VENDOR APPROVAL COMPLIANCE SHEET

PROJECT: MAKER MAXITY ALLIANCE JOB NO : 91008 SUBMITTAL NO : 91008-MAP-FAC-TDS-025

CLIENT: THE INDIAN FILM COMBINE PVT.LTD MAIN CONTRACTOR : LEIGHTON INDIA CONTRACTORS PVT.LTD DATE : 12/07/2017

CONSULTANT: ARUP INDIA PVT.LTD & AGP SUB CONTRACTOR : MERO ASIA PACIFIC PTE.LTD

REV.1 VENDOR APPROVAL FOR GFRC ( KAIVALYA ARCH PVT.LTD ) - RE - SUBMISSION & APPROVAL

COMPLIANCE TO COMMENTS ON REV.0 VENDOR APPROVAL

NO VENDOR APPROVAL COMMENTS ( BY ARUP & AGP ) MERO ASIA PACIFIC PTE LTD ACTION
1. PLEASE PROVIDE THE TRACKLIST OF PROJECTS WITH GFRC
1. ATTACHED GFRC PROJECTS TRACK LIST. ( PAGE : 4-5 )
SCOPE AND THE COVERED
2. SAMPLES SUBMITTED TO LEIGHTON AND APPROVED ( MAS No : 91008-MAP-FAC-TDS-025, Date :
1 2. TO PROVIDE THE FINSIH SAMPLES TO ARCHITECT FOR REVIEW
16/06/2017 ).
3. TO UPDATE THE ITP WITH NECESSARY QAQC TESTS AND
3. ATTACHED ITP. ( PAGE : 6-16)
THEIR FREQUENCY ETC AS PER MNL-130 & MNL-128
TRACK LIST OF PROJECTS
DEALS DONE
v Managing Director Ar. Sanjay Chitnis in 2005-2006 as partner of M/S Saurabh Developers
Successfully completed GRC installation (Shop drwgs, mould checking), roof tilling, granite and
marble moulding and fixing, hard land scape for M/S TAISEI CORPORATION at Djibouti Palace
resort
Which motivated our M.D to establish new private limited export oriented company M/S KAPL.
Director also completed many prestigious projects in India, Eritrea, Sudan, Qatar, Kenya as
ARCHITECT.
v Safari Club At Djibouti Palace-Italian Marble Turn key work with supply of material and
Installation
v TAISEI Corporation Djibouti Hotel Project with manufacturing, supply & installation of GRC and
also other jobs like fixing of Ceramic tiles, Danto bricks & Italian Marble etc. (Rs.1,30,00,000/-)
v HOMAN ENGINEERING Company JV SOPRIM Construction at Djibouti with manufacturing,
supply and installation of GRP for Executive villas.
v Hotel Sai International at Sangli with manufacturing, supply and installation of GRC lamp post
with GRC lamps. (Rs. 14,00,000/-)
v Hotel Emerald at Chinchwad (MIDC) with manufacturing, supply & installation of GRC grills.
v GRC Ceiling of temple for Reliance Eneregy, Dahanu. (Rs.41,00,000/-)
v GRC Coconut fruit counter for Masala Restaurant, Powai.
v GRC Pyramid cladding for Pawn Dham, Kandivli (Rs.18,00,000/-)
v GRC Ceiling & GRC doors for Swami Samarth Temple, Badalapur
v GRC zarokas, arches & decorative panels, borders for Amanora Mall project, Magarpatta, pune
v GRC korianthian 20 ft height and 2 ft diamtr coloumns, capital, cornices for
MOCCB School,dhanori, pune (42,00,000/-)
v Free standing grc 2 nos domes at bhayander for gautam estate
Size-dim-16 ht-8 thkness 25mm without steel framimg and reinforcement
v GRC cornices & arches for Hiranandani club house project, Powai
v GRG ceiling for Jeevan Vidya Mission Project at Karjat
v GRC 16 single piece carved logo for Central Railways
v GRC cornices for sharad krushi bhavan,kudal (Rs.52,00,000/-)
v GRC Column cladding, decorative elements, ceiling, temple Ghumat At Narayan Mandir, Asoli,
Sindhudurg
v Entrance Cupola for Taj Vivanta, Guwahati first of its kind. Contractors: Shapoorji and Pallonji.
(Contract Value Rs.72,52,900/-).
v Designer Columns, capitals and bases at Prakruti Resort, Kashid
v GRC custom faade for KBS group project in Andheri. By JTCPL architects.
v GRC Screens For NESCO Exhibition centre, Goregaon. (By Arch Interiors Pvt. Ltd.)
v GRC Screen and decorative panels along with granite cladding at W54, Matunga. Wadhwa
Group. Architect Hafees Contractor. (Rs.50,60,000/-)
v GRC designer Columns for MARRIOTT Indore by PIA designers, Hong Kong.

