final report - pdf form.pdf

8/14/2019 FINAL REPORT - PDF FORM.pdf

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NATIONAL INSTITUTE OF CONSTRUCTION

MANAGEMENT AND REASERCH

SUMMER TRAINING REPORT

1. Name of CompanyKirby Building Systems India Limited (KBSIL)

2. Name of the ProjectBangalore Metro Rail Project

Place of Work

Bangalore

3. DepartmentBuilders Training Department (BTD)

4. Name of StudentV. Jagdeep Naidu

5. Roll No :231121 Batch No:236 Mailing address

Company Personal

KirbyBuilding Systems India Ltd. V.Jagdeep Naidu

Plot No. 8 to 15, IDA Phase No-J 37, 1stMain Road, LN-Puram

Pashamylaram, Medak Dist. Srirampuram, Bangalore- 560021

Andhra Pradesh Karnataka

Phone No- 0845-5224425 Phone No- 09579151915

E-mail- [email protected]


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Acknowledgement

I am very thankful to Kirby Building Systems India Ltd. (KBSIL) for having given me the

opportunity to undertake my summer training at their prestigious Bangalore Metro Rail Project.

It was a very good learning experience for me to have worked at this site as this project involved

many new and unique construction practices and challenges.

I would like to convey my heartiest thanks to Mr. G. PrasadRaju, General Manager-BTD,

who directed me to this project and gave an insight in to what the project is all about. I would

also like to give my heart-felt thanks to Mr. Satish Reddy, Assistant Manager - BTD, who

guided me all through the summer training and imparted in-depth knowledge of the project.

I would like to thank all the department heads of KBSIL for giving their precious time and

valuable guidance during my orientation programme at the head office in Hydrabad.I would like

to sincerely thank Mr. P.M. Senthil Raj, Senior Engineer BTD, for his self-less help and

knowledge sharing which has helped me immensely in my learning and preparation of this

report.

Last but not the least; I would like to thank all the staff at KBSIL for being so helpful during this

summer training.

Name:V. Jagdeep Naidu

Date:26thJune 2010


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CONTENTS

CHAPTER-1INTRODUCTION Page No

1.1 About the organisation 51.2 Kirby Product Range 51.3 Customer base 61.4 Manuals & Brochures 71.5 Quality Policy 81.6 HSE Policy 81.7 HR policy 81.8 Kirby Values 91.9 Land Mark Projects 91.10 Induction Programme at Head Office 101.11 Departments & their Roles 10CHAPTER-2LITERATURE REVIEW

2.1 PEB- Revolution in India 12

2.2 Advantages 14

2.3 Challenges Ahead 15

CHAPTER-3 PROJECT DETAILS

3.1 Stabling Shed 16

3.2 Emergency Re-Railing Building 19

3.3 Repair Bay 20

3.4 ETU- Building 21

3.5 Inspection Bay 22


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3.6 Pit-Wall Building 22

3.7 Quality Management 22

CHAPTER-4 SKILLS LEARNT/KNOWLEDGE GAINED DIRING INTERNSHIP

4.1 Basics of PEB 30

4.2 Material Management 35

4.3 Safety at Site 37

4.4 Quality Inspection 39

4.5 Erection Process of Buildings 40

4.6 Report Generation 43

4.7 Obstacles to Progress at Site 44

CHAPTER-5 RECOMMENDATIONS FOR IMPROVEMENT

5.1 Recommendations 47

5.2 Responsibilities 48

5.3 Conclusion 48


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CHAPTER-1

1.1 About the organisation:

Kirby Building systems was established in the year 1976. It has its operations spread over 70countries. Over these years Kirby has come a long way becoming a global leader of Pre-

engineered steel buildings (PEB). Kirby is well known for providing global customers with

customized and cost effective building solutions.

Their steel buildings are designed and manufactured to international building standards for a

wide range of applications such as, industrial, commercial, recreational, warehousing and others.

Kirby is a wholly owned subsidiary of the multi-national conglomerate Alghanim Industries.

Kirby building systems India Ltd (KBSIL) has its head office at Pashamylaram in Hyderabad.

There are two plants in KBSIL, one in Hyderabad and one in Haridwar.All the necessary parts

and accessories are fabricated in these plants based on the requirement. The tailor made steel

members is shipped to various site locations. The responsibility of shipping lies with Kirby

which it does by subcontracting to various transport contractors. Kirby is not directly responsible

for erection of steel members. There are certified builders to carry out the erection work and only

monitoring is done and queries so arising are handled by Kirby. Kirby also takes the

responsibility of co-coordinating with the client for successful completion of the project.

The main goal of KBSIL is to design, manufacture and supply quality products conforming to

Global Standards, with the state of art technology and equipments to ensure total customer

satisfaction.

1.2 Range of Products offered by Kirby:

Kirby offers a wide range of solutions tailored to specific needs.

