Technical Training

Manual

INDEX

1. Technical Training Calendar for Year 2008-09 2. Flow Chart of Training & Training Effectiveness

3. Formwork

4. Concrete Technology

5. Project Operations- S Cadre

6. Introduction to Contracts

7. Introduction to Project Management

8. QA/QC on site

9. Safety in Civil Construction

10. Introduction to PMV Works on Site

11. Enterprise Resource Planning (ERP)

12. Quality Management System (QMS)

13. Finishes

14. Contract Management

15. Project Operation- E Cadre

16. Design and Build

Flow chart for Technical Training The Technical Training has been divided into two Cadres- S and E. Step 1: At the beginning of the financial year the schedule for the training is sent to all GM’s and the HR heads in the regions. Care is taken to see that only one training is conducted in a region per month. Step 2: The master trainer list is sent to all regions along with a request to choose the regional trainers. The regional trainers in future will take over from the master trainers and conduct training for their respective regions. The presentation for the training module will be prepared by the Master Trainer which will remain as standard across regions. Step 3: At the beginning of each month a mail is sent out from the HO Technical Training department reminding them of the training to be conducted in the region for that month. Consent is also taken from the GM regarding the training. Step 4: The participant list is sent by the RO to the HO for information. Step 5: The training is conducted on the date as agreed by the RO. After the training is over feedback is taken from the participants. A short test is conducted by the trainer to assess the comprehension of the training. Step 6: The feedback form, test papers are sent to the HO by the RO. The data on the same is compiled at the HO and records are maintained. Step 7: Three months after the training is conducted a training effectiveness form is sent to the RO to be forwarded to the superior of the participant. The form tries to capture the improvement of the individual on site after training. The forms are compiled in the HO and a report goes out to the region giving them a complete insight into the training

Formwork Duration: The training session is for 2 days with 3 workshops. Eligibility: The training is for site engineers. The participants will

be essentially S & E Cadre people who are on Project Sites.

Key Features:

1. Requisites of a good formwork system on site and implication on

Quality. 2. Knowledge of formwork systems and its components being used in

the organization. 3. The quality requirements of formwork.

4. An Introduction to formwork design, planning & practical

implementation.

5. Workshop on preparing scheme drawings and Material Quantification.

6. Understanding of Shuttering Usage Ratio and Labor Productivity.

7. Costing of formwork –Material Cost, System and consumable

concept, impact of extended stay on cost of material on site. 8. Good housekeeping & storage practices to reduce wastage cost. 9. Safe practices in Formwork.

10. Case Studies involving minimum cycle time & challenging designs.

The training is followed by an assessment test.

Curriculum: 1. Introduction (a) What is formwork? (b) Requirements of good formwork

(c) Materials used in Formwork (d) Factors to be considered in design

2. Timber Formwork

(a) Components of Timber Formwork (b) Design of formwork for footings (c) Design for Columns (d) Design for Walls (e) Design for beam sides / bottoms (f) Design for slab soffits

3. Proprietary systems for staging / formwork

(a) Props and Acrow spans (i) Design for beam bottom (ii) Design for slab soffits

(b) H-frames (i) Design for beam bottoms (ii) Design for slab soffits

(c) Cup lock system (i) Design for beam bottoms (ii) Design for slab soffits

(d) DOKA System (i) For columns and walls (ii) For beams and slabs

4. Formwork for other elements

(a) Staircases (b) Circular columns (c) Precast elements – Kerbs, lintels (d) Cantilever slabs /beams (e) Waffle slabs

5. Introduction to special formwork (a) MIVAN Tunnel system (b) Slipforming (c) Domes (d) Tableform system

6. Quality Requirements

(a) Checking line, level, plumb and finish in footings, columns, walls, beams, slabs

(b) Corrective measures (c) Special care for water tight structures, pumping

7. Deshuttering

(a) Deshuttering period for various elements (b) Sequence of deshuttering of slab soffits

8. Planning of Formwork

(a) Understanding of cycle time and repetitions (b) Wall beams and slabs

9. Productivity

(a) Understanding shuttering usage Ratio, Labour productivity (b) Measures to increase productivity

10. Introduction to costing

(a) Concept of depreciation (b) Elements of costing of formwork – labour, materials, plant,

etc. (c) How the tender direct cost is worked out

11. Care of Formwork

(a) Care in storage (b) Care in handling especially during deshuttering (c) Reconciliation of materials

12. Safety (a) Shoring in unsafe excavation (c) Use of PPE – helmets, gloves, safety shoes, safety harness,

nets (d) Precautions when working at heights (e) Provision of access – staircases, platforms, gangways

13. Case Studies

(a) One where min. cycle time was achieved (b) On involving design challenge.

14. Discussions & lessons learnt 15. IN THE SITE:

(a) Demonstration of erection of columns shuttering Demonstration of deshuttering of slab

Concrete Technology Duration: The training session is of 1.5 days. Eligibility: The training is for site engineers in the S Cadre who

are in core execution. Key Features:

1. Constituents of concrete like different types of cement, Additives, different properties & requirements of concrete as per IS Codes.

2. Complete idea of IS Code for mix Design of Concrete and how

higher durability and strength can be obtained through it.

