Quality Plan for Manufacturing TBM Precast R/C Segment by Taisei Gama-Nurol Joint Venture MARMARAY PROJECT- Contract BC1 ‘Originating Organloation’s Responsible Personnel: ‘Contractor's Divisional Project Manager Reviewed Status MT pat pe , oo asrono0s | —‘wAgiKeoz | DO GAPAN|~GALPER [| TIMAlSH | 1™"leeue Tv [ Tose Date | Prepared | Reviewed | Approved | Approved Descipon fanaa Format ee. ‘This Contractor's Notice hereby states that ‘4 ie paper says thie Document is considered ready, both fr Total Number Approved Geagen 0 1 Approved win comments review in accordance with COC, Clause 5.2, ttetaing thiapage) Nac and for use, Thi Document compiles with 25.10.2005 S.NATARAJAN A the Contract, 8 5 Typect —_Cost_—‘Mainfaclty Sub facity Serial Number Revision Variation Order 3 Document Center Coden coden Counter ‘Number No vow -r] [2 ][o[s] fo o[¢][e[s [elo] [ofo] [ojoTalsel Gama Nurol Joint Venture Marmaray Project - Contract BC1 Revision History Quality No. BC1-MFQP-TEMO2 Quality Plan for TBM Precast RIC Segment Production on ER's Rev, Submit | Submit |Submit Ref. | Resp. [ER's Resp. No Deserpion Siaus | Date [ete o | Dao |ioterno’ | Ve" (00 rst Full Submission REV 25072005 Remarks ‘Submit Status: REV|For Review), INF(For information} Resp. Date: Response Date of E's Letter ER's Resp, Letter No. Response Lette No. of &R ‘Submit Date: Submission Date ofthe cover letter forthe submitted document ‘Submit Ref, Letter No: Submission No. ofthe cover letter forthe submitted document 0: Compliance with Contract ER's Review Status 4: Non-Compliance with Contract ‘Submission No. TGN-BC1-52-05-00-00-0590#00.00 Page 2 of 24 Revision No.00Talsei Gama Nurol Joint Venture Quality No. BC1-MFQP-TBM02 Marmaray Project - Contract BC1 ty Plan for TBM Precast RIC Segment Production Table of Contents Purpose and Scope of the Work cece 4 Definitions......-sccesossesseseee . oe 5 References to the Requirements, 6 1 2 3. 4, . foes 5. Programme ss. sessseestenenteneensns 6 7. 8 Organization, Responsibility & Authorit 7 secseesseeenenseeeeeen 10 Method & Sequence of the Work... eee cece osc ee ees cee ene ceetersnsevees enaenen 12 Plant Machinery and Equipment ses ceseeeeneceeseseeesenanecanenensnenranens@, Materials... . 23 9. Inspections & Test Plan 23 10. Acceptance Criteria 141, Management of inspection and Testing Equipments. cose cooceeeeeenn BB 12. Health, Safety & Environment .. 24 13, Emergency Procedure ... 24 14, Documents & Records - secs soneenes canensnunsenne 24 15, Attachments, eoccssnnnee senannsnevanennennenes 25 ‘Submission No. TGN-BC1-52-05-00-00.0590#00-00 Page 3 of 24 Revision No.00Taisel Gama Nurol Joint Venture Quality No. BC1-MFQP-TEMO2 Marmaray Project - Contract BC+ Quality Plan for TBM Precast RIC Segment Production 1 Purpose and Scope of the Work The purpose of this Manufacturing Quality Plan of Precast Concrete Segments is to define the sequences and methodology of production including organizations, responsibilities, work activities, accompanying with Quality and HSE issues, for the production of the TBM Precast Concrete Segments. The production plant is located at Yedikule (old gashouse of |.€.T-T) as shown at below picture. ert) oes ‘Two types of precast concrete rings shall be considered for this project. * 7,64 m outer and 7,04 m inner diameter, 0,30 m thickness ‘* 7,68 m outer and 7,04 m inner diameter, 0,32 m thickness Totally 12.539 nos of precast concrete rings shall be produced and one ring shall consist of 7(Seven) segments, including 1 key segment. 18 sets of mould and attached air-propelled vibrators shall be used for the production. TGN's target is to produce 22 RIC rings per day. ‘Submission No. TGN-BC1-52-05-00-00-0590#00.00 Page 4 of 24 Revision No.00Taisel Kumagai Gama Nurol Joint Venture Quality No. 8C1-MFQP-TBMO2 Marmaray Project - Contract BCt Quality Plan for TBM Precast RIC Segment Production 2 Definitions Employer is the party which initiates the project and ultimately pays for its design and construction of the Marmaray Project, Contract Package 8C1. DLH General Directorate is the Employer. Employer's Representative (ER) means person or persons, firm, partnership, corporation ‘or combination thereof appointed by Employer to act on behalf of Employer for the purposes of the Contract. Employer's Representative is Avrasya Consult Joint Venture ERQ; Employer's Requirement TGN JV: Taisei Gama Nurol Joint Venture AFA: AFA Prefabrik Prefabrike Beton Sanayi ve Ticaret A.S., sub-contractor for the production of R/C Segments. ‘The Supplier is any organisation or person providing a product to the Contractor. ‘The Sub-Contractor is any supplier, vendor or consultant of the Contractor. Quality Assurance (QA) is part the of quality management focused on increasing the ability to fulfil quality requirements. Quality Control (QC) is the operational techniques and activities that are used to fulfil the requirements for quality. The Quality Management System (QMS) is a management system to direct and control a organisation with regard to quality. PMP: Project Management Plan HSE: Health & Safety and Environment QP: Quality Plan MFQP : Manufacturing Quality Plan CIQP Construction and Installation Quality Plan DQP_ : Design Quality Plan MS — : Method Statement ITP: Inspection & Test Plan RA: Risk Assessment ‘Submission No. TGN-BC1-52-05-00-00-0590#00-00 Page 5 of 24 Revision No.00Taisel Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP.TBMO2 Marmaray Project - Contract BC1 Quality Plan for TBM Precast RIC Segment Production 3 References to the Requirements. Conditions of Contract ERQ Chapter 3.3/6 / 6A ISO 9001:2000 OHSAS 18001 Iso 14001 Regulations for Labour Safety and Hygienic HS Manual HS Plan Environmental Manual Environmental Plans Project Management Plan BC1-PR-02 Project Management Procedure for Preparing of Quality Management System Documents BC1-PR-05 Project Management Procedure for Control of Documentation BC1-PR-07 Project Management Procedure for Procurement Process BC1-PR-08 Project Management Procedure for Controlling Suppliers &Vendors QMS BC1-PR-09 Project Management Procedure for Preservation of Materials at Site BC1-PR-10 Project Management Procedure for Site Receipt Inspection & Reporting BC1-PR-11_ Project Management Procedure for Permits BC1-PR-12 Project Management Procedure for Control of Monitoring, Surveillance ‘Supervision of the Works BC1-PR-13 Project Management Procedure for Quality Control & Verification of Works * BC1-PR-15 Project Management Procedure for Identification and Traceability * BC1-PR-16 Project Management Procedure for Calibration of Monitoring and Measuring Devices © BC1-PR-17 Project Management Procedure for Control of Non-conformity, Corrective! Preventative Actions for Non-Conformities BC1-PR-18 Project Management Procedure for Control of Quality Records BC1-PR-19 Project Management Procedure for Quality Auditing Related standards and codes referred in to the ITP “QP for Pre-Testing of Constituent Materials for Concrete Works" issued as BC1-52-00- (00-00-0302#03-00 * “QP for Pre-Testing of Mixes for Concrete Works” issued as TGN-BC1-52-00-00-00- 0316#01-00 Related Drawings ‘+ Technical Specification for Produetion of Precast Concrete Lining as TGN-BC1-70-05-00- 00-0583#00-00 * Detail Design for TBM Segments ‘Submission No. TGN-BC1-52-05-00-00-0590#00.00 Page 6 of 24 Revision No.00Taisei Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP-TBMO2 Marmaray Project - Contract 8C1 Quality Plan for TBM Precast RIC Segment Production | 4 Organization, Responsibility & Authority DLH General Dir. TGN JV ORGANIZATION (OLH 4th Division) i ER (QUALITY MANAGER Avrasyaconsult ‘TBM DIVISION TIMAISHI Project Manager TEM TKOVANAGI TESTING AGENGY-ITU Asst. Const. Manager TTU Lab, Manager Yilmaz AKKAYA, ‘TBM Supenvisor TTU Lab. Engineer —T_ TTU Lab. Technicians SS APPROVED RAW MATERIAL SUPPLIERS ‘Submission