Project Review Presentation (2)

Welcome

Multi-Crop Breeding Station at

Chandipa

Hyderabad, 29th Aug 2012

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]

mailto:[email protected]

Site Layout

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


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



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

Quality training photos

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


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


Sl

NoCode Description

Amount As Per


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


Sl

NoCode Description

Amount As Per


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

Construction Schedule Planned

Construction Schedule Actual

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

Thanks

Thanks

Documents

Project Review Presentation (2)