3. Safe handling & Pouring of concrete on various surfaces. An in-depth knowledge of how Quality is achieved and how testing of concrete is done.

4. Control of wastages in cement, sand, aggregates which affect the

costing of the project.

Case Studies of high and large pours are discussed.

The training is followed by an assessment test. Curriculum: 1) Concrete

(a) Constituents of concrete (b) Introduction to different types of cement (c) Introduction to additives (d) Properties and requirements of concrete (As per IS)

- Durability - Workability - Density

2) Mix design for concrete (a) Introduction to design of mix (b) Effect of variation in constituents (c) Design for waterproof concrete (d) Fly Ash concrete (e) Temperature controlled concrete

3) Mixing of concrete

(a) In Mixers (b) Using mini batching plants (c) Batching plants

4) Transport and placing of concrete

(a) Using wheel barrows, mini dumpers (b) Transit mixers (c) Pouring in : i) Foundation and rafts ii) Columns and walls iii) Beams and slabs (d) Arrangements for large pours (>100 M3 or 5 hours)

5) Consolidation and finish (a) Use of vibrators (b) Effects of over and under vibration (c) Finishing of concrete

6) Concrete in Floor Finishes

(a) IPS Flooring (b) VDF Flooring

7) Quality Assurance

(a) Cube Test for compressive strength (b) Slump tests (c) Other tests

i) Cores ii) NDT iii) Ultrasound iv) Hammer rebound

8) Post Concrete (a) Curing

i) vertical surfaces like columns, walls ii) horizontal surfaces like slabs, footings

(b) Rectification i) Minor honeycombing ii) Major honeycombing iii) Grouting iv) Bulging v) Leakage in water retaining structures/slabs

9) Productivity

(a) Productivity expected from batching plants (b) Labour productivity – manual and pumped concrete (c) Measures to increase productivity

10) Introduction to costing

(a) Elements in the cost – labour, materials, plant i) The cost of batching plant / pump / crane

(b) How the tender direct cost is worked out (c) Cost control

i) Reducing wastage ii) Cost of rework / rectification

11) Safety (a) Use of PPE (b) Precaution when working at Heights

12) Housekeeping and maintenance

(a) Cleaning excess concrete (b) Keeping floors clean (c) Cleaning of mixer drums (d) Cleaning of pump & pipeline

13) Case Studies

(a) One involving a large pour and high rate of pouring (b) One involving innovative placing technique

Discussions & Lessons learnt

Project Operations- S Cadre Duration: The training session is of one day duration. Eligibility: The people who should be selected for this training

should be from all across S-Cadre inclusive of Planning, Billing and core site execution.

Key Features:

1. Image Management – How to put up a site office 2. Site Execution from excavation to formwork, reinforcement, &

concrete and Finishes.

3. Quality Plan & Control over Quality.

4. Handling of Equipment.

5. Safety

6. Planning- for material, manpower & resources.

7. Function of Stores & how material are handled.

8. Cost Control & Wastage management.

9. Customer Relationship

The training is followed by an assessment test.

Curriculum: (A) SITE EXECUTION:

1. Formwork (a) Formwork systems for:

(i) Footings (ii) Columns (iii) Walls (iv) Beams and slabs

(b) Quality Requirements

(i) Checking line, level, plumb and finish in footings, columns, walls, beams and slabs

(ii) Special care for water light structures, pumping

(c) Deshuttering Deshuttering period for various Elements

(d) Planning of formwork

(i) Understanding cycle time and repetitions (ii) Understanding shuttering usage ratio, labour

productivity (e) Care of formwork (f) Safety in formwork

2. Reinforcement

(a) Detailing of reinforcement in: (i) Footings (ii) Columns (iii) Walls (iv) Beams (v) Slabs

(b) Quality Requirements (i) Checking dia size, spacing, cover and lap length

(c) Preparation of Bar bending schedules (d) Reinforcement Planning

(i) Labour Productivity (ii) Reconciliation of Steel (iii) Reducing wastage

3. Concrete (a) Properties and requirements (b) Introduction to Mix Design (c) Mixing of Concrete (d) Placing of concrete (e) Pouring of concrete in: (f) Consolidation (g) Quality Assurance (h) Post Concrete (I) Curing

4. Blockwork

(a) Testing of bricks and blocks (b) Preparation of Mortar (c) Execution (d) Quality checks

5. Finishes (a) Plastering

i) Difference bet internal and external plaster ii) Preparation prior to plastering iii) Execution iv) Quality checks

(b) Floor Finishes i) Cast in situ floor finishes – IPS & VDF ii) Tiling with ceramic, terrazzo, granite etc.

