INTERNSHIP REPORT

GOUTHAM.J

M.E Structural Engineering

SNS College of Technology, Coimbatore

Mail : tcegoutham@gmail.com

TEEMAGE PRECAST IN

College Road, 1

Tirupur

Mobile: +91 8220051777, +91 7708073369

TEEMAGE PRECAST IN

College Road, 1st

Cross Street,

Tirupur – 641602. TamilNadu, India.

Mobile: +91 8220051777, +91 7708073369

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

SERVICES OFFERED

� Design & Detailing

� Planning

� Production

� Transportation

� Erection

TYPES OF BUILDINGS

� Commercial

� Industrial

� Institutional

� Residential – Villas

� Residential – Apartments

� Multi Level Car parking

Industrial Building

Institutional Building

Residential

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.

� 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

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 IT-

beams 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

PRODUCT PHOTOS

Hollow Core Slabs Wall Panels

Column

Beam & Column

Staircase Erection

Report on a Overall Operations functioning over Teemage Precast IN-

Kangeyam

Visit to a Teemage Precast in (Production plant) - Kangeyam for a week (14.07.2014 –

19.07.2014) 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

Schedule making for day by day work.

Fabrication

Reinforcements that are to be used are to be fabricated based on the schedule.

Production

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.

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

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.

Loading

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

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

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.

Grout Sample

Grout that is to be used should be checked for 2 days once.

Quarry Visit

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.

Report on Erection process occurred over M/S Garson’s Private Ltd. – Hosur

Visit to M/S Garson’s Pvt. Ltd. For a week (23.7.14 to 28.7.14) 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 1st

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.

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

D. Electrical & Plumbing

Sealant Sealant with border Polyurethane sheet

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

1

Grouting Grout Surface Finish

Lifting Rod Cutting Screed Reinforcement over slab

Dowel rod check Lifting Wall

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.