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NATIONAL INSTITUTE OF CONSTRUCTION MANAGEMENT AND REASERCH

SUMMER TRAINING REPORT

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.

Name: V. Jagdeep Naidu Date: 26th June 2010

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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16 19 20 21 22

3.6 3.7

Pit-Wall Building Quality Management

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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

CHAPTER-1 1.1 About the organisation:


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

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 of Builders 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.

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 3rd May 2010 to 7th May 2010 and during this programme, 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 Saradhi, Sr.Manager-Drafting, Mr.Sudarshan DGM-Designs, Mr. T.V.P K.G.K

Rao.S,Senior Manager-EHS, Mr.

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 the country. 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 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.

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 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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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 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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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 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.

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 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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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: 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.

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 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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