Final draft Report Harsh

Industry Training Report

By

Harsh Vikram Singh

MBA-CPM

A 13559014056

School of Construction

RICS SBE

Amity University, Noida

May-July 2015

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SUMMER TRAINING REPORT SUBMITTED TOWARDS THE PARTIAL FULFILLMENT OF POST GRADUATE DEGREE IN CONSTRUCTION PROJECT

MANAGEMENT

“TOWARDS AN UNDERSTANDING THE MANUFACTURING AND ERECTION PROCESS OF PRECASTED BUILDING ELMENTS IN SUPERCAST LTD.”

SUBMITTED TO: SUBMITTED BY:

Ms. Shalini Priyadarshini Harsh Vikram Singh Asst. Professor MBA-CPM (2014-16) School of Construction A13559014056

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DECLARATION

I Harsh Vikram Singh, bearing Registration No. A13559014056 a student of

MBA(Construction Project Management), RICS School of Built Environment humbly

submit that I have Completed from time to time all the works assigned to me and the

essentials required to prepare during my Summer Internship From 21st May 2015 and ending

on 08th July 2015 as described in this report by my own skills.

I certify that I have not copied the report or its appreciable part from any other literature in

contravention of academic ethic.

Registration No: A13559014056

Course: MBA-CPM

RICS School of Built Environment

Date: 25th July 2015 Signature:

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Faculty Guide Approval Page

This is to certify that Harsh Vikram Singh has conducted Industry Training of 8 weeks in Supertech Precast Technologies Pvt. Ltd. at Greater Noida west (U.P.) under my guidance.

___________________

Faculty Guide Signature

(Name of the Faculty Guide)

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Acknowledgments

The Internship opportunity I had with Supertech Precast Technologies Pvt. Ltd. was an awesome chance for learning and expert improvement. Along these lines, I see myself as an exceptionally fortunate individual as I was given a chance to be a piece of it. I am additionally thankful for having an opportunity to meet such a large number of grand individuals and experts who drove me however this temporary job period.

I would specially like to thank Mr. Kumar Rabish and Mr. Siddhartha Sharma (Production Head) for proving the nice ideas to work upon. Not only did they advise about my project but listening to their discussions in weekly meeting had evoked a good interest in Production analysis. I am also highly indebted to my supervisors AravindSingh and RakeshSharma, who seemed to have solutions to all my problems.

Harsh Vikram Singh

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Table of Content

1. Title Page……………………………………………………………………………..…22. Declaration……………………………………………………………………………..33. Faculty Guide Approval Page…………………………………………………...44. Industry Guide Approval Page …………………………………………………45. Acknowledgement…………………………………………………………………...56. List of Tables/Figures………………………………………………………………..77. Training Certificate from the Training Organization……………….…88. Executive Summary………………………………………………………………….99. Introduction……………………………………………………………………………1010. Precast Concrete construction processes………………………………..1111. Work Measurement………………………………………………………………..1312. Quality measures…………………………………………………………………….2013. Stock and Dispatch Department………………………………………………2814. Erection Operations………………………………………………………………...2915. Productivity Analysis……………………………………………………………….3216. Costing exercise…………………………………………………………………….…3517. Learning Outcomes………………………………………………………………….3718. References……………………………………………………………………………....3819. Annexure I - Copy of Log books………………………………………………..3920. Annexure II – Copy of WPRs ……………………………………………………. 46

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List of Tables

Table 1- Work Measurement of Hollow core slab …………………….13

Table 2- Work Measurement of precast solid slab ……………………15

Table 3- Work Measurement of precast solid beam…………………16

Table 4- Work Measurement of precast wall panels…………………18

Table 5- Design mix of M40 for shed-A ………………………………..21Table 6- Design mix of M50 for shed-A……………………………………21Table 7- Design mix of M50 (hollow core) for shed-A………………21Table 8- Design mix of M40 for shed-B……………………………………22Table 9- Design mix of M50 for shed-B……………………………………22Table 10- Design mix of M60 for shed-B…………………………………22Table 11- Hollow core slab load test ………………………………………26Table 12- Various test conducted for building elements …………27Table 13- Weekly Production at Shed A …………………………………..33Table 14- Chart of weekly production at Shed A………………………34Table 15- Cost of hollow core slab/sqm. ………………………………….35Table 16- Cost of precast wall per m3……………………………………….36

