QUALITY PLAN

1.0 SCOPE:
This document describes the quality control programme followed by BDS for materials, fabrication and inspection to ensure that pre-fabricated items confirm to the client’s requirements.

2.0 MATERIAL:
Structural steel members and design used shall conform to
IS 800-1984,
IS 811-1987,
IS 875 (part 4)-1987
Circular hollow tube sectionIS-1161
IS 875 (part 1) -1987
SP6(5) -1980
IS 1161:1998
For Plain & Reinforced concrete code of Practice-IS 456-2000.
Fibre cement flat sheets as per – ISO 8336, IS 14276,1995
Sheeting as per -  IS 277:1992

3.0 CONTROL PROCEDURES

3.1 Drawings and specifications
3.1.1 All drawings and specifications will be reviewed prior to fabrication to ensure that only correct copies are used for fabrication.

3.1.2   Drawings used will be those submitted to the client and confirmed for use.

3.1.3   All accepted drawings and/or specifications shall be made available to client’s inspector.

3.2   Shop Fabrication:
3.2.1 Production personnel will monitor fabrication as dictated by the quality programme and follow procedures cordially

3.2.2  Documentation shall be completed as per 4.1. These quality control checks will not preclude any additional checks required by the client.

3.2.3 QUALITY CONTROL RECORDS:

3.2.4 Records will include information concerning the items being fabricated and also include information obtained as a result of inspections carried out by clients’ inspector. Records will be maintained for each item fabricated with following details:- 
1)   Drawing  
2)   Shop inspection report
3)   Client’s inspection procedure / report
4)   Material log sheets
5)   Fabrication log sheets
6)   Final inspection log sheets

3.2.6 All records will be made available to client’s inspectors.

THE CONCEPT OF PREFABRICATED STRUCTURE:-
Prefabricated structures essentially mean structures that are fabricated in the factory and then transported in knocked down condition to the site of construction. There these components are assembled to form the required accommodation/building.

In today’s world, no institution- private or government can afford to waste time in conventional construction. Bricks and mortar construction by its very nature is time consuming and require a long lead-time for curing. Prefab accommodation/buildings can also offer the luxury of alterations and additions at a later date.
Prefabricated structures find applications as offices, factory shed’s, officer’s accommodation, resorts, barracks, schools, shopping complex. Industrial Godowns, Hangers, CPA etc.

TYPES OF PREFAB ACCOMMODATION:--

1. PUF insulated shelters
2. Cement board shelters
3. Aerocon panel shelters
4. Steel tubular shelters and Pre-engineered buildings

1. PUF INSULATED SHELTERS:-
These shelters offer a high degree of insulation and are especially suitable in very high altitude areas. These shelters can also be used as mobile shelters & they are much lighter in weight compared to other types of shelters
These shelters are made of pre-coated GI sheet panels with PUF insulation of required thickness and density sand-witched in-between. The panel are joint together using cam locks and tongue and groove arrangement for complete sealing. These panel are used for walling, false ceiling and can even be used for flooring. For smaller structures these panel can be used as load bearing panels
span structures these act as filler walls and are supported by a structure of columns,  trusses and purlins.

2. CEMENT BOARD SHELTERS:--
In cement board shelters the walls are made of two asbestos free cement sheets (thickness as per requirement) and EPS (compressed thermocole)/PUF insulation in between to form a composite insulated sandwich panel. The false ceiling is also made of the same material and it can also be insulated. The doors and windows are all built into the panels themselves and can be of pressed steel or aluminium Section.

These cement board shelters are asthetically very good to look at and are increasingly being used by the public and private sectors. These shelters also offer high degree of insulation and comfort.

3. AEROCON PANEL SHELTERS :--
Aerocon panels have been developed by Hyderabad Industries for use in prefab construction. These are factory manufactured panels made out of 4mm thick fibre reinforced cement sheets on both sides with an insulated core consisting of a mix of Portland cement, binders siliceous and micaceous aggregate. Aerocon panel have a tongue and groove system for easy joining and complete sealing. These panels are available in 40mm, 50mm and75mm thickness and appropriate thickness can be used as per individual job requirement.

4. STEEL TUBULAR SHELTERS:--
These shelters have a tubular structure with outside cladding of pre-profiled colour coated /CGI sheets and inner cladding of insulated wooden /cement board panels. These shelters are suitable for use in areas with temperature ranging from +40 to –25 degree celcius. These are extensively used by defence and para military forces due to fast and easy construction. These can also be dismantled in a very short time and moved from one location to another. These shelters have the advantages of simplicity, interchangeability, transportation, ease of erection and protection against dust, storms, rain and snow. These pre-engineered buildings and steel tubular shelters are especially suitable for storehouses, warehouses, factory sheds, aviation hangers and other large span buildings.

5. PRE-ENGINEERED BUILDINGS:--
Pre-engineered buildings are factory manufactured steel buildings with outside cladding of pre-profiled Colour Coated/CGI sheets. These buildings can also be insulated with inside cladding of insulated panels if required. These buildings are manufactured in the factory and brought to site in knocked down condition. Factory manufacturing ensures perfect matching of various components and these are assembled at site to form the required building.

DGS&D RATE CONTRACT SYSTEM FOR PREFAB SHELTERS:--

The DGS&D has approved cement board shelters for rate contract of prefab shelters/ huts. The DGS&D system uses two 10mm thick asbestos free cement boards inserted into W shaped GI- profiles and filled with 27mm thick EPS insulation in-between. The false ceiling is of single skin panel with 6mm thick cement sheet and 32mm EPS insulation. The steel structure comprises of trusses, purlins and columns with CGI sheets for roofing

ADVANTAGES & CHARACTERISTICS OF PREFAB CONSTRUCTION:--

• The cost of prefab construction is less than the cost of conventional construction.
• These structures are especially useful in inaccessible areas or hilly terrain. Where conventional construction is not possible .
  
• Economical in construction & Speedy erection
  
• Structures are insulated and provide protection against both hot and cold weather conditions.
• Easy to dismantle and reassemble any number of times without any damage.
  
• Flexibility of additions or modifications in floor plans.
  
• Environment friendly, totally asbestos free, top class fibre cement sheet panels.
  Safe for earthquake prone areas .
  
• Can be constructed by semi-skilled workers swiftly, without using any special tools or machines.
• The prefab structures can be erected on light foundations.