No. TGN-BC1-52-05-00-00-0590#00-00 Page 7 of 24Taisei Kumagal Gama Nurol Joint Venture Quality No. BC1-MFQP-TBMO2 Marmaray Project - Contract BCt Quality Plan for TBM Precast RIC Segment Production AFA PREFABRIK ORGANIZATION CHART PROIEST MANAGER THFTHANAGER | SARTWATACER a PRODUCTION 0 FrCUTeS TRUE, RS. evGngeR ENGNEER(Y ESTMATON ENG [BEECHNICANS ey] | [WAWENNTCE A STORE FORTIES REPAR CREW) FOREMANS 0) FOREMAN TORO EPONT Teo STORAGE CREW FOTING A crew) WORKERS GASKET CREW pAocuc ox cre} TaNsueR OPERATORS 1 ‘The number of AFA personnel involved in the production of Precast R/C Segments is given in Table 1 Table 1: Direct and Indirect Personnel of AFA Electrical Technician Mechanical Technician Operators for Batching Plant Helpers for Batching Plant __ Operator for Transit mixers Description Nos INDIRECT PERSONNEL Day Shitt_|_ Night Shift Project Manager 1 = Construction [Shift Mananers / HSE Representative 1 1 Bopariment, [Production Engineers 1 4 Facilities Engineer 4 : Storage and Estimation Engineer 4 Quality Engineer i - Oc Dept OC Technicians i f DIRECT PERSONNEL — [_Day Shit | Night Shift Foremen. I 2 2 Shall be arranged according tothe production schedule Worker ‘Submission No. TGN-BC1-52-05-00-00-0590#00-00 Page 8 of 24 Revision No.00Taisel Kumagai Gama Nurol Joint Venture Quality No. 8Ct-MFQP-TEMOz Marmaray Project - Contract 8C1 Quality Plan for TBM Precast RIC Segment Production JOB DESCRIPTIONS TBM Supervisor TBM supervisors, who are under-control of Project Manager of TBM Division, are responsible for the management of the interface with AFA’s manager and site staff of TBM Division. He shall attend Inspection and Test in hold point and inspection point determined by ITP. He shall arrange the technical meeting with AFA and coordinate with other suppliers and/or sub-contractors related to the production and transportation, such as raw material supply, loading and transportation of segments. In case of non-compliance, the report shall be instructed by TBM supervisor and submitted to AFA's Quality Engineer. In case of emergency received from AFA’s HSE Representative, he shall inform to HSE Team of TGN JV adequately, TBM QC Technician TBM QC Technician shall implement his work under control of TBM Supervisor. He shall contro! the quality of raw material preliminary by visual inspection and if he has any suspicion, he shall directly inform the TBM supervisor. He shall be responsible recording of received raw material and sampling, Job description of each key personnel of AFA related to production of R/C Segments is as below. 4.1 Construction Team (AFA) 4.4.4 Project Manager (1) Project Manager is responsible from all the management activities including correlation with TBM supervisors and performances of segment production plant. He will manage and organize all the production, quality control and HSE of segment production plant processes according to contract requirements. He will be the first person in communication with TBM Supervisors. 4.1.2 Shift Managers (2) They will work under-control of project manager. They will prepare production, QC and HSE plans according to contract requirements. They will organize their shift teams, which are responsible to different activities, with the coordination to other shift teams. They will save the records to provide traceability of products. They will manage third party inspection tests, if required and save their records. Shift managers shall also be act as a Health, safety and environmental responsible. 4.1.3 Production Engineers They will arrange daily production plans in accordance with shift managers to get on time production. They will check all production activities according to confirmed blue prints. They will save all production records to get traceability of products. ‘Submission No. TGN-BC1-52-05-00-00-050#00.00 Page 9 of 24 Revision No.00Taisel Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP-TBM02 Marmaray Project - Contract BCt Quality Plan for TBM Precast RIC Segment Production They will direct activities in nonconformity situations. To detect the causes of nonconformities and to correct them, they will make examinations in the team works. They will prepare the plan and direct all maintenance works. They will manage all the repairing activities compatible to production plans. They will check and prepare all the required minimum amounts of spare parts and maintenance materials. They will direct steam-curing process according to steam curing reports, given by QC engineer. 4.1.4 Estimation and Storage Engineer He will pursue production amounts to prepare progress reports. He will arrange moving out and storage works in accordance with production schedules. He will direct actions to enable transportation vehicles on correct positions and correct paths. He will manage the placement of precast elements in the storage area. 4,2 QC Department (AFA) 4.2.1 Quality Engineer He will be responsible for product quality control inspections including first, process and final stages together with Taisei’s responsible. He will arrange steam curing regime and check and execute relevant activities. He will be responsible whether to give permissions or not to production team for demolding of precast elements. He will be responsible from monthly output list of concrete batching plant. He will arrange all the calibration processes of laboratory. He will supervise and report all enlisted field tests mentioned in attachment-3. He will join at all nonconformity situations in accordance with relevant procedure. 4.3 Health, Safety & Environmental Responsible (AFA) Shift managers shall be responsible for all Health, Safety and Environmental issues. They will be responsible for implementation of health, safety and environmental procedures during the production of R/C segments. They will instruct the workers and construction team to comply with TGN's HS manual, health, safety, environmental plans, regulation, and any laws governing the work, if any deviation from those is observed. In case of emergency, they shall treat the suitable action mentioned in emergency plan to prevent the dangerous situation and inform to Project Manager and TGN JV site supervisior. 5 Programme Please find the detailed schedule for overall R/C segment works including mobilization, production, transportation and de-mobilization please refer to Attachment-1 ‘Submission No. TGN-BC1-52-05-00-00-0580#00-00 Page 10 of 24 Revision No.00Taisei Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP-TBMOZ ‘Marmaray Project - Contract BC Quality Plan for TBM Precast RIC Segment Production Please find the sequence of precast R/C segment production as below. Mobitizatio Design & Drawings _ [Manufacturing of ‘Moulds Baicing Plant and ether Equipments |_"*catttration —_} ‘Equipment Check rath rere 4+| Transportation To Site Flowchart-1 ‘Submission No. TGN-BC1-52-05-00-00.0590#00-00 Page 11 of 24 Revision No.00Quality No. BC1-MFQP-TBMO2 Talsel Kumagai Gama Nurol Joint Venture Marmaray Project - Contract BC1 Quality Plan for TBM Precast RIC Segment Production Please find the steps of the tests for precast R/C segment production as below. 