Report Dhaval

8/9/2019 Report Dhaval

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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 on some of their Mega Projects. It

was a very good learning experience for me to have worked on theseprojects

whichinvolved 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 mein these projects and gave an insight in to what these projectsare

all about. I would also like to give my heart-felt thanks to Mr. P.V.Rao, Manager -

Construction, who guided me all through the summer training and imparted in-depth

knowledge of the project. I would also extend my sincere thanks to Mr.Philipose, VP,

Operationsfor inspiring and motivating me through out the training.

I would also like to thank the entire BTD teamfor their self-less help and knowledge

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

report. I would also extend my thanks to the entire PMG team, the Design and Drafting

teamfor their help and guidance during the training.

Last but not the least; I would like to thank all the staff atKBSIL for being so helpful

during this summer training.

Name:Dhaval Gandhi

Date:25th

June 2010


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CONTENTS

CHAPTER 1 INTRODUCTION Page No.

1.1 About the Organization 4

1.2Product range offered byKirby 4

1.3 About PEB (Pre engineered building) 5

1.4 Advantages ofPEB 6

1.5 Induction Programme at Head Office 6

1.6 Kirby Flowchart 7

CHAPTER2 PROJECT DETAILS 9

2.1 General Details 9

2.2Paint Shop 9

2.3 Trims & Chassis Building 10

2.4 Stamping Building 11

2.5 Body Shop 12

2.6 Power Train 13

CHAPTER3SKILLS LEARNED/KNOWLEDGE

GAINED DURING THE INTERNSHIP

3.1 Basics ofPEB 15

3.2 Material Management 19

3.3 Erection Process of the buildings 20

3.4Safetyproceduresinvolved in erection and sheeting 233.5Quality Inspection 23

3.6 Report Generation 24

3.7 Obstacles to Progressat site 26


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Chapter -1

Introduction

1.1 About the Organization:

Kirby Building Systems India Ltd is an affiliate of Alghanim Industries Kuwait, a

multinational organization with diverse interests in Industrial and consumer products.

It launched its technology-driven Pre-Engineered Steel Building Solutions (PEB) in

India around the dawn of year 2000 with an avowed aim of serving the multifarious

needs of the Indian construction market. Its over 30 years of experience (in PEB)

abroad prior to entering the Indian landscape has crystallized into a wide range of

time-tested innovative solutions to specific needs.

KIRBY's Product range covers buildings tailored to customers' unique requirements

with a variety of accessories that go into making the buildings, which are not only

aesthetically brilliant but also majestic and structurally stable and sturdy. 'Quality' for

KIRBY epitomizes a combination of speed of construction, safety of the structure,

sustainability against natural and man-made disasters, suitability to the purpose,

unmatched pre- and post- sales service, scalability, and substantial savings in terms of

both time and money.

While serving the various needs of the customers across a wide spectrum of industries

in India through its vast network of Sales offices, KIRBY from its inception in India,

has highly esteemed every stated or implied need of the customers and exemplified

the "total value" offered to the customers for their money.

KIRBY'S state of art manufacturing facility was setup in April 2000 at Pashamylaram

near Hyderabad in Andhra Pradesh spread over sprawling 30,000 meter square and

over 30 acres of land was commissioned in a record period of seven months is the

epicenter of all its activities (backed by a highly qualified, dedicated, experienced &

seasoned pool of engineers, designers, professionals) that synergies to create efficient


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need-based permanent building solutions. As a part of its expansion programme,

KIRBY has setup another plant at Haridwar, Uttaranchal State in April 2006.

KIRBY is an ISO 9001 certified company and a market leader in Pre Engineered

Buildings in India. Till date Kirby supplied more than 2500 buildings to 2000

customers proving its engineering excellence in various projects and over the years

KIRBY has earned a remarkable reputation for providing cost effective solutions for

buildings manufactured to the highest standards and suited to all environments. Some

of the factories constructed in India and abroad using Kirby concept are model by

themselves.

Today, Kirby is well positioned as the global leader of pre-engineered steel buildings

(PEB). Kirby is well known for providing global customers with customized and cost

effective 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.