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List of Figures

Figure 1- HOLLOW CORE SHED A ........................................................12Figure 2- WALL PANELS SHED B ……………………………………………………….12Figure 3- Cube filling before cube test..................................................24Figure 4- Concrete cube test.................................................................24Figure 5- Hollow core slab load test.....................................................25Figure 6- Rectification work of solid slab..............................................25Figure 7- lifting of staircase...................................................................28Figure 8- dispatching of wall panels to site. ..........................................28Figure 9- Stock Yard................................................................................28Figure 10- Assembling of wall panel and slab at site..............................30.Figure 11- Assembling of Bars, Conduits before Screeding at site……….31

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Training Certificate

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Executive Summary

Precast Concrete Technology, the purported innovative technique in an Indian Space can encourage both pace and nature of the development and in the meantime misuses the points of interest that these expansive scale tasks offer as far as volume turnover and there petitions.

With the changing face of realty part in Indian market, the change of development system is unavoidable.

This paper point sat showing how the Precast Concrete Technology can be productively and successfully utilize wears different Indian Projects in the light of Projects.

The substance of realty market in India has changed quickly in the course of recent years. The huge activities including Townships, Mass Housings, IT/ITES parks and SEZs 'are of normal event nowadays and will just develop exponentially sooner rather than later.

Majority of such activities are as yet being developed utilizing the traditional methods. Thus the innate point of preference that these tasks offer as far as reiterations and colossal volume turn over stay unexploited.

Also, these vast scale undertakings developed utilizing customary routines convolutes the Project Management in terms of speed and nature of the development.

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Introduction

Supertech Precast Technologies Pvt. ltd is Supertech gatherings attempt under the brand name of Supercast. Supercast is into precast innovation in which cement is cast into a reusable mold, cured, transported to the development site and lifted into spot as contrasted and ordinary cast-in-situ development. Supercast uses front line innovation in precast assembling considering all the quality principles guaranteeing that the completed item is as desirable.

Super cast Factory has Various Department and I had allocated to each and every department by my Industry Guide. There are some major Departments:-

1) Production Department2) Plant and machinery maintenance Department3) Quality Department4) Design Department5) Planning Department6) Dispatch Department7) Store and safety Department

Production Department is the heart of whole factory and building element casting done in two Sheds.

Shed A- Hollow core Slab, Solid Slab, Beam, Staircase, Columns, Mummties etc.

Shed-B- Wall Panel and Kerb Stone.

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Processes of casting of such Building elements

Hollow core Slab:

Hollow core precast slabs are broadly used as a part of an extensive variety of structures as floor/rooftop parts.

These hollow core pre-stressed concrete slabs units are made utilizing long line extruders. Supercast Hollow core precast slabs are 1.2 meters wide and 114 meters in length and the plant has the ability to produce 1036.8 sq. mts. of empty center sections for different sizes and in changed thickness.

These Hollow core slabs offers the perfect basic segment by reducing deadweight while giving the greatest supporting proficiency inside of the Slabs profundity. Including focal points, for example, longer compasses and phenomenal burden bearing limits, these demonstrated innovations for Hollow core slab permit you to manufacture extensive ranges with fewer requirements for parcel dividers, bringing about extraordinary design opportunity amid and after development.

There are various steps for preparing a hollow core slab-

Step 1- Pre cast Bed Cleaning by Multipurpose trolley/ (Bed Master)

Step 2- Oiling the Bed by Multipurpose trolley/ (Bed Master)

Step 3 – Pulling of Stranding wires and tightening with barrel batches for prestressing.

Step 4- Pre-Stressing of stranding wires for providing strength in slab.

Step 5- pouring the concrete into overhead bucket and then into Casting Machine (Slip former)

Step 6- casting the concrete to make pre cast slab

Step 7- De-stressing the pre-caste slab after 24 hrs with grinder.

Step 8- Cutting of pre cast slab with Saw cutter Machine.

Step-9 -Quality check before lifting and Stacking

Then, Lifting and stacking of pre cast slab using clamps with EOT Crane.

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Fig 1HOLLOW CORE SHED A

Fig 2WALL PANELS SHED B

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Work Measurement

It is the application of techniques designed to establish the time for a qualified worker to carry out a specific job at defined level of performance, with the help of watch method I calculated/recorded the time for following work.

Why it is required?