6.1 QC Testing for Precast RIC Segment Production ‘Testing For Precast RIC Segment Production Production Testing m4 ‘ Pre-Testing nak SSS 7] ST | Material Tests Constituent Material Tests —| *| According to the BC1-CIOP-TGN-01 Lt Lo —__" SSS Fresh Concrete Tests [| According to the LO BC1-CIOP-TGN-02 Li Lo SS »| Hardening & Hardened Pre-Testing of Properties Concrete Tests LI of Concrete r —*] According to the bo BC1-CIQP-TGN-03 a Full Scale Trial Pre-Testing of Mixes | [| CIPQ Shall be submitted | | | accordingly bo '—>) Approval of Mix Design Flowchart-2 ‘Submission No, TGN-BC1-52-05-00-00-0590#00-00 Page 12 of 24 Revision No.00sei Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP-TBMO2 Marmaray Project - Contract 8C1 Quality Plan for TBM Precast RIC Segment Production For pre-testing of mixes, pre-testing of properties of concrete shall be carried out by I.T.U Laboratory , which has been already recognized by ER. Production testing of precast R/C segments shall be performed both at field and by ITU Laboratory. Fresh concrete tests such as slump test, temperature check and density test, sampling of concrete and concrete compressive strength tests shall be performed on-site, The separate CIQP shall be prepared to define and explain how to implement the field tests during R/C segment production. Please find Attachment-3 for detailed information for QC tests. The necessary testing equipments shall be provided on site for field tests. Calibration certificates of equipments such as concrete compression testing machine, balances, thermometers shall be kept on site. Please find the field-testing equipment list in Article 7 table 4. Other tests during R/C segment production tests shall be performed by 1.T.U Laboratory. For that reason, the responsible person and his contacts for I.T.U Laboratory have been determined as below: Assoc.Prof.Yilmaz AKKAYA Istanbul Technical University Civil Engineering Faculty, Materials Science Department Tel : (0212) 285 37 69 Mobile: (0536) 586 22 77 E-mail : akkayayil1@ins.itu.edu.tr As seen in Flowchart-2, the 1 (one) m’ trial mix is not considered in pre-testing works. The reason for that, our segments can be produced in original size. In addition, this procedure gives us a chance to get accurate information regarding the compressive strength data after actual curing condition (steam curing), efficiency of curing time, possible defects during demolding and surface condition on real production. In order to save time, we are planning to proceed with full-scale test without performing 1 (one) m’ trial. 6.2 Storage of Materials The raw materials to be utilized from approved source, shall be transported from production yard to our site by truck, Aggregates shall be kept in open stockpiles. Stockpiles shall be located under batching plant and separated by separating walls to protect materials from intermingling. Cementitious material shall be stored in two separate cement silos free from moist. The capacity of each silo shall be 100 tons. Concrete chemicals shall be stored in chemical admixture tank. Al reinforcing steel received on the project shall be stored off the ground and kept free from dirt, oll, and grease. The reinforcing steel shall be stored on enough number of wood blocks or similar devices to prevent the reinforcing steel from sagging and coming into contact with the ground ‘Submission No. TGN-BC1-52-05-00-00-0580#00.00 Page 13 of 24 Revision No.00Taisei Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP-TBMO2 Marmaray Project - Contract BC1 Quality Plan for TBM Precast RIC Segment Production The other auxiliary materials (such as release agent, etc...) shall be kept according to the manufacturers recommendations. Embedded materials (such as erector hole, grout hole, assembly sockets, bolt boxes, catanary sockets) shall be kept on warehouse. The storage areas for each constituent material shall be identified with clear markings. 6.3 Control of Materials Receiving of constituent material shall be performed under control of site supervisor. Traceability shall be maintained by keeping a log sheet, containing the following information; a) Material type b) Quantity ¢) Delivery No. / Date / (and time if necessary) d)Received by ) Sampling information The inspection sections (lots) shall be followed from this log sheet top get sampling. Sampling of constituent material shall be done according to the related standards and the tests shall be done in accordance with ITP for Constituent Materials “BC1-MFQP-TBM-02- ITP-01-00". The frequency of sampling is mentioned in ITP. 6.4 Production of Spacers ‘One type of spacer shall be used for R/C segment production. The spacer mould shall be prepared same shape and dimensions as mentioned in the drawings. Same constituent materials and same concrete mix design shall be used as R/C segment production for the spacers to get the same durability as surrounding concrete. The binding wire shall be ductile steel wire with @ diameter > 1,5 mm and spacers shall be cured by steam curing and/or water curing until a maturity of a minimum 120 hours obtained. Each production shall be packed separately and marked by label indicating; * Date of casting * Date of packing * Earliest date for use ‘Spacers shall not be used before they obtained a maturity of a minimum of 7 days Dimension Allowable Tolerance (mm) (mm) | X_|_ Tobe amouncediater | To be announced later Y 25 To be announced later Z_|_ Tobe announced iater_| To be announces later (Typical spacer) ‘Submission No. TGN-BC1-52-05-00-00-0590#00.00 Page 14 of 24 Revision No.00‘Taisei Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP-TEMO2 Marmaray Project - Contract BC Quality Plan for TBM Precast RIC Segment Production Production steps of spacers shall be controlled in accordance with ITP for Spacer Production “BC1-MFQP-TBM-02-ITP-03-00" 6.5 Reinforcing Bars Yield strength (f,) of reinforcing steel shall be 420 N/mm? The reinforcing bars shall be cut, bended and placed in the position shown at related drawings. The reinforcing bars shall be kept free from dust, rust, oil and any other contaminated material caused bonding problems or corrosion. 6.6 Preparation of Formwork RIC segments moulds (please see attachment 9) will be fitted and mounted into the production area with an accuracy and will be protected against weather conditions. Their placement will be arranged ring by ring with enough working spaces. The faces of the forms shall be smooth to impart a good finish to the concrete. The moulds shall be braced and tight sufficiently to prevent leakage of mortar. Accordingly, they will be cleaned and treated with release agent properly before each concreting. No material that is to be embedded in the concrete shall not be in contact with release agent. After installation of reinforcement, covers shall be checked according to the related drawings. 6.7 Concreting * Moisture Correction Moisture check shall be done at least three times per production day for related constituent materials. Accordingly moisture correction of concrete mix design shall be done. Each constituent material shall be weighted according to the corrected concrete mix design. * Constituent Material Tolerances The constituent material shall be batched in accordance with the following tolerances; Cement +3% Fine Aggregate +3% Coarse Aggregate + 3% Water +3% ‘Admixture + 5% + Batching Controls The batching shall be controlled by an automatic system and the constituent material tolerances shall be followed by this system. Batch reports shall be printed for each mixing and operator shall keep reports. Maintenance of batching plant shall be performed in accordance with the maintenance programme mentioned in attachment 4 ‘Submission No. TGN-BC1-52-05-00-00-0590#00-00 Page 15 of 24 Revision No.00Talsei Kumagal Gama Nurol Joint Venture Quality No. 8C1-MFQP-TBMO2 Marmaray Project - Contract BC1 Quality Plan for TBM Precast RIC Segment Production and reported accordingly, Calibration of batching plant shall be performed in accordance with the calibration plan mentioned in attachment 5 and reported accordingly. + Casting of Concrete Concrete will be transported from concrete batching plant to the casting area immediately after mixing and loading to the transit mixers. Castings will be executed directly from transit mixers to moulds at suitable heights and will be vibrated and compacted by mould vibrators. Please find detailed information regarding the mould vibrator on Attachment-10 . Enough number of poker vibrators shall be stored on site as stand-by. In case of break down of mould vibrators, poker vibrators shall be used in order to finish placing of concrete. The surface finishing shall be considered immediately after placing concrete. The moulds shall be covered against evaporation and kept for 2 hours for pre-setting. 