Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
ON
PRECAST CONSTRUCTION
AT
By
VAIJAYANTI JENA
(Roll No. 1517028)
November 2018
DECLARATION
I hereby certify that the work which is being presented in the report entitled "Summer
Internship Report on Precast Construction at KEF INFRA, Bangalore" in partial fulfilment
of the requirements for the award of the Degree of Bachelor of Technology in School of
Civil Engineering under Kalinga Institute of Industrial Technology, Deemed to be
University, Bhubaneswar is an authentic record of my own work. I have tried my best to
keep report simple yet technically correct.
The matter embodied in this report has not been submitted by me for the award of any other
degree of this or any other University/Institute.
Vaijayanti Jena
ii
ABSTRACT
The summer internship report contains broadly the chapters in which I have tried to explain
my one month training done in my hosting organization namely KEF INFRA, a world class
precast industry leader working on a wide range of construction projects pan India.
As I was posted at the company‟s state of the art fully automated precast plant site I covered
the complete precast process from design to erection works by doing rotation through
various departments like Design, Planning and Shop floors for all manufacturing process of
precast elements required by the projects. I also had an opportunity to go on site to see the
erection works. The contents of all chapters cover the practical aspect at factory works as
seen and learnt by me during the internship period.
In the opening chapter, I have mentioned the company‟s background details including its
mission, vision, key projects. The plan layout of the organization is world class as can be
seen from the details provided.
The second chapter explains about precast and its various systems. Also types of
connections required in precast construction are mentioned and described.
Overall, the internship program that I undertook at KEF INFRA has given me an in-depth
knowledge about the works done in a precast industry. I am confident that precast process is
going to be the future of construction industry in India.
iii
TABLE OF CONTENTS
DECLARATION .............................................................................................................ii
ABSTRACT .....................................................................................................................iii
TABLE OF CONTENTS .................................................................................................iv
1. INTRODUCTION .......................................................................................................1
1.1 About the Organization ..................................................................................1
1.2 Work Culture .................................................................................................2
1.3 Vision .............................................................................................................2
1.4 Mission...........................................................................................................2
1.5 Core Values ....................................................................................................2
1.6 Manufacture ...................................................................................................3
1.7 Company Address ..........................................................................................3
1.8 Global Presence ............................................................................................3
1.9 Organization Structure ...................................................................................4
1.10 Awards .........................................................................................................4
1.11 Key Project ..................................................................................................5
2. PRECAST ....................................................................................................................7
2.1 Types of Precast System ................................................................................7
2.2 Difference with cast in-situ ............................................................................8
2.3 Typical Connections of Precast Concrete Elements ......................................8
2.4 Precast Connections .......................................................................................9
3.DEPARTMENTS COVERED DURING INTERNSHIP .........................................12
4. DESIGN .......................................................................................................................13
5. PLANNING .................................................................................................................18
6. PRODUCTION ............................................................................................................19
6.1 Bay 1 Hollow Core Slab ................................................................................20
6.2 Bay 2 Column & Beam ..................................................................................29
6.2 Bay 3 Wall Panels ..........................................................................................36
6.4 Bay 4 Mesh ....................................................................................................38
6.5 Bay 5 Stirrup Binder ......................................................................................42
6.6 Bay 6 Column, Beam & Staircase (Customised Elements) ...........................43
7. ERECTION ..................................................................................................................45
REFERENCES ................................................................................................................46
ACKNOWLEDGMENT..................................................................................................47
iv
1. INTRODUCTION
Mr. Faizal E. Kottikollon set up his first business - Al Ahamadi General Trading, a scrap
metal trading and recycling business in Ajman, UAE in 1995. In 1997, he set up the first
foundry Emirates Techno Casting (ETC) in Ajman, UAE. JC Middle East was established
in year 2002 for trading valves at Hamriyah Free Zone, UAE. Then in 2003 Emirates
Techno Casting FZE was set up in Sharjah and in the next 3 years it grew quickly to
become an internationally renowned valve-casting brand.