(c) Wall Finishes i) Wall tiling ii) Painting

6. Waterproofing

a) Tanking – membrane b) Basement waterproofing

c) Waterproofing in Toilets d) Roof Waterproofing

7. External works

(a) Roads

(B) QUALITY ASSURANCE / CONTROL 1. Quality Plan 2. Checklists for key activities 3. ISO procedures

(C) SAFETY

1. Safety plan 2. Use of Protective Personal Equipment 3. Safety measures

a) Deep excavation b) Working at heights c) Edge and opening protection d) Electrical e) Operation of crane, builders hoist

(D) PLANT

1. Earth moving / compacting machinery – JCB, Excavator, Vibro rollers, plate compactor

2. Concreting plant – Mixers, Batching Plant, Concrete Pumps, Vibrators

3. Reinforcements plant – Bar bending and cutting machinery 4. Material handling plant – Mini dumpers, Tower Cranes,

Mobile Cares and Hydra, Builders Hoists 5. Pumps – Dewatering and curing 6. Generators 7. Welding transforming and rectifier 8. Others – Drilling machines, Compressors and Jack hammers For all above i) Capacities and capability

ii) Guidelines for proper use iii) Care and maintenance

(E) PLANNING

1. Understanding the MSP Programme a) Weekly targets based on above

2. Preparation of Progress Reports a) Weekly b) Monthly (MIS Report) c) Client Reports

3. Resource Planning a) Lab our

i) Productivity of Carpenters, Fitters & Masons

ii) Requirements based on MCP

b) Materials i) Repetitions in Formwork, requirements as

per MCP ii) Delivery lead times for various materials

c) Staff i) Staff Productivity ii) Typical Site Organization Structure

d) PMV i) Plant requirement based on quantum of

work and MCP

4. Preparing Pre start Estimate a) Principles behind PSE b) Importance of PSE c) What is C2C ? d) C2C as a key control tool

(F) QUANTITY SURVEYING 1. Preparation of labour bills 2. Extra Items / variations

(G) STORES 1. Procedure for indenting materials

a) Local Purchases b) Purchases through RO / HO

2. Procedure for receiving and issue of materials a) DMR Register b) MIV c) MTV

3. Inspections carried out by stores 4. Debits to subcontractors 5. Demobilization 6. Housekeeping

Introduction to Contracts Duration: The training session is for 2 days. Eligibility: This training should be for people who are core civil

engineers (S Cadre & E Cadre) from sites and RO who need to understand what Contracts is.

Key Features:

1. An Idea of different types of Contracts and their features, and its making.

2. Awareness of the company’s Procedures (PSE, C2C, P&L).

3. Awareness of Preparation of Claims during the Contractual Period.

4. Maintenance of transparency with client & PMC.

5. Overcoming the Contractual difficulties w.r.t original contract.

6. Price Escalation during project duration and related claims.

The training is followed by an assessment test.

Curriculum: 1. Different types of Contracts

(a) Item Rate (b) Lumpsum (c) Cost plus

2. Contract Documents

(a) Invitation to Tender (b) Form of tender

(c) Annexure to Form of Tender (d) General Conditions (e) Special Conditions (f) BOQ (g) Technical Specifications (h) List of drawings (i) Tender correspondence (j) Letter of Intent (k) Contract Agreement

3. Important features in the Contract

(a) Completion Period (i) Mobilization Period (ii) Intermediate milestones

(b) Payment Terms (c) Mobilization Advance (d) Bonds and Guarantees

(i) For Mobilization Advance (ii) For Retention (iii) Performance Bond

(e) Retention (f) Liquidated Damages (g) Secured Advance (h) Insurance Requirements

(i) Contractors All Risk Policy (ii) Workmen compensation

(i) Escalation (j) Delay in completion (k) Handing over (l) Final Bill

4. Nominated Sub-Contracts 5. Preparation of RA Bills

(a) Read the Contract (b) Measurements to be preferably approved before submission (c) Recoveries (d) Follow up for Payment Certificate

6. Final Bill and Closure of Contract

(a) Work to be re-measured. Use RA Bill measurements (b) Claim maximum work done in pre-final bill (c) Ensure all claims and extra items are included (d) Comply with contract requirements respecialist guarantees

and As Built Drawings (e) Follow up rigorously for payment

7. Preparation of Claims

All contractual correspondence – letters, MOM’s., Approvals, transmittals to be meticulously filed. Also press clippings relating to inclement, weather, strikes, increase in prices to be maintained. Client’s letter should be replied immediately. (a) Extension of Time (b) Escalation (c) Damages caused by other agencies

Forward claim immediately after the incident (d) Idle labour due to holds / lack of fronts

8. Variations and Extra Items

(a) Inform Client in writing about variation / extra item (b) Submit cost and time implications. Use dayworks rates for

labour and PMV. Note that small jobs done after completion of main work require disproportionate supervision and productivity will be low. BOQ rates are not applicable for new work done after expiry of original completion date.

(c) Preferably execute variations / extra items only after rates for same are approved.

(d) Include complete list of variations / extra items / claims in each RA Bill.

(e) In Meetings, remind Client about approval and inform them about the effect on our Cash flow.

9. Preparation of PSE, C2C and P & L Statements

(a) PSE Statement

To be prepared within 45 days of award of contract. Great care to be taken as this is a very important document and is reviewed by top management as it has an impact on the Organizations profitability.

(b) C2C Statement

Prepared every quarter, this statement reflects the actual financial health of the project. It compares actual performance vis-à-vis PSE and also projects performance in the future.

(c) P & L Statement:

Prepared in conjunction with the Accounts department, this statement will report the current profitability of the project based on actual expenditure (payments made to labour, vendors, suppliers, staff salaries, etc. including provisions made for future payments). The statement will split expenditure on labour, plant, materials, sub contractors, etc. and give the cost incurred for Major activities vis-à-vis. PSE provision. This would enable the management to take corrective action well in advance.