6.8 Testing of Concrete + Fresh Concrete Fresh concrete properties shall be tested and recorded as per attached ITP for Precast RIC Segment Production “BC1-MFQP-TBM-02-ITP-02-00". The fresh concrete tests cover air content, density, temperature, workability and sampling of concrete. * Hardened Concrete One set of sample will be taken during concreting from each 50 m* concrete and one set will consist of 5 nos of 150/300 cylinder samples. Two-cylinder sample shall be tested immediately after steam curing; remaining three-oylinder sample shall be tested after 28 days to determine the concrete compressive strength of concrete. Please find detailed information on attached ITP for Precast RIC Segment Production "BC1-MFQP-TBM-02- ITP-02-00" 6.9 Curing of Concrete Curing of concrete comprises evaporation protection and early-age crack control. The protection against evaporation shall be maintained until the concrete gain 96 maturity hours. Steam curing is considered for precast RC segment production in order to get high early strengths, Meanwhile, this process will help to reach 96 maturity hours as early as possible for the protection of the concrete units against evaporation and early age cracks. After application of designed curing time, the samples will be checked for demoulding strength and if the necessary strength is achieved, the R/C segments will be demoulded. At that moment, if the 96 maturity hours are not obtained, concrete units shall be protected against evaporation with isolated barecloth jacket until 96 maturity hours are gained, Please find our intended steam curing period and maturity calculation as below. ‘Submission No, TGN-BC1-52-05-00-00-0590H#00-00 Page 16 of 24 Revision No.00Talsel Kumagai Gama Nurol Joint Venture Quality No. 8C1-MFQP.TBMO2 Marmaray Project - Contract BC1 ity Plan for TBM Precast RIC Segment Production Blaine (Ken ‘Temperature (°C) p= 22100.6(C A) (CAB) (Blain) kt eh ube GEIR paacat Q(1/TR-1/Tb) x FeStineRsed SanCrna od _ Cig Maia A a 20 16 fe 1a] u Ga a ANF au E(1/Mi. Tas tars ‘sine Tie of caring Denton of betting Col Prod or 2s #5 FETE THN RHE HHT BHM ABs Tee tour ‘Submission No. TGN-8C1-52-05-00-00-0590#00-00 Page 17 of 24| Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP.TBMO2 Marmaray Project - Contract BC1 Quality Plan for TBM Precast RIC Segment Production ‘As seen form our intended steam-curing chart, our steam curing process consists of 3 steps 1-Pre setting (120 minutes) Steam curing shall not commence until the concrete has been in place a minimum of 2 hours. However, if the air temperature is at low points, light steam curing shall be applied to keep the concrete from cold. 2-Steam curing (180 minutes) The maximum ambient temperature inside the curing jacket shall not exceed 80 °C, and temperature increase rate shall not increase 30°C/hour (+ 6°C/hour) 3-Cooling period (960 minutes) Concrete units shall be jacketed by isolated barecloths for 16 hours to obtain 96 maturity hours cooling period after demoulding, 6.10 Demoulding of Concrete Units Number of fresh concrete specimens, casted into the cylindrical moulds, will be placed near to segment moulds to be exposed same curing regime of precast concrete segments. After the steam curing process, specimens shall be tested for their demoulding compressive strength. After achieving required demoulding compressive strength, that is 30% of the 28 days’ characteristic strength, the concrete segments shall be demoulded by the order of QC engineer or technician approval for demoulding. 6.11 Labeling of Segments Labeling system shall be used for the definitions and traceability of segments. Segments shall be labeled by definition plate, which was embedded into concrete faces of their moulds. The production dates of segments will be written by ink. - Example: TB2L1= T ——: Tapered B Segment Type 2 Mould Type L : Left Tapered 1: Left Tapering Type - Production Date 23.08.2005 23° rd of August 2005 6.12 Storage Totally, 7780 m® storage area shall be prepared for R/C segment storage and approximately 768 nos of ring shall be stored at production storage yard at Yedikule. The segments will be stored concave up position and supported by timber from two points. The wedges will be placed that vertical centerlines of cross-sections perpendicular to the ground. jon No. TGN-BC1-52-05-00-00-0580#00-00 Page 18 of 24 Revision No.00Taisoi Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP-TEMO2 Marmaray Project - Contract BC1 Quality Plan for TBM Precast RIC Segment Production 6.13 Transportation of RIC Segments RIC segments shall not be transported to job site until they have achieved the 28-day compressive strength. R/C Segments shall be loaded on truck inner face up position. One trailer shall transport one ring (6 concrete segments + 1 keystone) at one time. Please find the detailed drawings for typical loading of precast elements as below. 00 O- 8409 308 Illustration of One Set of Precast Element on Trailer For safety of the precast R/C segments during transportation, sponsets, locking apparatus and rubber bands shall be used. For reference only ‘Submission No. TGN-BC1-52-05-00-00.0590#00-00 Page 19 of 24 Revision No.00Taisei Kumagai Gama Nurol Joint Vonture Quality No. BC1-MFQP-TBMO2 Marmaray Project - Contract BC1 Quality Plan for TBM Precast RIC Segment Production Sponsets are typical synthetic strip elements used for lashing. Mechanical locking apparatus is used for tightening the sponsets and lashing the load on to the trailer. Rubber bands are used in order to prevent the element from possible damages. Lifting equipments such as mobile crane, portal crane shall be used for loading and unloading of precast elements. Transportation route of R/C segments form Yedikule production yard to Yenikapr construction site and Yedikule production yard to Ayrilikcesme construction site are shown as below. During the process, enough number of trailers shall be used for the transportation. ‘Submission No, TGN-BC1-52-05-00.00.0590#00-00 Page 20 of 24 Revision No.00Taisei Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP-T8MO2 ‘Marmaray Project - Contract BC1 Quality Plan for TBM Precast RIC Segment Production 6.14 Installation of Gasket This process shall be described in Method Statement for Segment Assembly. 7 Plant, Machinery and Equipment 7.1 Plant Facilities Please find the definitions of the plant / equipment and laboratory equipments that shall be used during the production of R/C Segments at table-3. The locations of the facilities are described in Attachment-6. Table - 3: Production Plant / Machinery / Equipments #| Production Plant / Machinery / Equipments capactty _| QUANTITY 1 feet Moulds T1-G type * 4 sets 2 [Steel Moulds '1-B Bolt Box type - I set 3 [Convertible Taper for Liner for Modification (T-B mould to TI- - Dsets lad and TI-AJ2) 4 Steel Moulds T2-G type : 12 sets 5 [steel Moulds T2-B Bolt Box type : 1 set ¢ [Convertible Taper for Liner for Modification (T2-B mould to T2- to [aJI and T2-AJ2) : 7 [vibrators 3 1S aes 8 [batching Plat 60 m3 /hour | 1 nos 9 [overhead erane 7.5 tons 6 mos 10 stam biter 3500Ke/h | 2m08 U1 [Transit mixer - 8 m’ capacity 2nos 12 Rebar Cutting Macbime : 3 nos 13 febar Bending Machime 5 3 nos 14 |Compressor 16 m3/min | I nos Table — 4 : Field Test Equipments # FIELD TEST EQUIPMENTS. CAPACITY | QUANTITY 1 [Concrete Compression Testing Machine 0-300 IL 2 [oven 0- 120°C 1 3 [Slump Test Set : 2 | 4 (Volumetric Bucket 714i 2 ‘Submission No, TGN-BC1-52-05-00-00-0580#00-00 Page 21 of 24 Revision No.00Taisei Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP-TBMO02 Marmaray