Work in Hand
- Reserve Bank of India Holiday homes in Lonavala For Parelkar & Dallas Architects
- Maker Maxcity MERO- BKC.
- NUDE Architecture Nuru Karim prayer hall in Oshiwara.
- Designing and building of our 1st in-house housing project, using 350 unique existing moulds
in an eclectic style at a 5.4 acre site in dapoli

Ar.Sanjay Chitnis
M.D
M/S Kaivalya Arch Pvt. Ltd.
INSPECTION & TEST PLAN

INSPECTION AND TESTING

PROCESS OF MANUFACTURING

Interaction of Processes

Receiving Raw
Materials



Raw Materials Inspection as per Quality Plan





If OK sends for stock If rejected send back to
(Maintaining Stock Register) suppliers



Fitting Issue for Production


Molding as per
Final Checking
requirement


Packaging Casting Process



If found OK ready for
Curing Process
dispatch



Finishing

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ITP (INTERNAL TEST PLAN)

PROJECT- Gfrc Works At Maker Maxity, BKC.

CLIENT- Maker Maxity
CONSULTANTARUP
MAIN CONTRACTORLEIGHTON / MERO
GFRC CONTRACTOR- Kaivalya Arch Pvt. Ltd.

REFERENCE TECH SPECSECTION-034900

PCI MANUAL 130: Manual for quality control for plants and production of Glass
Fiber Reinforced Concrete products.
PRE PRODUCTION TESTS

1. SLURRY CONSISTANCY SLUMP TEST:

Every week test, prior to production start, minimum 3 readings refer attached test
procedure.

2. DETERMINATION OF SLURRY FLOW RATE-BUCKET TEST

Every week, prior to production, refer attached test procedure.

3. DETERMINATION OF GLASS FIBRE CHOPPING RATE-THE BAG TEST

Every week prior to start. Refer attached test procedure test

4. DETERMINATION OF WET DENSITY

Every week prior to start, refer attached test procedure.

5. FLXURAL STRENGTH (BENDING STRENGTH), TEST, DETERMINATION OF

L.O.P. and M.O.R. VALUES.
As per requirements of tech specs 034900, refer clause, i-1c, i-1d,
L.O.P---5-8 M.P.A, M.O.R---10-14 MPA. BY HAND CAST-PREMIX OPERATION.
These tests are carried by independent third party labs.

6. DETERMINATION OF DRY BULK DENSITY AND ABSORPTION

As per requirements of TECH SPEC 034900, refer test procedure.

7. RAW MATERIAL TESTING

Basic raw materials like white cement, silica sand, alkali resistant glass fibre are not
tested at in house Lab. mill test certificates and raw material test certificates by
suppliers are maintained in line with incoming supply.

Following tests are not conducted, even though procedures are part of this ITP:
---Shear Strength and Anchor Pull Off-By Third Party Lab
---Face Coat Absorption Test and Bulk Density Test.

INSPECTION

Necessity for Inspection

To ensure that proper methods of all phases of production are being followed and
the finished product complies with specified requirements, inspection per- sonnel
and a regular program of inspecting all aspects of production shall be provided in all
plants. Inspectors shall be responsible for the monitoring of quality only and shall
not be responsible for or primarily concerned with production.

Every effort toward cooperation shall be observed be- tween production personnel
who are responsible for quantity and quality and inspection personnel who are
responsible for observing and monitoring quality.

Scope of Inspection

To establish evidence of proper manufacture and quality of GFRC products, a

system of records shall be used in each plant. The system of records shall provide
full information regarding the materials, proportioning, spraying, curing, inspection
of finished products, member dimensions, and GFRC strength.

In general, the scope for quality control inspections to be performed in GFRC plants
shall include, but not necessarily be limited to, the following:

1. Inspection of raw materials and embeds required for acceptance prior to

spray-up and daily check testing for quality maintenance.!

