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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
INTRODUCTION
CODE COMPLIANCE
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
INTRODUCTION :
M/s Sentini Santiaryware Private Limited has constructed a sanitary ware factory developed at Amberpeta Village,
Bhimadole Mandal, West Godavari district, Andhra Pradesh, India to facilitate their manufacturing business of sanitary
wares. The factory has been constructed in the location due the availability of the raw material locally. The entire
factory has different types of building based on the process of the manufacturing. The buildings have been
constructed basically with PEB structures and cast in situ reinforcement concrete. The construction has commenced
in the year 2015 and the factory is currently in the testing phase.
M/s LIXIL intends to buy the factory and has plans for expansion for higher capacity of the manufacture. M/s KPMG
has been assisting the entire transaction between both organisation. M/s Ramboll India Private Limited has been
appointed as the structural engineering consultant to provide the technical due diligence of the factory for the civil and
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
The different buildings and their structural configuration has been provided in the list below.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
Cast in situ RCC Structure with RCC
10 Canteen Block Completed, Commissioned and in operation.
foundation, Column, Tie beam, Beam & Slab
Cast in situ RCC Structure with RCC
11 R.O Plant Completed, Commissioned and in operation.
foundation.
Cast in situ RCC walls with RCC foundation.
12 ETP and STP Completed, Commissioned and in operation.
Cast in situ RCC Structure with RCC
13 LPG Yard foundation for LPG Bullet tanks. Completed, Commissioned and in operation.
The total built-up area of all the buildings shall be around 48000 sq. m. The buildings have additional tanks, machine
foundations for the ball mill, blungers. The length and breadth of the buildings vary for each building with maximum of
198m X 72m for the ware house building. The site slopes naturally for 3m from north to south direction from natural
ground level of 98.50m to 95.50m. The site slopes gradually for 1.5m from east to west direction from natural ground
level of 98.0m to 96.5m. The soil report provided by Dr. D.Baburao recommends having foundation placed at 2m
depth from the natural ground level which has 30T/sq. m as safe bearing capacity of the soil.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
RAMBOLL INDIA PRIVATE LIMITED – INTRODUCTION
Ramboll is a leading engineering, design and consultancy company founded in Denmark in 1945. We employ 13,000
experts and have a strong presence in the Nordics, North America, the UK, Continental Europe, Middle East and
India, supplemented by a significant representation in Asia, Australia, South America and Sub-Saharan Africa. With
almost 300 offices in 35 countries, we emphasise local experience combined with a global knowledge-base. We
constantly strive to achieve inspiring and exacting solutions that make a genuine difference to our customers, end-
users and society as a whole. Ramboll works across the markets: Buildings, Transport, Planning & Urban Design,
Water, Environment & Health, Energy, Oil & Gas and Management Consulting.
Ramboll India Private Limited is part of Ramboll Middle East Asia (MEA) and has about 800+ experts with offices at
Gurgaon, Mumbai, Bengaluru, Hyderabad and Chennai. Ramboll India has designed industrial complexes such as
Scania Bangalore, Embassy Industrial Park in Pune, etc. They have also undertaken structural due diligence for
properties for acquisition, such as for Ingredion, USA and Virtuous Retail.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
CONTOUR PLAN , SOIL REPORT AND IMPLICATIONS
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
The site is sloping naturally for 3m from north side to south side from the Reduced Levels of 98.5 to 95.5 and the site
slopes gradually from reduced levels 98.0 to 96.5 from east side to south side. The formed ground level of the internal
road and for buildings has been taken as reduced level of 99.0. Hence there has been fill of 2.5m to 3.5m done for the
buildings at the rear end of the site. The soil report provided by Dr. D. Baburao recommends the SBC of 30t/sq.m at
2m from these natural ground levels. The structural DBR provided by M/s R.S.Consultants and the con call
confirmation by them have taken the SBC on the conservative side of 12 t/sq.m to 18 t/sq.m at 1.5m from NGL. There
are two level of tie beams provided at the foundation level and plinth level to take care of additional fill of 2 to 2.5m.
The footings of the clay washing area and LPG yard are placed at 94.0 level which is 1.5 m from the natural ground
level of 95.50. The formed ground level at this area is 99.0 level and there are two tie beams each at 95.5 level and
99.0 level provided. These beams are in filled with 230mm thick brick work, to resist the fill inside and provide
consolidation.