Kirby solutions caters to applications such as warehouses, factories, showrooms, shopping

malls, offices, camps, supermarkets, workshops, mosques, aircraft hangars, car parks, gas

stations, sports complex and schools among many others.


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Their products include low rise and medium rise pre-engineered buildings, conventional

structural steel buildings, primary and secondary frames, mezzanines, fascias, canopies, cranes,

open web joists and trusses. Secondary members such as Purlins, girts and related accessories,

either painted or pre-galvanized, are produced in-house to complement the whole structure and

provide clients with an all inclusive package.

Roof and wall cladding systems can be supplied in a wide range of profiles and colours.

Insulation is also available in single cladding with fibre glass insulation or in polyurethane

insulated panels.

Kirby has pioneered the introduction of Industrial racking systems, offering a One Stop

complete warehousing solution.

Kirby also offers a wide range of Structural Steel products which covers applications in several

market segments including

Oil & Gas onshore & offshore

Heavy IndustryPetrochemicals, Steel, Aluminium smelters, Cement, Fertilizers

InfrastructureBridges, Power, Desalination plants, Airports, Seaports, Railways

BuildingsHigh-rise residential and commercial buildings, Malls, Car parks, leisure,

special purpose/heavy duty factories & warehouses

Structural Steel products meet the highest design and manufacturing standards in the industry.

1.3 Kirby Customer Base:

KBSIL has several hundreds of satisfied customers. The secret behind Kirby being in the top

position in Pre-Engineered buildings is its commitment and dedication in providing quality

products. Kirby enjoys a market share of more than 50%. Some of the satisfied customers of

Kirby are:

Tata

Reliance

General Electricals

Hero Honda


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Toyota

General Motors

Chevron

Pepsi

Nissan

Unicef

BMW

P&G

Unilever

Bridgestone

Tata power

Nokia

Henkel

Apex and many more.

1.4 Kirby Manuals and Brochures

Kirby offers a wide array of metal building products and it also provides Catalogs and manuals

which may be used as ready reckoner by existing as well as new customers. The main purpose of

these manuals and brochures is to provide necessary information and to clear the queries ofBuilders and customers.

Kirby Corporate Brochure

Kirby Technical Hand Book

Erection Manual

Product Guide

Kirby Safety Manual

These manuals and brochures may also be directly downloaded from the official website of

KBSIL.


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1.5 Quality Policy

KBSIL is committed to design, manufacture and supply quality products conforming to Global

Standards, with the state of art technology and equipments to ensure total customer satisfaction.

It also aims to maintain leadership in this industry by continuously upgrading its technology,

Quality management systems and skills of its Employees.

1.6 Health, Safety and Environment (HSE) Policy

KBSIL is committed to provide safe and healthy environment during design, manufacture and

supply of building systems.

Objectives:

KBSIL strongly believes that good health and safety performance is an integral part of efficient

business.

To ensure compliance to all statutory rules on health safety and environment.

To train all builders and employees in advance on erection, sheet laying, operations of

material handling equipments and latest techniques on safety.

To provide appropriate training and information to enable all employees and builders to

appreciate and accept individual responsibility for Health and Safety.

To provide and maintain facilities and working conditions which are safe for employees,

visitors and customers at the project premises.

To be a leader in Health Safety and Environment practices through continual

improvement in its HSE performance.

1.7 HR Policy:

Kirby provides an environment where human resources are nurtured and developed to achieve

organizational goals, while in the process providing adequate scope for individual growth. Kirby

takes pride in saying We build careers as strongly as we make our buildings.

Kirby gives importance to:

Career Management

Training and development programs


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Equal opportunity

Communication channels and feedback mechanisms

Activities promoting work life balance

1.8 Kirby Values:

Straight Talking: They encourage open debate where the best ideas win

Customer Centric: They put the customers at the center of their focus and initiatives with the

objective of providing them with unmatchable levels of services and products.

Teamwork: They actively share information and ideas; enthusiastically work to make those

around them better

Diversity and Respect: The diversity of their workforce is an asset and they treat everyone with

dignity and respect regardless of status, gender, education, ethnicity or religion

Empowerment:They empower people to make decisions with a bias for action

Employees as core assets: They believe that their employees are the most valuable resource and

do whatever it takes for their continuous training, development and motivation.

Meritocracy: The reward and career advancements of their people are based on their

performance and capabilities, not on their wasta (influence).

The work environment is based on their corporate values---- straight talking, customer centric,

teamwork, diversity and respect, empowerment, employees as core assets and meritocracy.

1.9 Land mark Projects of KBSIL:

Aanchoor Daewoo Industries, Haridwar, India

Kalyani Brakes, Pune, India

Nokia Factory, Chennai, India

Quest Smartech electronic component factory, Bangalore, India

Suzlon Power generation factory, Kundali, India

Swaraj Mazda factory, New Delhi, India

BMW Car Manufacturing Unit, Chennai, India

Fox Conn, Chennai, India

Delhi Metro railway Station and Maintance Workshop, Delhi, India

Renault Nissan, Chennai, India


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Wipro call center, Bangalore, India and several others.