Inspired by the desire to contribute to society, the founder of KEF Holdings set up the
Faizal & Shabana Foundation as well as KEF Holdings was created as parent company to
the group in 2007. ETC became a fully automated and integrated valve manufacturing
facility when a manufacturing agreement was signed with JC Valves.
In 2008 Dubai International Capital, the investment arm of Dubai Holdings, acquired 45%
stake in KEF Holdings and also forged a key partnership that supported the company‟s
expansion plans. And by the year 2011, Tyco International, a 20 billion USD global
conglomerate, acquired a 75% stake in KEF Holdings for 300 million dollars. The
remainder of the 25% stake was sold in 2012, making the total sale value a 400 million
USD.
The KEF Company Ltd. established as the corporate headquarters of the group in Dubai‟s
International Financial Center (DIFC). And plans for innovation in the hospital sector in
India was unveiled by the year 2013. Precast and modular construction technology to be
used to make the hospital projects affordable and build facilities at a rapid pace.
At KEF INFRA they are transforming the way buildings and basic services are created and
delivered in India. KEF INFRA is ushering in Industrial Revolution 4.0 i.e smart factory
by integrating world-class technology with software solutions thus significantly reducing
costs and increasing efficiency in infrastructure development.
1
Offsite Manufacturing Facility
KEF INFRA- One Industrial Park in Krishnagiri, Tamil Nadu, is the world‟s largest and
most integrated offsite manufacturing facility. It is spread over 42 acres and features
cutting edge manufacturing. Its integrated factory has units for:
Precast
Joinery works
Stone processing
Transparency
1.3. Vision
Together, we make a difference to people and societies by improving their quality of life.
KEF INFRA shall move beyond incremental fixes to an era of transnational change in how
we design, engineer, and deliver building.
1.4. Mission
Integrity: We build relationships based on mutual respect, and always behave with
integrity.
Humility: We enjoy working collaboratively and care about people and the
environment we live in.
2
1.6. Manufacture
Hospitals
Homes
Hotels
Schools
Commercial buildings
2. India :
3
1.9. Organization Structure
1.10. Awards
Mark of Excellence - Employer of the Year Award 2017, HR Summit & Expo 2017
4
Key projects
5
KEF INFRA ONE PARK
ALUMINIUM &
GLAZING
JOINERY
PREFABRICATED
PODS
PRECAST
PLAN LAYOUT
6
2 PRECAST
The concept of precast construction includes those buildings, where the majority of
structural components are standardized and produced in plants in a location away from the
building, and transported to the site for assembly. These components are manufactured by
industrial methods based on mass production in order to build a large number of buildings
in a short time at low cost.
The main features of this construction process are as follows:-
The divisions and specialization of the human workforce.
The use of tools, machinery and other equipment are usually automated in the
production of standard, interchangeable parts and products.
Plant casting allows increased efficiency, high quality control and greater control on
finishes.
7
2.1.2 Frame systems
Precast frames can be constructed using either linear elements or spatial beam column sub-
assemblages. Precast beam column sub-assemblages have the advantages that the
connecting faces between the sub-assemblages can be placed away from the critical frame
regions. However linear elements are generally preferred because of the difficulties
associated with forming, handling and erecting spatial elements. The components of a
precast reinforced concrete frame are shown in figure.
8
2.4. Precast Connections
Precast connections ensure safety and durability of a precast building. They carry the
predefined loads in different building structures and resist fire and water.
There are several pretested connection types for precast structure and they are:
2.4.3 Coupler
It is used for rebar mechanical splicing in the concrete structure. It can connect re-bars
of same or different diameters laterally, vertically and slanting. It is mostly adopted
under base slab and middle section of R.C. Column.
Advantages:-
Good performance of self-lock and sealing.
Good performance of centering, simple to operate, high work efficiency.
9
2.4.4 Lifting socket
It provides simple lifting and transporting for most kinds of precast concrete units,
particularly when casting into thin concrete panels. The sockets are available in both
high grade zinc plated carbon steel and 304/316 grade stainless steel.