Please do find with the listed table where the formed ground level, natural ground level, footing bottom level and the
difference from the plinth is provided. The foundations of any blocks are not resting on the filled up soil, but grounded
1.5m or 2m from the existing natural ground level.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
DIFFERENCE OF
NATURAL GROUND FORMED GROUND FOOTING BOTTOM
Sl.No NAME OF THE BUILDING LEVEL FROM FTG REMARKS
LEVEL IN M LEVEL IN M LEVEL IN M
TO NGL IN M
Footing provided at 2.0m from
1 Ware house 97.00 99.00 95.00 2.00 the NGL as per the soil report
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
CODE COMPLIANCE STATEMENT FOR STRUCTURAL DESIGN
S.
STANDARDS & CODES DESCRIPTION COMPLIED
NO.
1. National Building Code of India (NBC) - 2005 All the structural sizing , loading and structural system
2. IS 456 :2000 All the structural design involving the concrete, materials and expansion joint provision
3. IS 800 :2007 All the structural design involving the MS or Structural steel , materials.
4. IS 875 : 1987 (Part 1 to 5) All the Design loads are as the codal provisions
6. IS 2974 : Part 1 to 5 All the machine foundation design for the equipment
7. IS 3370 : Part 1 to 4 All the liquid retaining structures either underground or over head
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
S. NO. STANDARDS & CODES DESCRIPTION COMPLIED
8. IS 1904 :1986 All the raft foundation, individual footing and combined footing designs.
11 IS 875 (Part 5) & IS 1893 :2002 The load combination for the earthquake loads
The design and analysis of all the buildings are in compliance with the IS Codes and statuary norms. The drawings
provided were checked with the analysis files provided. The manual review of the buildings was done in absence of
the analysis files from the client. Please find with the listed the compliance statement as whole for the each building.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
DESIGN AND ANALYSIS COMPLIANCE STATEMENT
ANALYSIS DESIGN
Sl.No NAME OF THE BUILDING REMARKS
COMPLIANCE COMPLIANCE
The building is compliant with both analysis and design for intended
1 Ware house
loads as provided in DBR.
The building is compliant with both analysis and design for intended
2 Shuttle Kiln
loads as provided in DBR.
The building is compliant with both analysis and design for intended loads as
3 Glaze house provided in DBR. The slip tank at mezzanine floor needs to be reviewed
The building is compliant with both analysis and design for intended
4 Clay wash Building
loads as provided in DBR.
The building is compliant with both analysis and design for intended
5 Casting Hall
loads as provided in DBR.
The building is compliant with both analysis and design for intended
6 Substation
loads as provided in DBR.
The building is compliant with both analysis and design for intended
7 Store and Workshop
loads as provided in DBR.
The building is compliant with both analysis and design for intended
8 Admin Building
loads as provided in DBR.
The building is compliant with both analysis and design for intended
9 Toilet Block
loads as provided in DBR.
The building is compliant with both analysis and design for intended
10 Canteen Block
loads as provided in DBR.
The building is compliant with both analysis and design for intended
11 R.O Plant
loads as provided in DBR.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
The tanks are designed for the intended loads and are compliant with
12 ETP and STP
design and analysis.
The LPG yard flooring and dyke wall details are not executed as
13 LPG Yard
per the drawings provided.
The flooring of the LPG yard and dyke walls has not been executed as per the drawings issued as
GFC to the site. The LPG Bullet tanks are rested on the RCC wall with foundations at 94.0 Level. The
area then has been filled for achieving the formed ground level of 99.0. The flooring has been done
with no proper compaction, gravel soling instead of plain cement concrete and then cement mortar to
have clean floor finish, in place of RCC grade slab. There has been subsidence of the flooring
noticed for about 150 mm to 225mm. The soil in this site is rich in the sodium nitrate and becomes
slush once it comes in contact with the moisture. The heavy rains in the recent monsoon has made
this soil beneath the flooring slushy and caused subsidence. The RCC wall with the foundation was
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
found intact. There is proposal of the piped gas being brought as the alternative fuel, as these LPG
Bullet tanks are the primary source of fuel to the operation of the factory. Any corrective action to
relay the flooring as per the GFC drawings issued for the hard floor, dyke wall can be taken once the
alternative fuel is in operation.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
2.SLIP TANKS ON THE MEZZANINE FLOOR :
There are circular tanks of 4.5 m dia and 2.9 m height is placed on the RCC slab on mezzanine floor.
