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Machine Fabricated
Gabions – Nepal
Rural Access
Programme (RAP)
Phase 3
State-of-the-Industry
Report
June 2016
State-of-the-Industry (Gabion boxes) Report
1. Summary ................................................................................................................. 1
3. Desk Study.............................................................................................................. 4
3.1. Maccaferri ..................................................................................................................................... 4
3.2. Historical Development - Nepal .................................................................................................... 5
5. Conclusion ............................................................................................................ 10
5.1. Findings ...................................................................................................................................... 10
5.2. Recommendation ........................................................................................................................ 11
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State-of-the-Industry (Gabion boxes) Report
TABLE OF FIGURES
Table 1: Combination of mesh type, mesh wire and box size: ............................................................. 3
Table 2: List of Factories visited by CMS.............................................................................................. 4
Table 3: Weight of Wires for Machine woven and Hand woven gabion boxes .................................... 5
Table 4: Diameter of wires in Standard Specifications ......................................................................... 6
Table 5: Factory Inspection Plan........................................................................................................... 7
Table 6: Summary Table ....................................................................................................................... 8
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State-of-the-Industry (Gabion boxes) Report
DOCUMENT CONTROL
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State-of-the-Industry (Gabion boxes) Report
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State-of-the-Industry (Gabion boxes)
1. SUMMARY
Rural Access Programme – Phase 3 (RAP3) is a 4-year DFID funded project covering 14 Districts
in Nepal. It aims to improve people’s incomes and resilience through employment, sustainable
access to markets and improved access to economic opportunities. Expected outputs include
improved and sustainable access due to climate resilient rural transport infrastructure,
maintenance, upgrading and road/trail-bridge construction.
New road construction projects have been commenced in 4 core districts – Humla, Mugu, Bajura
and Kalikot, prioritised as per DoLIDAR’s DTMP procedures. For these new construction roads
huge quantities of gabion boxes are required. As planned, procurement of gabion boxes and its
delivery were performed in Yr-I and Yr-II. However, during February 2016 on a DC field visit note
(Refer Annex1: FIELD VISIT REPORTs) to Kalikot (03rd - 15th January 2016) and later to Bajura
(12th -19th February 2016), some quality issues had been raised regarding gabion boxes supplied
by Hulas Wire Industries Ltd. The quality issues were: mechanical connections of end panels to
main body and size of diaphragms and end panels of the gabion boxes.
TMO held a meeting on 27th January 2016 and 25th February 2016 (Refer Annex2: Meeting Notes)
with Hulas. Meeting discussed on quality issues, possible solution, resumption of supply for
balance quantities and field visits. Meeting on 25th decided that a cost reduction in the invoices is
acceptable to Hulas for rectification done by RAP-3 on already delivered items. Similarly, a pro-
rata basis cost reduction in the invoices was agreed for undersized diaphragms and end panels. It
was agreed that RAP-3 would not continue receiving additional poor quality gabion boxes and
would only resume receiving goods if RAP-3 had the assurance that Hulas can supply gabion
boxes according to RAP-3 standards. In addition, it was decided that, RAP3 would send CMS to
carry out factory visit to see if there are scopes to improve the production technique. CMS visited
six numbers of mechanical weaving suppliers to understand the status and capability of the
industries in Nepal and to explore to what extent Hulas and other factories were following the
standard specification.
CMS visited six factories in which four viz Hulas Wire Industries Limited (Hulas), Kamal Rolling
Mills Pvt. Ltd. (Kamala), Pioneer Wires Pvt. Ltd. (Pioneer) and Premier Wires Pvt. Ltd. (Premier)
are based at Biratnagar, Morang and two viz Super Wire & Steel Industries Pvt. Ltd. (Super Wire)
and Gabionet Environment Solution Pvt. Ltd. (Gabionet) are based at Hetauda, Makwanpur.
Based on the findings from factory visit, a meeting was organised with Hulas on 11th April 2016.
RAP-3 suggested the Supplier to add Cut-Edge selveding machine in their armoury so that the
product substantially matches to the standard specification. However, to re-start ongoing supply
RAP-3 asked Hulas to improve the tightness of mesh to selvedge wire connection by stringent
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manual means and shall use a common selvedge wire for joining end panels to the main body.
