SETSCO Services Pte Ltd Form.

Ref: SS/QA-4
Daily Inspection Report
Date 01/11/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, DTL2 and NSLE at For LTA C9309
ACPM Factory, Pontian, Johor Contract

Production
OBSERVATION (S) Action
Area
Setsco Start 0830hrs - finish 2030hrs.
Inspec
tor
(i) Mainline Sleepers:
a. Transfer age average cube strength test results at 12hrs - 42.55 & 43.45N/mm 2.
b. De-tensioning/cutting/de-moulding/trimming of PC wires - start 1130hrs - stop
1600hrs.
De-moulding (ii) Turnout Bearers:
(Min. No activity.
30.0 N/mm2) (iii) Depot Ballasted Sleepers:
No activity.
(iv) Guard Rail Sleepers:
No activity.
(i) Mainline Sleepers:
Preparation of moulds and inserts - start 1330hrs - stop 1700hrs.
(ii) Turnout Bearers:
Preparation of moulds and inserts - start 0930hrs - stop 1230hrs.
Mould
(iii) Depot Ballasted Sleepers:
No activity.
(iv) Guard Rail Sleepers:
No activity.
(i) Mainline Sleepers:
Preparation of PC wires - start 1710hrs - finish 1950hrs.
(ii) Turnout Bearers:
PC Wire Preparation of PC wires - start 1400hrs - finish 1620hrs.
Installation (iii) Depot Ballasted Sleepers:
No activity.
(iv) Guard Rail Sleepers:
No activity.
(i) Mainline Sleepers:
Tensioning of PC wire - start 2000hrs - finish 2030hrs.
(ii) Turnout Bearers:
Tensioning of PC wire - start 1630hrs - finish 1700hrs.
Tensioning
(iii) Depot Ballasted Sleepers:
No activity.
(iv) Guard Rail Sleepers:
No activity.
Reported by Setsco Inspector: Zainal B. Sariman Vetted by QA Engineer: Tan HK
SETSCO Services Pte Ltd Form. Ref: SS/QA-4
Daily Inspection Report
Date 01/11/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, DTL2 and NSLE at For LTA C9309
ACPM Factory, Pontian, Johor Contract

(i) Mainline Sleepers:

Casting - start 2200hrs (01/11/13) - finish 0005hrs (02/11/13).
Volume of concrete - 9m3.
Test cubes: 2 sets of 10 cubes.
(ii) Turnout Bearers:
Casting - start 1730hrs - finish 1900hrs.
Volume of concrete - 5m3.
Test cubes: 1 set of 12 cubes.
Casting
(iii) Depot Ballasted Sleepers:
Casting - Nil.
Volume of concrete - Nil.
Test cubes: Nil.
(iv) Guard Rail Sleepers:
Casting - Nil.
Volume of concrete - Nil.
Test cubes: Nil.
(i) Mainline Sleepers:
Start 0200hrs (02/11/13) - finish 1000hrs (02/11/13).
Steam Curing (ii) Turnout Bearers:
(max. Start 0100hrs (02/11/13) - finish 0900hrs (02/11/13).
allowable (iii) Depot Ballasted Sleepers:
50ºC +/- 5º C) No activity.
(iv) Guard Rail Sleepers:
No activity.
(i) Mainline Sleepers:
a. Minor repair/ touch up work of mainline sleepers - start 1030hrs - stop 1230hrs.
b. Water jetting for roughening of mainline sleepers - start 1600hrs - stop 1700hrs.
c. Joint inspection check on sleepers for delivery - start 1500hrs - stop 1600hrs.
Inspection/ d. A total of 96nos of monoblock Type 1 were delivered to ALSTOM DTL trackwork
repair/delivery site in Singapore. Breakdown is as presented in Table 1.
of monoblock
& single block
sleepers, turn- (ii) Turnout Bearers:
out bearers, No activity.
ballasted
sleepers and (iii) Depot Ballasted Sleepers:
guard rail No activity.
sleepers
(iv) Guard Rail Sleepers:
No activity.

Reported by Setsco Inspector: Zainal B. Sariman Vetted by QA Engineer: Tan HK

SETSCO Services Pte Ltd Form. Ref: SS/QA-4
Daily Inspection Report
Date 01/11/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, DTL2 and NSLE at For LTA C9309
ACPM Factory, Pontian, Johor Contract