At KBSIL (Kirby Building Systems India Ltd.) all the necessary parts and accessories

are fabricated at the plants in Hyderabad and Haridwar. The assembling and erection

works are usually subcontracted. Only monitoring is done by KBSIL and queries so

arising are handled.

But the Renault Nissan project was a turnkeyproject handled by Kirby and hence

they were directly answerable to the clients though the erection works were sub

contracted like in all projects.

Kirby India has a total annual installed capacity of 100,000 MTPA expanded to

175,000 MTPA in July 2007:

Hyderabad: from 60,000 MT to 100,000 MT, this is the largest PEB plant of

its kind in the world.

Haridwar: from 40,000 MT to 75,000 MT


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Ki Indi S l s Netwo k

Company has an all India sal s net ork comprising of 25 offices & 110 B ilders who

have been trained and Certified on Kirbys Erectionprocedures.


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1.2Product Range offered byKirby:

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

y Oil & Gas onshore & offshore

y Heavy IndustryPetrochemicals, Steel, Aluminium smelters, Cement,

Fertilizers

y InfrastructureBridges, Power, Desalination plants, Airports, Seaports,

Railways

y 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.


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1.3Pre Engineered Building:

A Pre engineered building is a steel structure built over a structural concept of

primary members, secondary members, and the cover sheeting connected to each

other. The structural members are custom designed to be lighter in weight as well as

high in strength. For today and in the future, Steel has become the material of choice

in building construction, compared to concrete and timber. Thus steel building

designs have become more flexible, durable and adaptable.

Pre Engineered Steel Buildings (PEB) revolutionized the construction market using

built-ups in place of conventional Hot Rolled Sections. PEB is a steel structure built

over a structural concept of primary members, secondary members, and the cover

sheeting connected to each other. The structural members are custom designed to be

lighter in weight as well as high in strength. Pre-Engineered Steel Buildings can be

fitted with different structural additions like trusses, mezzanine floors, fascias,

canopies and crane systems as per user requirements.

As a leading PEB manufacturer, Kirby provides the complete service of engineering

and fabrication thus ensuring better quality control at every stage of the process.

1.4 Kirby Customer Base:

Companys customer base include all top MNCs, large industrial houses &

government

Select private Sector clients:

Tatar Power

Reliance

General Electric

Hero Honda

Nokia

Suzlon

Renault Nissan

A V Birla Group

Regency Ceramics


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Bridgestone

Pepsi

Toyota

Pipavav

Tata Motors

It also exported buildings to Mauritius, Turkmenistan, Mozambique, Sierra Leone and

U.K.

1.5 Kirby Manualsand Brochures

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

Catalogues and manuals which may be used as ready reckoner by existing as well asnew 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.

1.6 QualityPolicy

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.


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1.7 Health, Safetyand 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.

1.8 HRPolicy:

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

Equal opportunity

Communication channels and feedback

mechanisms Activities promoting work -

life balance


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1.9 KirbyValues:

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

Customer Centric: They put the customers at the Centre 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 valuableresource 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 theirwasta (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.

1.10 Advantages ofPEB:

Reduced construction time

Lower cost

Flexibility of expansion.

Large clear spans

Higher quality control.

Lower maintenance or high durability Energy efficient roofing and wall systems (very well insulated)

Architectural versatility.

Single source responsibility(single vendor supplies all members)


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1.11 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. Ramchandra Rao(HR Manager) who further introduced

us to Mr. Prasada Raju (GM BTD) who is the head of the Builders Training

Department. Initially for the first two days we studied the Technical Handbook and

Erection Manual in detail. Our familiarisation with the manual was very important

before we moved ontoour projects as the manual included the basics of PEB, its

erection procedure and Kirby terminology so used.

After this, our visits to various departments in the organization were arranged. We

visited almost all the departments of the organization (Design, Drafting, Production,

Shipping, PMG, Quality and Safety) and everywhere we were given all possible

information by the concerned official. Then we had a plant visit wherein we got to

know about the entire fabrication process in detail.

