NCR - CROOKED/MISALIGNED BEAM

Case Study 2022 - Somewhere in Johor

Non-Conformance Report (NCR), Class : Major, Subject: Crooked/Misaligned Beam Installation - Housing Project

1) Description of Non-Conformance - During site inspection, it was observed that a reinforced concrete beam has been installed out of alignment (crooked) and does not conform to the approved construction drawings, specifications, and tolerances.

2) Reference Documents

• Approved Structural Drawings No.: ___

• Project Specifications,

• MS EN 1990 1991, 1992-1-1 (Eurocode), BS 5606, MS EN 13670, MS EN 206, CIRIA C660 & C766, CIDB Qlassic or CONQUAS w/a, JKR Standard Specs

• Method Statement for RC Works

Note :

Engineer’s Rule of Thumb (Quietly Used on Site)

• ≤10 mm = BS 5606 tolerable deviation (with PE acceptance)

• >10 mm = Structural justification mandatory

• >25 mm = Eurocode eccentricity risk = rebuild or strengthen

3) Potential Risks

The deviation may affect :

• structural load transfer,

• alignment of slabs/walls above,

• architectural finishes and services installation

4) Possible Root Causes

• Incorrect setting-out or survey control,

• Formwork not properly braced or checked before concreting,

• Movement of formwork during concreting,

• Inadequate supervision and quality checks

5) Immediate Action

• Stop further works affecting or supported by the affected beam,

• Barricade the area if necessary for safety,

• Submit as-built measurements showing the extent of misalignment

6) Assessment Criteria

The Contractor shall assess:

• Degree of deviation (mm offset and rotation),

• Structural adequacy under design loads,

• Impact on adjoining elements (slab, column, wall, finishes)

Assessment to be endorsed by the Professional Engineer (PE/C&S)*

Note : Within ..... days, the Contractor shall submit the following for Engineer’s review:

Accurate as-built survey measurement indicating:

1. Structural assessment endorsed by the Professional Engineer (C&S), addressing:

2. Proposed rectification method statement, if required

Failure to submit the above within the stipulated timeframe may result in instruction for demolition and reconstruction at Contractor’s cost.

*Note : Engineer’s Conditional Acceptance Clause (If Applicable) Conditional acceptance may only be considered subject to all of the following being satisfied:

• The measured deviation does not exceed 10 mm from the designed beam axis,

Structural analysis confirms no adverse effect on:

• Load path

• Structural capacity,

• Durability and cover requirements,

• The deviation does not induce eccentric loading on columns, walls, or slabs

Written confirmation is issued by the Professional Engineer stating that:

• The structure remains fully compliant with design intent,

• Long-term performance and safety are not compromised

In the absence of such written confirmation, the beam shall be deemed non-compliant and unacceptable.

7) Rectification Methods (Subject to Engineer’s Approval)

Note : 6. Rectification Requirement (If Conditional Acceptance Is Not Granted)

Where the deviation:

• Exceeds 10 mm, or

• Cannot be justified structurally, or

• Affects architectural alignment, finishes, or future services

The Contractor shall, at no additional cost to the Employer:

• Carry out approved structural strengthening, or

• Demolish and reconstruct the affected beam in accordance with approved drawings,

The selection of rectification method shall be at the sole discretion of the Professional Engineer.

7.1 Option 1: Minor Deviation (Within Structural Tolerance)

If confirmed structurally acceptable: Engineer to issue formal acceptance with conditions

Localized:

• Non-shrink grout,

• Structural repair mortar,

• Adjustments in non-structural elements (plaster, finishes)

Note: Acceptance must be in writing.

7.2 Option 2: Moderate Deviation (Structurally Safe but Non-Compliant)

Structural strengthening such as:

• RC jacketing,

• Steel plate bonding,

• FRP wrapping (if approved)

Repair method statement to be submitted and load testing may be required

7.3 Option 3: Major Deviation (Structurally Unsafe/Excessive Misalignment)

Demolition and reconstruction of the affected beam

Works to follow approved:

• Demolition method statement,

• Temporary support/propping design,

• Recasting procedure

8. Preventive Action

• Reverification of setting-out points before formwork installation,

• Mandatory formwork inspection checklist,

• Surveyor confirmation prior to concreting

• Increased supervision during concrete pour

9. NCR Closure Requirement

• Approved Engineer’s rectification proposal,

• Photographic records before, during, and after repair,

• Updated as-built drawings

• Engineer’s written confirmation of compliance

• Risk Register Updates - See 10.

10. Risk Register Update

This non-conformance involves a primary structural element and has potential implications on structural integrity, construction sequencing, and downstream works. Accordingly, the Contractor shall update the Project Risk Register to reflect this non-conformance as a live structural risk, including:

• Description of the risk arising from beam misalignment,

• Risk rating prior to corrective action,

• Mitigation and control measures,

• Residual risk after rectification,

10.1 Responsible party and monitoring actions

The updated Risk Register shall be submitted together with the engineering assessment and rectification proposal.

The NCR shall not be closed until the Risk Register update is reviewed and accepted.

Sample Risk Register Update

Legend :

• 🟢 Low Severity : No impact on structural safety or design intent; acceptable with monitoring.

• 🟡 Medium Severity : Limited impact - requires engineering review and mitigation.

• 🔴 High Severity : Affects structural safety, load path, or compliance with approved drawings; immediate action required.