1.10 Induction Programme at Head Office:

The induction programme was held from 3

rd

May 2010 to 7

th

May 2010 and during thisprogramme, we were briefed about the organization, its extent, its structure, its scope of work

and its working culture. Further, we were detailed about the role of Builders Training

Department (BTD) in the organization as we were to be associated with it for the coming days.

On the first day, we met Mr. Ramachandra Rao (HR Manager) who further introduced us to Mr.

Prasada Raju (GM BTD) who is the head of the Builders Training Department. The first two

we studied the ERECTION MANUAL as it was very important for our next two months in

site. During these two days we understood the erection process and other technical aspects. We

were also cleared about our queries regarding the same. During the next three days we were

introduced to various department heads who briefed us about the functioning of various

departments and their coordination with other departments. During these days we met Mr. K.G

Philipose, Vice President-Operations, Mr. Venumadhava Reddy DGM-Designs, Mr. T.V.P

Saradhi, Sr.Manager-Drafting, Mr.Sudarshan Rao.S,Senior Manager-EHS, Mr. K.G.K

Chowdary,Head-QA and Mr. Krishnam Raju, DGM, Project Management Group.

We were permitted for a plant visit and all our queries were answered by the plant engineers. We

were given a demo of working of SAP which was very informative and helpful. We were also

given a contract document to read and understand based on our request. On a whole our

induction programme was well planned and streamlined.

1.11 Kirby Departments and their roles:

Sales and Marketing Department: Kirby has several sales offices in all parts of thecountry. The main role of Sales personnels is to generate enquires and create an enquiry

bank. They meet consultants, contractors, builders and other potential customers. They

explain the benefits of Kirby products and thus maintain cordial relationship with clients.


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Design Department: They are responsible for estimation of tonnage, design of various

structural elements. The loads that come on the structure are considered and thus an

economical design is arrived at for the benefit of the client. They use design packages

such as STAAD Pro at the job stage and SMARTEST at the quote stage

Drafting Department: They prepare detailed drawings and drawings which are to be

sent on the site. They prepare three types of drawings: Approval Drawings meant for

approval from client, Fabrication drawings meant for fabrication in plant and Erection

drawings meant for site erection engineers for execution.

Project Management Department: They play a major role in Kirby. They are involved

in contracting of a new order, order processing, amendment of drawings and prices,

material planning, production planning, shipping planning, erection scheduling and

material scheduling.

Construction Management Department: Once the material reaches the site, the site

engineers and managers of this department verify the shipper and packing lists. Make

proper arrangements for material storage. They also verify the drawings and co-ordinate

with the builder and client. Kirby engineers and managers at site supervise and inspect

the entire erection process, get necessary approvals from client and guide the builder so

as to complete the work within the given time schedule. They also co-ordinate with plant

and head-office regarding the materials to be received and progress of work respectively.Credit Department: They take care of all the financial aspects of the organisation. Kirby

extends credit to its customers by accepting a letter of credit or a bank guarantee. They

give open credit to bigger companies such as Nokia, Suzlon etc. and to obtain this type of

credit, prior approval is required from the Kuwait head office of Kirby building systems.

Quality Department They take care of the quality of the materials which are being

supplied. They perform various tests on the lots randomly (1 in 10) and certify the

material as OK. Quality inspection at Kirby is done in three stages:

Raw Material stage inward stage In process stage Outward Shipping stage.


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CHAPTER-2

LITERATURE REVIEW

2.1 PEB-Revolution in India

Technological improvement over the years has contributed immensely to the construction

Industry. One such revolution was the pre engineered buildings. Through its origin can be traced

back to 1960s its potential has been felt only during the recent years. This was mainly due to the

development in technology, which helped in computerizing the design and construction practices

at site.

Though initially only off the shelf products were available in these configurations aided by the

technological development tailor made solutions are also made using this technology in very

short durations. A recent survey by the Metal Building Associations (MBMA) shows that about

60% of the non residential low rises building in USA are pre engineered buildings.

Although PEB systems are extensively used in industrial and many other non residential

constructions worldwide, it is relatively a new concept in India. These concepts were introduced

to the Indian markets lately in the late 1990s with the opening up of the economy and a number

of multi nationals setting up their projects. The market potential of PEBs is 1.2 million tons per

annum. The current pre engineered steel building manufacturing capacity is 0.35 million tons per

annum. The industry is growing at the compound rate of 25 to 30 %.

With respect to design of the structure and aesthetic appearance India is way behind. Indian

manufacturers are trying to catch up; comparatively PEBs is a new concept in India. Beside, in

fabrication and other areas of PEB India is very good. As compared to other countries Indiancodes for building design are stringent but safer. IS standards are upgraded continuously. In

India, American codes are also followed.