1- Planning need of workforce

2- Facilitating operation scheduling

A– Hollow core slab (114mx 1.2m)

S.no. Processes Duration Required manpower

1 Bed cleaning 45 minute 1 operator 1 helper2 Mould/ Bed oiling 10 minute 1 operator 1 helper3 Fixing of stranding wires on bed 15 minute 1 operator 1 helper4 Pre-stressing work 15 minute 1 operator 2 helper5 Casting of bed 140 minute 1 operator 6 helper6 De-stressing 20 minute 1 operator 1 helper7 Cutting of bed 120 minute 1 operator 2 helper8 Marking and quality check 20 minute 1 helper9 Lifting of complete bed 90 minute 1 operator 1 helper

Table 1- Work Measurement of Hollow core slab

Requirement of building Material for casting a hollow core slab

1. RMC – M50/M40

2. Shuttering oil- 0.04 liter/sqm.

3-Stranding Wires (Diameter- 12.7mm /9.5mm/7mm)

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How to Find Volume of Hollow core slabs??

V=Length x Breadth x Thickness x saving factor

Saving factor for thickness- 100 mm is 10%

120mm -20%

150mm – 25%

180mm-30%

200 mm-35%

Advantages of Hollow Core Slabs

1) Lesser weight in comparison to Cast-in situ concrete slab of same size.2) Slab thickness varies from 100mm-300mm and Span length can move up to 13 m.3) Reduction of in-site concrete.4) Cast in lifting hooks5) Speed of erection etc.

B- Solid slab:-

The solid slab is a customized, loosely reinforced, full concrete slab which is used in residential and industrial construction.

Steps for preparation of Solid slab

1- Bed preparation

(A)- Mould fixing and cleaning

B- Mould oiling

C- Re-baring work or mesh fitting on bed

D- Embedding (Electrical conduits, dowel tubes) -

E- Final checking

After 1 Hour

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2- Casting work

After 18 hours

3- De-moulding

4- Quality check

Work measurement for Solid slab (5190mm X 1675mm)


1 Mould fixing and cleaning 45 minute 1 welder,2 helper2 Mould oiling 10 minute 1 helper3 Re-baring work or mesh fitting in

mould 15 minute 1 welder,2 helper

4 Embedding (Electrical conduits, dowel tubes)

15 minute 1 welder,2 helper

5 Final checking 5 minute Quality supervisor6 Casting work 15-20 minute 1 mason,1helper7 De-moulding (after 18 hrs.) 20 minute 1 welder,2 helper 8 Quality check 10 minute Quality supervisor

Table 2- Work Measurement of precast solid slab

BEAMS:-

Precast solid Beams are productive and practical answer for a quick development process. Precast Beams are accessible in standard widths from 190mm to 600mm wide and authority molds are accessible on solicitation.

Steps for preparation of Solid slab

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1- Bed preparation

(A)- Mould fixing and cleaning

B- Mould oiling

C- Re-baring work or mesh fitting on bed

D- Embedding (Electrical conduits, dowel tubes) -

E- Final checking

After 1 Hour

2- Casting work

After 18 hours

3- De-moulding and 4- Quality check

Work measurement for Solid beams (5905mm X 300mm)


1 Mould fixing and cleaning 45 minute 1 welder, 1helper2 Mould oiling 10 minute 1 helper3 Re-baring work or mesh fitting in

mould 15 minute 1 welder,1 helper

4 Embedding (Electrical conduits, dowel tubes)

15 minute 1 welder,1helper

5 Final checking 5 minute Quality supervisor6 Casting work 15-20 minute 1 mason,1helper7 De-moulding (after 18 hrs.) 20 minute 1 welder,1 helper 8 Quality check 10 minute Quality supervisor

Table 3- Work Measurement of precast solid beam

Advantages of Solid slabs and Beams

1. Attractive appearance because of steel structure completes and chamfered edges. 2. Flexibility in configuration, shape and application

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3. Extremely tough contrasted with option building materials 4. Fast establishment and autonomous of climate conditions 5. Works well with other precast parts, for example, divider boards, empty center and twofold tees to frame an aggregate precast application. 6. No insulating/fire proofing needed

Shed B- Precast Wall Panel:- Precast walls supports the vertical loads from the floors and the upper structure. These can likewise perform just as isolating walls. Here, the sandwich components comprise of two solid layers with a protection layer in the middle. The outside layer is for the most part in engineering solid while the inward layer is in gray cement and may be designed as load bearing or non-load bearing components.

