NC ANALYSIS REPORT

PROJECT : ABC
ISSUE
NC No

Issue
Month

Date of NC
Raised

Nature

Nature of
Occurrence

Category of NC

Major/
Minor/
Critical

New /
Repetitive

Workmanship /
Material /
Process
/Supervision/
Design

Trade

Area/Location

CLOSURE
Contractor to
whom NC was
given

Description of NC

Issued by

Root Cause for NC

Correction

Corrective action for closure of NC

TPQA/Site
QAQC/Co
QAQC/Site Exec

With ref. to additional 12 bore

holes and 11 PDA test geo
technical consultant has classified
the zones for design papameters.

To be filled in by
Project Head

To be filled in
by Project
Head

11 Additional PDA conducted as per

Consulatant and SEC instrcution and Additional
Design
12 Bore holes connducted for Zone
lassifiaction and design Parameters finalisation

3/6/2015

Major

New

Design

Geo technical

6/10/2015

Minor

New

Process

Drawings

Tower-3

Site Exe.

Work in progress without approved GFC drawingas and

Site QA/QC
approved Pile co-ordinate drawings

Tower-3 drawings has been revised

Approved GFC drawing has been Drawing protocol has been raised and the
and the softcopy approvals are
brought from strcutural consulatnt without approved GFC drawing no work will be Design
available.but the Hard copy not
the issued and recorded
allowed at site
been available for longtime at site

17/06/15

Minor

New

Supervision

Piling

P1-201

DPJ

immediate heavy vehicle just edge of the pile after

casting

Improper supervision

23/06/15

Minor

New

Supervision

Tools

Tower-3

DPJ

Total station used for surveying without submitting the

Site QA/QC
calibartion certificate

Surveyor(Sub Contractor) Came

with the new total station machine Calibartion certificate shared for
and started working without
approval and record
informing

24/06/15

Major

New

Material

Testing

Tower-3

DPJ

There are some cubes attain more strength than other

cubes in the same set. And there is no strength gain
Site QA/QC
after 7 days normally but in some cases there is huge
strength gain in 28 days comparing to 7 days results

For the Strength Variation - Poor

Workmanship.
For Less strength Gain- Fineness
content is more in Cement

Improper Supervision and Poor

Workmanship

Proper Steel Base fabrication done Fixed steel base in all around the fabrication
Poor Workmanship and Supervsion for Fabrication and Concrete Has yard and other places has been barricaded
been poured n the Sings zone
properly.

Mar-15

June'15

Design team

The root cause for failure has been

that because of insufficient Site
Investigations, the variations in
the strength and quality of the
rocks have not been taken into
account.

Proposed Date
of Closure

Total Re-hab
project

End bearing capacity of the Rock value is been

considered high than the rock condition.

Departmental
Responsibility

Site QA/QC

8/11/2015

Minor

New

Supervision

Process

Cube Casting yard DPJ

Cube moulds dismantled in 10 hrs. and the Gunny

bags also not used for covering until demould.
Cube found with honeycomb and aggregates visible
Site QA/QC
separate.
Out of 8 cubes 7 cubes are in improper size/shape and
edges broken

8/21/2015

Minor

New

Material

Stocking

Steel Yard

DPJ

Improper steel stocking, Poor platform, No barrication

and Rings lying on ground

Aug'15

OCPPL Site Exe.

Site QA/QC

closed

23/06/15

23/06/15

closed

Fixed 4 cubes casting team will be Team has been fixed and training will be given
used with proper training for one and the after onemonth the strength details
Site Exec.
month.the analyse the report
will be verified and procured further

7/28/2015

7/30/2015

closed

Cubes should be demoulded after

Cubes has been tested at thirdparty lab. Third
Site Exec.
24 hrs. until the time it should be
Party Govt. Lab results shows satifactory
covered with gunny bags(wet).

9/7/2015

9/8/2015

closed

Site Exec.

8/22/2015

8/22/2015

closed

Site Exec.