Pre engineered steel buildings can be fitted with different structural accessories including

mezzanine floors, canopies, fascias, interior partitions etc. and the building is made water proof


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by use of special mastic beads, filler strips and trims. This is very versatile buildings systems and

can be finished internally to serve any functions and accessorized externally to achieve attractive

and unique designing styles. It is very advantageous over the conventional buildings and is really

helpful in the low rise building design.

Pre engineered buildings are generally low rise buildings however the maximum eave height can

go up to 25 to 30 metres. Low rise buildings are ideal for offices, houses, showrooms, shop

fronts etc. The application of pre engineered buildings concept to low rise buildings is very

economical and speedy. Buildings can be constructed in less than half the normal time especially

when complemented with the other engineered sub systems.

The most common and economical type of low rise buildings is a building with ground floor and

two intermediate floor plus roof. The roof of low rise buildings may be flat or sloped.

Intermediate floors of low rise buildings are made of mezzanine systems. Single storied houses

for living take minimum time for construction and can be built in any type of geographical

location like extreme cold hilly areas, high rain prone areas, plain land obviously and extreme

hot climatic zones as well.

Applications of Pre Engineered Buildings (PEB)

1. Warehouses

2. Factories

3. Workshops

4. Offices

5. Gas stations

6. Vehicle parking sheds

7. Showrooms

8. Aircraft hangars

9. Metro stations

10. Schools

11. Recreational


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12. Indoor stadium roofs

13. Outdoor stadium canopies

14. Bridges

15. Railway platform shelters

2.2 Advantages of Pre Engineered Buildings:

REDUCED CONSTRUCTION TIME: Buildings are typically delivered in just a few

weeks after approval of drawings. Foundation and anchor bolts are cast parallel with

finished, ready for the site bolting. PEB will reduce total construction time of the project

by at least 50%. This also allows faster occupancy and earlier realization of revenue.

LOWER COST: Due to the systems approach, there is a significant saving in design,

manufacturing and on site erection cost. The secondary members and cladding nest

together reducing transportation cost.

FLEXIBILTY OF EXPANSION: Buildings can be easily expanded in length by adding

additional bays. Also expansion in width and height is possible by pre designing for

future expansion.

LARGE CLEAR SPANS: Buildings with large clear spans can be easily constructed.

QUALITY CONTROL: As buildings are manufactured completely in the factory under

controlled conditions the quality is assured.

LOW MAINTENANCE: Buildings are supplied with high quality paint systems for

cladding and steel to suit ambient conditions at the site, which results in long durability

and low maintenance coats.

ENERGY EFFICIENT ROOFING AND WALL SYSTEMS: Buildings can be supplied

with polyurethane insulated panels or fiberglass blankets insulation to achieve energy


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efficiency thus encouraging GREEN BUILDING CONCEPT".

ARCHITECTURAL VERSTALITY: Building can be supplied with various types of

fascias, canopies, and curved eaves and are designed to receive pre cast concrete wall

panels, curtain walls, block walls and other wall systems.

SINGLE SOURCE RESPONSIBILTY: As the complete building package is supplied by

a single vendor, compatibility of all the building components and accessories is assured.

This is one of the major benefits of the pre engineered building systems.

2.3 CHALLENGES AHEAD:

Like any other industry PEB industry is also facing several challenges which are to be addressed.

Some of them are:

Lack of Skilled Manpower.

Higher taxes

Increasing Transportation costs

Variation in Steel prices

Changing the mindset for acceptance of a PEB vis--vis a conventional steel or concrete

building.

Providing fire resistance at elevated temperatures at reasonable costs.


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CHAPTER-3

PROJECT DETAILS

General Details: Bangalore Metro Rail Project is being carried out by Kirby at Byappanahalli in

Bangalore (Karnataka). The project was started in January 2010 and is in progress at this point of

time. This project is very special because it is one of the very few curved structures carried out

by Kirby. The project consists of six buildings and has both structural steel and roofing systems.

The entire project including all six buildings involves 1200 tons of steel. The clients are URC

constructions and the consultants are the General Consultants (RITES-PBI-PCI-SYSTRA). The

total built up area of all the buildings is 26,000sq.m and the job code of Kirby BMRC project is

HY-02358.

The six buildings are Stabling Shed, Emergency Re-railing, ETU, Repair Bay, Inspection Bay

and Pit wheel/Inspection Lathe. Since each building has to be completed one after other as and

when the front is provided by the civil agency, all the buildings are subcontracted to a single

builder. The entire package of all Kirby undertaken BMRC works is subcontracted to Kirby

certified builder (Hi- Tech Builders). The supervision and inspection work is done by Kirby. The

details of these buildings are as follows.

3.1 STABLING SHED:

This building has MS-BC1 (MS refers to mild steel and BC is the Kirby terminology and refers

to Beam-Column) type of frame. This structure needs at most accuracy and expertise to both

design and erect as it is a CURVED STRUCTURE. This building is referred as building E.