(i) Mainline Sleepers:

a. Cube testing (for mainline sleepers cast on: 25/10/13)
Ave 7 days cube strength - 53.00 & 50.85N/mm2.
b. Shoulder height, inclination, dimensional check, Outer to outer/Rail seat Go -
NoGo gauge test on monoblock sleepers Type 1 and singleblock sleepers type 1
start 0930hrs - stop 1230hrs.
- All test results are satisfactory; 88 nos. monoblock sleepers Type 1 and 16 nos.
singleblock sleepers type 1 accepted.
(ii) Turnout Bearers:
a. Cube testing (for bearers cast on: 25/10/13)
Ave 7 days cube strength - 50.60N/mm2.
QC testing b. Cube testing (for bearers cast on: 11/10/13)
Ave 21 days cube strength - 59.95N/mm2.
c. Cube testing (for bearers cast on: 04/10/13)
Ave 28 days cube strength - 70.75N/mm2.
d. Inclination, dimensional check, Go - NoGo test on bearers - start 1400hrs - stop
1500hrs.
- All tests results are satisfactory and 29 nos. of bearers accepted.
(iii) Depot Ballasted Sleepers:
No activity.
(iv) Guard Rail Sleepers:
No activity.
(i) Mainline Sleepers:
Stacking of mainline sleepers - start 1700hrs - stop 1900hrs.
(ii) Turnout Bearers:
No activity.
Storage Yard
(iii) Depot Ballasted Sleepers:
No activity.
(iv) Guard Rail Sleepers:
No activity.

a. ACPM office will be closed on the 02/11 & 05/11/13 due to public holidays.
b. Casting of depot ballasted sleepers was temporarily stopped since 29/06/13 due to
Remarks current available moulds are used for casting of BBG-JV Project. No information
is received from ACPM on the date of resumption of casting.

Safety Issues
(i) No major breach of safety rules.

Instruction or Non Conformance Notices Issued

Nil.

Closed Out of Non Conformance Notices

Nil.
Reported by Setsco Inspector: Zainal B. Sariman Vetted by QA Engineer: Tan HK
SETSCO Services Pte Ltd Form. Ref: SS/QA-4
Daily Inspection Report
Date 01/11/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, DTL2 and NSLE at For LTA C9309
ACPM Factory, Pontian, Johor Contract

NCRs with Corrective Action raised/closed out by Summary of NCRs raised/ closed
Nil.
ACPM
Nil.

A. Highlights of Inspection

(1) Production Related

(i) As to date, the mainline sleeper production (since 28/09/10) is summarized in table 1 below.

Table 1: Summary of mainline sleepers production as at 01/11/13:

Note:
Type of Sleeper Produced Unchecked Quarantined Rejected Accepted Delivery “*”-
(no.) (no.) (no.) (no.) (no.) (no.)
Mainline Sleepers -
39880+88 88+88 0+0 618*+0 39086+88 36375+96
Monoblock Type 1
Mainline Sleepers -
1127+0 0+0 0+0 50*+0 1061+16 485+0
Single block Type 1
Mainline Sleepers -
6120+0 0+0 0+0 87*+0 6033+0 5612+0
Monoblock Type 2
Mainline Sleepers -
448+0 0+0 0+0 42*+0 406+0 385+0
Single block Type 2
Inclusive of 27 nos Type 1 monoblock, 7 nos Type 1 singleblock, 24 nos Type 2 monoblock and
7 nos Type 2 singleblock selected for 3rd party testing at DNV.

(ii) As to date, the turnout bearer production (since 19/07/11) is summarized in table 2 (Depot, Mainline,
NSLE & BTW) below.
Table 2: Summary of turnout bearers (Depot, Mainline, NSLE & BTW) production as at 01/11/13:

Produced Unchecked Quarantined Rejected Accepted Delivery

(no.) (no.) (no.) (no.) (no.) (no.)
Turnout Bearers
(Depot, Mainline, 5885+27 0+27 0+0 92+0 5764+29 *4912+0
NSLE & BTW)
Note: “*” - Inclusive of 10 nos. turnout bearers selected for 3 rd party testing at DNV.

Reported by Setsco Inspector: Zainal B. Sariman Vetted by QA Engineer: Tan HK

SETSCO Services Pte Ltd Form. Ref: SS/QA-4
Daily Inspection Report
Date 01/11/13
QA/QC Inspection of prestressed sleepers for track work for DTL1, DTL2 and NSLE at For LTA C9309
ACPM Factory, Pontian, Johor Contract

(iii) As to date, the depot ballasted sleepers production (since 24/10/11) is summarized in table 3 below.

Table 3: Summary of depot ballasted sleepers production as at 01/11/13:

Produced Unchecked Quarantined Rejected Accepted Delivery

(no.) (no.) (no.) (no.) (no.) (no.)
Depot Ballasted
19638+0 0+0 0+0 168+0 19470+0 *19175+0
Sleepers
Note: “*” - Inclusive of 24 nos. ballasted sleepers (prototype) selected for 3 rd party testing at DNV.

(iv) As informed by ACPM/ALSTOM, production of guard rail sleepers was stopped on the 06/12/12 as
the required quantity had been achieved. Detailed breakdown of the guard rail sleepers production and
delivery as at 07/12/12 is as presented in table 4 below.

Table 4: Summary of guard rail sleepers production and delivery as at 07/12/12:

Produced Unchecked Quarantined Rejected Accepted Delivery

(no.) (no.) (no.) (no.) (no.) (no.)

Guard Rail Sleepers 440+0 0+0 0+0 6+0 434+0 416+0

(2) Factory Visit

(i) Nil.

(3) Others

(i) Nil.

Reported by Setsco Inspector: Zainal B. Sariman Vetted by QA Engineer: Tan HK