INTERNSHIP REPORT GOUTHAM.J

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1 INTERNSHIP REPORT GOUTHAM.J M.E Structural Engineering SNS College of Technology, Coimbatore Mail : tcegoutham@gmail.com

2 TEEMAGE PRECAST IN College Road, 1st Cross Street, Tirupur TamilNadu, India. Mobile: ,

technology. Precast Manufacturing facility is situated in Kangeyam, TamilNadu over 22 acres of land with a 1,00,000 sq.ft of factory shed and separate administrative, design and hostel buildings.

3 ABOUT TEEMAGE Teemage Precast In belongs to The Chennai Silks group of companies. Company started journey in the Precast Industry in 2011 and committed to take strides to become the leader in arena of Precast Concrete Construction by embarking on modern and sophisticated technology. Precast Manufacturing facility is situated in Kangeyam, TamilNadu over 22 acres of land with a 1,00,000 sq.ft of factory shed and separate administrative, design and hostel buildings. They employed European Technology for the manufacturing of the precast elements. With Computerised batching plant, Battery moulds, Tilting tables, Slip-former, a Fleet of specialized trailers and experienced personnel. Having a capability to produce Hollow-core slabs of varying thickness, Prestressed beams, Columns, Wall panels, Stairs, Slabs and various other products required for Commercial, Institutional, Industrial and Residential Projects. We offer total solution in terms of Design, Production, Transportation and Erection using In-house teams and equipments. In the first two years of their existence, they have completed nearly 25 precast projects with combined area of 7Lakh Sq.ft and have multiple projects in Pipeline Teemage Factory - Kangeyam

Commercial Industrial Institutional Residential Villas

4 SERVICES OFFERED Design & Detailing Planning Production Transportation Erection TYPES OF BUILDINGS Industrial Building Commercial Industrial Institutional Residential Villas Residential Apartments Multi Level Car parking Residential Institutional Building

PRECASTING A Precast Building consists of all the same elements as a conventional building which includes floors, roofs, walls as well as beams, columns and stairs, the only difference is that these

5 PRECASTING A Precast Building consists of all the same elements as a conventional building which includes floors, roofs, walls as well as beams, columns and stairs, the only difference is that these elements are manufactured in a controlled environment and transported to the site for Erection, Connection and Commissioning. The industrialization of Construction Industry implies the change of the whole building process. The need to build better, faster and in an economically viable way led to the precasting technology to attain a strong foothold in the industry. Proper planning, Detailing design & Coordination of the project prior to construction activities to be considered to minimize the changes at site. MANUFACTURING PRODUCTS Hollow Core Slabs Wall Panels Beams & Columns Stairs & Slabs Boundary Walls / Fences Other products.. A. HOLLOW CORE A Hollow core slab, also known as avoided slab or hollow core plank, is a precast slab of prestressed concrete typically used in the construction of floors in multi-storey buildings. They are widely used throughout the world as flooring and roofing solutions. Teemage hollowcore slabs are nominally 1200, wide and are available in thickness of 150mm, 200mm, 250mm, 300mm and 400mm. All the slabs are cast with high strength prestressing cables to provide the load carrying capacity Hollow Core

Features & Advantages Varying thickness of (150-400)mm available and large spans up to 18m can be obtained at costs which are lower than conventional flooring systems.

6 Features & Advantages Varying thickness of ( )mm available and large spans up to 18m can be obtained at costs which are lower than conventional flooring systems. The casting is sequenced in such a way that every floor of building is stored and ready to be delivered for installation as quickly as required at the site. Expensive formwork and propping is eliminated thus improving productivity and access within the site is vastly improved. Once erected, Hollowcore slab can be used as instant work deck and thus decreases the delay due to curing or removal of formwork. The hollow cores reduces the overall weight of the structure thus economizes the foundation system. The top surface is roughened for accepting a nominal screed of concrete or smoothens for direct installation of floor tiles. The speed of erection is unlike any other system, with a crane and a small crew at the site, 4000 sq.ft of slabs can be placed in 8 working hours. Hollowcore is considered as a Green Building Product because of the efficient use of materials and resources and also because of its reuse and recyclable properties, Hollow Core Ranges