10. ERP

(a) Control Estimate module (b) Client billing module

Introduction to Project Management Duration: The training session is of one day. Eligibility: The people who should be selected for this training

should be from S-Cadre & E Cadre essentially Planning & Billing Engineers and Construction Managers.

Key Features:

1. Basics of Project Management & Interlinking between Planning, execution and billing in a project.

2. The essential features of the contract document and why it has to

be understood.

3. An in depth study of Master Construction Programme and how it should be done.

4. Various other aspects like Resource Planning and Mobilization.

5. Billing, Cost & Progress Monitoring including preparation of

various reports.

6. Contractual Correspondence and Preparation of claims.

7. Contract Closure.

The training is followed by an assessment test. Curriculum: 1. Study of Contract Documents

(a) Conditions of contract i) Advances ii) Performance Bond

iii) Payment Terms iv) Retention v) Insurance vi) Liquidated Damages vii) Variations viii) Delays in execution ix) Final Bill and Virtual Completion Certificate

(b) Technical Specifications i) RCC ii) Tolerances

(c) BOQ i) Preamble

(d) Drawings i) Register ii) Drawing Control

e) RFI i) Check drawings ii) Bring discrepancies to Client’s notice f) Salient features of specifications, programme,

methodlogy and resourcing to be discussed with engineer/subcontractor before start of activity

2. Preparation of Master Construction Programme

Of immense importance, Contractor will be expected to comply with the same. Delays will lead to blame game and needless correspondence. It should be prepared with great thought.

3. Resources Planning

(a) Organization structure Client may not accept any change from the chart submitted during tender.

(b) PMV Requests Client may again not accept any change from the commitment submitted at Tender Stage.

(c) Labour:

Shortage of labour is one of the main reasons for delays in progress. Labour especially skilled may not be easy to mobilize and undergo sharp dips during festive seasons like Holi, Puja and harvest season. Arranging labour is primarily a site responsible.

(d) Bought out Items Specialist subcontractors – waterproofing, Aluminum Works, Hand-railing, False Ceiling, Granite, Painting – have a major role as their performance can affect both the progress and quality of the job.

(e) Formwork Requirement i) Formwork scheme will be finalized with the regional

coordinator on receipt of LOI and requirements worked out. These quantities will be considered in the PSE.

ii) As formwork is an expensive component, high shuttering usage ratio is required. Otherwise additional material will be required to meet the programme resulting in higher depreciation costs.

iii) It is essential to anticipate additional formwork atleast a month in advance, as the system may not be available ex-stock. Failure to arrange formwork in time is another common reason for delays.

iv) Planning Manager should review with the Construction Manager if the formwork being executed on site is as per the Project Scheme.

(f) Reinforcement Requirement

A key material in RCC, shortage of reinforcement has, on occasions, slowed down the work. Most often, the site had given the requirement very late. Certain diameters – 25/32 especially – may be out of stock. There is heavy demand for steel from the main producer and prices keep fluctuating. This is a sellers market. This is the reason RO’s have a system of asking monthly requirements from site at least 15 days in advance.

i) On receipt of LOI, steel requirements should be

worked out at least to Ground floor slab level. Foundation steel will be required on the 7th day in some cases.

ii) In absence of further GFC drawings, Client should be asked to give the quantities dia wise for procurement purposes.

iii) There should be at least two alternate suppliers. iv) The minimum stock requirement is 15 days. v) In emergencies, approach client for substitution of

dias. 4. Temporary Infrastructure Layout

This is a requirement in some tender submissions. But in any case, finalization of the temporary Infrastructure Layout (in Consultation with the Project Manager and Plant Manager) is to be taken up immediately on award of the contract. A well-designed layout will facilitate work resulting in higher productivities.

5. Quality and Safety Plans

These are to be submitted during the mobilization period. They are usually prepared by the QA/QC and safety officers respectively with their regional coordinators. The Planning Manager has to essentially follow up and submit to client.

6. S Curve and Cash flow

When the cumulative billing month wise is plotted on a graph, it has the shape of a S curve. The S curve is ideal as it indicates a gradual start and closure with the peak at the midway point. The S curve is part of the MIS Report. The cash flow is to be prepared for our Accounts to enable them to plan the financial requirements. Both the S curve and cash flow would require to be revised accordingly to the progress.

7. Progress Monitoring

The progress of the project is to be monitored at every stage. Corrective action is to be taken when delays occur.

8. Cost Monitoring As important as progress monitoring is the Cost Monitoring. A loss-making project is like a terminally ill patent. A good Project Team should ensure that this situation does not arise.

(a) Pre Start Estimate (PSE). (b) Labour bills (c) Purchase of materials at site (d) Cost to complete (C2C) statements (e) P & L statements

9. Billing

Billing – Clients and labour – should be done immediately at the start of the month for the work done in the previous month. Any delays will affect the Project’s; Cash flow and cause discontent in the labour force. (a) The RA bills.

(b) Labour bills (c) “Unfavorable Items”.

10. Project Control

There are other parameters, which are deployed to check if the project execution – especially with respect to time and cost – is under control. (a) Material Reconciliation

(b) Labour Productivity (c) PMV output.