Also, we got an opportunity to learn about the SAP module in which the company hasinvested a huge amount to monitor all the projects running round the globe.


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1.12Kirby Flow Chart:

Down Payment

Credit

Release

Design Sketch with details

Shipper List

Erection Drawings

Shop Drawings

Shipper List

Erection Drawings

Shop Drawings

Fabricated building material

Shipper list

Shipping advice / shipper list / erection dwg

To inform the customer

Customer / Job site

Area Sales office, Kirby

Design Dept / Pace II

Estimating

Customer Service Dept

(Master File)

Design Department

Drafting Department

Production Control

Plant / Q.C.

Shipping & Packing

Dept. / Transport

Credit Department

Enquiry Proposal contract

QRF sketch Book pricerecommendations

SignedOrder

ErectionDrawing

ShippersLists

Signed

Offer/D

P

ShippingDocuments

Sales Office

ErectionDrawing

ShippersLists


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The roles of the various departments are as under:

1. CSD Customer Service Department This department is the single point

contact for the client and all the queries are directed over here. Thus, it is that part

of the organization which co-ordinates all the activities of other departments. They

are responsible for executing the project as per the time frame.

2. Sales & Marketing Department They book jobs i.e. they get customers/clients.

They target the clients and get work orders. It is one of the largest departments at

KBSIL. Kirbys market segment is a niche market. They have grown very much

in the past four years with major breakthroughs in the automobile sector.

3. 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:

a. Raw Material stage inward stage

b. In process stage

c. Outward Shipping stage

4. Drafting Department. They prepare detailed drawings and drawings which are

to be sent on the site. They prepare three types of drawings:

a. Approval Drawings meant for the approval from the clients

b. Fabrication Drawings element wise drawings meant for the fabrication in the

plant.

c. Erection Drawings detailed drawings to be provided to the erection

engineers at the site for the purpose of execution.

5. Design Department They design the building based on the data of the site

available and by keeping other standards, rules and customer requirements in

mind. They use design packages such as STAAD Pro at the job stage and

SMARTEST at the quote stage.

6. 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.


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Chapter - 2

Project Details

2.1 General Details:

The following projects were undertaken during the summer training period.

1. Toshiba JSW - Chennai

2.

MRF Ltd. - Trichy

3. Star Panel Boards Ltd. - Bangalore

4. Sterilite Infra Tech Ltd. - Aurangabad


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Project 1 - Toshiba JSW

Project Details:-

Bldg A - Main Building # 10

Job No : - 2619

Location :- Chennai, Tamil Nadu.

Client :- Toshiba JSW Turbine & Generators Ltd.

Total Quantity of Steel : -5413 MT.

Total area of the building : - 42,240sq.m(C/C)

TentativeFabricationand ErectionSchedule.

Revised Fabrication and Erection Schedule.

Bldg B Blade Shop Building # 50

Job No :- 1004U

Location :- Chennai, Tamil Nadu

Client :- Toshiba JSW Turbine & Generators Ltd.

Total Quantity of Steel : - 213 MT.

Total area of the building : - 1964.16sq.m(C/C)

Tentative Fabrication and Erection Schedule.

Revised Fabrication and Erection Schedule.


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Project 2 - M/s MRF Limited, Trichy

Bldg A1: Truck Radial Plant

Project Details:-Job No :- 2683

Location :- Trichy, Tamilnadu.

Client :- M/s. MRF Ltd.

Sub-Contractors :- 1. Sree Building Solutions Package I2. Pearl City Engineering Builders Package II

Total Quantity of Steel is 6412MT.

Total area of the building is 53692.20sq.m(C/C)

Current Status:-y The start of the project has been delayed and the revised schedule has been

prepared.

y The type of contract is Lump Sum contract.

Bldg B1: Non Truck BiasPlant

Project Details:-

Job No : - 2687

Location : - Trichy, Tamilnadu.

Client : - M/s. MRF Ltd.

Sub-Contractors : - SS Constructions package III

Total Quantity of Steel is 3627MT.

Total area of the building is 28207.62sq.m (C/C)

Tentative Schedule for Fabrication and erection.