The tonnage of stabling shed is 460 tons.

Technical Specification of Stabling Shed is as follows.

Building Width- 76800 mm centre to centre.Bay Spacing (mm)- 20@7100(14200mm c\c)

Roof KR-26GA (KR refers to Kirby Roof)

Wall- KW-26GA (KW refers to Kirby Wall)

Eave Height-6250mm clear.


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The Structure is designed for a Wind load of 47m/sec and the Live loads on frame and roof are

taken to be 0.75 KN/sqm.

Purlins (flush)-250Z2.5 and side wall grits are 200Z2.5. End Bays (14:2) lap and intermediate

bays- 200 Z2.5. The roof panels are of 550 Mpa and 345 Mpa and either of the two is to be

selected on approval of the Client which would be decided based on mock up of the roof

sheeting.

End Wall Framing of Stabling shed being erected


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Roofing for Stabling Shed: Roof sheeting work of Stabling shed is yet to be started but a mock

up of roof sheeting was conducted to decide on the type of roof sheeting in the presence of the

consultants and client.

Mock up of 550Mpa roof sheet

Status of Stabling Shed as on 26th

June 2010

Primary Erection: 100% completed (Involves erection of Columns and rafters)

Secondary Erection: 100% completed (Involves erection of Purlins, Shrut tubes, Built up

beam, sag rods and angle bracing).

Roof Sheeting to be started.

Wall Cladding to be started.

Roof Monitors 99% completed.


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3.2 EMERGENCY RE-RAILING BULDING:

The scope of work for Kirby in Emergency Re-Railing Building is limited to only Roofing

Systems. The RCC columns are built over which Kirby roofing system is erected. The Area of

this building is 310 sqm and a tonnage of over 10 tons. This building is referred to as building

D.

Status as on 26th

June 2010

Anchor Bolting completed. Painting of steel members as per sequence of erection is in progress.

Erection of main frames completed and side wall framing in progress with dash fastener type of

bolts.

Anchor bolts of Emergency Re-Railing building before concreting


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3.3 REPAIR BAY

The Scope of work in this building includes Roofing Systems with Crane beam. This building is

used as a workshop for repair and maintenance of Metro trains. The area of this building is

7665sqm and has a tonnage of 503 tons. This building is referred to as building B.

Status as on 26th

June 2010

Materials supplied as per Kirby Shipper (Bill of Materials). Materials are unloaded and stacked

with proper care to prevent any deterioration. Anchor Bolting completed and the steel members

are painted and kept ready for erection.

Picture showing the Anchor bolts of Repair Bay after concreting


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3.4 ETU BUILDING:

This building has an area of 990sqm and a tonnage of 400 tons. This building is referred to as

building F. The civil works of this building is in progress.

Picture showing the ETU building


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3.5 INSPECTION BAY:


building A. Civil works are in progress and PEB-works are to be started.

3.6 PIT WHEEL BUILDING:


building C. Civil works are in progress and PEB-works to be started.

3.7 QUALITY MANAGEMENT:

Kirby gives top priority to quality at site, whether it may be in assuring quality of materials or

quality of erection process. The Quality policy of Kirby is very stringent and it allows very little

room for error. Apart from plant, even at site all records relating to quality are maintained as per

the requirement of the client. In BMRCL project the clients were very particular about quality.

The various records relating to quality that were maintained in site are:

Material flow chart.

Shear Inspection report.

Inward and lab inspection report.

Final inspection report.

Painting inspection report.

Welding inspection report.

Ultra sonic inspection report.

Dye-penetration inspection report.


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Material Flow Chart


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Shear Inspection Report


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Material Properties Inspection Report


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Paint Test Certificate


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Dye-Penetrant Inspection Report


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Ultrasonic Inspection Report


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Welding Test Report


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CHAPTER 4

Skills Learnt/Knowledge gained during the internship

The following areas were focused upon during the internship:

4.1 Basics of PEB:

A Pre engineered building consists of following components:

a. Structural Systemsb. Secondary membersc. Sheetingd. Accessories

a) Structural systems (Primary members):

They are the main load carrying and support members of a pre- engineered building. The shape

and size vary based on application and requirements. The main frame is the main load carrying

member of a structural system which includes columns, end wall posts, rafters and other main

support members.