9/18/2015

9/18/2015

0 closed

DPJ Exec and KDS

After RNC
excavtion done

3/26/2016

Closed

PIT achived 100%

closed

P1-203 Concrete done on 26/12/15

DPJ

Concrete Cube tank with less water than required level

Site QA/QC
and Cubes are not stocked properly in the curing tank

Cubes are removed for testing so

the water level got
reduced.refilling process not
carriedout and while removal
falldown cubes not rearranged

Oct'15

10/6/2015

Minor

new

Process

Process

P3-346

DPJ

P3-346 pile concrete without collecting approval from

OCPPL Rep. for Before flushing and after flushing
parameters of bentonite and Concrete Slump
requiremnets/

Poor Workmanship and Supervsion

PIT to be conducted in that pile to Authorities has been cleraly explained to
of the Piling Engineer and
prove that is Ok
Contractor
authority issues

12/1/2015

Minor

New

Supervision

1/4/2016 Major

New

Process

11

Jan'16

Excavation

Tower-3

12

RNC

RNC

2/20/2016 Major

New

workmanship/
supervision

Concrete

Tower-1

13

Tower-3 dewatering process has not been ensured

properly.water level found always above the Pile Cutoff
Site QA/QC
level. Due to that continuous water stagnation Pile
reinforcemnet started corroded.

The Pile cap PC3H,Grid -A6 and A7 found with Too

much Honey Combs, dense less concrete patch,
Bulging and cold joints and Tope level issue(Tie beam
depth).

RNC
Feb'16

14

2/26/2016 Major

New

2/27/2016 Minor

Process/
supervision
Material

Concrete

Tower-2
RNC

The steel has found stocked in water at site. Cover is

provided at top but the water stagnated all around
bottom.

After Proper Hacking and cleaning

with approved procedure of
the MS for under casted pile has been finalised
DPJ Exec and KDS
Structural consultant Pile casted
and approved
upto Pile cutoff level

Dewatering pumbs needs to be

increased and Cement coating
needs to be applied for the
Reinforcement protection for the
Initial period

After Hacking of pile Immediate Cement Slurry

Application on pile Reinforcemnnet needs to be
Site Exec.
done. And it has to be cleaned using wire
brush before Pile Cap concrete

pile cap will be rectified with

proper grout and Non shrink grout Drawings needs to be checked before work.
packing by approved method by
Additoonal carpenter during concrete has to be
OCPPL Site Exec
External agency
ensured and Supports at bottom needs

Improper Coordination. Poor

Planning

If any issue aries contrctor has to

be rectify the total pile cap
without any additional cost with
accpetable /Approved standards

Method statemnet need to be follwoed

Poor Supervision and improper

stocking of material

Steel has to be stocked in proper

place

Steel stocked need to be done at dry area with

RNC
proper runner base

OCPPL Site Exec

Tower-1

1. Without enough equipment like additional pump car

how the Mass concrete work has been allowed to pour
at site?
Site QA/QC
2. As the Mass concrete of 180 cum was started after
the comparatively small pile cap i.e 80 m3. How the
importance has been considered?.

Poor Resourceplanning and

management

Porper Pouring plan estabilshed at Proper Resource planning needs to be ensured

OCPPL Site Exec
site
based on site condition

Cover blocks casted at site are found not as per mix

design

Lack of invovemnet and

importance on this work

Casting cover block carried out under lab

Casted cover blocks sent out from
control and cubes to casted and test needs to
site
be verified.

Poor Supervision and Not follwing

sequence of activity

Porper cleqaningn needs to be

done before comemncing
reinforecment work

15

2/27/2016

Minor

New

Supervision

Concrete

16

3/3/2016

Minor

New

Processs

Concrete

Cover block
casting yard

17

3/5/2016

Minor

New

Supervision

Formwork

pile cap 2nd lift

area Grid K, Tower RNC
- 03

RNC

Site QA/QC

The Soil stored in pile cap not cleaned even after

number of informations which is leading to corrosion
of pile cap Top reinforcement. And further yesterday it
Site QA/QC
has been noted the Beam Reinforcement work and
Dead wall shuttering works also started without
cleaning the soil stored in pile cap 2nd lift area

12/15/2015

1/6/2016

12/20/2015

1/11/2016

3/3/2016

closed

7/12/2016 Open

Method statement for rectification done by

Contrcator. SEC rejected the proposal and
asked for another material for Filling honey
comb else asked for other MS

Prof.Diaz has visited and given points for this

pile cap under review with SEC for proceeding
with closure of this issue

Reinforcement

PC2J ( Tower 2) pile

and PC3L ( Tower OCPPL
1)

Site QA/QC

Water Refilled and stocking re

Warning has been issued to the conccern
done properly.Testing will be done
engineer and process training given for the
at the cubes at Third Party Govt.
cube area
Lab.

Tie beam drawings not available

improper supports at bottom of
pile cap
Non availability additional
carpenter during concrete

Site QA/QC
PC2J Pile cap concreting from Tower-2 has been
completed without following the approved method
statement for Thermal control testing /monitoring

New

Mar'16

Site QA/QC

Improper Dewatering

Site Exec.

