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Final Report - PDF Form PDF
Final Report - PDF Form PDF
Final Report - PDF Form PDF
1. Name of Company Kirby Building Systems India Limited (KBSIL) 2. Name of the Project Bangalore Metro Rail Project Place of Work Bangalore 3. Department Builders Training Department (BTD) 4. Name of Student V. Jagdeep Naidu 5. Roll No : 231121 6 Mailing address Company Kirby Building Systems India Ltd. Plot No. 8 to 15, IDA Phase Pashamylaram, Medak Dist. Andhra Pradesh Phone No- 0845-5224425 Personal V.Jagdeep Naidu No-J 37, 1st Main Road, LN-Puram Srirampuram, Bangalore- 560021 Karnataka Phone No- 09579151915 E-mail- jagdeep.naidu@gmail.com Batch No : 23
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.
CONTENTS
CHAPTER-1 INTRODUCTION 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 About the organisation Kirby Product Range Customer base Manuals & Brochures Quality Policy HSE Policy HR policy Kirby Values Land Mark Projects Induction Programme at Head Office Departments & their Roles
Page No 5 5 6 7 8 8 8 9 9 10 10
CHAPTER-2 LITERATURE REVIEW 2.1 2.2 2.3 PEB- Revolution in India Advantages Challenges Ahead 12 14 15
CHAPTER-3 PROJECT DETAILS 3.1 3.2 3.3 3.4 3.5 Stabling Shed Emergency Re-Railing Building Repair Bay ETU- Building Inspection Bay
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3.6 3.7
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CHAPTER-4 SKILLS LEARNT/KNOWLEDGE GAINED DIRING INTERNSHIP 4.1 4.2 4.3 4.4 4.5 4.6 4.7 Basics of PEB Material Management Safety at Site Quality Inspection Erection Process of Buildings Report Generation Obstacles to Progress at Site 30 35 37 39 40 43 44
CHAPTER-5 RECOMMENDATIONS FOR IMPROVEMENT 5.1 5.2 5.3 Recommendations Responsibilities Conclusion 47 48 48
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.
Toyota General Motors Chevron Pepsi Nissan Unicef BMW P&G Unilever Bridgestone Tata power Nokia Henkel Apex and many more.
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
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 Saradhi, Sr.Manager-Drafting, Mr.Sudarshan DGM-Designs, Mr. T.V.P K.G.K
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.
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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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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 Indian codes 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.
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
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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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.
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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.
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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.
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.
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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.
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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.
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4.1 Basics of PEB: A Pre engineered building consists of following components: a. Structural Systems b. Secondary members c. Sheeting d. 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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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 the planes 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 high rise 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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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 before choosing 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.
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 ThirdParty. 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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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: 1st coat-75 micron, 2nd coat-35 micron, 3rd
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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 erected along 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.
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.
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 dumping large 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 which there 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 material management 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 and managers 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.
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