STEPS INVOLVED IN CASTING A WALL PANEL

1. Fixing the Mould

2. Cleaning the bed

3. Apply Shuttering Oil

4. Placing the Wire Mesh using EOT crane

5. Fixing Embedment’s (Dowel Tubes, Junction Boxes, and Electrical Conduits etc.)

6. Quality Checking.

7. Concrete Casting (M-40,M-50,M-60)

8. Shifting to another table by Central Shifting

9. Leveling

10. Demoulding

11. Placing in Curing Chamber

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Work Measurement of wall panels


1 Mould preparation (fixing, oiling etc.) 50 minute 1 welder, 1helper2 Placing wire mesh 25 minute 1 operator ,1 helper3 Embedding (Electrical conduits,

dowel tubes) 20 minute 4 helper

4 Final checking 15 minute Quality supervisor 5 Casting work 15 minute 1 mason, 2 helper6 Leveling 20 minute 1 mason,1helper7 De-moulding (after 24 hrs.) 30 minute 1 welder,1 helper 8 Quality check 5 minute Quality supervisor

Table 4- Work Measurement of precast wall panel

Advantages of Precast Wall Panels

1. Great adaptability in outline, shape, completion and application

2. Used as cladding or auxiliary (protected or non-protected) application

3. Its thickness changes from 75mm to 250mm

4. Extremely solid and sound safe, contrasted with option building materials

5. Quick establishment takes into account a quick building walled in area, before inhabitant and lower financing expenses

6. Various completions accessible relying upon the necessity

7. Easily versatile to other building materials

8. Indoor assembling guarantees steady quality and takes into account year around creation

9. Various flame evaluations can be accomplished to address work particular prerequisites.

Precast Concrete Construction Process

Precast Elements Manufacturing Process

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Hollow Core Slabi:

The architectural drawings are utilized by our basic architects to plan the exceptional altered or customized slab.

•The Hollow core pre-stressed slabs are casted on beds.

•First, strands are being pulled & pushed through stressing on machine.

•Concrete is then exchanged to the concrete distributor machine from flying bucket.

•Casting is being conveyed in two layers specifically bottom layer and top layer.

•Vertical set patterns are being made on Fresh concrete and horizontal set patterns after the cement is hardened.

•Once the components are cured, , hollow core slabs are cut into pieces of required size.

•Hollow core slab pieces are lifted and sent to stockyard.

•Hollow core slabs are transported to the site in extraordinary transportation racks that are lifted and placed onto the trucks.

Precast Wall Panelsii:

The architectural drawings are used by our structural engineers to design the special customized wall panels.

Precast Wall panels are casted on tables which are mounted on clamps fixed with rollers.

Concrete is then poured into the moulds through concrete pouring machines. Steel reinforcement mesh is inserted into the mould and mould is preceded towards

casting station. After concrete pouring, elements are compacted through vibrators attached with

the tables and finally finished. Once the elements are cured, the moulds of wall panels are hydraulically tilted to

vertical position for de-molding. The panels are removed from the mould in one day and stood in the drying rack

using hooks. This enables the manufacturing of panels in higher volumes. The panels are then stacked in special drying racks that allow the panels to dry

standing up, enabling even curing of the panels. The panels are transported to the site in special transportation racks that are lifted

and placed onto the trucks.

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Quality Measure

Quality department insures the quality before Erection to the finished casted material.

Material which comes on site has to get approval by the quality department. During construction also checks are implemented for the quality. If, any material fails in test proper step to be taken for the strength achievement.

Quality of the company is managed as per ISO 9001-2008. Quality Management System is used in Precast Factory for monitoring the quality.

There are two separate batching plants for each shed A and B with different capacity.

Shed A – 45 cum/hr

Shed B- 60 cum/hr

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Design Mix

In both Batching plants, they prepare various grade mixes M40, M50 and M60. Each shed has different Design mix; I calculated cost of each mixes as per Store documents.