Revised Schedule for Fabrication and erection.

Note: This Schedule is for both the Buildings.


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Project 3 - StarPanel Boards Limited, Bangalore

Project Details:-

Location :-Karnataka, Bangalore.

Client :-Star Panel Boards Ltd.

Sub-Contractor :- M/s. Hi-Tech Builders (For Painting and Erection works).

Total Quantity of Steel is 1523 MT.

Total area of the building is 38,837.30 sq.m (C/C)

Present Status:-y The project is in the initial stages.

y There has been a delay in the start of the project.

y It is due to delay in final approval of G.A. drawings as well as delay in release

of shop drawings for fabrication.

y The current status as on 17/05/2010 is that the anchor bolt casting is 100%

complete.

y The sheeting material is yet to be received as there was a change in the

profile.

y 34 loads of Red Steel (693 tonnes) has already been sent to the site as on

12/05/2010. Out of which 9 loads of steel is yet to be unloaded.y The erection operation is yet to begin.

y The fabrication and dispatch of the sheeting is expected to be completed as

scheduled.

Schedule for Fabrication and Erection.


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Project 4 - Sterilite Infra Tech Limited, Aurangabad.

Project Details:-

Location :- Aurangabad, Maharashtra.

Client :- M/s Sterilite Infra Tech Limited.

Sub-Contractor :- Sangha Erectors.

Total Quantity of Steel is 1428 MT.

Total area of the building is 32,854.48sq.m (C/C)

Schedule for Fabrication and Erection.


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Chapter 3

Skills Learnt/Knowledge gained during the internship

The following areas were focused upon during the internship:

3.1 Basics ofPEB:

A Pre engineered building consists of following components:

a. Structural Systems

b. Secondary members

c. Cladding

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

Single Slope

Multi-Span


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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 Zsections. 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 intersectionof 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.

iii)Cable bracing: This member is designed to ensure the stability of the buildingagainst forces in the longitudinal direction due to wind, cranes, earthquakes. It

is made of a cable which is forged into a rod terminal and this arrangement is

then fixed on a structure using a hill side washer, nut washer and a nut.


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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 / aluminium 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.

i) Kirby RibProduct Description:This type of panel has coverage of 1 m. It ismade 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.

ii) Kirby Wall Product Description:As the name would suggest; this type of panel is used for wall panelling 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.

iii)Kirby Decking Product Description:Typical applications of decking panelsare 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 s follows:

Walk doors

Sliding Doors

Aluminium Windows

Insulation

Louvers

Fasteners

Power Ventilators

Skylights & Wall Lights

Ridge Ventilators

Roof Jacks

RoofCurbs

The following figure shows the various elements of a PEB:


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3.2 Material Management:

This was the main responsibility that was assigned to me at the site. Kirby being the

supplier of the materials had to maintain perfect records of the material available on

site and the material which is to be shipped. Especially the material required for the

priority area had to be shipped on time so that the erection process is not delayed.

The materials received were updated in an excel sheet and the balance materials to be

received were kept track. 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 Piece 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.

A material storage yard adjacent to the building


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Suggestions forimprovement in thisaspect:

The subcontractors had dumped the material in their yard in a haphazard manner

as shown in the picture. This resulted in a lot of wastage of time in searching for

the appropriate material. Instead the materials can be unloaded and stacked

according to their load numbers so that they can be retrieved easily when required.

The builders need to keep track of the materials required in the priority areas and

maintain separate lists for those materials which would help in preparing the list

of balance materials to be received.

Sometimes the shippers lists were not available till the latest date of revision and

this posed problems during the updating process. A proper communication

between the shippers department personnel and the site personnel would help

avoid this problem.

3.3 Erection Process of the 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:

y Anchorbolt testing Pedestal testing: 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 CCCL, a Chennai based company. Only the testing for the

alignment of the anchor bolts is done by Kirby. This is termed as the Pedestal

testing. In this test, 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.

y Primary elements erection: Once the pedestal test has been performed, the

erection of the primary elements is started. The primary erection includes the

main frame elements such as columns, beams and rafters. These elements are

erected with the help of cranes and ropes. Once the columns have been


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erected, their stability becomes very important and hence they should be

fastened with ropes so that they do not sway in the wind.