After remedying the defects, RAP-3 allowed the suppler to re-start the supply with extended time
up to 17th June 2016.
Adjust specification to acknowledge that bulk of Nepal factories are not equipped with
Mechanical Selvedging Machine and also cannot mechanically join end panels to main
body. However should use a common Selvedge to join the end panels to main body.
Incorporate incentives to seek to improve the industry, e.g. a financial preferences in
evaluation for those equipped and using mechanical selvedge machine. Thereafter once a
base of factories are equipped, make this mandatory.
2.1. OVERVIEW
What is a gabion? A meaning of gabion in Wikipedia is ‘A gabion (from Italian gabbione meaning
“big cage”, from Italian gabbia and Latin cavea meaning “cage”) is a cage, cylinder, or box filled
with rocks, concrete, or sometimes sand and soil for use in civil engineering, road building, military
applications and landscaping’.
In Standard Specification for Road and Bridge works under a Gabion heading it has been
described as ‘Gabion shall consist of steel wire mesh crates. The steel wire shall be mild steel wire
complying with NS 169-2045. All wires used in the manufacturing crates and diaphragms, binding
and connecting lids and boxes shall be galvanised with an heavy coating of zinc by an electrolytic
or hot dip galvanising process. The weight of deposition of zinc shall be in accordance with NS
163-2045. Zinc coating shall be uniform and be able to withstand minimum number of dips and
adhesion test specified as per NS 163-2045. Tolerance of diameter of wire shall be +/- 2.5%
percent. The tensile strength shall be 380 to 500 N/mm2’.
However, there are Special clauses used similar to RAP3 and Maccaferri’s product specification.
SP 200: Specification for machine made gabion wire net (Matches with Maccaferri’s product
speciation) describes:
Gabion definition: Gabions are boxes made of hexagonal double twisted woven wire
mesh, divided into cells by means of diaphragms which helps to reinforce and strengthen
the structures. They are interconnected with other similar units and filled with stones at the
project site to form flexible, permeable and monolithic structures such as gravity retaining
walls, channel linings, weirs etc.
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Manufacturing: All gabions shall be machine woven rectangular units made from double
twist hexagonal mesh of heavy galvanized mild steel wire.
Selvedging:
Main body: All edges of standard gabion should be mechanically selvedged in such
a way as to prevent unravelling of the mesh and to develop the full strength of the
mesh.
End panels and internal diaphragms: Alll sides of end panels and internal
diaphragms, except the bottom should be mechanically sevedged in such a way
as to prevent unravelling of the mesh and to develop the full strength of the mesh.
Connection of end panels to main body: The end panels in Box gabions should be
mechanically connected with the main body at the manufacturing site by selvedging both
to a common selvedge wire in such way to prevent the separation of the end panel from
main body even in extreme conditions.
Connection of internal diaphragm with main body: All the gabions having length equal
or more than 2.0m must have internal diaphragms at a distance not more than 1.0m. All
the diaphragms of the gabions should be connected with spiral wires.
Wire Specification: The wire used for the manufacturing of gabions and mattresses shall
be annealed mild steel complying with BS 1052:1980 or NS 169:2045 with an average
strength of 380-500 N/mm2 and shall be galvanized before weaving as specified in BS
443:1982 or NS 163:2045.
Combination of mesh type, mesh wire and box sizes: Gabions and mattresses shall be
of the mesh type, wire diameter and box sizes as shown on the table below:
Nowadays, Gabion structures are being used in various Civil Engineering structures. A gabion
wall is a retaining wall made of stacked stone-filled gabions tied together with wire. Gabion walls
are usually battered (angled back towards the slope), or stepped back with the slope, rather than
stacked vertically.