For SHED-A

S.NO Description (M-40) Qty Unit Rate Amount1 Cement (OPC grade 43) 410 Kg 4.42 1812.202 Coarse Aggregates (10mm ) 454 Kg 1.43 646.953 Coarse Aggregates (20mm) 680 Kg 1.20 813.964 Fine Aggregates 695 Kg 1.43 990.385 Water 195 Litre 0.00 0.006 Admixture (CICO PC) 4.5 Kg 57 256.50 Cost of 1 Cum 4,519.99₹

Table 5- Design mix of M40 for shed-A


Table 6- Design mix of M50 for shed-A

S.NO Description (M-50) HOLLOW Qty Unit Rate Amount1 Cement (OPC grade 43) 400 Kg 4.42 1768.002 Coarse Aggregates (10mm ) 1076 Kg 1.43 1533.303 Coarse Aggregates (20mm) 0 Kg 1.20 0.004 Fine Aggregates 780 Kg 1.43 1111.505 Water 160 Litre 0.00 0.006 Admixture (CICO PC) 0 Kg 57 0.00 Cost of 1 Cum 4,412.80₹

Table 7- Design mix of M50 (hollow core) for shed-A

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For SHED-B


Table 8- Design mix of M40 for shed-B

S.NO Description (M-50) Qty Unit Rate Amount1 Cement (OPC grade 43) 445 Kg 4.42 1966.902 Coarse Aggregates (10mm ) 431 Kg 1.43 614.183 Coarse Aggregates (20mm) 647 Kg 1.20 774.464 Fine Aggregates 719 Kg 1.18 849.505 Water 145 Litre 0.00 0.006 Admixture (CICO PC) 5 Kg 57 285.00 Cost of 1 Cum 4,490.03₹

Table 9- Design mix of M40 for shed-B

S.NO Description (M-60) Qty Unit Rate Amount1 Cement (OPC grade 43) 460 Kg 4.42 2033.202 Coarse Aggregates (10mm ) 407 Kg 1.43 579.983 Coarse Aggregates (20mm) 610 Kg 1.20 730.174 Fine Aggregates 767 Kg 1.18 906.215 Water 140 Litre 0.00 0.006 Micro silica 25 kg 14.25 356.257 Admixture (CICO PC) 5 Kg 57 285.00 Cost of 1 Cum 4,890.81₹

Table10 - Design mix of M60 for shed-B

They are using Ultra Red oxide cement with OPC 43 Grade and Kotputli sand (fine aggregates) in respected batching plants.

In quality lab various tests conducted during Pre-pour and Post pour processes

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SLUMP TEST

This test is used for the fresh concrete. Workability of the fresh concrete is checked by this as per IS: 1199- 1959

APPARATUS:-

Slump cone and temping rod is used for this.

PROCEDURE:-

The internal surface of the mould is thoroughly cleaned and applied with a light coat of oil.

The mould is placed on a smooth, horizontal surface, rigid and nonabsorbent surface.

The mould is than filled in four layers with freshly mixed concrete each approximately to one fourth of the height of mould.

Each layer is tamped 25 times by the rounded end of the tamping rod. After the top layer is tamped, the concrete is struck off the level with trowel. The mould is removed from the concrete immediately by raising it slowly in the

vertical direction. The difference in level between the height of the mould and that of the highest

point of the subsided concrete is measured.

The difference in height in mm is the slump of concrete. This test conducted done during Pre-pour process.

Cube Test:-

The acknowledgment criteria of nature of concrete are set down in IS: 456-2000. The criteria are obligatory and different procurements of the code must be gone along before the nature of concrete is acknowledged. In every one of the cases, the 28-days compressive strength might alone be the paradigm for acknowledgment or dismissal of the cement. Keeping in mind the end goal to get a moderately faster thought of the nature of concrete, discretionary test for 7 days compressive strength of concrete is done.

6 Cubes of 150 x 150 x 150 mm measure (the ostensible size of total does not surpass 38 mm) should be cast, 3 for 7-days testing and 3 for 28-days testing. An arrangement of 3 cubes specimen (example) normal quality will be a sample. The individual variety of an

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arrangement of 3 cubes samples ought not to be more than ± 15% of the normal. On the off chance that more, the test consequence of the example is invalid.

Fig 3 Cube filling before cube test

Fig 4 Concrete cube test

I also performed hollow core slab load test,

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Fig 5 Hollow core slab load test

RECTIFICATION WORK OF SOLID SLAB AT SHED A

Mostly due to improper handling if any casting element damaged at factory then quality team rectify to that element, they use some chemical compounds like – conceressive 2200, curing compound for slab rectification work and check after successful completion.