One of the Raftersbeing erected.

y 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.

Erection of Bracings with the help ofa crane.


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y Roofsheeting 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. The workers are

instructed to wear the safety gear which includes safety ropes and helmets

before carrying out this operation as it is done at great heights. Any fall from

such a height would result in fatal injuries to the victim. Hence Kirby takes no

chances in this aspect of safety.

Wall cladding along withscaffolding.

The roof sheeting is carried out in three stages. Initially the wire mesh is laid and then the

insulation is laid on top of this. Finally the roof sheeting panels are laid and bolted. The

wire mesh acts as a support to the insulation and the roof sheets.

Roofsheeting in progress Picture showing wire mesh & Insulation


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3.4 Safetyproceduresinvolved in the Erection and sheeting:

As mentioned earlier, safety is given utmost importance by Kirby and also the

clients. The safety supervisors were appointed by Kirby who used to keep a

constant check on the safety aspects in the various buildings.

The roof sheeting is usually done at great heights and hence the appropriate

safety harness is to be worn. PPEs such as helmets and safety ropes were

mandatory for the laborers who used to climb on the roof.

Even for the wall cladding, the safety ropes were mandatory and these were

attached to the scaffolding erected for this purpose.

A safety supervisor was appointed by the client as well and he used to conduct

frequent checks on the site and provide any suggestions if required. If there

was any discrepancy in this regard, strict action was taken against the safety

engineer in charge on the site.

3.5 Qualityinspection:

Generally quality inspections are not carried out by Kirby on the site. It is done only

at the plant before the material is shipped. Since this project is of a bigger nature in

terms of built up area and tonnage of steel, the clients have made a special request to

provide a quality inspector on the site to perform the inspection during the painting of

the members.

y Paint inspection using WFT gauge to test the WFT(Wet film thickness).

o This test can be performed when the paint is applied fresh, i.e. before the

paint gets dried.

o The gauge is placed on the freshly painted metal and the thickness is

checked based on the readings available on the teeth of the gauge. In this

project, Kirby maintains the WFT at 120 microns.

y Paint inspection using Elcometer to test the DFT (dry film thickness) of the

paint.

o This test is performed 8 hours after the painting operation is completed.


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o 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.

o The knob gets rewound automatically and stops at the exact thickness level

of the paint on the metal.

y Alignment and plumb testing for the columns:

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

checked on the flange as well as the web.

y Torque tightening test using torque tightening machine:

o The torque to be maintained depends on the diameter of the bolt used. The

torque tightening machine is set to the required torque and then the bolts are

tightened.

o For e.g.: A torque of 431 Nm is maintained for 20 mm diameter High

Strength Bolts.

3.6 Report generation:

Along with material management, emphasis was given on report generation

during the training. I was involved in the preparation of various reports such as Daily

manpower report, Daily Progress Report, Sheeting and cladding progress report.

y DailyProgress Report (DPR):

o This report was to be submitted by KBSIL to the client (RNAIPL) on a daily

basis and it consisted of all the details of the work done on site relating to

various activities going on at site like Roof Sheeting, Wall Cladding,

Downspout fixing, window and door fixing etc.

o It was prepared daily and handed over to the client. It was prepared by the

erection engineers on the site and I was involved in this process.

o Each building had a separate engineer in charge and hence separate DPRs

were prepared by them and a copy was forwarded to the head office, to keep

them informed about the activities which weregoing on at the site.

o This DPR is a very important report as it depicts the current status of the

project and also gives an idea about the pace at which the work is being

carried out.