11. Delay Analysis

(a) Most projects extend beyond completion date and if we are to avoid Liquidated Damages or claim for associated costs, correspondence reality to delay should be maintained from DAY ONE.

(b) Common causes for delay on project not attributable to contractor:

(c) Record the reasons in letters, MOM’s. Record dates of receipts of drawings and Site Instructions (confirm if verbal).

(d) Submit letter for Extension of time with all backups, atleast 30 days ahead of Project Completion date.

(e) Claim for associated costs to include site overheads, labour establishment (but not labour cost), PMV and formwork depreciation, bank charges.

12. Closure of Contract

QA/QC on Site

Duration: The training session is of one day duration. Eligibility: The participants chosen should be essentially QA/QC

engineers or those earmarked for QA/QC. Key Features:

1. Quality awareness amongst engineers & supervisors 2. Project Quality Plan and its execution.

3. Setting up a lab & testing of materials.

4. Execution as per ISO procedures and documentation of it.

5. To understand the non-conformity in products.

6. To give a product according to customer satisfaction.

7. Conducting and preparing for external and internal audits.

The training is followed by an assessment test.

Curriculum: 1. Preparation of Project Quality Plan

- Features - To be Site Specific

2. Testing of materials

(a) Cement i) Initial and final setting times ii) Compressive Strength iii) Fineness iv) External tests

(b) Sand

(i) Grading (ii) Silt Content (iii) Other visual checks

(c) Aggregates i) Grading ii) Fineness Modules iii) Flakiness Index iv) CBR Test v) External tests

d) Mortar i) Compressive strength

e) Blocks i) Compressive strength ii) Water absorption

f) Reinforcement Steel i) In the lab – Unit weight for rolling margin ii) External Mechanical

- Yield Stress - Ultimate Tensile Strength - Bend / Re bend

iii) External Chemical - Carbon content

g) Soil i) Atterberg’s limits ii) Bearing capacity iii) Optimal Moisture Content iv) Proctor density v) Understanding geotechecnical reports

3. Design of Concrete Mixes

(a) Various methods for designing mixes (b) Testing of individual constituents (c) Batching of ingredients and preparing trial cubes (d) Corrections for moisture content, workability (e) Using concrete from RMC with their design mix

4. Setting up of laboratory (a) Basic layout of lab- Curing tank for concrete cubes (b) Soil testing

i) Core cutters ii) Oven

(c) Cement- i) Vicat’s Apparatus (d) Aggregates- i) Sieves (e) Concrete

i) Cube Moulds iii) Slump test apparatus iv) Comp. Strength testing machine

(f) Mortar- i) Moulds (g) General

i) Weigh balances ii) Calipers

(h) Calibration of testing apparatus 5. Compliance with ISO

(a) ISO 9001 as applicable to site (b) Internal Audits (c) External Audits

6. Documentation

(a) Registers- i) Cube testing (b) RMC Delivery Challans (c) Cement and steel Test Certificates (d) Site checklists (e) Method statements (f) Calibration reports

7. Best practices in Construction (a) Composition in fill / back fill (b) Formwork finish (c) Consolidation of concrete (d) Laying of Blockwork (e) Plastering (f) Ceramic tiling (g) Granite / Marble Works (h) Painting (i) Road works (j) Waterproofing

8. Quality Inspection on Site (a) Shuttering (b) Concrete - Before Pouring - Port Concreting (c) Blockwork (d) Plastering (e) Tiling Mockup (f) IPS Flooring Mockup

9. Rectification of defects

(a) Concrete finishes - Honeycombing - Fins and bulging

(b) Variation in concrete dimensions beyond tolerance (c) Cube strength below acceptable level

- Cores - NDT Tests

(d) Rehabilitation of defective concrete - Epoxy treatment - Retrofitting - Demolition

(e) Blockwork - Additional thickness of plastering

(f) External Plastering - Not in plumb - Shade variation

(g) Tiling - Lack of slope in wet areas - Uneven joints - Insufficient bedding

(h) Leakages - Roof waterproofing - Toilets - Basement walls - External Walls

(i) External Works - Settlement

10. Case study and lessons learnt

Safety in Civil Construction Duration: The training will be of one day duration. Eligibility: It is meant for all Safety officers at sites. Key Features:

1. Preparation of Safety plan for the site. 2. Various procedures of safety right from excavation stage.

3. Setting up of First Aid Rooms and First Aid Boxes at the sites.

4. Educating staff and workers on all safety procedures and

practices.

5. Ties up with hospital & health care centers in case of accidents & other emergencies at sites.

6. Case Studies

The training is followed by an assessment test.