10
2.4.9 Cast in channel
The channels are of a rectangle profile are bonded to the concrete by means of anchors
fitted to the channel which transfer the carrying tension and shear loads directly into the
concrete.
11
3. DEPARTMENTS COVERED DURING
INTERNSHIP
My hosting company is undertking many projects all over India as I have mentioned in the
company profile above. As KEF INFRA is a technology-driven company & integrated
offsite factory, I had the opportunity to work on rotation in various departments which are:
The details of the works done in various departments are described in following pages.
12
4. DESIGN
In civil engineering, designing means finding out the dimensions of a structural member and
amount of other materials (reinforcement, prestress etc.) which will be sufficient to
withstand different types of loads and forces applied on that member, at the same time it
will be economic and providing serviceability.
Methodology:-
13
Unit Values
1. Strands
5 19.6 0.15
2. Steel
160 0.099
200 0.1095
250 0.1365
320 0.1568
400 0.1973
500 0.2503
14
Calculation
We know that
Stress = Force
Area
E = Strain
Stress
Strain = Stress
E
Example 1
Given
Mold length = 120 m
Force or pull = 61.2 KN
Area of Ø 9.5 Strand= 54.8 mm2
Stress = Force
Area
Strain = Stress
E
Elongation = 672 mm
15
2. To find the number of bars
Example 2
1180 mm
850 mm
= 6 no. of bars
= 8 no. of bars
16
3. Bar bending schedule (BBS)
Example 3
17
5. PLANNING
Planning is done to determine and develop the most suitable and economically viable
construction and engineering methods for project.
Supervising the project at all the stages and providing solutions to problem.
Collaborating with site managers, surveyors, engineers, site worker and other
professionals.
All the above things are recorded by planning department and it is noted down in tracking
schedule.
A tracking schedule is a mechanism to communicate what tasks need to get done and which
organizational resources will be allocated to complete the whole project.
18
6. PRODUCTION
A bay is a section or area where all the elements to be casted are categorized. There
were total 7 bays in site which were:
19
6.1. BAY 1 - HOLLOW CORE SLABS
About the element: A hollow core slab is a precast slab of pre-stressed concrete
typically used in the constructions of floors in multistory apartment buildings. It has
tubular voids extending the full length of the slab. This makes the slab much lighter
than a massive solid concrete floor slab of equal thickness or strength.
Advantages
Tubular void can be used to run mechanical and electrical equipment.
High-strength hollow core slab can provide floors that support heavy loads.
Hollow core slab act as a ceiling and flooring unit and reduces the building
height while saving the cost.
Easy to demolish.
Specification of bay 1
Number of casting pallets : 8
Length : 120m
Breadth : 1.2m
Thickness : 160mm, 200mm, 250mm,
320mm & 400mm
Strands: Ø5mm, Ø9.5mm, Ø12.7mm &
Ø15.3mm.
Curing : Hot bed curing
Lifting capacity : one crane - 10 ton
Transport : Maximum 18m HCS can be
transport & trailer capacity is 35 ton
20
Machine and equipment
Extruder
Concrete saw
Erection clamp
Lifting clamp
Casting pallets
Stressing machine
Abutment
1. Description
1.1. Abutment is designed for holding stressing strands of the hollow core slab
during stressing.
1.2. Abutment is to be mounted in concrete foundation.
1.3. The maximum pre- stressing force that the abutment can take is 300 ton.
21
Precast Production Bay 1
1. Casting pallets or bed are cleaned with water and then dried.
2. According to the shop drawing the strands are selected and layered.
3. One end is fixed with barrel at abutment and other end with wedge.
4. Oil is applied throughout the bed to easily de-mold it.
5. Strands are then pulled slowly and marking is done after every inch till the
required elongation is achieved.
6. Extruder is then placed by crane, according to the thickness required given in
drawing. And concrete is poured.
7. Concrete slab is marked when it is wet for cutting it easily.
8. Hacking and cutouts are done at the extreme width side of every slab and filled
with concrete. This is done to prevent from seepage.