All new tools and equipment without apporval

Site Exec.
should not be used. informed in the survey
redords machine number should be displayed

Curing Tank

Due to presence of underground

service lines (pipes). This pile was
concreted up to casing and after
flushing concrete over the
temporary casing, it was removed.
Then the concrete may flow
through these pipes and it is
inevitable to control it.

Considering the wide variation in the rock

strata at our site location, more number of
bore hole investigations would have assisted in
identifying the constraints at an earlier point of
time

Stocking

P1-64 Pile has been found under catsed than the cutoff
Site QA/QC
level.

closed

7/18/2015

Supervision

DPJ

3/25/2016

16/07/2015

Have to accryout the PIT and PDA After 28 days from concreteing date. PDA will
to analyse the pile
be conducted to analyse the efficiency of pile

New

P1-64 and P1-203

To be filled in by Project Head if required

closed

Minor

Piling

Remarks

9/18/2015

Dec'15

NC
Status

11/6/2015

Sep'15

10

Delay
(Days)

11/6/2015

Site QA/QC

Actual Date
of Closure

Sequence of activity needs to bee followed.

3/3/2016

7/15/2016 Open

2/27/2016 27.02.16

3/1/2016

Closed

3/1/2016

closed

RNC

3/16/2016

closed

RNC

3/19/2016

closed

Mar'16

18

3/21/2016

Minor

new

Material

Reinforcement

Steelyard

19

3/29/2016

Major

new

workmanship/
supervision

Concrete

PC4L @ A/5, PC1D

A2/2 &A3/3,PC4
RNC
Grid C/5,PC3J A/4

NC - 20/ RNC
-009

Apr-16

NC - 21/ RNC
-010

RNC

The Steel yard has been closed temporarily due to

Improper maintenance, Poor Steel stocking, Mixing of
old and new steel, New steel used without
acceptance /approved test results.

Site QA/QC

Proper Segregation needs to be

Non availability of material. Delay
done. As per approved steel yard
in testing time
plan work s has to be done

28 days cube failure

Site QA/QC

Workmaship issue in cube casting

Additional cube test needed to be

Training has to be given on periodic basis
done

28-04-16

Major

New

Material

Concrete

Tower-1 @PC3H

RNC

12 @ PC3H loaction for Honeycomb, the expired

material has beem nbrough to site. Approval not taken
Site QAQC
to use the materil with OCPPL at iste after brough to
site

Material inward noot done and

Expired material has to be send
materil approval after brought to out from site. New material has to
site not taken considering this as a be brought and used with proper
additional material
approval for rectification

5/26/2016

Major

New

Supervision

Concrete

PC1B Tower-2

RNC

28 Days strength Failure

Poor Workmanship as the 28 days

strength is less sthan 7 days
strength

Site QAQC

5/27/2016

Major

New

material

Tower 2 (PC4G)
Reinforcement and Tower-1 (PC3N
& PC5)

OCPPL

steel after fabrication found inside water

Site QAQC

Heavy rain, Less no. of Pump for

Dewatering from the pile cap Pit.
And Less manpower

RNC

All materials used for constrcution needs to be

approved by OCPPL Rep. before use at site.
Failure of that the work cannot be certified as
completed

RNC QA/QC

Cube casting trainings has been given to the

Core cutting needs to be done to
Lab helpers. And Instructed to write the cube
evaluate the area
details using nail instead of marker and sticker

RNC QA/QC

May'16
NC - 22/ RNC
-011

Approved steel yard paln needs to be followed RNC

Full dewatering needs to be done

and Scaling needs to be checked

Get an inspection done by SEC team also and

take appropriate action as per the physical
conditions and relevant areas. Where the steel
is submerged have asked for immediate
evacuation of water and then remedial action
as required. Where there are elements which
are getting delayed please get the cement
slurry applied immediately to arrest
deterioration

3/24/2016

3/28/2016

closed

3/30/2016

6/29/2016

90

closed

4/30/2016

4/30/2016

7/29/2016

OCPPL Site Exec.

Closed

closed

closed Closed at site but document not yet closed

July'16
At Tower-3, Grid J - C16 has been noted with column
cover issue around 15 mm short from actual cover.As
per our Spec, Acceptable tolerance limit for this work is Site QAQC
+10mm and 0 mm.