Curriculum: 1. Preparation of Safety Plan 2. Safety during Execution

(a) Earthworks i) Barrication around excavations ii) Stability of cut slopes iii) Movement of vehicles

(b) Works at a height i) Safe ladder access ii) Barricading edges iii) Use of safety belts, nets, fall arrestors iv) Prevention of falling objects

(c) Material handling i) Testing of crane slings, builders hoist ii) Precautions during crane movements iii) Safe storage of materials

(d) Scaffolding i) Stability ii) Access for people iii) Working platforms

(e) Electrical and welding i) Jointing of cables, Use of ELCB’s, plugs ii) Check hand tools iii) Earthing of equipment iv) Gas cutting operations – Flash arrestor

(f) At the labour camp i) Hygiene ii) Toilets and garbage disposal iii) Safe water

(g) House keeping 3. Inculcating Safety Culture

(a) Induction for new workers and staff (b) Tool Box talks (c) Safety campaigns (d) Meetings of Site Safety Committees (e) Conducting safety audits

4. First Aid and Stores

(a) Setting up First Aid Room (b) Identifying and tie up with local doctor / hospital (c) Stores

5. Safety Records (a) At Site (b) Reports to be submitted to RO / HO

6. Human Relations (a) With workers and subcontractors (b) With colleagues and staff (c) With client

7. Emergency Response

(a) Major Incident (b) Post incident measures

8. Case study and Lessons learnt (At least 2 Projects)

Introduction to PMV Works on Site Duration: The training session is of one day duration. Eligibility: This training is for all PMV staff including all the

Mechanical GET’s. Key Features:

1. Creation of site PMV & Electrical infrastructure including of positioning of PMV.

2. Determination of power requirements and lighting of the whole

site.

3. To install, commission & maintain various PMV systems.

4. Maximize the utilization by allotting proper trained manpower and proper maintenance.

5. Adherence to ISO systems.

6. Costing of PMV inclusive of fuel, spare parts.

7. Preparation of various reports

The training is followed by an assessment test.

Curriculum: 1. Site Infrastructure

(a) Determining the normal and peak power requirements (b) Selecting and locating Generators (c) Electric Supply Layout (d) Water supply layout (e) Location of major plant – Batching Plant, Tower Crane,

Wood M/c.

(f) Bar bending and cutting machines (g) Location and layout of PMV workshop (h) Lighting Layout in site (i) Labour camp

2. Installation and commissioning of following plants

(a) Batching Plant (b) Tower Crane (c) Generators (d) Bar bending and cutting machines (e) Builders Hoists

3. Operation and Maintenance of Key Construction Equipment

(a) Earthworks (b) Concrete (c) Reinforcement (d) Pumps (e) Material Handling (f) Others

4. Maintenance of Records

(a) Registration, Fitness certificates, Insurance, Taxes (b) History Sheets, Job Cards (c) Utilization (d) Vehicle Inspection certificates (e) Safety Certificates for cranes, etc.

5. Other Procedures

(a) Demobilization (b) Transfer to other sites / central yard (c) Hiring of PMV (d) Purchase of spares and repair of PMV outside site.

6. Introduction to costing

(a) Depreciation costs (b) Hire costs (c) Operation costs

i) Fuel / Power ii) Lubricants iii) Spares

(d) Operator costs (e) Efficiency Ratios (f) Productivity of major plant

i) Batching Plant ii) Transit Mixers iii) Concrete Pumps

(g) Cost of breakdowns / non-availability of plant 7. Troubleshooting common problems in PMV 8. Case Studies and Lessons learnt

(a) One major project with extensive PMV deployment (b) Innovative repairs of PMV

Enterprise Resource Planning (ERP) Duration: The training will be of three days duration. Eligibility: The training will be essentially for

Planning/Billing/Contract Engineers who will be actually working on ERP modules.

Key Features: The system is an integrated information system that serves all departments within an enterprise. The ERP system will give insight into

• Tendering • Planning • Execution • Accounts • Purchasing & Stores • Plant & Machinery • Human Resource • Payroll • Client Billing • Control Estimate

The training will help the employee to minimize costs, maximize service, performance and information quality. Produce immediate data flow between modules and avoid duplication of data. It generates instant company wise information across various modules. It helps in streamlining systems and procedures within the organization.

The training is followed by an assessment test.

Quality Management System (QMS) Duration: The training is for one day’s duration. Eligibility: The training is for all employees for all cadres. Key Features:

• Definition of Quality, Quality Assurance & Quality Control • Definition of Process, Process Approach & PDCA Cycle • Quality Management Principles • Advantages of ISO • Six Mandatory Procedures • Current Master-list of General Procedures • Details of ISO 9001: 2000 Certificate & scope • Advantages of using Checklist • System of Internal Quality Audits • Customer Satisfaction • Attending Customer Complaints, Defects on sites & Vacating

NCR’s • Measures taken to ensure Quality during construction • Format of reporting of Corrective / Preventive Action Reports

The training is followed by an assessment test.

Finishes Duration: The training is of one day’s duration. Eligibility: The training is for all site engineers in S cadre who are

in execution and in Finishes. Key Features:

1. Emphasis the importance of quality in execution of all types of Finishes.

2. Execution of blockwork according to Specs and drawings.

3. Various types of plastering and execution of the same with

emphasis on quality.

4. Various types of Floor Finishes with emphasis on material selection and quality.

5. Different types of Paints & Preparation of various surfaces before

application of paint.

6. A visit to site to witness the actual execution of Finishes.

The training is followed by an assessment test.