All structural steel sections and welded plate members shall be designed in accordance with the

applicable sections, relating to design requirements and allowable stresses, of the latest edition of

the American Institute of Steel Construction Specification for the Design of Cold Formed Steel

Structural Members. The following are the structural systems used by Kirby according to the

requirement and the type of the building:

Rigid Frame

Beam & Column

Lean to

Space Saver

L Canopy

Butterfly Canopy


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Single Slope

Multi-Span

b) Secondary members:

The secondary members are load carrying members suitable to ensure the stability of the

building against forces in any direction. They primarily include Purlins and girts, eave struts,

cable bracing and open steel web joists.

i) Purlins & Girts: These are structural members made up of cold formed steel Z sections.They are supported on columns, rafters or building walls. The girts and Purlins can be

lapped and nested at the supports which creates a continuous beam configuration. They

are placed on the roof and perimeter of the building. Hence they serve as a support to the

roof sheeting and wall cladding.

ii) Eave struts: Structural members located along the sidewall; at the intersection of theplanes of the roof and wall. It is constructed from cold formed 'C' sections and is rolled to

suit the roof slope.

Application:Joins the roof and wall cladding.


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c) Cladding:

Kirbys pre- painted sheeting is a multi-layer coating system to ensure long life and optimum

coating adherence. The steel substrate is hot dipped galvanized zinc or hot dipped zinc /

aluminum coated. The surface of the metal coatings is then given a series of pre treatments to

ensure that they are completely clean. Kirby claddings can be used for roofs and walls and are

available with or without insulation.

Kirby Rib Product Description:This type of panel has coverage of 1 m. It is made up of major

ribs and minor ribs so placed as seen in the diagram below. The main purpose of this type of

panel is for roof cladding.

Kirby Wall Product Description: As the name would suggest; this type of panel is used for

wall paneling purpose. Its profile is as shown above. In between the major ribs, the panels have a

valley like shape. Each panel shall provide one meter coverage.

i) Kirby Decking Product Description: Typical applications of decking panels are in highrise buildings, office buildings and mezzanine floors in industrial buildings and

warehouses. Decks can be used as a permanent shuttering to support the wet concrete and

help in creating composite slabs and floor beams. The continuous flange stiffeners and

deep embossments increase the load carrying capacities. They provide for a stable and

rigid working platform without any need of propping.


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d) Accessories:

In addition to the main building components, Kirby provides a wide range of building

accessories. They are as follows:

Walk doors

Sliding Doors

Aluminium Windows

Insulation

Louvers

Fasteners

Power Ventilators

Skylights & Wall Lights

Ridge Ventilators

Roof Jacks

Roof Curbs


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The following figure shows the various elements of a PEB:


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4.2 MATERIAL MANAGEMENT:

Material constitutes to nearly 60- 70% of the total project cost and therefore in order to make

desired profit in any project the contractor or the agency involved should take necessary steps to

efficiently manage materials at site. In Pre-Engineered Buildings where the construction is steel

intensive, Activities such as loading, transportation, unloading, staking and preventing the

material from any deterioration before erecting and during the erection process plays a pivotal

role.

This was the main responsibility that was assigned to me in site. Kirby is the supplier of

materials for BMRC project. The responsibility of maintaining perfect records of materials that

are shipped and materials those are yet to be shipped at site lies on Kirby. This is required to

prevent disputes that may arise in future. Materials from plant are shipped as per the priority and

sequence of erection. Usually the work is carried out in phases. The material is also received in

phases and on priority of work so that work is not delayed due to non-availability of materials.

The shipping department in Kirby released the list of materials required for the project; building

wise in different phases and revisions. These lists were termed as Shippers lists which were sent

to us via e mail. These lists were used to update the required quantity of materials in the excel

sheet. The materials were shipped to the site in trucks and each load of materials had a packing

list attached to it which carried a unique load number and L.R. (Lorry Receipt) number. These

packing lists were arranged in files according to the load number and according to the building

for which it has been sent. Each material had a unique Part Mark number attached to it and this

was also updated on the excel sheet in order to retrieve the status of the material quickly. The

materials which arrived in trucks were unloaded directly at the material storage yard of the

respective builder or subcontractor.

It is the responsibility of client to provide sufficient space for storage of materials and also

choosing a yard of storage is an important task. Several things are to kept in mind beforechoosing a storage yard like it should be very close to painting yard and site of erection. It should

have sufficient space for crane movement and erection equipments. The ground should be hard

enough to support bulky steel members and also should have sufficient security against theft and

environment hazards.


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Care should be taken to prevent accumulation of moisture to protect steel members from

RUSTING.

Steel Purlins ready for erection at stabling shed

The picture above shows purlin members which are placed over wooden planks with no contact

with ground and sufficient space for air-circulation.


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4.3 SAFETY:

Safety at site is safe tea at home- This single phrase explains all. Safety plays a major role in

the productivity of any site. It takes years for organisations to build reputation and a single

accident at site destroys them all. Safety affects several factors such as cost, quality, time and

productivity.

Safety at Kirby:

Kirby follows all mandatory safety principles mentioned in Kirby safety manual. Kirby

engineers and managers at site ensure that all workers use Personal protective equipments

(PPEs) like safety shoes, safety belts, safety helmets and help-lines while working at

heights and safety harnesses.

Kirby also conducts tool box talks every morning for all erection workers.

