Ahmed Masri

Production Engineer 1-Rami Barhowm

2-Hossam M Kouta

Pipe M/C Operators 1- Shabir Ahmed 2-Saphul Miya DP 3-Mohd. Yusf DP

4-Ram Narayan DP 5-Mohammed Imran

B. Plant Operator 1-Dominaor M Bajo

2-Prince Gnanapaulton-M

General Manager Nasser Kammar

ITU Amir Isreb

Secretary / DC A.V. Nair

Maintenance Foreman 1-Edwin

Safety Officer 1-Monish M.

Asst, Lab. Technician 1-J.Johny Sugin 2-Mohd. Shakil

Yard Supervisor 1-Alfredo Castaneda

Yard Asst. Foreman 1-Mohd. M. Hussain

QC Inspector 1-John Joy Babu

2-V. Chandra Sekaran

Delivery Clerk 1-Vishal Tamang

Yard Foreman 1-Sardar Ali

Cage M. Operator 1-Khem Raj Rejmi

2-Mohd Minhaz Uddin 3-Prince Gnanapaulton-M

Liner Fabricator 1-Bimal Bahandari

2-Nizamudin Pathan 3-Abdul Mannan

Welder 1-Sham Kumar Yadav

2-Pravesh Kumar 3-Dhrisht Singh

4-Shivkumar Mukhyia 5-Shree Narayan Mala

6-Saif Ullah 7-Harans Singh

8-Karamjit Singh 9-Ram Labhaya 10-Faqir Singh

11-Gurrjinder Singh 12-Sukhvinder Singh

Fabricator/Steel Fixer 1-Bhawan singh Sarrt

EOT Crane Operator 1-Khushwant Singh

2-Balbir Singh 3-Oman Kumar Limbu 4-Gaya Ram Pardeshi

Mason 1-PranotGosum

2-Sablaniya Bhana Ram 3-Bijay Kumar Yadav 4-Budheshwar Yadav

5-Gopal Lal Balai 6-Harun Shekh

7-Nasharuddin Shekh 8-Bhushna Kumar

9-Ajay Kumar 10-Des Kumar

11-Harjinder Singh 12-HarDev Lal

13-Kewal Krishan 14-Kesaria Mirja Ram 15-Charnjeet Kumar

Helper 1-Mahindra Das 2-Nagendra Roy

3-Mohammas Israfil 4-Mohd Munsur Rain

5-Uday Kumar Ray 6-Karan Bahadur

7-Ram Bikas Kapri 8-Tara Chand

Carpenter 1-Shiv Kumar Goit

2-curdev Singh 3-Baldev Singh

4-Nek Chand Grpal 5-Afsar Khan Sargand 6-Kuldeep Diya Singh

7-Kewal Nazar

Fork Lift Operator 1-Alberto Cruz

2-Jeffre J. Castaneda 3-Mohd. Kabeer Shah

Shovel Operator 1-Sandeep Kumar Raju

2-Japal Amar Chand

Cut/Mill M. Operator 1-Nasser Hassan 2-Lok Bahadur

Painter 1-Nagendra Kumar Yadav

2-Bahar Kabir 3-Khongpet W.

4-Surendra Yadav 5-Sanjay Pasman

6-Skindar Sah 7-Rakesh Kumar Yadav

8-Nagendra Prasad 9-Balvir Kumar

10-Ajay Kumar Jagdish 11-Sandip Singh

Mason 1-Mohan Durga

2-Prem Nath 3-Param Jit

4-Satish Prakash 5-Ras Lal Yadav

6-Alberto Serrano 7-Said Ur Rehman 8-Manjith Singh 9-Mohd. Ashfaq

10-Sulinder Raunki 11-Charanjith Singh

12-Mohd. Kamrul Hussain 13-Raj Kumar

14-Balvir Singh 15-Harjinder Singh

16-Surjeet Khan

Carpender 1-Kundan Lal

2-Gurcharan Singh 3-Ashwani Kumar

4-Ranjith Baktour Singh 5-Amirik Singh

Helper 1-Umesh Kumar Shah

Mechanic 1-Mohd. Ashraf Cholayil

Plumber / Asst. Elect. 1-Ram Kumar Yadav

2-Dipendra Kumar M.

Administrator Twafik

Accountant Smeeah Liftikhar

Coordinator Emil K. Melven

Store Keeper Surender Anandan

Driver 1- Brahma Dev 2-Kamal Budha

Purchaser 1-Gul Shamir

2- Kais Al Tujar

Others 1-Bishnu Mani –Off. Boy

2- Parmesh –Off. Boy 3-Dhan Raj –Security.

4- kabindra S.- Store Help 5-Ram Udagar-Villa Help

House Keeper

1-Ranjeet Mandal D.

Rev-04 Dated: 01-02-2014

QA/QC Engineer(Trainee)

A.Algerry

Coat. Machine Operator 1-Mohd.Mahmud

Asst. B.Plant Operator 1-Baiju Babu

Helper 1-Manjit Singh

Asst.EOT Crane Operator 1-Mohd. Yusuf


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1 - Company Profile