Fig 6 Rectification work of solid slab

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Table 11- hollow core slab load test

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S. No. Material List of tests1 Coarse aggregate 1. Specific gravity

2. Fineness modulus

3. Crushing value

4. Impact value

5. Flakiness index

6. Water absorption

2 Fine aggregate 1. Fineness modulus/gradation

2. Silt content

3. Specific gravity if applicable

3 Concrete 1. Slump value

2. Compressive strength

4 Cement 1. Fineness

2. Standard consistency

3. Setting time

4. Compressive strength

5 Steel 1. Rolling margin (external agency)

2. Elongation ( external agency)

3. Ultimate tensile strength ( External agency)

4. Proof stress (external agency)

5. Bend test if applicable ( external agency)

6. Rebind test if applicable (external agency)

Table 12- Various test conducted for building elements

Water – PH value should not be less than 6.8.

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STOCK AND DISPATCH DEPARTMENT

Dispatch department is responsible for all stacking lifting handling and dispatching process for casted building elements.

Fig 7 lifting of staircase

Fig 8 dispatching of wall panels to site

Fig 9 Stock Yard

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Erection operation

General:

Proper planning and preparatory work are required before the actual erection of precast concrete ensure efficient and quality installation. The following items should be carefully watched:

Method and sequence of assembly and Erection Method of providing temporary supports Provision for final structural connections and joint details Erection tolerances. Handling and rigging requirements

Precast Elements Erection Process

A strip foundation or a regular foundation is laid at the site, depending on the geophysical characteristics of the site. The panels are brought in by truck and Stacked into site stock yards as per site logistic plan.

Panels are fitted into the floor by inserting the vertical reinforcing bars protruding from the floor slab into large holes (Dowel tubes) in the panel. These large holes are called Dross Backs.

The panels are vertically positioned on the floor slab, so that the reinforcing rods from the floor fit perfectly into the Dross Backs. Once in position, grout is pumped into the lower of the two small holes (Dowel tube) on the side of the panels, filling the tube and locking it to the reinforcing bars.

The hollow core slabs are laid over the vertically erected panels. Flooring is completed along with doors and windows fitting. Finishing works are completed and the building is ready for Possession.

Steps of Erection of wall panel

Lift and Stack the panel in their respective place as per given drawing. Adjust the panel to position and secure it with diagonal props. Leveled and make aligned it properly. Prepare and Apply non-shrink mortar to seal the gaps along the bottom edge of

inner side of panel. For Corrugated Dowel tube, prepare and pour non shrink grout into pipe inlets

provided. In addition of another wall , One connecting bar of 12 mm will be provide in both

wire loops and seal it with non shrink mortar for jointing of two walls while wire loops provided in each panel.

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Time Report of Erection process

The panels are lifted using a suitable tower crane and the approved lifting clutches is placed in lifting holes of loops cast in panels. This is done after a proper study of the lifting capacity of machines, lifters, chains and slings against weights of panels before handling, which ensures lifters and chains are fully secured. The lifting and installation is carried out after thorough preparation & with methodical precision, as well follow all safety standards.

Lifting of Hollow core slab = 6-7 min (from ground floor to 16th floor) with the help of tower crane

Stacking of Hollow core slab to their position = 6 min

Lifting and stacking operation for Single wall panel = 20-25 min

Sealing of gaps for single panel = 20-30 min

Grouting work for single panel = 15 min

Fig 10 Assembling of wall panel and slab at site

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During fixing of elements they use Props for holding such element, generally site peoples called its name by Jack.

Props can be removed after 3 day of Screeding work.

RMC M-35 used for screeding work.

M-65 MYK/ GP-2 used for Grouting.

How to prepare Grouting material for Grouting?

Take 25 Kg of dry material and mix it with 5 liter water and repeat it 3 times and mix it with grinding machine.

Grouting Process in Single wall can be done within 15 minutes after proper leveling.

Fig 11 Assembling of Bars , Conduits before Screeding at site

Screeding thickness over Hollow core slab = 75 mm

Before screeding process embedded all Electrical conduits and Bar mesh as per drawings.

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Lattice bar will be used for jointing of two hollow core slabs.

*In a golf village project 6 ton bars used for screeding of 1 floor in C4 tower.