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y Daily Manpower Report:

o Since the availability of adequate strength of labour was extremely vital for

the smooth progress of the project, a daily manpower report was prepared

and maintained in order to have an idea about the labour strength on the site.

o This proves to be extremely helpful in planning the progress of the various

activities as the amount of labourers available would determine the pace at

which the work can be carried out.

o This report was prepared on a daily basis by the Project Manager at the site

and I was also involved in this report generation.

o The number of labourers present in each building was reported by the

engineer in charge of that building and this was put together to form the

manpower report.

o A copy was sent daily to the client as well as the head office in order to keep

them updated about the situation at the site.

o The format of the manpower report so generated is as follows:

KIRBY DAILY MANPOWER REPORT DT 25-06- 2009

Stamping Bodyshop Paintshop T&C Powertrain

BUILDING C E A B F UTILITY TOTAL

UNLOADING & SHIFTING 4 11 15

PAINTING 5 6 31 8 50

ERECTION PRIMARY 12 8 20

ERECTION SECONDREY 59 10 33 62 19 8 191

MONITOR ERECTION 12 8 41 61

PROCESS

BEAM&MEZZANINE 28 10 25 63

ROOF SHEETING 44 62 38 144

MONITOR SHEETING 11 6 17

WALL CLADDING 16 25 10 8 59

GENERAL & ALIGNMENT 3 12 15

TOTAL 124 126 70 256 43 16 635

y Sheeting and cladding progressreport:

o This report was prepared to depict the progress of the roof sheeting and wall

cladding for each building.

o Since these two activities were the major activities carried out on the site, a

separate report was prepared for this purpose.


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o This was done exclusively by me in the excel format and I updated the

report on a daily basis by interacting with the engineers in charge for the

various buildings. They used to carry out the updating on the drawings

manually and this was done on the system by me so that a copyofit can be

sentto the Head Office fortheir reference.

A lic tion of SA in Ki :

SAP (Systems Analysis and Programme Development is a business management

software tool for realtime 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.


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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.

3.7 Obstacles to Progressat Site:

Though I was not present at the site for a longer period, I observed some obstacles

that were hampering the execution of the project. This was learning on its own. The

following reasons can be attributed for the slow progress of work at the site:

y The mid day temperatures soared to 42 degrees Celsius on a daily basis and

this sweltering heat was a major obstacle for the progress of work, especially

for roof sheeting since it had to be done in the direct exposure to the sun.

y The turnover of labour was also a big issue as most of them fell sick due to the

extreme heat conditions.

y The material storage yards were not properly maintained by the builders and

hence a lot of time was wasted in searching for the appropriate materials as

they were dumped haphazardly.

y There were frequent dust storms in the region and usually lasted for almost an

hour in the evening times and this was a huge problem as the work usually

progressed at the quickest pace only after 4 PM when the heat receded.


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A picture showing the dust storm.

y At times there was rainfall accompanied by heavy winds and this was also a

major obstacle to progress. There was one such incident when the wind was

very heavy and this caused a lot of damages to the roof sheeting.

(i)The scaffolding which collapsed (ii) The roof sheeting which was damaged

Effects of the wind storm.


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CHAPTER 4

RECOMMENDATIONS FOR IMPROVEMENT

During my two months of training at Kirby, I totally felt the dedication and

commitment of the Kirby employees towards improvement a every step. Some of the

areas in which a lot of improvement is required are:

1. Even though some amount of discipline was observed 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 a lot of wastage of

time in searching for the materials. Instead, the builder can take more

care in staking the materials separately according to material size,

purpose and frequency of use.

2. It is important to educate the supervisors and labor about the

importance of material management which may help to achieve greater

control over the materials.

3. It would be better if the materials from the plant are shipped based on

the priority of phases. Many a times it so happens that the materials

that are required at a much later stage arrives at the site and those

which are required at utmost priority.

4. SAP:

SAP- ERP software may be upgraded so that it can be used by

site engineers and managers to update the daily progress of

various activities which helps the middle and top management

to get the real time status of various projects at different

locations. This helps to exercise greater control over the

projects and in taking strategic decisions.


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CHAPTER 4

CONCLUSION

It was indeed a wonderful learning experience to be a part of such a huge

project, be it in terms of tonnage of steel or cost of the project or the manpower

involved. I have gained a lot of insight into PEB, its functioning and its erection

process. Also material management is very important in such projects and hence

utmost importance must be given to this aspect. I was trained very well in this regard

and I am sure that this experience will help me in the future.

Report Dhaval

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