9. Then the bed is covered with tarpaulin sheets.
10. Hot water is passed through the slab for curing. For checking the temperature of
the water there is sensor after every 40mm. It generally takes 8-10hrs for curing
but can vary depending on the thickness.
11. Tarpaulin cover is removed but before that De-stressing is done.
12. Cutting of slab is done by concrete blade wherever marking is there.
13. Name is written in every slab using paint.
14. All the slabs are De-molded, lifted and stacked in stock or else transported to
site for erection.
22
Step 1. Bed Cleaning
Step 4. Oiling
23
Step 5. Strands are stressed
24
From Shuttle to distributor.
25
Extrusion
26
Step 12 & 13.Cutting using
concrete blade and writing
name.
27
Stored in stockyard
28
6.2. BAY 2 - COLUMNS & BEAMS
Elements produced
1. Beam
1.1. L-shaped
1.2. Single tee
1.3. Double tee
1.4. Inverted tee
1.5. Rectangular
2. Column
2.1. 1/2/3/4 corbels
Advantages of pre-stressed
They are free from cracks as concrete is under compression.
Advantages of precast
Since precast is manufactured in a controlled casting environment it is easier to
control the mix, placement and curing.
Quality can be controlled and monitored much more easily.
Weather is eliminated.
29
Specification of bay 2
Number of casting pallet : 3
Length : 110m
Width : 1.5m
Height : 0.6m, if more is required than it is fabricated
Strands : Ø5mm, Ø9.5mm, Ø12.7mm & Ø15.3mm
Bars : Ø8mm, Ø10mm, Ø12mm, Ø16mm, Ø20mm & Ø25mm
Curing : steam
Lifting capacity : one crane - 10 ton
Stressing machine
Welding machine
Needle vibrator
Abutment
1. Description
1.1. Abutment is designed for holding stressing strands of the prestresseded beam
during stressing.
1.2. Abutment is to be mounted in concrete foundation.
1.3. The maximum pre- stressing force that the abutment can take is 300 ton.
30
Precast production Bay 2
1. Casting pallets or bed are cleaned with water and then dried.
2. Oil is applied throughout the bed manually to easily de-mold it.
3. Along the breath sides the shuttering is done with the help of welding, according to
the shop drawing. .
4. Dowel pipe are placed in rebar cage according to the shop drawing and then Rebar
cage is placed by crane. After that end shuttering is done that is along the length
side
5. At the top, bars are welded on the edges along the length sides to avoid the shutter
to fall.
6. For prestressed beam strands are pulled slowly and marking is done after every
inch till the required elongation is achieved.
7. Pouring of concrete and vibration is done manually. Elements are marked for easy
installment.
8. Then the bed is covered with tarpaulin sheets.
9. Pipes are placed on top of the elements under the tarpaulin sheets for steam curing
process. It generally takes 8-10hrs for curing but can vary depending on the
thickness.
10. Tarpaulin cover is removed and de-stressing is done by help of circular saw blade.
11. Name is written in every element using paint.
12. Casted element is lifted and stacked in stock or else transported to site for erection.
31
Step 1 & 2. Bed cleaning and oiling is done manually
32
Rebar cage is placed with the help of crane.
33
Step 10. De-shuttering is done
34
Step 12. Element is lifted to stack in store or else transported to site
35
6.3. BAY 3 - WALL PANELS
Elements produce
1. Precast wall panel
1.1. Facade
1.2. Solid panel
1.3. Double wall
1.4. Cladding panel
About the element: A panel is a single piece of material, usually flat and cut into a
rectangular shape, that serves as the visible and exposed covering for a wall.
Advantages
Cost effectiveness: Installing of panels is inexpensive.
Durability & performance: offers unbeatable protection against weather and erosion.
Swiftness of construction: these systems can be installed in a quick process.
Environmental soundness: it reduces the space needed on a job site as it is
manufactured in a production facility.
Easy to demolish.