Curriculum:

1. Introduction

(a) Importance of quality in Finishes (b) Features of Finishes works

- Procurement planning to be done well in advance - Co-ordination with services work - Supervision of specialist vendors - Sequencing - Protection of Finished works

2. Blockwork

a) Selection of materials - blocks, sand i) Testing of blocks

b) Preparation of mortar c) Execution

i) Study of drawings for openings ii) Laying first course iii) Arrangement of materials

- Planning in multistoried buildings - Scaffolding

iv) Quality checking - Line, Plumb, Right angles, thickness of joints, closing at top

- Size & Location of openings d) Curing

3. Plastering

a) Types of plastering b) Preparation of mortar for various types of plastering c) Preparation prier to plastering d) Execution e) Curing f) Preparation of Mockup

4. Floor Finishes

a) Introduction to various types of floor finishes b) Granolithic Flooring

i) Preparatory work ii) Execution

c) VDF Flooring d) Tiling

i) Inspection of materials for size, squareness, colour variations. ii) Wall Tiling

iii) Floor Tiling iv) Staircases

e) Rectification of defects in floor finishes

5. Painting

a) Introduction to different types of paints b) Preparation prior to paint

- c) Application of finish coats d) Quality checks

e) Preparation of Mockup 6. Introduction to other specialist finishes

a) ACP cladding and structural glazing i) Civil requirements

b) False ceilings i) Different types ii) Sequence of erection iii) Co-ordination with services

7. Lesson learnt 8. Case studies

a) Toilet finishes in a large project b) External painting / VDF flooring

9. Discussions

Contract Management Duration: The training is of one day duration. Eligibility: The training is for E Cadre engineers who are in site

execution as well as in contracts. Key Features:

1. Understanding the Contract Documents including Technical Specifications & Drawings and implications of key contractual condition.

2. Importance of maintaining of all contractual correspondence on

site during execution.

3. Preparation of Claims and responding to extra claims and other correspondence from the employer’s side.

4. Master Construction Programme.

5. Closure of Project.

The training is followed by an assessment test.

Curriculum:

(A) Understanding Contract Documents

1) Tender Documents 2) Addendums 3) Submissions 4) Letter of Intent 5) Contract Agreement

B) Contractors Obligations

1) On award of contract during mobilization period i) Submission of BG’s for Performance Bond, Advance

Payment and Retention Money ii) Submission of Insurance – CAR Policy, Workmen’s

Compensation iii) Submission of MCP, temporary infrastructure layout,

list of vendors, details of staff, safety plan, quality plan, Progress Report Formats, Cash Flow

iv) Submission of mix design, method statements for initial activities

v) Mobilization of equipment, supervisory staff and construction of site facilities including labour camps.

2) Execution Phase

i) Execution of work as per GFC drawings, Tender specs and in line with MCP

ii) Selection of materials and vendors as per approval iii) Submission of monthly R.A.Bills iv) Submission of progress reports, method statements,

RFI’s v) Attend Meetings

3) On completion i) Demobilize ii) Attend to Snags iii) Apply for virtual completion certificate iv) Submit Final Bill

C) Employer’s Obligations

1) On Award of Contract 2) Execution Phase 3) On Completion

D) Handling Changes

1) Changes – Deviations in any form from The Original Contract

2) How are changes handled in the Contract

E) Claims 1) Difference between claims and variations

2) Grounds for claims 3) Claims likely from Employer’s side.

F) How should the Contractor prepare for variations and

claims?

1) Proper Records .

2) Correspondence The most important record of the history of the project and the key component of any dispute resolution. Letters should be written without fail to record the following: a) Drawing b) Holds c) Clearances / Approvals. d) Payments e) Execution f) Other Contractual

i) Inclement weathers especially rains. This would not only affect progress on site but supplies too. Offsite production unity too could be affected.

ii) Transporters strikes. Both National and local. Attach press clippings.

iii) Increase in rates of basic materials and changes in taxes. Attach press clippings.

3) Minutes of Meetings:

This has equal importance as formal correspondence.

(a) In the meetings, insist that our concerns on delays in drawing issue, approvals and payments are recorded. Our views on delays in execution should also be recorded.

(b) Put on record our disagreement with recorded minutes and let this be connected in the next MOM.

4) Master Construction Programme: (a) If there is a major delay and the cause is not

attributable to us, we can revise the MCP. The MCP should be submitted for approval of client. Follow up for approval of revised MCP.

(b) Follow up for approval of revised MCP. Any monitoring of progress should be with respect to revised MCP.

G) Important Contractual Communication: Listed below are the key contractual communications, which should not be neglected. 1) Client complaints on Quality & Progress

(a) Quality (b) Progress

2) Escalation: Non-private sector contracts will not award escalation costs during the tenure of the contract period. But in the extended phase, they can either revise the BOQ rates or pay escalation costs on the work executed during the extension phase. Anyway, there is no harm in presenting an escalation claim.

3) Extension of time: Almost all projects today extend beyond the original

completion date for a variety of reasons – due to both the contractor and the client. In many cases, the client suffers financial losses (or at least opportunity costs) if the facility is not handed over in time. The client would try to recoup some of the losses by levying Liquidated Damages (LD) on the contractor. The contractor also is losing money on additional overheads expenses and will try to recover these costs from the client.

4) Request for Virtual Completion Certificate. When the works are substantially complete viz. no new works are balance, the contractor should apply for the Virtual Completion Certificate. This certificate is vital since it marks the commencement of the defect liability period and is proof that the building has been handed over for the clients use.