Gabions have been used from ancient times but only recently it has been used widespread. In
Nepal both handmade and machine made gabion boxes are in use. However, the Standard
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specifications for Road and Bridge works, mentions about handmade gabion boxes and its wires
requirement for fabrication but nothing has been mentioned about the machine made gabion
boxes. CMS had carried out an extensive study on machine made v/s handmade gabion boxes
about two years ago and came into conclusion that machine woven gabion boxes are superior in
terms of uniformity, strength, looks and are easily available which has been producing by 6/7
suppliers in Nepal. However, it is very costly to be transferred to the district like Humla and thus
recommend as a special case in inaccessible districts to use the hand woven gabion boxes as
gabion wires manual transportation is easier than machine made gabion box manual
transportation.
Initially, only handmade gabion boxes were in use in Nepal. Maccaferri initiated for machine
fabricated gabion box production and first production of gabion boxes was in 1996. Since then
many gabion box factories are in operation. Following are the list of factories that were visited by
CMS for his study. Though Maccaferri was approached for factory visit on several occasion
(verbally and in writing), but researcher did not receive authorization from Maccaferri.
3. DESK STUDY
3.1. MACCAFERRI
Maccaferri is an International pioneer and world leader in the production of gabions and retaining
structures used for river training, earth control, soil conservation etc. It was established in 1879 in
Italy. Over the last 130 years Maccaferri has been producing mechanically woven hexagonal
shaped double twisted steel wire mesh products. Over the time, it has developed technically
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efficient and economic combination of mesh wire, mesh sizes and box sizes. Now it’s a global
company, with more than 70 subsidiaries operating in 5 continents, with an on-site presence in
more than 100 countries, and nearly 3000 employees. It has highly-specialized professionals
trained in designing and developing complex solutions in the civil engineering, geotechnical and
environmental construction markets. It has environmentally-friendly products and applications.
Maccaferri (Nepal) Pvt. Ltd. established in 1997 in Nepal is an associated company of Officine
Maccaferri, Italy. Its product machine made mechanically selvedged double twist gabion boxes are
being widely used in Nepal, but whether it is made in Nepal or imported from India is doubtful. It’s
a pioneer in Nepal and other agencies in Nepal followed its specification for the production of
gabion boxes. Now, apart from gabion boxes, Maccaferri has other products in market such as
geotextiles, geosynthetics, geo-grids to geomembranes, etc.
Recently upon RAP3’s request Maccaferri conducted a workshop in RAP3, TMO, Lalitpur, which
was brief but was able to provide knowledgeable information on machine fabricated gabion boxes
such as mechanical connection in between selvedge and mesh connection. In fact this workshop
was very valuable for conducting research on gabion producing factories in Nepal.
When did gabion structures start in Nepal? Perhaps, there is no concrete answer for it. Years
before Maccaferri was established in Nepal, handmade gabion boxes were used for civil
engineering retaining structures. For example Lamosangu-Jiri feeder road (110Km) was first build
under LEP approach in 1985 that extensively used handmade gabion structures. There are many
heavy coated machine fabricated gabion box factories now in Nepal. In parallel to machine
fabricated boxes, handmade gabion boxes are also extensively being used in the Civil Engineering
structures. The researcher carried out extensive study for machine fabricated v/s handmade
gabion boxes about two years ago. The result of the study was the hand weaving gabion boxes
require extra thickness of wire to compensate for equivalent retaining force. Additionally, machine
made gabions are considered better due to tightness of twisting, uniformity of mesh which is good
for uniform load distribution, stronger than handmade gabions whatsoever big size of the mesh
wire is used, high productivity, etc.
Table 3: Weight of Wires for Machine woven and Hand woven gabion boxes
Weight in Kg per box for Hand Weight in Kg per box for Hand
Gabion box woven woven
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However, in a wider context, a gradual move to machine fabricated gabion boxes by projects is
taking place in Nepal. RAP-3 has given emphasis on machine fabricated gabion boxes and it is
procuring it in all districts except Humla. In Humla, machine fabricated gabion boxes transportation
is costly through air lift and it is near impossible by other means. Hence, in district like Humla where
road is not accessible, handmade gabion boxes shall be a better solution as GI wire transportation
is easier.