Specification of bay 3
Number of casting pallets : 39
36
Machine and equipment
Magnet based shuttering (RATEC)
37
6.4. BAY 4 - MESH
About the element: In reinforced concrete, an arrangement of steel bars or wire normally
in two directions at right angles, tied or welded at the intersections of interwoven.
Advantages
High tensile strength
Durability
Controls cracks
Less deflection
About bay 4
Steel Quality: up to 550N/mm2
38
Samples of customized meshes
39
MESH MANUFACTURING PROCESS IN FULLY AUTOMATED MACHINE
Step 1: Bars are cut to size Step 2: Bars are moving to get placed
40
Step 5: Welding of bars Step 6: Mesh are welded and transported
41
6.5. BAY 5 – STIRRUP BINDER
About the element: Stirrup is a closed loop of reinforcement bar that is used to hold the
main reinforcement bars together in an RCC structure.
Advantages
In column it prevents buckling
About bay 5
Steel Quality: up to 550N/mm2
42
6.6 BAY 6 – COLUMNS, BEAMS & STAIRS
Elements produced
1. Column
2. Beam ( precast & prestressed)
3. Staircase
4. Drains
About bay 6
1. Stair
1.1. Thick: 10-18 cm
1.2. Height: 90-160 cm
1.3. Length: 60-800 cm
1.4. Riser: 14-18 cm
1.5. Tread: 27-33 cm
1.6. No. of steps: 4-14
Mold can fabricate locally according the requirement.
Stressing machine
Welding machine
Needle vibrator
43
Precast production Bay 6
1. Casting pallets or bed are cleaned with water and then dried.
2. Oil is applied throughout the bed to easily de-mold it.
3. Along the breath sides the shuttering is done with the help of welding, according to
the shop drawing.
4. Dowel pipe are placed in rebar cage according to the shop drawing and then Rebar
cage is placed by crane.
5. MEP & inserts are placed. And the end shuttering is done that is along the length
side.
6. At the top, bars are welded on the edges along the length sides to avoid the shutter
to fall.
7. For beam where the elements are to be stressed then, strands are pulled slowly and
marking is done after every inch till the required elongation is achieved.
8. Pouring of concrete and vibration is done manually. After that final finishing is
given. Elements are marked for easy installment.
9. Then the bed is covered with gunny bag. Curing is done by wet covering.
10. Gunny bag is removed but before that De-stressing is done if it is a prestressed
beam and cut by circular saw blade.
11. De-shuttering is done & name is written in every element using paint.
12. Casted element is lifted and stacked in stock or else transported to site for erection.
44
7. ERECTION
The hoisting and installation of the structural components of a building, using crane, hoist,
or any other power system. In other words assembling of precast elements.
Work Sequence:
1. Receipt of erection layout is received from Principal Design to Precast design,
planning and production.
2. Procurement process is done for the request of inserts, grout material, tools, props
etc. and is delivered for inspection by senior construction manager.
3. For transporting the elements 72 hour notice in advance erection is done by
stockyard supervisor to transport coordinator as well as erection team.