The confirmation of the loading from the structural consultant for the design of the slab during the con
call was for 1200 kg /sq.m floor loading, though it was mentioned as 750 kg/sq.m in the structural
DBR provided. The specific gravity of the slip is 1.6-1.8 g/cc. Hence the density of the slip shall be
1800 kg/cu.m. The slab , beam size and reinforcement provided in the GFC drawings suffices the
1200 kg/sq.m. This implies the height of the slip inside the tank shall not exceed 0.67m out of 2.90m
and maximum of 1m if we take into account the loading factor of 1.5 used in the design. In the event
of the slip inside the tank more than 0.67m, the load due to the tanks to the slab shall exceed the
design capacity of the slab. The columns, beams and slabs in this area need to be retrofitted for the
additional loading. The loading is expected to be more than 2.5 times if we consider the height of the
slip at 2.5m inside these tanks.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
3. CONSTRUCTION ISSUES – EXECUTION FLAWS :
The construction has been done from the team from M/s Sentini. There are lot of issues in terms of
the quality of the construction. The common problems noticed at the site are
1. The improper treatment of the expansion joint, where either the expansion is covered with
external plaster between two columns or the expansion joint gap is provided 25mm to 50mm
more than the expansion joint 50mm required.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
2. The column starting from the starters (adjacent to the PEB steel columns) were out of plumb by more than
3. There were lot of honey combing issues noticed which could have caused during to excess vibration during
concreting leading to bleeding of concrete and expose of coarse aggregate and reinforcement in some places.
4. The raw material storage RCC walls were not in alignment either horizontal or vertical. Though this would not
affect the internal RC walls, the external wall needs to finished with uniform thickness and cannot be just
plastered.
5. There were issues of the proper shuttering line dimension tolerances not maintained resulting in either local
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
COST ESTIMATE FOR THE RETROFITTING
The cost of the retrofitting measures to be taken has been approximately calculated in INR and listed below.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
DESIGN EXECUTIVE SUMMARY AND CONCLUSION
1. The structural design of the all the buildings of the factory are found to be done in accordance with the codal
norms and statuary norms available. The building is found to safe and sound for the purpose for which it has been
built.
2. There is issue of subsidence observed in the LPG yard where the flooring has settled, as the GFC drawing details
was not followed and sub-standard engineering practice was executed. The soil in the site is rich is sodium nitrate
which become slushy when it comes in contact with moisture or water. The recent heavy rains during monsoon
has caused the soil beneath the flooring (done with coarse aggregate and cement mortar) to settle and the dyke
wall was also not constructed with RCC which could have retained the soil. Hence the entire flooring needs to be
redone, only after the alternate fuel of the piped gas is in operation. However, the RC wall with the foundation
supporting the LPG bullet tank is founded at 94.0 level and found to be intact. All the other footings of the
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
buildings are kept 1.5m or 2.0m from the natural existing ground level as per the soil report. The STP base slab is
rested on the natural ground level. The subsidence issue that has occurred in the LPG yard is localized and
doesn’t apply to the other buildings. The approximate cost to do the flooring of the LPG yard with the GFC
3. The slip tank in MS is loaded on the mezzanine floor which needs to restrict with the height of the slip inside the
tank to 0.67m to 1m of 2.9m total height to ensure it is within the designed capacity of 1200 kg/sq.m. The slab,
column and beams supporting the slip tank shall need to be retrofitted, if the height of the slip would be more than
1m. The retrofitting of the slab, beam and columns (if required footing) shall be around INR 8 million.
4.There are issues in the construction which would not affect the stability of the structure, but shall need some
repair works for the expansion joint between columns, local bulging of the column, beam or slab, honey combing
observed in the columns and plumb issues both horizontal and vertical for the RCC walls in the raw material storage
area. The approximate estimated cost for this corrective measure is about INR 1 million.
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
ANNEXURE 1
INPUT DATA
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DD- SENTINI-STR-FINAL DRAFT REPORT- C01
Q03-QUICK PROJECT WORK PLAN
cal\Temp\Temp1_LPG Yard
74 LPG Yard Anx-5 (Glode gas) YES-DWGS PDF 10/24/2017 E CLIENT 17 DETAIL OF HARDSTAND
Anx-5.zip\LPG Yard Anx-
cal\Temp\Temp1_LPG Yard
75 LPG Yard Anx-5 (Glode gas) YES-DWGS PDF 10/24/2017 E CLIENT 19 CHAIN LINK FENCING
Anx-5.zip\LPG Yard Anx-
cal\Temp\Temp1_LPG Yard
76 LPG Yard Anx-5 (Glode gas) YES-DWGS PDF 10/24/2017 E CLIENT 20 MAIN GATE
Anx-5.zip\LPG Yard Anx-
cal\Temp\Temp1_LPG Yard
77 LPG Yard Anx-5 (Glode gas) YES-DWGS PDF 10/24/2017 E CLIENT 21 EMERGENCY GATE
Anx-5.zip\LPG Yard Anx-
cal\Temp\Temp1_LPG Yard
78 LPG Yard Anx-5 (Glode gas) YES-DWGS CAD 10/24/2017 E CLIENT INSTALLATION LAYOUT
Anx-5.zip\LPG Yard Anx-