DoR specification (as of July 2001) is related to the hand woven gabion boxes and it does not
speak about machine woven gabion boxes. The specification for machine woven gabion boxes
shall be included in DoR specification. The difference in DoR specification and standard machine
fabrication gabion boxes in use are as in table 4:
4. FACTORY INSPECTION
4.1. PROCEDURE
A data sheet was developed (Refer Annex 3: Factory Inspection Data Sheets) for a number of
variables checked during factory inspection to know whether gabion box product matches to the
standard specification or any difference therein.
In general, all the factories produce mesh by mesh weaving machines and its edges being
mechanically connected with selvedge wire. However, all factories except Kamala Rolling Mills
have manual connection of Selvedge wire to mesh in cutting edge portion. Interestingly, Hulas
Wire Industries uses two separate selvedge wires for end panels to main body joint but all other
factories uses only a common sevedged wire in this connection.
4.2. PROGRAMME
A factory inspection plan was as shown in the following table. On 16th to 18th March, CMS inspected
Biratnagar based factories on companion with Morang DTA team [On 16th: Harihar Bhandari (DTL),
Dristi Lamichnaney (Graduate Engineer), on 17th: Hem Bahadur Thapa (SAME) and on 19th: Ram
Ratan Yadav (SAME)] and on 9th April, he inspected Hetauda based factories on companion with
GE, Biraj Adhikari.
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4.4.PHOTOGRAPHS
Photographs 1 & 2: A meeting before factory Inspection between RAP team (Premier) and
factory team and a mesh weaving machine (Pioneer)
Photographs 3 & 4: Cut-Edge selvedging machine (Kamala Rolling) and mostly women
group working for cut edge selveding and end panel connection to main body (Hulas)
Photographs 5 (Premier) & 6 (Superwire): RAP-3 team inspecting the size of Gabion box
and two selvedge ends
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Photographs 7 & 8: Tensile strength testing machines (Hulas) and a factory lab for zinc
coating test (Pioneer)
5. CONCLUSION
5.1.FINDINGS
Total six numbers of machine fabricated gabion box factories were visited by the researcher.
Interesting findings of the Inspection are:
All factories have mesh weaving machines producing mesh size of 100mmx120mm but
Gabionet can also produce mesh size 60mmx80mm using mesh wire 2.2mm and selvedge
wire 2.7mm.
Kamala has cut-edge sevedging machine. Gabionet has small 2m width cut-edge selveding
machine but has not used till the date due to its short length.
No factory except Kamala complies the standard International / RAP3 specification
(Maccaferri) in totality such as mechanical connection of end panels with the main body.
All factories except Hulas use a common selvedge wire for the connection of end panels to the
main body.
End panels and diaphragms shall be 1mx1m size with respect to the standard specification,
but it is found that all the manufacturers are using the size 0.95mx1m. It is due to the mesh
size is of 100mm x120mm and diaphragms or end panels used 9 mesh + ½ mesh =9x100 +
1x50 = 0.95m.
All factories uses mesh wire (3mm), Selvedge wire (3.9mm) and binding wires (2.4mm) for
mesh size 100mmx120mm.
Four Biratnagar based factories produces GI wire and uses the same wire for gabion box
production. Two factories Super wire and Gabionet uses domestic wires produced by these 4
factories.
All factories have lab facilities in its factory premises except Superwire who conducts test on
lab at Kathmandu four times a month and received wires with test certificates.
Kamala Rolling only uses male workers whereas other factories uses about 70% women as
factory workers.
All factories use labours between age group 18 to 55 years.
Factories like Hulas, Pioneer supplies GI wires and gabion boxes to India.
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Apart from zinc coating gabion boxes PVC coating gabion boxes are also being produced by
some factories which can be used in corrosive climate or under water gabion structures!
5.2.RECOMMENDATION
The factory inspection was a very relevant and important means to understand about the gabion
boxes that are being producing in Nepal and whether these match to the standard specification or
not. This inspection gave ideal knowledge to the researcher. He shall review bidding document
and amend the specification in upcoming procurement of gabion boxes to make sure there is
correlation in what RAP-3 can practically accept such as size of diaphragms and end panels i.e.
0.95mx1m instead of 1mx1m.