2. Providing and checking conformity of mix designs for all face mixes and
required ingredients for concrete testing. !

3. Inspection of molds and new setup changes prior to spray-up.

4. Checking of blockout positioning, sealing strips, rustication

5. strips, cast-in items, positioning of panel frames or integral ribs, and any
other critical tolerance items, as well as the proper securing of those items
during placement of GFRC. !

6. Checking of molds and appurtenances for adequate maintenance by

verification of tightness, dimensions, and overall general quality. !

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7. Inspection of batching, mixing, conveying, placing, spraying, compacting,
curing, and finishing of concrete facing and GFRC backing. !
8. Daily inspection of stripping product from the mold!

9. Monitoring of plant, equipment, working conditions, weather, and other

items affecting production. !

10. Preparation of test boards for GFRC testing both wet and after curing,
including fiber content, unit weight, flexural strength tests, bulk density tests.!

11. Inspection of finish to make sure that the product matches the standard
established by the approved project mockup or sample in color, texture, and
uniformity. Finish defects, cracking, and other problems shall be reported
and a decision made as to acceptance, repairs, or manufacturing change.
Units that are damaged shall be recorded and marked. !

12. Check of finished product against approved shop drawings and approved
samples to ensure that proper finishes are on all required areas, product
measurements are correct, cast-in items are correctly located, panel is
properly identified and marked, and all measurements are within allowable
tolerances. !

13. Monitoring of storage area for proper blocking, methods for prevention of
chipping, warping, cracking, contamination, or blocking stains and any other
items that may adversely affect the quality of the product. !

14. Inspection of product during loading for proper blocking and to detect
stains, chips, cracks, warpage, or other defects. !

15. Inspection of products following any repair. !

16. Disposal of nonconforming products. !

Testing

- Cement MTC
- Glass Fibre MTC
- Compressive test
- Flexural test
- MOR
- Physical / Practical testing for custom items.
- Sand bag impact test, if required.

Project Specific Inspection:

- Make sure all screws are sealed properly

- Filling of screw holes is done properly such that from the outside one cannot
make out where the screwing has been done,
- Finishing done to such that the piece appears seamless.
- All gaps are maintained within tolerances.
- All groves in Panels are maintained within tolerance.

Product Tolerances

During the pre- and post-spray-up check of dimen- sions, the inspector shall have
access to the approved shop drawings for reference. Discrepancies shall be noted
on the post-spray-up record and transmitted to management or engineering for
their evaluation.

GFRC panels shall be fabricated within tolerances shown in Fig. 6.3(a).

Figure 6.3(a) Tolerance locations

a. Overall height and width of units measured at the !face adjacent to the
mold:!1. 10 ft (3 m) or under ......... 1/8 in. (3 mm) 2. 10 ft (3 m) and
over ......... 1/8 in. per 10 ft !(3 mm per 3 m); 1/4 in. (6 mm) maximum !
b. Edge return ...+1/2 in., 0 in., (+13 mm, 0 mm) !
c. Thickness:
d. Architectural face mix thickness +1/8 in., 0 in. !(+3 mm, 0 mm) !
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e. GFRC backing ................... +1/4 in., 0 in. !(+6 mm, 0 mm) !
f. Panel depth from face of skin to back of panel frame or integral rib ...
+3/8 in., 1/4 in. !(+10 mm, 6 mm) !
g. Angular variation of plane of side mold .....1/32 in. per 3 in. (1 mm per
75 mm) depth or 1/16 in. (2 mm) total, whichever is greater. !
h. Variation from square or designated skew (differ- ence in length of two
diagonal measurements) .....1/8 in.per6ft(3mmper2m)or1/4 in.(6mm)
total, whichever is greater. !
i. Local smoothness .....1/4 in. per 10 ft!(6 mm per 3 m) !
j. Bowing: Bowing shall not exceed L/240 unless it can be shown that the
member can meet erection tolerances using connection adjustments. !
k. Length and width of blockouts and openings with- in one unit
..................... 1/4 in. (6 mm) !
l. Location of window opening within panel ......................................1/4
in. (6 mm) !

m. Warpage: Maximum permissible warpage of one corner out of the

plane of the other three shall be 1/16 in. per ft (5 mm per m) of
distance from the nearest adjacent corner, unless it can be shown
that the member can meet erection tolerances us- ing connection
adjustments. !

n. Position of integral items

a. Panel frame and track ......... 1/4 in. (6 mm) !

b. Flashing reglets at edge of !panel ............................ 1/4 in.