7 B.WALL PANELS Precast Wall Panels are widely used as load bearing elements in commercial and Residential projects and high rise buildings. Other uses are Facade elements, Cladding panels, Insulated panels etc. Types Cladding Panels Solid Panels Insulated Sandwich Panels Benefits Combines as load bearing and facade elements. Various and distinctive surface finishes can be provided. Architectural and aesthetic touches can be applied. Short construction period and low maintenance cost. Heat resistance due to insulation. C. STAIRS Precast concrete stairs are an integral part of a precast building, they are erected along with the floor and several dual purpose of transporting men and material up the floors during construction. The benefits of using precast stairs are obvious, providing unobstructed and safe access throughout the building. Benefits Eliminates the need of expensive on site shuttering and supporting scaffolding. Precast stairs are produced with smooth surface finish with a high grade concrete. Fast and very easy to install. Top surface of the stair is cast against the mould, so no finishing required at site.

D. Beams & Columns Standard beam c/s includes rectangular beams, curved beams, ledger beams and ITbeams and column c/s include rectangular and circular columns.

Very fast construction and erection. Quantity of beams and columns can be reduced by efficient design. Long spans possible using Prestressing capabilities. E.

8 D. Beams & Columns Standard beam c/s includes rectangular beams, curved beams, ledger beams and ITbeams and column c/s include rectangular and circular columns. Customized sizes and shapes are provided upon client requirements. Benefits No need for expensive on-site form work. Flexible with design as various cc/s are available. Very fast construction and erection. Quantity of beams and columns can be reduced by efficient design. Long spans possible using Prestressing capabilities. E. BOUNDARY WALLS / FENCES Precast concrete fences and boundary walls are used for variety of purposes such as privacy, security, freeway sound barriers and perimeter safety barriers. Benefits Design flexible in providing variety of shapes and heights. Architectural and aesthetic uniqueness by providing various surface finishes and textures. Low maintenance cost. More life duration when compared to block walls or chain link fences. Fast Construction and less erection time. F. OTHER PRODUCTS

9 PRODUCT PHOTOS Hollow Core Slabs Wall Panels Column Beam & Column Staircase Erection

10 Report on a Overall Operations functioning over Teemage Precast IN- Kangeyam Visit to a Teemage Precast in (Production plant) - Kangeyam for a week ( ) to know about the works that is to be done there. Following are the works done in Teemage precast in Kangeyam, Planning Fabrication Production Quality Control Loading A. In Brief Planning Fabrication Production Schedule making for day by day work. Reinforcements that are to be used are to be fabricated based on the schedule. Managing elemental production of (Pre-stressed Hollow core slabs, Precast Solid slabs, Precast Wall panels, Precast Columns & Beams, Prestressed Beams, Precast Stairs, Boundary Walls, Trenches) Quality Control Following are the process done by QC a. Mould Checking Based on programme given by planning department respected mould get prepared and checked by QC. b. Reinforcement Programme for fabrication is issued to respected person based on that they prepared.

11 c. Pre Pour Check Before concreting mould and reinforcement details get checked by QC by referring piece drawings. Respected person must approve for concreting. d. Post Pour Check After Concreting and lifting for curing, QC persons must check that, it should be suitable for loading operation or not. If not proper rectification operation should noted and inform to respected person to do so. Final Inspection Loading Here based on the piece drawings element should be checked and approved to next stage. If any correction exists, rectification work should be done before going to next stage. It should be done based on the programme given to loading department. Before loading finishing work should be done for the respected element that should be checked by QC. After approval from the QC it should be loaded and final call from security to QC it should be allowed out of the gate. B. Material Checking Sand Aggregate I. Sand of River Sand and M Sand get used. II. When river sand load arrives it should be checked its quantity and in QC lab sieve analysis should be done to know its quality on day by day basis. Aggregate of size 10mm & 20mm should be used. It should be checked before concreting. Sample Mix Admixture that is to be used, it should be checked in the case of sample mix by making a concrete into the mould of (150x150x150) mm Concrete-Compressive Strength On daily basis concrete that should be used for a day that should be checked for compressive strength.