Further, we can encourage the factories to produce the gabion boxes that more closely match the
standard specification. For that the factories shall add cut-edge sevedging machine to their
armoury so that the product matches to the standard specification which stresses that ‘The end
panels in Box gabions should be connected with the main body at the manufacturing site by
selvedging the both to a common selvedge wire in such a way to prevent the separation of the end
panel from main body even in extreme condition’. RAP proposes to amend its bid document giving
preference to the factories which provides mechanical cut edge selvedging.
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FIELD VISIT REPORT
Purpose: Engineering Monitoring Visit from TMO on two district roads in Kalikot: Sanighat-Shipkhana (SS)
and Jarkot-Ramnakot (JR)
Visit Team: Hom Nath Lamsal, Bishnu Ram Bista (DTL), Sunil Tandukar (RE), Mahesh Bhattarai (NGO
PC) along with 3 IoWs and all STSs on their respective road sections (IoW of JR was on
leave, who was met on the way back to site)
1. Overall Impression
The physical progress is encouraging on SS and construction is on full swing with
mobilisation of almost all RBGs. However, quality of works is not satisfactory at all. What
was observed at sites indicates that there has not been much senior level (RE, EO and
DTL) interventions towards quality assurance of works. The lower tier of supervising
staffs (STSs and IoW) does not seem to have been guided and backstopped in a proper
and timely manner as part of engineering control from DTA management. Whatever was
achieved seems to have been merely from the effort of STSs. The major noticeable
deficiencies pinpointed during last TMO’s visit by BS and HNL (March 2015) still
continues to appear till now. Even though there has been noticeable progress in settling
issues like land disputes in some sections, relocation of electric poles; one cannot see
progress on quality management of works. DTA management should put well thought-
out plans and strategies in place to rescue from current haphazard and ad-hoc site
management. Adequate orientation and training to field technicians (especially IoWs
and STSs), regular field supervision and monitoring by RE and EO, standard work
procedures (method statements) as defined by the specifications and necessary
checklists for supervision of major works needs to be immediately in place so as to
streamline construction procedures in pursuit of quality throughout the length of the
road.
The physical progress on JR is not as encouraging as on SS mainly because of one year
late start of work and harsh/steep/rocky terrain. It is likely that this road may still remain
incomplete by the time all other RAP’s 6 new roads are completed. Even with full efforts
in place, it looks challenging to complete the road in three working seasons including
this year.
2. Issues on Quality and Work Management
2.1 Gabion work (lacing, bracing and stone filling)
The proper method of gabion crates filling, lacing and bracing (horizontal) does not EO/RE/IoW/STS
seem to have been followed. The lacing of gabion boxes with each other is found only
on the front face sides and not on the inner sides, and in some cases there is no lacing
even on front face. Horizontal bracing also lacks many things. It was so frustrating that
selvedge wires of adjacent boxes have been twisted each other to tie one box to other
in many cases. Selection and laying of stone inside the box looks good on the front face
whereas the inner part of the box has been packed so carelessly as if it is a simply heap
of stone made in a haste. (ref: photo 7)
Discussed with field team and explained the proper method. Field team needs to refer
to LRN training manual and road specifications as well to develop a “method
statement”. Continuous spiral lacing with three turns at approx. 15 cm on all sides of
8. Visit to DDC/DTO
A courtesy visit was paid to acting LDO (DTO chief). He was briefed about the current
changes made to the implementation arrangements of SED. He requested to speed up
the process for DTO building construction. Nothing was assured in this regard, however
he was informed that Design of the building is still underway. He also requested RAP for
support to revise/update DTMP because DDC thinks that it does not address fully the
need of the district.