Project - Contract BC1 Quality Plan for TBM Precast RIC Segment Production Table — 4 (continue) : Field Test Equipments # “FIELD TEST EQUIPMENTS capacity _ | QUANTITY 5 Mechanical Balance 0- 100kg 1 6 [Electronic Balance 0-5Kg 1 7 |onronometer = 1 [8 (caliper 0 50.em 1 9 [Measuring Glass 0 1000 ml | 10|Air Level 0-70em 1 11 Pigital Thermometer 0- 100°C 2 12 Set of Test Sieve (ASTM) 2 i 13\Ventical Capping Set - | 14 Cylindrical Concrete Test Specimen Moulds : 50 15 Laboratory Sieve Shaker - | 8 Materials Regarding to the constituent materials such as aggregate, cement, admixture and water the necessary tests have been tested by recognized laboratories in accordance with Quality Plan for Pre-Testing of Mixes for Concrete Works “TGN-BC1-52-00-00-00-0316#03-00" According to the test results, the materials shall be decided and concrete mix design shall be performed in accordance with Quality Plan for Pre-Testing of Mixes for Concrete Works "TGN-BC1-52-00-00-00-0316#01-00". Other materials such as reinforcement bar and segment accessories, the materials shall be selected in conformity with “Technical Specification for Production of Precast Concrete Lining” and “Employer's Requirement’ 9 Inspections & Test Plan Please refer to Attachment - 2 for Inspection and Test Plan. 10 Acceptance Criteria ‘The acceptance criteria for the activities are described in the corresponding ITP. 441 Management of Inspection and Testing Equipment As described in ITP, calibration & test for measuring equipments shall be done. Please refer to Attachment-4 for Maintenance Programme of Production Plant, Equipments and Measuring Devices and Attachment- for Calibration Pian, which is the part of the Quality System of the Afaprefabrik. ‘Submission No, TGN-BC1-52-05-00-00-0590#00-00 Page 22 of 24 Revision No.00Taisei Kumagai Gama Nurol Joint Venture Quality No. BC1-MFQP-TBMO2 Marmaray Project - Contract BCt Quality Plan for T2M Precast RIC Segment Production 12Health, Safety & Environment During the production, AFA shall follow and implement the TGN's Health and Safety Plan, Environmental Plan, Emergency Plan, HSE procedures and instructions. All staff and visitors shall be informed according to the TGN’s general HSE instructions before entering the site by AFA’s HSE responsible All MSDS of chemicals shall be gathered and kept on site together with the materials during production for the purpose of using them in case of emergency. Please refer to Attachment-6 for Risk Assessment Table. 43Emergency Procedure Emergency network and Responsibilities shall be applied as mentioned in Attachment-7 for any case of incident or accident. After setting up the factory facilities, Emergency Plan Instruction shall be prepared and submitted accordingly. 14Documents & Records ‘The documents & records to be produced are following. 14.1 Documents before Production Following documents are attached in this document. * Production plant lay out (Attachment-8) + Drawings for moulds (Attachment-9) © Technical sheets for plant and equipment (Attachment-10) Following documents shall be attached in this document later. + Concrete mix design for R/C segment ‘© Test results of corresponding mix design. 14.2 Production Report & Record Following reports and records shall be gathered and documented during the production. ‘+ Material certificates (if available) + Calibration Certificates © Material test reports ‘+ Work inspection records ‘* Inspection forms (for pre-concreting, concreting & post-concreting activities) ‘Submission No. TGN-BC1-52-05-00-00-0580#00-00 Page 23 of 24 Revision No.00‘Taisei Kumagai Gama Nurol Joint Venture Marmaray Proj * Maintenance Forms Please find the samples of above-mentioned forms in Attachment-11. 15 Attachments Quality No. BC1-MFQP-TBM02 Plan for TBM Precast RIC Sogi No | Title Total Pages 1__ | Work Schedule 1 [2 | Inspection and Test Pian 8 3. | Quality Control Tests 2 4 | Maintenance Programme of Product Plant, Equipments 1 & Measuring Device 5 _| Calibration Plan 1 6 _| Risk Assessment Table 4 7 | Emergency Network & Responsibility 1 | 8 _ | Production plant lay out 1 @ | Drawings for mould 24 40 _| Plant and Equipment 26 11_ | Production Report and Record Forms 6 it Production ‘Submission No. TGN-BC1-52-05-00-00.0590#00.00 Page 24 of 24 Revision No.00ATTACHMENT - 1 (WORK SCHEDULE)ra a Oe TTT TTA (ae ee a PON A a weoyeoma | ne crocs 28s, | ‘sort eee0 ano ‘sisaz uonanporg || q sere wis we Aunsea jeu wowiag | oro wear uaisog xi ai000) | rs) on retsreyy warssv09 30) 01d | Me vu nas uojonasiog Zupuing ines WoMg i ! slepocesser 00 208 A Buumsejnuey, WweUUBag 21010U0) 1Se9a1 40} @MPOYDS YONATTACHMENT -— 2 (INSPECTION AND TEST PLAN)‘aqaodsoy drow) cones ae] APA | anledaieal weave Peete | soozower fea WOLDVHINOOINS GAS —_COASHENS = S TRON ALG WO WORNGINS = BTS VON ANOLON] = 17] woLasdsw AUT) = ID, USaNONS NOUYOHRIA WOM =3AMMA wosnuaens 3S = SS = SalimiaisNods3u 9D 01430 Gl wow. 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YEDIKULE SITE EMERGENCY COMMUNICATION Position Name, Surname Phone HSE MANAGER iZZET TUNAKAN Mobile: 0 532 464 84 07 Office: 142 ERT LEADER TSUKASA KOYANAGI | Mobile: 0 533 482 42 81 DEPUTY ERT MEHMET SAVASKAN | Mobile: 0 532 453 44 60 LEADER TBM PROJECT IMAISHI TAKASHI Mobile: 0 533 491 31 73 MANAGER TBM PROJECT CONTROL MANAGER HOUHANA SHINJI Mobile: 0 533 491 31 37 FIRE BRIGADE 410 POLICE 155 TRAFFIC POLICE 154 GENDARMERIE 156 AMBULANCE 112 HOSPITALS CERRAHPASA HOSPITAL 0212 414 30 00 HASEKI STATE HOSPITAL 0212 529 44 20 ISTANBUL HEALTH DEPARTMENT 0212 638 30 00 EMINONU EMERGENCY AID & RESCUE CENTER 0212 513 3111ATTACHMENT - 8 (PRODUCTION PLANT LAY OUT)ATTACHMENT - 9 (DRAWINGS FOR MOULDS)tov ne sana sem amram, [gy peas eater a — 4ODEXBENLXOISLE ‘aL] “09 @1MOW VIO \_ 78 ev annnes Toe Ava 1S? awe] HM aecowsin |_H _aponowser uma 9 war, JO 20K] PINOW ste-oveziwa | ob Bw wh 19 ACL pinOVY vib oreL/W | eb 9 ZL J0 @CAL Ino, eh-oveL/my | zh sz EZ $0 OOKL PINOY zib-oreziwa | bb be abU-Z_Ly 10 BAL PINOY Feb OpOd / WH OF Tausenn @ 193000 JO ]OF TEEN ezs-orex/wa | ez DEVEL, 40 80AL INOW ou-ovexiw | 6 yey9eq 9 OP FENUALA;LIROND vee-oraziwa | zz WEL, 30 8dAL pinoy eor-orez/n | 8 BADAID JO JULOF [EIPEY 2p OPOL / Wz .2P-ZL.J0 edA| juaWBes: 204 - 0P9L/ WH a @ADDID JO WUIOr 426 OP9L WH oz ubPV-ZL.J0 8dX, juawiBas: 901 - OFOL/ WH 9 ubjsag ue) xe, jUaLUBeg 22b- ObSL/ WH 6b 6G-Z.L, J0 odh1 juawbeg S01 - OPOL/ WH s 20K 4 =O AT PINON eit-orezwm | a (E21. 10 OdkL weuBes ror-orez/wy | > 2dKL 2a, IMO Ae7 pinoy eit-oveziwa | at WU-ZL. 0 edky weusBes eor-orez/wx | © 8641.1, 10 Ae7 pinowy zib-oraziwa | 9 WZ TCL JO Odky wousBas, zor-ovaziwa | z 20KL = 390 £7 PIMOFY atr-orez/wa | St WL, 40 06K WEUIBeS vo-oveziwy | t NOLLdIDS3q “ON ONIMVEG “ON NOLWdiHoSa0 “ON ONIMWHO “ON ism ONIMWHG GINOW LNaINDaSHO sanwan | NOS Tore vawnaye | @11 “OD GOW VO Wi sacoense [Ht ANSWOSS 3dAL LVZLwom | jo0exeenixongee — | weenie a “Po ous a1] “09 ano VaHOH \_ ae INAWOSS S¢AL ZLnoevaen0r8L SEERA. 