Work permits and fitness certificates of erection equipments were inspected by a Third-

Party.

Wire ropes chains and lifting gears are inspected and tested regularly

During Roof sheeting work when the laborers are working at heights, ladders, scaffolding

etc are inspected regularly

A safety supervisor was appointed to look into all safety aspects and also there was a

safety officer from client side who used to inspect safety aspects every day.

Riggings were inspected before lifting and the capacity of lifting equipments were

inspected so that the members that are to be lifted are well within the maximum capacity

of lifting equipments.

Weekly pep-talk with client were arranged to effectively communicate safety aspects and

the dos and donts.


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Tool Box Meeting at Site

Steel Columns being led safely using PP Ropes


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4.4 QUALITY INSPECTION

Bangalore Metro Rail project is a government project. Stringent quality checks were conducted

by Kirby as well as the client. Most of the quality checks were conducted in plant where as some

quality checks are also conducted at site and also these quality inspection reports are maintained

at site.

Torque testing of bolts: The torque to be maintained depends on the diameter of the bolts and

also on the design criteria. Torque wrench is used to tighten as per the required torque. In

Stabling Shed a torque of 745 Nm was given to 24 dia & 85mm length bolts.

Main Frame Rafter Bolts being tightened using Torque Wrench

Structure Alignment and plumb testing for Columns:

A plumb bob is suspended on a fulcrum and the verticality of the columns is checked on the

flange as well as the web and level is transferred as per drawing using tube level. Also the

straightness of Rafters and Purlins are inspected.

Paint Inspection using Elcometer:

Paint is applied in 6 layers to the steel members. It consists of 2 coats of primer and 4 coats of

paint. The thicknesses of various coats are as follows: 1stcoat-75 micron, 2

ndcoat-35 micron, 3

rd


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coat-35 micron, 4th

coat -90 micron, 5th

coat-30 micron and 6th

coat-30 micron. The total

thickness to be maintained in BMRC project is 295 micron. This thickness is inspected using

Elcometer. To perform this test the knob of the elcometer is wound to a particular level and then

the elcometer is placed on the metal which is painted. The knob gets rewound automatically and

stops at the exact thickness level of the paint on the metal.

Elcometer

4.5 ERECTION PROCESS OF BUILDINGS:

The buildings were erected in accordance with the erection manual provided by Kirby. This

manual had the detailed procedure to be followed for safe erection at the site. Safety is always

given utmost importance by Kirby and they followed stringent safety rules and practices on the

site.

The erection sequence is as follows:

Anchor bolt testing Pedestal Inspection:The foundation part is generally not executed by

Kirby. It is carried out by a civil contractor. In our site, it was carried out by URC Constructions,

an Erode based company. Only the testing for the alignment of the anchor bolts is done by Kirby.This is termed as the Pedestal Inspection. In this process, the anchor bolts are checked for their

alignment and for their levels so that there is no problem when the column is placed over the

bolts. After concreting Kirby does a post-pour inspection before taking over the pedestals.

Primary elements erection: Once the pedestal Inspection is completed, the erection of the

primary elements is started. The primary erection includes the main frame elements such as


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columns, beams and rafters. These elements are erected with the help of cranes and ropes. Once

the columns have been erected, they are fastened using ropes to prevent sway in wind. Erection

is carried out in the braced bay to give more stability to structure. Once rafter is erected

immediately secondary members like Purlins and angle bracings are bolted as shown in the

figure

Erection of Main Frame Rafters using Cranes

Secondary elements erection: Once the primary elements are erected, the secondary elements

such as Purlins, girts, bracings and others should be erected. Some Purlins and girts are erectedalong with the primary members for the stability of the columns and beams. Secondary members

are as important as the primary members of the structure because they provide the required

stability and proper connections to the primary members. Secondary members include Purlins,

Angle bracings and Sag rods.


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Erection of Angle Bracing

Roof Sheeting and Wall cladding: The roof sheeting and wall cladding are the final stages of

erection. The wall cladding operation is carried out after a proper arrangement has been made for

the scaffolding. Sheeting can be started from either end of the building but sheets are to be

applied towards the direction of the prevailing wind. Good alignment of fasteners helps in giving

a professional look. Correct degree of tightness is to be maintained to achieve water proof

connection. A screw gun of can be used for this purpose. Roof sheeting is done in a regular

sequence which saves time in picking up sheeting corners and ensures a sealed four lap

connection.


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4.6 REPORT GENERATION:

Report generation helps to maintain up to date record of all documents in site. This helps to

prevent any future confusion or disputes. This also helps for effective progress at site and to

provide necessary information for the client at any point of time without any difficulty. Some of

the registers maintained in BMRC site are:

Anchor Bolt checking Register- All the Anchor bolts before concreting that are cleared

and rejected by Kirby are mentioned in this register with signatures of contractor, Kirby

and Client.