Photographs:
Photo 1: Retaining wall in progress at 8th hairpin Photo 2: Retaining wall in progress at 10th hairpin
bend ch 2+640 - SS bend ch 3+000 - SS
Photo 3: 11th hairpin bend is nearing completion Photo 4: Spoil management by building toe walls
- SS plus bioengineering (brush layers) ch 3+380 - SS
Photo 5: A recently finished section with Photo 6: A poorly built toe wall to contain spoils,
composite retaining walls and toe walls ch at least top portion needs to be rectified with
11+760 - SS larger stones ch 14+850 - SS
Photo 9: Insufficient width of foundation base of Photo 10: Reinstatement of foot trail ch 16+000 -
retaining wall already built (in water-logged area), SS
which needs to have adequate base width and
foundation drain for the remaining part 16+470 -
SS
Photo 11: Damaged wheelbarrows dumped at Photo 12: Surprisingly broken sledge hammers -
store yard- SS SS
Field visit report (KAL) – 03 to 15 Jan 2016
Photo 13: Farmland destroyed by debris from Photo 14: RBG members engaged in retaining
road construction which needs to be properly wall construction ch 2+280 - JR
reclaimed/reinstated ch 2+120 to 210 - JR
Photo 15: A steep section encompassing four Photo 16: Jarkot village, the zero point of the
hairpin bends in steep slope is difficult to work road starts right from the suspension bridge – a
on concurrently from ch 2+550 to 3+340 - JR long bridge (>100m) is required as the Karnali
Corridor Road is on the other side (right side) of
the river
Purpose: Engineering Monitoring Visit from TMO on two district roads in Bajura: Maure-Kailashmandu (MK)
and Maure-Toli-Chhatara (MTC)
Visit Team: Hom Nath Lamsal, Ramesh Neupane (DTL), Kamal Bhandari (EO), Janak Kharel (GE),
Rukmini Maharjan (GE), along with all IoWs and STSs on their respective road sections.
1. Overall Impression
The physical progress is encouraging on MTC despite some bottle-neck sections being
still remained un-started. There seems noticeable improvements on quality aspects of
works. However, field team needs to make further attempts to improve quality as
pinpointed in the subsequent Paras.
MK has seen less physical progress as compared to MTC, mainly because of having a
large of nos. of hairpin bends (21 nos.) on 11 km length, around one third of the bends
not being started yet. The period from the last few months onwards has witnessed a
tangible improvements in the quality of works.
Distribution: SMT, ETL, SED TL, All DCs and DTA KAL
Photographs:
Photo 1: A gabion retaining wall recently built Photo 2: A recently finished road section with
with significant improvement in quality 8+0660- reinstatement of approaches of an existing foot
MTC trail 8+910 - MTC
Photo 5: Improvements are being made in lacing, Photo 6: The initial section of MK just before the
bracing and filling of gabion boxes-MTC 1st hairpin bend
Photo 7: Laying gabion boxes just started at 13th Photo 8: Women RBG members in hauling the
hairpin bend 5+480 - MK excavated soil with wheelbarrow - MK
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Meeting Notes
Meeting Notes
Date, Time: 27 January 2016, 15:00-15:45
Location RAP3 Meeting Room
Subject Quality Issues in Fabrication of Gabion Boxes
(Supply of Heavy Coated Machine Fabricated Gabion Boxes and GI Wires to
Kalikot – Contract No: RAP3/2015/006)
Present RAP:
Bill Seal (BS)
Mahendra Shrestha (MS)
Hom Nath Lamsal (HNL)
Hulas:
Keshab Timilsena (KT)
Raju Khadka (RK)
Reported by: HNL
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Meeting Notes
delivery site based on the original bids received and an amendment be issued by RAP to this effect.
However this issue was discussed with the Supplier (KT) just after the contract concluded and it was
informally agreed with the Supplier that he supplies the quantities as per bid document i.e. delivery
of SN A and B items to RAP3 Store, Piplang, Humla and SN C and D items to RAP3 Store,
Shreenagar, Humla
NEXT MEETING: To be called as required
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Meeting Notes
Meeting Notes
Date, Time: 26th February, 2016, 11:00 hours
Meeting for
Subject
Supply of heavy coated machine fabricated gabion boxes and GI wires for Bajura and
Kalikot (RAP3/2015/005 and 006 respectively)
Supplier( Hulas )
Attendees 1. Keshav Timilsina, Managing Director, KT
2. Raju Khadka, Sales Officer, Kathmandu Branch -RK
3. Sanjeev Kr. Jha , Marketing Manager+ Chief Technical Officer-SKJ
RAP-3
1. Bill Seal, ETL - BS
2. Ram Prasad Thapaliya , LRN CS – RPT
3. Hom Nath Lamsal, LRN CS - HNL
4. Mahendra K Shrestha, CMS – MS
5. Ashrika Sharma, Graduate Engineer –AS
Reported by: AS
Background/Purpose
1.