5) Submission of Final Bill The contract is usually very explicit in the procedures for preparation, submission and processing of the Final Bill.

(i) Since balance payment in the Final Bill is a long time in coming (60 to 120 days after issue of Virtual Completion Certificate), please ensure that the pre-final bill is as high as possible and no work is left unbilled.

(ii) If variations and claims are settled during the contract period, it will not delay the processing of the Final Bill.

(iii) As the final bill is a re-measurement of the entire project, make proper measurements during the RA Bill and use the same in the Final Bill. A good Qs will not re-measure for the Final Bill. He / she will only combine them from previous bills.

(iv) Before the payment certificate is issued, the Client would – if specified in the contract – ask the following requirements to be met.

iv) Submission of 10 year guarantees for items like anti termite treatment and waterproofing

v) Submission of “As Built” drawings vi) Evidence that payments have been made to sub

contractors vii) Mutual argument on claims (v) Unconditional acceptance by the Contractor of the

Final Payment Certificate would any scope for discussion of claims / disputed items in the future.

6) Completion of Defect Liability Period:

On completion of the defect liability period, the contractor should request release of balance retention money and return of the Performance Bond.

Project Operations – E Cadre Duration: The training is for one day’s duration. Eligibility: The training is for all Senior E cadre Engineers who

are managing the site. Key Features:

1. Raise the awareness of site managers in planning all resources – Manpower, Material, Money & Machinery.

2. Prepare the Engineer to anticipate all difficulties which could arise

in execution.

3. Provide a complete insight into Costing and monitoring the cost.

4. Explain the importance of Productivity and how it can be increased.

5. Importance of working with best vendors.

6. Throw light on Project Closure

7. Evaluate on Manpower Management – Motivation of Staff &

Labor.

The training is followed by an assessment test. Curriculum: 1. Increasing Productivity

(a) Motivation i) Motivation of Labour / Sub Contractor ii) Motivation of Staff

(b) Mechanization i) Earthworks ii) Concrete iii) Blockwork iv) Finishes

(c) Erection

i) Earthworks ii) Concrete iii) Formwork and Reinforcement iv) Blockwork & finishes

- (d) Resource planning

i) Minimum stock of one week consumption for cement ii) Reinforcement to be atleast 20% surplus. Extra care

for higher dia. iii) Stock aggregates before monsoon & festival season iv) Give 15 days lead for manpower mobilization. Keep

20% surplus v) Aluminum works, finish doors, granite, etc. are long

lead items. Select vendor atleast 4 months in advance. 2. Cost Control

(a) Elements of activity cost i) Materials ii) Labour iii) Plant and Machinery iv) Indirect costs v) Profit and overheads

(b) Materials i) Wastage to be minimum ii) Cost of poor quality of materials iii) Order correct quantities iv) Demobilize formwork material immediately to reduce

depreciation cost.

(c) Labour i) Award work on piece-rate. Monitor productivity to avoid

claims ii) Avoid excessive labor supply iii) Use correct category of labor for type of job

(d) Plant & Machinery i) Poor condition will result in high maintenance costs ii) Idle time will result in high depreciation costs iii) Higher utilization will result in higher productivity iv) Productivity important especially in hired plant

(e) Indirect costs i) Includes power, water, salaries, labour establishment,

Bank charges ii) Delay will increase Indirect Costs iii) Acceleration in work – if not accounted for - will

increase indent costs iv) Poor infrastructure planning will increase – Indirect

costs v) Demobilize staff in time

(f) Profit and Overheads i) Overheads are RO & HO overheads. Compulsory

administration costs not in control of site. ii) Profit (Margins) is essential for the company to grow

and value.

(g) Main causes for spiraling costs i) Materials – High wastage. Depreciation of formwork ii) Labour – Low Productivity, High Labour Supply iii) Plant and Machinery – High Maintenance Costs iv) Indirect costs – Project Delays v) All of above will reduce margins

(h) Measures to control costs 1. Materials 2. Labor 3. Plant and Machinery 4. Indirect Costs 5. Select sub-contractors well in advance

3. Vendor Control

(a) Suppliers (b) Sub contractors

4. Project Monitoring

(a) Construction Programmes (b) Resource Planning

MCP and other programmes are the basis for resource planning: i) Materials ii) Labour iii) Plant and Machinery iv) Staff

5. Getting the best out of PMV

(a) Choosing the right equipment (b) Using the equipment

6. Introduction to Contracts

(a) Claims (b) Extra works and variations (c) Extension of Time (d) Virtual completion certificate

Design and Build Duration: The training is of one day duration. Eligibility: All engineers in S, E And C Cadres who need to

understand the concept of Design & Build. Key Features:

1. Design – Build Concepts

2. Design – Build Project flowchart – Pretender / Post tender

3. Costing process for DB Projects – Budgetary Offer / Detailed Costing

4. Value Engineering Methodology

5. Design – Build Contracts – Terms & Conditions

6. Advantages of executing Design – Build Projects to RO’s

7. Integration of ‘Design & Build’ with ‘Site Operations’ based on

‘failures & lessons learnt’

8. Business Development for Design & Build.

9. Project Management as an instrument for Time Extension & Cost Deviations.