Reasons for material wastage and prevention

Reasons of excessive material wastage

1. Poor storage: cement hardening by moisture, rusting of steel, damage of bricks and tiles in the open.
2. Careless handling and transport: breakage, spillage during loading and unloading.
3. Over-ordering and obsolete stock: unused, expired material.
4. Poor estimating and cutting plans: unsuitable bar lengths, tile sizes, giving large offcuts.
5. Rework due to design change or poor workmanship; mistakes in setting out.
6. Poor supervision and lack of skilled labour; wrong mix proportions, over-mixing.
7. Theft and pilferage because of weak security and records.
8. Bad site layout: materials stored far from use or rehandled.
9. Weather effects, such as rain on concrete or unprotected sand.
10. Poor quality materials that are rejected.

Preventive measures

• Safe, covered, well-drained storage; stack cement off the floor, FIFO issue.
• Order as per EOQ and the work programme; buy standard sizes.
• Cutting plans for bars and pre-planning of tile and block layout; use of precut and prefabricated items.
• Training of workers and strict supervision; check mixes and batching.
• Proper handling methods and mechanical aids; protect from weather.
• Stock records, issue against requisitions, and security measures.
• Fix wastage standards, compare actual consumption, and recycle materials where possible (reuse of formwork, crushed concrete).
• Good site layout, minimising handling.