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WEIGHT:4,0ton 6) 339158 | SET BIB sqyg | BAT uy YP BRE ERT a een [ennui WaT \ Korea MouLp Co, Ltp.070 020 “B2" TYPE MOULD WEIGHT:4,0ton | v 047 ey ar 5 Tat ar [say TR67) “t | 301 Kin [ "2005, 08.26 on [a SONG RGD yg | DT PORT ana = BC \ Korea Moutp Co, LtD.B641XOISLO "417 “0D aINOW YBHON \_, uo4S':LHOIAM, INOW 3dAL ub. wove sm) fea oar 3a wr we Ber 16% rar Tomes es x8671X a a soon | Foam | pane 158-A ygy | A 0? CUOOM YAHOO ye wibla 10 804, + + + + Tew f | f 4mn Sn ee Woe [ET avs | A scone | iogexagnixovare | RAETREE TS | ay “09 GTNOW VRHON \_ TZEOPSL/AO awenmenn | U060 $002 ey [HOE wh su genre xo ANIO? WILNAYASNNOMID Ter ar ver TwOE TE 1H T --— J TOE eve eree| 2 ee we pre woe gree |e w wewoe aa wr em [_ DROS ssennm | 4o0Exg6nx019Le 12-0810 wun 10 60°00 sve |_HD we “ax] “0D GINO V3HOH w 3 ANior Iwiava Ente Tove rn wr tS a ve FE Te THE 3 w e % 5RING ~ 13EA RING - 6E. RING ~ 6EA TOD a THT song | Bee | Eg 87640x1498x300t arn TEWO ewarea | SNOS_ wwemmao SEES. |917 405 amon va40y Wi jecoaee | HO ecncaaer seme q eseATTACHMENT - 10 (PLANT, MACHINERY AND EQUIPMENT)[tVouvaAA Bo¥m > Lom oor oost | tnt ware vava 0005] O50] 0806] ENA) Ose | 000 3/ Ose€} Os08 tnd 2{afafolelwv| van (Snoishania wivn) [waIMaTO vay BETON SANTRALI CONCRETE MIXING PLANTITVULNVS NoLaG waxin nya ANV Id ONIXIN 3LaYONOD Wits:CMA Hoisting unit designation Hoisting unit type Falls Drum size Duty group___ Nominal Load (SWL) Voltage 1 (main) Voltage 2 (contro!) Frequency Hoisting height Hoisting motor power/poles Hook Block Wirerope type / diameter Hoistin speed (normal) Hoistin speed (creep) Trolley speed Trolley motor power Trolley type Trolley duty group - Trolley wheel dia. Control pannel Pushbutton lenght Hoist and trolley weight Color End Carriage Type Whee! Diameter Wheel axis Connection type Lenght Drivetype Long travel speed Gearbox output rpm Girder, platform and portals Girder span Girder type Girder rail Color Platform and catcher Portals Girder electrical components AFA PREFABRIK CRANE DATASHEET CM3ID.CM3.L06.67.1 et 3 FEM M5(2m) kg 15.000 380 220 50hz meter 6 9.5/1.6 KW 12/2 Poles 3 Pulley DIN 15401 Single 14mm 6x36 warrington seale TS1918 26 04 16/4 0.75/0.18 KW Double Girder FEM M5(2m) mm 250 8 movements m5 Kg 1380 RAL 3020 MB.2800W315. mm 315 3500 Over head mm 4000 GTS Direct drive 2015 midak 30 mm 20.000 DB18 Welded box 40x30 St52 solid Energy tines Control lines Control type Connections Components Crane electric supply ‘Conductor elements RAL 3020 All along single side 40-50cm depth _ Rounded box mm 20000 mm 20000 Pendant control with two steps Plug&socket Siemens Meter 720CMINK ara prerasrik CRANE DATASHEET Hoisting unit designation Hoisting unit type CM2I0-CM2.He-L06-6T Falls én Drum size 2 Duty group FEM M5(2m) Nominal Load (SWL) kg 7.500 Voltage 1 (main) 380 Voltage 2 (control) 220 Frequency 50hz Hoisting height meter 6 Hoisting motor power/poles __ 4,910.8 KW 12/2 Poles Hook Block 3 Pulley DIN 15401 Single Wirerope type / diameter 12mm 6x36 warrington seale TS1918 Hoistin speed (nor 29 Hoistin speed (creep) 05 Trolley speed 16/4 Trolley motor power 4 Trolley type Double Girder Trolley duty group FEM M5(2m) Trolley wheel dia. mm 160 Control pannel 8 movements Pushbutton lenght m6 Hoist and trolley weight Kg 830 Color RAL 3020 End Carriage Type MB.2800W250 Wheel Diameter mm 250 Wheel axis 2800 Connection type Over head Lenght mm 3100 Drive type GTS Direct drive Long travel speed 20/5 midak Gearbox output rpm 30 Girder, platform and portals Girder span mm 16140 Girder type 0B18 Welded box Girder rail 40x30 St52 solid Color RAL 3020 Platform and catcher All along single side 40-50cm depth Portals Rounded box Girder electrical components Energy lines mm 16140 Control lines mm 16140 Control type Remote pendant contro! with two steps Connections Plug&socket Components Siemens Crane electric supply Conductor elements Meter 82Information Tok 900-216 6740474 Fou 716 STAREGA Wacker Mabinala Ltd SL Karamancifigh God Wo: $5. 24750 K BabhamSplatndy) Ref.: Wacker PAR 60/2 Pneumatic Vibrators Genera information Tnoroughiy lw ut ie pressure line corning from the compressor before comactng the equipment Check to see thal the coup. sieve and gasket len, Dra wale rom compressor cen ding ne winter mons fo avoid tang up ‘of compressor of pressure reserva. Use a wate ap (separa) i case of igh humidty Jarsanty and Recommendation ‘Oue othe fact that hese vitals wi run fora long ime dung the tunneling provess we suggest lo input ‘compressed a reted wih a der. ‘Tha der nstllaton could vad tho erosence of condensate nsd the pneumatic crcut {ts very imparian\ to felew his recceamendoson because hs condense presence could determinate a matoncson of te vibrator vrh a consequent vaneecking or addtional instruction & wit be sent he complete user and maintenance manu ‘Maintenance ‘Werecommend the use of maintenance uns wih smne ofers curing appicatons, Fastening Asitfening profile (.g, 60) shoul be stated et te corresponding fring pints of the enterna vibrator (1) ‘the formwork. Eier the thing device (2) forthe extemal vxator (1) ofa separale olae-iled steel plate forthe fing ofthe frg dave (2) shen tobe weed othe sifening pec Al the welding jis are to be cated ulin a non-coninuous (sep by step) weld The incorporate tug ole externa! wrt (1) ‘pushed underneath ie bt (3) af the fing deve (2) and than the externa betr sto be sacuroly tasted ‘by way of he spit nose included inthe motor housing (4) with the colar nut (6) of Yo aye Bot recommended torque wer seting i $0 - 180 Nn). The extemal vate (1) canbe moved in accordance to he pourng sequence @ sufiiet bang devces (2) ate avaiable Loosen the coir nut (6) at ne hung dex (2), move {he vitealor tothe rest point and then securely fasten vibrator again‘PAR 60/2 Technical Data {eludes quick-ennnect clamp device, operator's manual and parts book. ‘P= Pneumatic 60 = Centrifugal force (kt) AR = Exteel vibrator 2 = Quck-comect amp device Length x width x height (with quiek-connect clamp device) ‘Shipping size (1x1 xh) Weight (without quikkeconnect camp device) ‘Sipping weight (including packaging) Centrifugal force Vibrations Dee Operating pressure ‘Air consumption mm 180 x 242 «215 mom 250x200%270 hy 165 xg 60 Afenin 14.500 compressed alr ber 6 m3 fmnin 18USING DRINKi RUSTY DIRTY . GERMY ; WATER FOR HOUSES =, APARTMENTS FACTORIES... THE MOST PRACTICAL AND PERMANENT i ©SOLUTIONS...| Meoksis) winousry since< | WHAT IS MODULAR TANK? ~=MATERIAL ALTERNATIVES * It is @ special tank whose parts are * Stainless - Inox sheet connected to usage area without * Hot galvanized shest stool welding. + Painted sheet stool WHY MODULAR TANK ? MODULER TANK AND ACCESSORIES # It can be assembled easily passing $ Ss from the tightest places part by part. + There is no need of maintaining for many years. (tis so durable and hygienic. * If you want, it can be easily disassembled and carried to another place. » All parts are changable. ‘Tanks can be put on floats, roofs, towers} and inside the buildings. | * Itcan be manufactured or covered with different materials according to the properties of storage liquid. * There is no need of painting or welding at work site. * Itis lighter and stronger than simil 1) Water inlet and level flatour ighter ger ‘similar ones. 2) Water exit + Assembling period is shart. 3) Over flow pipe 4) Blow down * Damaged parts can be changed easily 5) ey indicator and valves 8) Bottom manhole * Capacity can be increased. 7) Top manhole 8) Air relief ini : 9) Module plate ‘« Transporting is ensy, because its parts are 10) Tank leg put one on the top of the other and within 1) Ladder the other. It occupies a little space during +2) Bolts transport. 