NC - 23 /
RNC -012

6/6/2016 Major

New

workmanship/
supervision

Concrete

Tower-3, Grid J C16 Column

OCPPL

NC - 24 /
RNC -013

6/7/2016 Major

New

workmanship/
supervision

Concrete

Tower-3 Lift pile

cap

OCPPL

Due to heavy rain after concrete, before Concrete

getting hard the Top surface got damaged, Contractor
have not put the sufficient Pump to dewater this area
as well.

NC - 25 /
RNC -014

6/7/2016 Major

New

workmanship/
supervision

Concrete

Tower-3 Lift wall

OCPPL

New

workmanship/
supervision

Concrete

Tower-3 Pile cap

and Semi
basement slab
concrete at Grid (11a),(I-J),(1-5a),(H-I)

As instructed by SEC and advised

Improper fixing of Column starter
by PH-OCPPL with Structural
bars to the Pile cap top
consultant approval , Column size
mate.Movement happened during
increase y 100mm with Architect
concrete
approval

As instrcuted by SEC, MS for column cover

issue and accptable tolerance has been
created and approved by SEC and all other
parties.

OCPPL Site Exec.

Non shrik grout + penetron admix

conccrete filling on the level less
Adequate precautionary measures to be taken
area and Penetron crystalline
with monsoon preparedlness plan
coating extended up to side of pile
cap

OCPPL Site Exec.

the Extra cover (More than 25mm from clear cover) for
outside lift wall and Less cover for inside reinforcement
Site QAQC
has been noted. Which is the deviation from our actual
tolerance limit i.e. +10mm/-0mm.

Improper fixing of wall starter bars

As instrcuted by SEC, MS for RCC cover issue
to the Pile cap top mate.Movement Additional Skin R/F to be provided and accptable tolerance has been created and
happened during concrete
approved by SEC and all other parties.

OCPPL Site Exec.

OCPPL

Cube test for Tower-3 Pile cap and Semi basement slab
concrete at Grid (1-1a),(I-J),(1-5a),(H-I), 5 out of 20
Site QAQC
cubes attain less strength than characteristic
compressive strength i.e. 40 N/mm2.

cube crushing maching

repeatability issue. Machine
Exra cubes send to Third party
checked. Balce cube send to Third lab.
party lab.

Instrcution given to Re calibrate the machine

and detailed report. Contrcator Repalced the
machine

Poor Compaction at the edges.

Honey Comb Repair using Non
Damaged shutter have been used shrink grout and WP Penetron
and it lead to grout leakages
slurry coat around that lift.

Formwork regiter needs to be monitored for

repaetataions and porpre vibration needs to be OCPPL Site Exec.
done.
confined spaces, DCPT can be accpted instaed
of layer by layer compaction.

OCPPL Site Exec.

As instructed by PH, With

Guidelines has been shared with contractor to
immediate effect slurry coat needs
ensure the corrosion of steel
to be applied

OCPPL Site Exec.

Site QAQC

No adequate Dewatering pump

and It was a heavy rainy day

6/16/2016

closed

Open

6/16/2016

Externa face closed but Internal surface not yet

closed

closed

June'16
NC - 26 /
RNC -015

6/8/2016 Major

NC - 27 /
RNC -016

6/14/2016 Minor

Repetative

workmanship/
supervision

Concrete

Tower-1 PC4F and

PC3B

OCPPL

The PC4F and PC3B having a worst honey combs, and

loose concrete pockets

NC - 28 /
RNC -017

6/16/2016 Minor

New

Supervision

Backfilling

Tower-3 lift pile cap

sides

OCPPL

around lift pile cap- Backfilling carryout improper waySite QAQC

Layer by layer compaction not ensured

Shroing has been removed without Layer by layer compaction needs

doing layer by layer so side earth to be done or DCPT needs to be
collapsed
done

NC - 29 /
RNC -018

6/17/2016 Maor

New

Material

Reinforcement

600mm dia pile

reinforcemnet at
Tower-2 and Tower1

OCPPL

Pile Reinforcement found too much corroded due to

delay in pile cap casting at Tower-2 2 nos. 600 mm
dia. piles near lift pile cap and Tower-1 Rainwater tank Site QAQC
side and near Sump piles and Under casted piles near
canteen

Delay in progress

Minor

New

Material

Concrete

at C7@ (5-G),C9@
(5-F) (6-F) (7F),C8@(C-6) (C-8)
(C-9),C15@(4a-H)

OCPPL

C 50 Concrete Strength failure at C7@ (5-G),C9@ (5-F)