4. Delivery inspection is done once the element has reached the site.
5. Erection of elements takes place.
Erection of column
45
8. REFERENCES
[1]https://www.aleono.com/product/standard-taper-threaded-coupler/
[2]http://www.euroacc.co.uk/products/double-walling-accessories/plastic-coated-rocket-with-
1-way-steps/
[3] https://www.jp-uk.com/products/united-kingdom-balcon-test/85/h-bau-double-wall-
transport-anchor-type-ke
[4]https://www.quora.com/What-is-the-meaning-of-Design-in-Civil-Engineers
[5]https://gradireland.com/careers-advice/job-descriptions/planning-engineer
[6]https://www.projectmanager.com/blog/what-is-project-scheduling
[7]http://www.ultraspan.ca/hollowcoresolutions/?gclid=Cj0KCQjwjtLZBRDLARIsAKT6fX
yHjzA_BRLAVrpcz cbNizqOLWAKs7cQl61Rkavir0gNoJyqhvhBpIsaAmFyEALw_wcB
[8]http://preca.in/blog/9-uses-of-hollow-core-slab/
[9]https://en.wikipedia.org/wiki/Hollow-core_slab
[10]https://en.wikipedia.org/wiki/Column
[11]https://en.wikipedia.org/wiki/Beam_(structure)
[12]https://www.quora.com/What-are-the-advantages-of-prestresseded-concrete
[13]https://www.concretenetwork.com/precast-concrete/advantages.html
[14]https://en.m.wikipedia.org/wiki/Wall_panel
[15]https://www.wellsconcrete.com/blog/benefits-precast-wall-panel-system/
[16]http://www.rfa-tech.co.uk/uploads/images/categories/category_394_seclanding1.JPG
[17]https://encryptedtbn0.gstatic.com/images?q=tbn:ANd9GcRQVqrikIPca7d7EzT5oiPOvhg
Ab1OK5CwOAER243WmeLXHL2im
[18]https://www.google.co.in/search?q=4.+Lifting+socket&num=20&source=lnms&tbm=isc
h&sa=X&ved=0ahUKEwi8gJHw9NXeAhUeinAKHUIRDBQQ_AUIDigB&biw=1366&bih
=587#imgrc=tMK2Y22-hV_rQM:
[19]http://www.uniferspa.com/wp-content/uploads/sites/5/2017/04/tralicci-foto-300x197.jpg
[20]https://www.google.co.in/search?tbm=isch&sa=1&ei=XSbtW4jyCIPqvgTunIWQBQ&q
=Locking+shims+in+precast+site&oq=Locking+shims+in+precast+site&gs_l=img.3...18420
8.184930.0.185099.5.5.0.0.0.0.157.747.0j5.5.0....0...1c.1.64.img..0.0.0....0.UIsGiYi_WvI#im
grc=uxDRaYk_y5kp3M:
[21]https://www.google.co.in/search?q=Cast+in+channel&num=20&source=lnms&tbm=isch
&sa=X&ved=0ahUKEwjKgKOC99XeAhVFto8KHbOnAb0Q_AUIDigB#imgrc=ghGpNtKe
VNisYM:
[22]https://www.google.co.in/search?q=Cast+in+channel&num=20&source=lnms&tbm=isch
&sa=X&ved=0ahUKEwjKgKOC99XeAhVFto8KHbOnAb0Q_AUIDigB#imgrc=Cj4X4YEj
G6OGXM:
[23]http://www.euroacc.co.uk/s/cc_images/cache_28291942.png?t=1395607083
46
ACKNOWLEDGEMENT
I am very thankful to KEF INFRA INDIA PVT LTD for having given me the opportunity
to undertake my summer intership at their prestigious company. It was a very good learning
experience for me to have worked at this factory as this project involved many unique
construction practices and challenges. It is with immense pleasure that I express my sincere
gratitude and humble appreciation to Mrs. Amritha Arvind, Head HR, who provided me
the opportunity for undertaking the summer internship.
I would also like to give my heartfelt thanks to Mr. Musharaf Mukadam, Design Head, Mr.
Syed Irfan, Planning Head, Mr. Zarar Ahmed Quazi, Production Head, Mr. K.
Balasubrimanium, Techno Commercial Manager & Miss. Anushree Ramesh, Project
Coordination who guided and encouraged me all through the summer training and imparted
indepth knowledge of the operation & project. I would like to thank all the engineer, staff,
site supervisor & workers, for giving their precious time and valuable guidance during my
internship programme.
Last but not the least, my institute, KIIT Deemed to be University, Bhubaneswar for
giving me the opportunity to have a precious and rewarding experience of internship in this
prestigious company.
I take this opportunity to thank all my scholar friends & family for their valuable support and
encouragement throughout the preparation of this work & especially to Cdr. Shahaji Pawar
for encouragement and support without him this internship would have remained a dream. I
also thank all those who have directly or indirectly helped in completion of this work.
47