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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:
This building has an area of 7665sqm and a tonnage of 350 tons. This building is referred to as
building A. Civil works are in progress and PEB-works are to be started.
3.6 PIT WHEEL BUILDING:
This building has an area of 2375sqm and a tonnage of 90 tons. This building is referred to as
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.