48) Silicone and EPDM rubber gaskets Itcan be manufactured at different NOT: There are no bottom manhole and ladder dimensions and large capacities. on single row tanks.MODULAR TANK ASSEMBLING ATTENTION STAGES BY. Ground which the tanks is put on, - ea must be straight and strong. ‘There must be space at both sides and upper side of the tank as the figure below. MODULE PLATE AND DIMENSIONS dame Module plate general view Module plate dimensions Assembling of side platesLAE Sion elem. Cay isa arn se) MODULAR TANK USAGE AREAS AND APPLICATIONS Factories tor any quid sto type CAPACITY Aparments : “ina or 0.16 The = Lag height (500mm) is added to tank height *Itean be manufactured at different dimensions and larger capaciies. "We keep the right to change the dimensions, TORY SINCAN Sane! 3. CD NOG? Smesesnicane TURKEY TEL. 0089212 2714305 00009312 271 77.78 FAK-aoMD 312 771.43 0a Wen vive meksis.comtr Email meksis@meksis com trTeuv.) tulltepl eV eld (ue, - LC elope ttlit Wenectarcs fekvikelann Isyerterinizee Eb HHidaihy, Lb SULL LE LaLieL perth PETE TIWWOP ULES cu DEeur GeslenMODULER DEPO NEDIR ? “¢ Modiler depo pura olarak imal eden, kulkumm yerinde parcalan kaynak iglemi yerektirmedten ‘abate brary getirerck deponun kompkesiin olusturulabilece@ NEDEN MODULER DEPO ? ‘ Fuelaeyerercen parca ane peinrck ste vere cahathkle monte edilebilir. rel bir depo seklidir ‘eT pang fark gr ‘wan yllar bakim gerektieme tem ve bijyeniktir (Gok uzun iii re drtiiginden Gok + Arzu eailigi take rahatlkla demonte exiterek fparcalanaraky baykayerlere taginabilie ‘& Tiim prgatan ich ile destinies cechlmigtir, itil tim pagar standart ofdlagundan learn csteuligindle fabrikaan teria eile rata lige. + Depalae ye kuletere ve meveur binaarigersine raha monte idhsck platformlar izing, anya, clei. % Depolinan sivinin dzeliklerine veya istenilen dlepolana Ralitesine pire disk malzemedten inl ceili veya hahaa. + Santiye veya montaj mahullinde Kayak ve boat gerektiome 4 Emsallerine gire hafif ve daha saglamdtr 4 Moiita sires! ks 4 Zedtelenen vers bozulan pargakin istendiginde olay deeb “4 Depoama kaptsies! eset, cevtese yea boat dave yaar kaptstes atin ‘Tim pargalary dist ste we ig ge honulailiginden nuakliyesiesnasmela cok: ver kapl. + Gok biivik kapasivelerde ve degigik Glgilerde Airtel (water Tank) Fe ue ROE MALZEME ALTERNATIFLERI 2x Pastanma stc-fnos + Sicak galvanizli gelilt sac + Bosal elk sac 2 ma ap gk ste MODULER DEPO VE AKSESUVARLARI skis aya Blof Sevive giserges. At kum ap takin Raa © Havaandrma a Meat Profil depo ayags “Taman merdve Ska ivan Geel silkon ve epietiven kaucuk contatar od Thrall al baka hp toca vert veiMODULER DEPO MONTAJ DEPO MONTAJI SIRASINDA SAFHALARI DIKKAT EDILECEK iB i? HUSUSLAR — Deponun kurulacaga zemin, depo ve igersindekt su fag tagsctiecck ve yk luna forme cloaca sapida olmalue Depo kenarfarnda ve dstinde asada postr salle bogtukar burakilmaldr. Bu boyluklar mont ‘estas eval sas anand iam bala bakin ign gered(weber Tank) PAF MODULER DEPO KULLANIM YERLERI KAPASITE VE EBATLAR Al VE UYGULAMALARI a [Ss ber ti sim depolamada Apartmanimada ienyerde mA igerisinde nya disarisinda. Ti eld yokseklif SOmm elfenecekti Dept tra ye fa cari iat pai ‘Gigi defigtirme haklemer mahturdur. Sanayilegen nied sri fil agi i nee Ernst; matts@retaiccomtr itera melsscomit halkamuzn hizmetindeFOR YOUR PRESSURIZED WATER NEEDS PACKET WATER PRESSURIZING . SYSTEM ___ HIGH PERFORMANCE — § | 4p ENERGY SAVING li oe PACKET UNIT Et + COVERSSMALLSPACE ¢ & SILENT WORKING *& SAFE YOUR PRESSURIZED WATER NEEDS SILENT and AUTOMATIC WATER =r 4 STSTEM WITH ITS EXPERIENCE, MEKSIS. INYOUR SERVICEWZA=. CKET WATER PRESSURIZING SYSTEM WHY PACKET SYSTEM = WHERE IT 1S USED Packet system ready to work, + Houses, apartments, schools, offices ® Factories, industrial factories... + Hotels, green houses, farms, watering systems. “+ Operates without a problem and has along life. 4 It requires minimum maintenance. + It provides energy saving. * vinalce, Syatem applied by tanks. CAPACITY and DIMENSIONS: Ta (MEKM [No of | MOTOR [Flow rescue] Dimensions (mm) | Connections TYPE |Pumoe| Power [H/H| HSS [A | B | C [Sccton[omiwm| MEKM TYPES. = T i a U fmemr-tT || 38] 1 TA is [35] 75] a0 | a0 | 1200 | ¥ T T t T t T i Jaoron| iow [rena Shermer) | Canmore Power HV! MS |X [8 [C [Scctoafpimn| MEKH TYPES Dy 30 | ieao | a00 [1400 PE | 3) ay fiona [500 [1500 [14 |e Si 40_| 1200 | 600 [1700] 11/4 | a4 30 [soe ano Caen Pe $150} 1300] 800 | 200 | ia | te Toy 60} 1300] 800 | 2500 | TTA | Te “60 [14a foo | oo [aL 2! 86 | 1500 [1100 | 2600 | 2i/4 | 2 30/80} 1500 [1000 [2400 | 5 T BOT OO | 1700 [ITO | 2550 [4 ¥ Ree eases FACTORY: scan snat sits! 3.00. vo? shams Wee 31271 7726 = 2 OS - 6 fa 312,274 OF Eonal :aukis@Qnesiccomu Inert: mebsiscontewater pressuriding System LEM rs ve vais am zo PAKET HIDROFORLAR ces * YUKSEK PERFORMANS ILE GARE =; ENERI TASARRUFU SAGLAR SR & PAKET UNITEDIR | * AZ YER KAPLAR ee | * SESSIZ CALISIR sian | »* GUVENLIDIR } MKM Tipi MKH Tipi Membranls Hava Paket jh Paket Hidrofortar lidroforlar SUREKLi VE BASINCLI SU iHTIYACLARINIZ icin Sessiz ve Tam Otomatik Caligan Dikey Santrafii] Pompalt Pena anes VZBED 2 Sanayilesen Turkiye’ Stet 3.0, 1097 Sn ‘Tocritbesi le Sanayimizin ve halkumzn hizmetinde IABRIKA : SnCAN Soul 1097 SHAAN MeO Si Ws am 6 ee ae Oa 10 Em) :meksi@eeksscame Inert: neicewater pressurizing, System [Meksi;/ PAKET TT NEDEN PAKET HIDRABGEM) «© KULLANIM ALANLARI “ fomple paket intel. KULANIMA RALRDIR, > Ever, apartmana, oh, jeter (aly ign sadece sve lari aglanan — Fabrkalar, endless, saniyeler aplmas yeti Otel, tal kr sera, ice ve sulama csleinde ve BASIL SUTUN ‘Ti calor bibicine uyumlo ve en kali eee HERO markalardan segiignden bidrofar PROBLENSIZ, SESSIZ GAUGIN ve (OX U2UN GHiiRiDGR, Paket mimimum balam gereineek sede divayn edilmigtc, bu nedenle BAKIM GERERSINMES! HINIMUMDUR, 1 Thi ve data fala papa ida kademel ‘aligtfindan, EMER)! TASARRUFU.SAGLAR. ‘ Hidfearda key santa bdo pomglan tallnldigadan SESIZ ve MONFORLU CALIIR. Paker Hidvoforun Maier Depoarta Uygulamas KAPASITE ve EBATLAR . fonoeoR | PonPA] oToR[OEnT [oxy |__| maguwian | MEKM TIP! MEMERANLI el | aocoi|otct-we am | ass” [a] PAKET HIDROFORLAR: NERS | eo | 300 THERA lOROFOR POMPE] HOTOR|OEBI [BAT | _EBATLAR (Nin | BAGUUNTIUR ] MEKH TIPI HAVA SARJLI iel___[aoeot [cliche] W/m | MSS A [8 | C—[EMAE] BASHA) PAKET HIDROFORLAR: =, Ce CT MEWS [| 1 | 3} a0 [ooo [soo | 1so0 [va [iva | * Oiler eMHS | ( 2 | S| 40 [rx00-| 600 [1700 wa [in| ebb Hens T3680 1500 [0 freon iva] * Aes dest HECK —| [| 880 1300-| 600 | 000TH Te | Palin ERHTO_[ Tt [35-| of 60 | 300,| 600 [2500 TVA | ine | biroforda fmenaiets [2] aaa [15 {60 [1400 | v000 | 2400 | 70 {2 planar eEWH-20-| 2 | B15 [20 | 0_| s00_[tt00 | 2600 | 214 2 sehen mart EKH-IO | —2-| Be10-[ 30 80_[1800 [1000 [2400 [312 paslanmat Mene-6o [3 | Sets | GO 80 [1700 [1100 [2650 | 413 pompalar falar. LAE ee ABRIKA:SNCN SuSE. .49. nO SHCANRA RL OBIL 27 TE 26-27 $3 G5 - 6 HH: ODN T114D OH eal: me@eekincont — Inenet: eksscnsrSCOTCH TYPE STEAM BOILERS AND PACKET STEAM GENERATORS STANDARD ~ — QUALIFIED | \ LIFELONG, | es ie Ramer) gf Sb dds : ss Ws ‘ nee qth) 5s IT IS COMPLETELY PACKET UNIT. READY TO OPERATE...VAS type steam boilers CAPACITY AND DIMENSIONS ‘ Ans yf t A Me cee SH : wv oe =o HEATING | STEAM Heat ] | Water | Steam ISURFACE| CAPACITY |capacty| £ |e | t ou | 6) & Te] Valume | | toh | ca | om | oem | o_o 28 rm 06 | it —s | ise 0000 | 1290 [1800 | eto 1970/2 a a yano00 | 1300 | 1900 | tao | 1300 | 2 225 | 480 00 | 1700 | 2240 "1600 [an i 1028 Ea ~ 860. 50 | 1140 | So 725 | reso 755 0 800 a % 1050 es az | zo | 2060 a 1200, Ce 6 1850) sao |2es0 | 65 | 32 | 27a | 288 a 1500 sea {3000 [so | a2 | rang | ze00 co 1800 26003403200 eo | 22 | ase | sso 7 2100 ‘e00 |sa00 [eo | 40 | 3820 | 3800 a 2600, ‘2720 | 3800/3400 100 | 40 | 4a7a 4578 CI 2700 ‘aso 100 | 40 | agra | 4780 ie r woo | 40 | 5045 | 6260 : a oe 70 | 800 15 _| 80 8568 75 | Beso (1s0_|e5_|7a50__[ 7160 Zo | 8500 5238 jm cic] 65 | weed | B65 [sea toon" a om) 122650 ‘o0__| soo |“ge50 | (014000 100 | see0_| 9760 (ao - 1760 100 | sa | se75 | (a0 17500 100 | 10760 | 9065] IT WORKS WITH HIGH EFFICIENCY, {Ss SAFE and RELIABLE, HAS A LONGLIFE DAP rebuhar kazanlari ve paket buhar iireticileri Standartlara uygun, —~ ~~ ( Stearn cilee) kaliteli, uzun 6miiriii, denenmig, emniyetli ..»; 2 Skoc tipi i | | yakit ve tabii gaz yakarSteam Boiler Sta Meee AWE La skoc tipi buhar kazanlart kapasite ve ana Olciileri } 6 K NY rm | Ne a2 _| 25 | 22 | 25 5 ag [25 | 928 20 [so | 25 | 1940 | 6 i 0 | 25 | 1e60_| 1788 | 30 1760 | 2150/9140 |7500| 65 | 32_| 2015 | 1868 Fa 150 | zaso | s140 | 2500 65_[se_| 2200 | 2060 40 1900 | 2300 | 3240 |2800| 65. 32 2800 2450 45, 1800 | 2300 |'s4n0|za50| 65 | 32 | 27a0 | 2548 o 2000 | 2400 | 3940 | 3000] 8a | 32_| ze00_| 2800 60 [ ‘soo | 3640 |3700| 80. 32 3845. 3580 70 ~ [200 | 2850 | aeea {3300 | a0 | 40 | gez0 | se00 | oa zee | 2730 seat | 3400 | 100 | 40 | 4678 | azo 0, 2 4 [2380 | 2810 | 4140 | 3600 100 | 40 | aare | 4760 | yaeo | 2950 4440/3600 | 100 | 40 | soa5 | S250 | 500 | 2860 | 4640 (4000 | 125 | 60 | sse0_| e050 | 150. 