12 Grout Sample Quarry Visit Grout that is to be used should be checked for 2 days once. When using of aggregate sample from new dealer person from Teemage should be visited to respected quarry and its quality should be checked. Repair Grout Grout that should be used for repair work should be checked. C. Recommendations for a co-ordination of work Proper availability of material makes the work better and faster. In Rare case: Reduced corrections from technical department makes QC and Production department to avoid confusions in piece drawings. Mutual Co-ordination between the functioning departments makes the work Easier, Better and Faster. Proper providing of revision drawings from planning department to make the corrections easier for other departments working depending on them. Quality for a respected work should be checked correctly without any issues based on piece drawings to avoid rectification work. After concreting element should be checked for its surface finish, if any should report to respected person to do so. Before loading element should be properly checked and make the surface finish better and dowel hole should be checked for undulations. Should work correct & better in urgent cases of delivery. Persons involved in work should have good communication between them. Out target is to produce a quality product, based on that we should work. Our primary Motto is Easier, Faster and Better.

13 Report on Erection process occurred over M/S Garson s Private Ltd. Hosur Visit to M/S Garson s Pvt. Ltd. For a week ( to ) to know about erection process and other process done over there. Following are the process held there, Erection Civil Waterproofing Electrical & Tile laying A. Erection a. This process is composed of unloading and erection, done by crane operator. Layout for the work gets prepared by technical team. Target for the whole work gets fixed. To reach the target whole team work spontaneously. b. Erection work mainly depends on elements that they getting over the site. Also sequence of elements that they want to get. If they working on Zone 2 Ground floor Hollow core, getting element of 1 st floor they won t do work. So, loading from production plant get planned based upon the work done over the site. c. Erection elements composed of column, beam, hollow core slab, stairs, wall etc. Erecting column, it takes much time with reference to Total Station. Levelling for the column is given by surveyor based upon that column erection process continued. Based on that beam and slab erected. d. While erecting level for the element is given by Sim pad, is a kind of element used to level the element and act as a vibration absorber during earthquake. e. Erection of beam and slab easy after proper erection of column. During erection must concern about the insertion of dowel hole and dowel rod and respected element levelling. Levelling is given with the help of jack. After erection following process is to be done for a respected element, Level check by plumb For column to column: distance check by laser meter Proper level parallel to other element given with help of jacks. For walls: Gap between two walls get closed by, 1. Rod insertion between the loops. 2. Filling grout & plaster with the help of foam.

concrete, and ramp concrete, patch works etc.

Based on the respected layout drawings work gets

Also before and after erection of precast elements

14 3. after 3 to 4 days removal of jacks. Likewise for all elements respected process get followed. B. Civil Work a. Civil work is composed of erecting footings, screed concrete, and ramp concrete, patch works etc. Separate Site engineer allotted to supervise the work. Based on the respected layout drawings work gets allotted to the workers. b. Also before and after erection of precast elements respected civil works get done if needed. C. Water Proofing It is to be done to the back side of wall Sealant Sealant with border Polyurethane sheet D. Electrical & Plumbing

15 Recommendations for an efficient work Proper element finish makes the work comfort Proper checking of element (dimensions, level, finish etc...) makes work perfect. Proper checking of dowel rod dimensions makes the erection process quicker & easier. Proper planning of loading of an element to site for erection makes the work easier. ERECTION PHOTOS Site Jacks Core Cover Sim Pad

16 1 Grouting Grout Surface Finish Lifting Rod Cutting Screed Reinforcement over slab Lifting Wall Dowel rod check

ISSUES THAT I SAW DURING ERECTION Defect: Crack in beam Reason a.

Defect: Improper stick between wall joint It occurs after the removal of jack from the wall

May due to improper insertion into dowel hole. b. May due to improper dowel rod spacing. c.

17 ISSUES THAT I SAW DURING ERECTION Defect: Crack in beam Reason a. Over dowel hole, steel rod gets fixed. So due to removal this crack occurred. Defect: Improper stick between wall joint It occurs after the removal of jack from the wall Reasons a. May be due to improper binding Defect: Cutting of Dowel rod Reasons a. May due to improper insertion into dowel hole. b. May due to improper dowel rod spacing. c. May due to difficult in erection. Defect: Improper insertion of core cover Reason a. May due to improper core cutting. b. May due to carelessness.

Emerging construction technologies

Emerging construction technologies C A PRASAD DIRECTOR METEY ENGINEERING CONSULTANTS, HYD/VJA Different types of construction technologies for high rise structures for speedy delivery Shear wall / Monolithic