Site QAQC
(6-F) (7-F),C8@(C-6) (C-8) (C-9),C15@(4a-H)

Failed on initial test i.e. 34.6

N/mm2 has attained 43.7 N/mm2
strength in the Retest on the same
extra cubes to approved Third
tested cube. Which is not correct.
party lab for review and analysis
Hence the machine has to be
rechecked with the supplier for the
further use

NC - 31/ RNC
-020

7/8/2016 Minor

New

Material

Concrete

At 1-K and 5A-K

OCPPL

C50 concrete cubes of Tower-3 columns at 1-K and 5ASite QAQC

K less strength at 28 days

extra cubes to approved Third

party lab for review and analysis

NC - 32/ RNC
-021

7/8/2016 Major

New

Supervision

Concrete

Liftwall @ Tower-3

OCPPL

Large honeycomb has been noted at the Lift wall

Tower-3.this issue is in Construction joint where the
PVC water stopper also available and its visible now
and its in UG area

Site QAQC

PVC waterstopper bend during

concrete which has restrcted the
concrete flow in that area. And
improper vibration

NC - 33/ RNC
-022

7/13/2016 Major

New

Design

Concrete

PC-5 Tower-1

OCPPL

Cracks at PC5 pile cap 2nd lift

Site QAQC

Thermal Crack due to temp

As per Prof.Dias report. Epox resin
Details needs to be ensured as per Prof.Dias
difference between core and
pressure grout on crack and other
report
surface exceeded. Prof.Dias report measures

OCPPL

Column, retaining wall at Tower-1 NE corner and Pile

-600mm dia. in East side podium piles has been
covered with soil without any precautionary measures
Site QAQC
and protection. Also the Casted concrete Tie beam has
been filled with soil and access has been made for
heavy vehicle movement

Poor Supervsion

NC - 30/ RNC
-019

7/5/2016

July'16

NC - 34/ RNC
-023

7/15/2016 Minor

NC - 35/ RNC
-024

New

7/21/2016 Major

Site QAQC

Untill the confirmation on the machinery. Pls.

inform RNC to carry out the testing at Third
party lab for acceptance.

RNC QA/QC

Open

July''16

closed

Closed at site but document not yet closed

Open

Test Done.approval pending with consuuctkatnt

6/29/2016 closed

OCPPL Site Exec.

Open

Advised RNC to carryout New mixdesign due to

continuous marginal results in C50 grade
OCPPL Site Exec.
concrete

Open

PVC water stopper has to be plced rigid and

It has to be treated with approved
not to bend using U-bar before
method with presence of WP
concrete.Balance 2 lift walls has to be casted
vendor or by WP team themsself
with the same method with precautionary
for satisfaction of Engineer
measures based on Root cause Analysis report

OCPPL Site Exec.

Open

OCPPL Site Exec.

Open

Its an OPC+ Fly ash concrete casted up to 1.3

m ht. size of the Pile cap is 13.5m x 13.05m. Its
and 2nd lift. 1st has been casted with OPC only
for 600mm ht. For this heights and mixture of
OPC and OPC + Fly ash we have approval from
all parties.

closed

Document closed on 05/08/16

Its an OPC+ Fly ash concrete casted up to 1.3

m ht. size of the Pile cap is 13.5m x 13.05m. Its
and 2nd lift. 1st has been casted with OPC only
for 600mm ht. For this heights and mixture of
OPC and OPC + Fly ash we have approval from
all parties.

July'16
element shown at site needs to be
cleared with all soil coverings and Backfilling and earrth filling with necessarty
proper access to be made
care to the adjacent structure.

Supervision

Backfilling

Tower-1 NE corner

Design

Concrete

PC4G-Tower-2

OCPPL

PC4G pile cap has been found with Thermal cracks

Site QAQC

Thermal Crack due to temp

As per Prof.Dias report. Epox resin
Details needs to be ensured as per Prof.Dias
difference between core and
pressure grout on crack and other
report
surface exceeded. Prof.Dias report measures

OCPPL Site Exec.

Open

Design

Concrete

PC4K - Tower01

OCPPL

PC4K pile cap has been found with Thermal cracks

Site QAQC

Thermal Crack due to temp

As per Prof.Dias report. Epox resin
Details needs to be ensured as per Prof.Dias
difference between core and
pressure grout on crack and other
report
surface exceeded. Prof.Dias report measures

OCPPL Site Exec.

Open

New
NC - 36/ RNC
-025

7/25/2016 Major

New

Document closed on 05/08/16