200 | 8050 | 6040 | 2400| 125 | 50 | soso | e568 | V5. ‘2p00 | 2250 | 5040 | 4400 180 | 86 7850 710 | 200 3000 | 9450 | 6040/4240| 150 | 65 | sees | eZee | 250, ‘6250000 | 200 | 9700 | 5140 |4500| 200 | @5 | 8960 6945 __| 300 {8300000 | s800-| se00 | ae0 | 6250 200 | eo | e250 | e345 350. 7350000 | 3700 | 350 | 6250 5560 | 200 0 8600 9650 | 400 ‘400000 | 3880/4180 | exso (660 | 260 | 100 | 900 | a7eo | 480 | torso was | 25 | 420 | gana | 700250100 9660_| 9875 | soo | 17800 [_Yesoo000 | 4000 | 460 | e560 | 5850 | 250 | 100 | 10180 9065 yiiksek rancimanh, giivenilir, emniyetli ve uzun Gmiirliidiir. igietiimesi, bakim ve tamiri kolaydir. FAs) EXAM SISTEULER MALNTVE MOREXDIGL ANON SE | ae ]“Makine dal kontrol lup ayeriar ve programlar LCD ekran lzerinde yapimskeadr. Bu dzeligincen dolayt seri islerde \ teroiedilen bir mekinade. BSD ITAL STEEL BENDING MACHINE (New Type) ‘The machine has digital control, and the adjustments and programs are made on an LCD monitor. Because of this feature it is preferred in serial operations. BN 7 Fano ane BOY AS ig/mere | SS Ta/me_ [BS kg/m BauxT | waext | OSEKT Bae [eso [aaa (ores res B98 MEKANK DEMIR BOKME MAKINAS! ‘Makinada 0g degjsik ayar yapiabiime olanatina sahip olup, otomstik ‘ve menuel olarak kumanda edilebilmekle bersber Saga ve sola d&nebilmektedir. Yerlesik olmayan insaat olaniarinda oldukca faullarush bir makinadir, Bu nedenle insast alenisnnde tercih ediien bir mekinedin. B 96 MECHANIC STEEL BENDING MACHINE ‘The machine has three different adjustments and can be controlled automaticaly and manually as well as being capable of turning both {eft and right. itis an ides! machine for unsettied construction ares ‘end especially preferred at unsettled construction sites, Tinian Ea Wael AS igen’ [SS eyewrt_ [85 ig/ene ‘YORSERLIEC Bae | ozext__jazext iee | oiexe [a 1exe VOLTA oiaa | a1ae e198 Lkmekanik insaat demiri kesme makinalari mechanic construction iron cutting machines M38 MEKANIK DEMIR KESME MAKINAS! ‘Mekanik tahridi olup ayak pedal ile kumanda ediimeltadir. Yerieskc olmayan insast alanla oldukea kullanish bir makinadir. Tekerlakl olup kisa_mesafelerde taginabilme imkanina sahiptir M36 MECHANIG STEEL CUTTING MACHINE It has mechanic drive system and controlled by 2 pedal. itis {an ideal machine for unsettled construction sites. tt has wheels therefore itis portable in short distances, MEKANIK DEMIR KESME MAKINAS! ‘Mekenik tahrildi olup ayak pedalt ile kumanda ediimektedir. | Demiristeme tesisleri ve insaat alanlarinda oldukca ~ Kullénigh bir makinadir. Tekerlokli olup kisa messtelerde tasinablime imkanina sahiptir. M55 MECHANIC STEEL CUTTING MACHINE It has mechanic drive system and controled by e pedal Ibis an eal machine for iron processing units and unsettied construction sitgs, It has wheels therefore it is portable in short distances. Safer Ram Kapastes! thn Conse TES [em—| | Baek] AB terror [ES Tame | BBIG/TE, fer 7 | 250, aa B36. 3 [KW] [eee 28 B25 waa [vorT | [a eee ‘aaa B20. eat [ka a_[ 820 220 B18ATTACHMENT - 11 (PRODUCTION REPORT AND RECORD FORMS)RS Corcoran Waa ape OH Gea OTT (KON) = Foo Rep RA Coa MARWARAY PROJECT Contract: BCT Rallway Bosphorus Tube Grossing, Tunnels and Stations RIC SEGMENT PRODUCTION CHECKLIST IP NO: BC1-MFaP-TEM-02-1P-02.00 of segmenting OBESE an A6GMEMT anny Produation Date [snit Won: [Report Wo. I PREPO O01 2,__PRE-CONCRETING OPERATION 4 =] tapectonions | Restoran | anakal | Fapeton Inspectea By Approved By Remanns TTR [Geanea o Raa soot spcaton 21 22 2a poss 25 |frmeateg natals atrial Daxarption Iepection tems cane caw | Crashed Sand | _ Natural Sana ‘oment War | Adicio ae fara fois os) RE far2 [Porecos Wort tay fara frame oo Senin PERE [Ro a al b.12 [oorecea wont [resoa By (Contotoa By Vaaproved By Ret fs3. [store va em [232 oenaiy tem) [233 oon Tene. Co) Inspection ems | Designvatue | Atowable Test Test? Test Remarks [3.4 sempioo senso core Frexea By [Eontrated By Ponared By RET __ inspection items Time (hour : minuto) i ara at] ae aot] ates a aes arr aa [stan at ho shows | shou | shours | ohours | 1shours | s7nours | 24 hours 2 [tetas or a sig cabinet °C) [inspected By [Controlled By 5___ POST CONCRETING) CONCRETE COMPRESSIVE TESTS: tps AT inspections | Des Actuals | Actual? [Average TestedBy | Contoled By [Avoroved By 51 [Mersieamaurea | > 52 [a 20 cay 220 Mpa 6,__ VISUAL & DIMENSIONAL CHECK AFTER DENOULOING: re Jnspection] Result of na, | Inspection toms | ection Inspected By | Approved By Remark 11 [Parmictie «of pores 12 [Pormisatio se of proe 13 [Colour and appreance 11 [orc [a1 fRepairnecessty [512 Pimesiona checkRS Cara Ram Cans TT tien WARWARAY PROJECT Goniract= BGT Ralway Boaphorus Tube Grossing, Tunnels ad Seaions | SPACER CHECKLIST I1P NO: Bc-NFGP-TaM.02sTP.03-00 ot spacer proaucos Prodvcton Bae oni. [Reson No TeNPRC.SPARGGT AE] tnsnecton meme Relate Dring | ‘Resalt fT Wspenon | nspectea By ropeoweey | Remarks yy [esenras Roa sce spesaton 22 [ering wre | 2. CONCRETNG OPERATION 1] econ une Tatra beeron 0 cane can | rosteu Sond | Waalsong | Goment water | Admire [mero woke oct fi oir y js12 areca wean ao) firs piomze RES a f.12 fearesea oon) Tesea by [canroner By mont iy Ae] tnapectontens | Omsignvaie | Alone Test 2 Test 3 — no] ‘oe i Dovatons Remar stamp va em) 5.3.2 foensty oem 3.3.3 |coe. Temp. 9 aalsancina a Tesea By [arated By [aeroret By TE] Inspection toms Time our minut) sae Sa aaa 43 [start at ‘nour | 2hours snours | snours | shows | hours | 13hours | s7hours | 21 hours ' Jeu eatin °0) | fnspectea By [convaraa ay 5.__ POST CONCRETNG: CONCRETE COMPRESSIVE TESTS, pa [ACT inspection toms | Design Value | Actual | Actual? Average Tested By | Contaled By [Approved y| 5 [B28 days = 80 Mpa 6. _ DIMENSIONAL CHECK AFTER DEMOULONVG 22) inspection toms [mspection) Result of | ingpocte rove ema 4] inspection tom: pection| Result of | inspocted By | Approved By RemarkROTTER “anerr miKeRS WORATORS, TWARNARAY PROJECT Contart 781 Raliny Bosphoras Tube Cong Tonnes wa ST MAINTENANCE CHECKLIST - week / per SMont per Bont 7 Angus! ae ot} Chace [ree CHRO. T0027 09-00 ee ceneon zn aa fapenostay | a pes luonesaie> wes] ‘vauney jwaudinba pawaNe en booo-wo-ouereL "ON Hodax, ooeranreo-WalsoswioE 1 (00-20-a-20-WAL'dDSIN-198 ON Al ASM493HD NOLLWAarIvo uoneig pus sjouuny “Gujssorp eqn sraoudeog Remeu 19g! WERUOD 193°OUd AVEVNRVA _arunsuon vasvunydey ¢sofotu| wuoroaygwsnuen wo fon (ae wood oi ewe SeuO0#S04-0¥d-WAL “OU WHO lonrsaa [0021 fons s24 02/7) Jonrsaa woos fon rsa =| 0027 lonrs3a oe 71 lows sax ogy" low saA | 0011 fon rsa 2 | Soo" lonrsaa = | Moos" fon sax ¢ 02/7" Jon saa [0021 lon s3A ozs" fon sax ‘00 /"""/) fonssaa ozs" fonssa4 | moos fonisaa oz) low ssax 1 jon sa | moves) fonssaa 0/7 lonsa4 “oz fonrs3a 0/7 swiuey eurwiny ‘on eunwiny | wey founwiny | nv pu ees que feowrerey | Hex |owours | wny | unr | x Serv | 2804 wondusseg ordues von edues | fe Suydwes wop3 ingen | oun oa Gomens| wey Jwewso| iva | eva | wo | zvo kg ponaroy eens 26) ypurje eunuinu - uayey aides 31 eApinas - ksoniea (ony) vert on euanen (9001 VEN &AAKL HEEL 131190 LIAYY SCOVAINYH - HOO NBLSIORY TWINALW MVE ‘SUOHPIS pue Syouuny Buysse ogni snIoydsog KEMIEN 15g! FEAT 1937 Od AVEVIWN (Ar NoML) perinsvon vasvunydsy sofort nero} ssou99 Ha: sForEw3 AP osny ewe seen oor; so12eH09 O€3|(TKGN WV) [EPC Contractor Taleel Kumagai Gama Nurol JV [Employer BLH General Directorate [Eiployers Rep-AVRASVA Consult IV MARMARAY PROJECT Contract: iC7 Railway Bosphorus Tube Crossing, Tunnels and Stations CONCRETE SAMPLE REGISTER BOOK - 8ETON NUMUNE KAYIT DEFTERI ‘Compressive Strengths Sample ID. No.of | Dato of ay Sloan Gorin = omarks (oroducton date-sit no-setco) | Sample | Sampling | After st 1s @ 28 day: Remark no. date no. date HEW-PRC-Oxe00%-0%-0x 5 2 nos, 3nos: Form no.: TBM-PRC-FOSHO0