Hulas is responsible for supplying machine made gabion boxes to RAP-3 new construction
districts like BAJ and KAL. One of the field visit from HNL, the District Co-ordinator’s (DC)
identified that the gabion boxes that had been dispatched in the site do not comply with the
technical specifications of RAP-3. As a result of which, RAP-3 instructed the supplier to stop
further supply and withheld any kind of payment in regard to the above mentioned contract
packages.
As a follow up to the meeting held on 27th January, 2016 held with RAP-3 and Hulas, today’s
meeting was called to find possible solutions to the issue.
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Meeting Notes
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Meeting Notes
The meeting was followed by a sample inspection in RAP-3 TMO itself. Which confirmed that
the connection of the selvedge wire of one wire to another were loose. The dimensions were
also checked against RAP-3 standard; the width of end panels were found to be shorter than
our requirement.
BS added that RAP-3 cannot continue receiving additional poor quality gabion boxes and
informed the committee that RAP-3 will only resume receiving goods if we had the assurance
that Hulas can supply gabion boxes according to RAP-3 standards.
Notes:
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State-of-the-Industry (Gabion boxes)
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A case study on ‘Supply of Heavy Coated Machine Fabricated Gabion Boxes for Bajura and
Kalikot District, Contracts: RAP3/2015/005 and 006’
RAP and Hulas Wire Industries Ltd signed contracts ‘Supply of Heavy Coated Machine Fabricated
Gabion Boxes for Bajura (RAP3/2015/005) and Kalikot District (RAP3/2015/ 006) on 23rd
September 2015. However, during February 2016 on a DC field visit note to Kalikot (03rd - 15th
January 2016) and later to Bajura (12th -19th February 2016), some quality issues had been raised
in Hulas-supplied gabion boxes. The quality issues were: mechanical connections of end panels
to main body and size of diaphragms and end panels of the gabion boxes.
TMO held a meeting on 27th January 2016 and 25th February 2016 with Hulas. Meeting discussed
on quality issues, possible solution, resumption of supply for balance quantities and field visits.
Meeting on 25th decided that a cost reduction in the invoices is acceptable to Hulas for rectification
done by RAP-3 on already delivered items. Similarly, a pro-rata basis cost reduction in the invoices
is agreed for undersized diaphragms and end panels. It was agreed that RAP-3 cannot continue
receiving additional poor quality gabion boxes and will only resume receiving goods if RAP-3 had
the assurance that Hulas can supply gabion boxes according to RAP-3 standards. Besides, RAP3
will send CMS to carry out factory visit to see if there are scopes to improve the production
technique. The factory visits to a number of mechanical weaving suppliers were to understand the
status and capability of the industries in Nepal and what to extent Hulas are following the standard
specification.
CMS visited six factories in which four were Hulas Wire Industries Limited (Hulas), Kamal Rolling
Mills Pvt. Ltd., Pioneer Wires Pvt. Ltd. and Premier Wires Pvt. Ltd. based at Biratnagar, Morang
and two were Super Wire & Steel Industries Pvt. Ltd. and Gabionet Environment Solution Pvt. Ltd.
based at Hetauda, Makwanpur.
After CMS visited the factories and formulated his findings, a meeting was organised with Hulas
on 11th April 2016. RAP-3 suggested the Supplier to add Cut-Edge selveding machine in their
armoury so that the product matches to the standard specification. However, to re-start ongoing
supply RAP-3 asked Hulas to improve the tightness of mesh to selvedge wire connection by
stringent manual means and shall use a common selvedge wire for joining end panels to the main
body. After remedying the defects, RAP-3 allowed suppler to re-start the supply with extended time
up to 17th June 2016.
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