Erection time Report

Erection of hollow core floor slabs 280-300m2/day Grouting of floor joints 470- 500 m2/day Erection of beams 13- 15 pieces/day Erection of walls 13-15 pieces /day Staircases about 2-3 floors/day

Productivity Analysis

Productivity Analysis is directed to distinguish zones for potential efficiency change ventures taking into account factual information gathered amid the investigation. The investigation likewise pinpoints ranges of postponements and intrusions that cause loss of profitability.

The initial phase in any productivity change activity is to comprehend the current condition of the operation. Productivity examination gives pattern pointers that will likewise yield information which will be utilized to focus conceivable efficiency change targets and potential expense investment funds.

Dependable information got from the profitability investigation additionally makes the accompanying results achievable:

Determination of productivity change objectives;

Quick disposal of non-esteem included exercises;

Capacity to gauge potential investment funds in view of the investigation results.

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I analyzed productivity which is totally depends upon master role and Production report ,here I am posting production report with manpower for finding productivity of shed A in a week except hollow core slab, it was weekly production that I made.

Table 13- Weekly Production at Shed A

Date Production (m3) Cumulative Production

Manpower Cumulative Manpower

21/5/2015 6.707 6.707 16 1622/5/2015 0 6.707 13 2923/5/2015 8.799 15.506 13 4224/5/2015 4.08 19.586 18 6025/5/2015 3.969 23.555 15 7526/5/2015 6.84 30.395 16 9127/5/2015 5.86 36.255 16 107

Productivity = Production (in Quantity)/ No. of Manpower used

Productivity = 36.2555/107

Productivity = 0.33 m3 per manpower

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Table 14- Chart of weekly production at Shed A

This result obtained from shed A.

Basically, Profitability is a normal measure of the productivity of creation. It can be communicated as the proportion of yield to inputs utilized as a part of the creation process, i.e. yield per unit of info. At the point when all yields and inputs are incorporated in the profitability measure it is called aggregate efficiency. Yields and inputs are characterized in the aggregate profitability measure as their financial qualities. The estimation of yields short the estimation of inputs is a measure of the pay created in a generation process. It is a measure of aggregate proficiency of a creation process and in that capacity the goal to be amplified underway procedure.

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Production (m3)0

1

2

3

4

5

6

7

8

9

21-05-15 22-05-15

23-05-15 24-05-15

25-05-15 26-05-15

27-05-15

Costing Exercises

During Summer Internship, I also computed Cost of Hollow Core Slab and Precast wall Panel as per their drawings.

Table 15- Cost of hollow core slab/sqm

Cost of Hollow Core SlabsS. No. Description Qty/Amt. Unit

1 Total qty. of Hollow core Slabs 7.13 Sqm

2 Total Material cost 4831 INR

3 Indirect Cost @ Rs 4620 cum 3161.41 INR

4 Labour Cost @Rs. 50/ Sq.mt. 357 INR

5 Total Cost 8349 INR

6 2.5% Contingencies 209 INR

7 Add 5% profit 417 INR

8 Total Charges 8975 INR

Cost of hollow core slab per sqm 1258.81 INR

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Table 16- Cost of precast wall per m3

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COST Of PRECAST ELEMENTSS. No. Description Qty/Amt. Unit

1 Total qty. of Precast Elements 196.11 m32 Total Material cost 2493689 INR3 Indirect Cost @4620/m³ 906043 INR4 Labour Cost @Rs. 2100/m3 411838 INR6 Mould Cost 3922.26 INR 7 Total Cost 3815688 INR8 2.5% Contingencies 95392 INR 9 Add 5% profit 195554 INR

10 Total Charges 4106634 INR

Cost of pre cast wall per m3 20940.12721 INR

Learning Outcomes

I had learnt the Production process, Quality assurance, Erection Process and Costing, now I am able to assess the suitability of using precast concrete for the building design .I will be able to assess the efficiency of the joint design prepared by third party, will be able to carry out joint design with reasonable complexity, will be able to prepare the method statement and quality assurance policy of the project in precast concrete. I also compared the cost of Conventional and Precast and computed both are about to same but Precast is very good in Speed as well as Quality work.

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References

1. www.supercast.in 2. www.gateprecast.com

3. www.hanson-inc.com

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http://www.hanson-inc.com/

http://www.gateprecast.com/

http://www.supercast.in/

i www.supercast.inii www.supercast.in

Documents

Final draft Report Harsh