Shipper Register- All the materials that are received at site are noted in this register with

their PART MARK and the numbers received as against the numbers that are to be

received.

Torque testing Register- This Register contains the details of all the bolts for which

torque tests are conducted with the approvals of Kirby, consultants and clients with

necessary remarks.

Paint Register- This Register contains the paint thickness inspection results which are

conducted for various members with the observed thickness and necessary remarks.

Structure Alignment Register- It contains column plumb levels transferred as per

drawing of mother column. This register also alignment values from web and flange of

column and deviations. This register will have the signatures of Kirby, consultants and

clients.

Column Rafter master plan- This contains updated details of availability of members

for erection in sequence.

Daily Manpower Register- This register is used to maintain the total manpower with

date for each day. This helps to increase or decrease man power based on the

requirement.

RFI (Request for Inspection)-This file contains all the RFIs that are raised by Kirby

along with RFI numbers.

Apart from the above registers, various files containing invoices, packing lists, weigh bridge

reports and are maintained and updated regularly at site


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Application of SAP in Kirby:

SAP (Systems Analysis and Programme Development) is a business management software

tool for real time processing of data and helps to take business decisions. It allows for open

communication within and between all company functions. It provides entire package of ERP

Enterprise Resource Planning. SAPs ERP solution includes several modules that support

key functional areas like Financials, logistics, human resource management etc.

In Kirby, SAP is implemented and used effectively for

business process

inventory reduction

saving in time

Improved customer service.

Kirby as an organisation has invested several crores in purchasing, implementing the SAPs

ERP tool and also in training its employees to effectively use this software. SAP in Kirby is

highly confidential and only authorized people with passwords may use it.

4.7 OBSTACLES FOR PROGRESS AT SITE:

During my two months internship at the BMRC site, I observed many things or events that

directly or indirectly affected the progress of work. Some of them were avoidable where as

several others were unavoidable. Kirby Engineers and Managers at site take all possible steps

and precautions to avoid any such obstacle that may be avoided and carry on with the work

smoothly and effectively.

Crane Owners Association of Karnataka called for a strike demanding tax deduction

of Quarterly tax on cranes due to which cranes were not available for 7 days which

affected the erection process of Kirby for over a week.


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Strike called by Karnataka Crane Owners Association

Frequent Rains in Bangalore made it very difficult for erection men to work

continuously due to which work had be stopped and had to be resumed when rain

stops. This affected workers productivity and also the daily schedule of work had to

be altered accordingly.

Picture shows the work been stopped due to rain


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Rains resulted in damp earth which affected crane and material movement.

Picture showing Crane struck in damp earth

Heavy Winds also posed certain amount of problem at site. In a certain case heavy

winds led to the collapse of paint yard fencing which had to be re-fenced later.

Picture showing the damaged paint yard fence


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CHAPTER-5

5.1 RECOMMENDATIONS FOR IMPROVEMENT

During my two months internship at BMRC site, I totally felt the commitment and dedication of

Kirby engineers and managers towards improvement at every step. These are some of my

observations that may help to further improve the overall productivity at site.

MATERIAL MANAGEMENT:

1. Even though some amount discipline was seen in the material storage yard in dumpinglarge members like primary and secondary members by the builder, the smaller items like

the sag rods, nuts and bolts were dumped haphazardly. This resulted in lot of wastage of

time in searching for the material. Instead the builder may take more care in staking the

material separately according to material size, purpose and frequency of use.

2. The approach road from the paint yard to the site of erection was narrow due to whichthere was difficulty in crane movement when carrying large and bulky steel members.

3. It is important to educate the supervisors and labor about the importance of materialmanagement which may help to achieve greater control over materials.

4. It would be better if the materials from plant are shipped based on the priority of phases.It so happens that the materials which are required at a later stage will arrive faster than

the material which is of at most priority. The same problem is faced in Repair bay where

out of 518 tons even though 400 tons reached site, it is not possible to erect a single

Rafter frame.


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SAP:

1. SAP-ERP software may be upgraded so that it may be used by site engineers andmanagers to update the daily or weekly progress of various activities which helps the

middle and top management to get real time status of various projects at different

locations. This helps to achieve greater control over projects and to take strategic

decisions.

5.2 RESPONSIBILITIES:

I was given certain responsibilities at site which was basically assistance kind of job which was

learning on its own. Some of them are:

Supervision and Inspection of erection work

Updating of Torque testing reports, paint inspection reports and alignment reports.

Raising RFIs and to get approval from client.

Accompanying the client during Structure alignment checking, Paint inspection and other

inspections and clearing their queries if any.

5.3 CONCLUSION:

It was a wonderful learning experience to be a part of Kirby for two months in Bangalore Metro

Rail Project. I gained a lot of insight regarding PEBs and their erection process. I was trained

well in the areas of material management, safety, quality management and report generation. I

hope this experience will surely help me in my future and also in shaping my career.

final report - pdf form.pdf

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