(6 mm) !

c. Inserts .......................... 1/2 in. (12 mm) !

d. Special handling devices .... 3 in. (75 mm) !

o. 5. Locations of bearings devices .. 1/4 in. (6 mm) 6. Blockouts

..................... 3/8 in. (10 mm) !

p. Panel frames shall be fabricated within the following tolerances

shown in Fig. 6.3(b). !

q.
r. l1. Vertical and horizontal alignment ............................1/4 in. in 10 ft
(6 mm in 3 m) !

s. l2. Spacing of framing members ........................................ 3/8 in.

(10 mm) !

t. l3. Squareness of frame (difference in diagonals)

............................................ 3/8 in. (10 mm) !

u. l4. Overall size of frame .............3/8 in. (10mm) !

7

Delivery, storage, and handling

A. Handle and transport GFRC panels to avoid damage.

1. Place nonstaining resilient spacers between panels.
2. Support panels on nonstaining material during shipment.
3. Protect panels from dirt and damage during handling and transport.
B. Store GFRC panels to protect from contact with soil, staining, and physical
damage.
1. Store panels with nonstaining resilient supports in same positions as
when transported.
2. Store panels on firm, level, and smooth surfaces.
3. Place stored panels so identification marks are clearly visible.

Erection tolerances

Tolerances below are PCI MNL 130 recommendations.

A. Erect GFRC panels to comply with the following noncumulative tolerances:

1. Plan Location from Building Grid Datum: Plus or minus 1/2 inch (13
mm).
2. Top Elevation from Nominal Top Elevation: As follows:
a. Exposed Individual Panel: Plus or minus 1/4 inch (6 mm).
b. Nonexposed Individual Panel: Plus or minus 1/2 inch (13 mm).
c. Exposed Panel relative to Adjacent Panel: 1/4 inch (6 mm).
d. Nonexposed Panel relative to Adjacent Panel: 1/2 inch (13 mm).
3. Support Elevation from Nominal Elevation: As follows:
a. Maximum Low: 1/2 inch (13 mm).
b. Maximum High: 1/4 inch (6 mm).
4. Maximum Plumb Variation over the Lesser of Height of Structure or 100
Feet (30 m): 1 inch (25 mm).
5. Plumb in Any 10 Feet (3 m) of Element Height: 1/4 inch (6 mm).
6. Maximum Jog in Alignment of Matching Edges: 1/4 inch (6 mm).
7. Maximum Jog in Alignment of Matching Faces: 1/4 inch (6 mm).
8. Face Width of Joint: As follows (governs over joint taper):
a. Panel Dimension 20 Feet (6 m) or Less: Plus or minus 1/4 inch (6
mm).
b. Panel Dimension More Than 20 Feet (6 m): Plus or minus 3/8 inch
(10 mm).

9. Maximum Joint Taper: 3/8 inch (10 mm).

10. Joint Taper in 10 Feet (3 m): 1/4 inch (6 mm).
11. Differential Bowing, as Erected, between Adjacent Members of Same
Design: 1/4 inch
(6 mm).

Repairs

Production blemishes are generally corrected at manufacturer's plant. Blemishes

occurring after delivery are normally repaired before final joint cleaning and sealing.

A. Repairs will be permitted provided structural adequacy of GFRC panel and

appearance are not impaired, as approved by Architect.
B. Mix patching materials and repair GFRC so cured patches blend with color,
texture, and uniformity of adjacent exposed surfaces.
D. Wire brush, clean, and paint accessible weld areas on prime-painted
components with same type of shop primer.

QUALITY GUIDE LINES : PRODUCT DEFECTS.

FOLLOWING DEFECTSIF OBSERVED NEED TO BE CORRECTED
PRIOR TO DISPATCH.

1 Ragged or Irregular edges.

2 Excessive air voids evident on exposed surfaces.

3 Lines caused by improper placement of Facemix.

4 Visible Mould Joints or Irregular Surfaces.

5 Stains on exposed surface.

6 Exposed GlassFibres or exposed anchors or embedments through

the Facemix.

7 Embedded foreign material on Face.

8 Visible Repairs at the 10ft and20ft viewing distance.

9 Shadow lines

10 Visible Cracks at 10 ftviewing distance.

10