kksp box culvert dial project

8/6/2019 Kksp Box Culvert Dial Project

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K K SPUN PIPES PVT. LTD.

THE LEADING

PRECAST CONCRETE INFRASTRUCTUREPROVIDERS

Address:7/18A, Sarvpriya Vihar, New Delhi -110016

Phone No. 41828557, 9810157899, 9810267226

E-mail : [email protected]


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COMPANY PROFILE

K. K. Spun Pipes is one of the leading manufactures and suppliers of the R.C.C. Pipes,Pre cast Concrete Products, and telecom infrastructures. Mr. Promod Gupta establishedthe company in 1987. Er. Himanshu Gupta joined this company after completing hisstudies in 2003. The factory is situated at Tigaon Road, Ballabhgarh (Haryana) and isfully equipped with all the infrastructure, Plant and Machinery, Laboratory and state ofthe art Moulds to produce the goods of high quality.

K. K. Spun Pipes is registered with Small Scale Industries Department, Haryana andpossesses the valid I.S.I. License to manufacture and supply NP2, NP3 & NP4 ClassR.C.C. Pipes of dia from 100mm to 2200mm confirming to I.S.I. codes andspecifications.

The Company is fully equipped with all infrastructures and in-house fabrication team to

develop and manufacture any type of customized Pre-cast Concrete Products, telecomtowers, shelters and other infrastructures for telecom and power sector.


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List of Clients

Bharti Telecom

Hutch

Tata Telecom

V S N L Reliance

Delhi Jal Board

Haryana Urban Development Authority

U.P. Jal Nigam

Public Works Department

Haryana State Industrial Development Corporation Limited Punjab Sewage Board.

Larsen & Toubro

International Metro Civil Contractors

Ondeo Degremont India Ltd.

Delhi Development Authorities.

AIMIL Ltd.


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Delhi International Airport Limited


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PrefacePrefaceAs a technological leap, the

construction of box culverts by

precasting has taken over from

conventional In-situ construction long

back. At L&T, a majority of places

particularly in Road sectors, we adoptthe precasting by Wet-casting.

However, it has many drawbacks.

The vertical casting method with dry

mix is versatile and could be a

trendsetter for the precasting we donow onwards

At DIAL we have used the system and

the result is very satisfying.

The following few slides enumerates

the process and result.

Drawbacks in ConventionalPrecasting

VerticalPrecastingwithDry mix

DetailofProcess withphotographs

Theway forward.


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MajorDrawbacks in ConventionalPrecastingMajorDrawbacks in ConventionalPrecasting

The shape of the precast pieces depends upon the fabrication accuracy of mould which

varies from mould to mould.

The vibration of concrete purely manual, hence the degree of compaction of

concrete is always questionable.

The shape of end connecting grooves varies piece to piece. Hence chances of

mismatching between two adjacent pieces are high and requires site alterations.

Requires huge manpower for handling of mould shutters, compaction ofconcrete, rebar tying, mould preparations etc

Large area is required for casting as the pieces are kept on the bed for a at least 2 to 3

days for the concrete to gain the strength.

More area to cover for the concreting crew with the machines for covering more

number of moulds.

Area is always untidy due to movement of transit mixers and water from the curing.


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The Concept .The Concept .

Concrete mix is prepared at a batching plant nearby with zero slump .

Reinforcement is prefabricated and placed over a pallet. The inner mould is

placed over the pallet and inserted into the outer mould as a single unit (bottom

pallet, inner mould, rebar cage).

The outer mould is fitted with a number of vibrators mounted on the surface and is

controlled with a control panel.

Concrete is placed directly from the batching plant into the mould and vibrated

through the surface vibrators. (at some cases, vibration tables are also used).

The vibration gives so much energy that the piece can be immediately removed from

the outer mould. Further, the pieces are cured by covering it with a jacket or by plastic

wrapping.

The Mould is ready within 20 minutes for casting of next piece.


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Batching Plant

Collection

Hopper

Radial

Placer

Radial

Distributor

Control Panel

Profiler

Mould


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Precast Cagebeingprepared

Precast Cage lowered over Pallet

Bottom Pallet


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InnerMould

InnerMouldbeinginsertedoverthe Cage

Internal Mould with pallet and rebar

cage inserted into Outer Mould

Outer Mould


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Concrete BeingPouredon theMould


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After concrete is over, the hydraulic profiler gives the groove shape


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The Box culvert is immediately pulled out from the outer mould


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The Box culvert Being madeupside down with Turning Table


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The Pieces are shifted to the stacking location


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Pieces are ready for dispatch


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Forklift being used for handling the pieces atstock yard

Pieces are loaded with forklift on to the

trucks.


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Advantages.Advantages.

Drastic reduction of Manpower for Precasting.

Factory like environment and complete control on rate of pouring and

compaction levels.

Transportation of concrete completely omitted hence reducing the chances of loss of

strength of concrete during transit.

Concrete placing machinery are nil , hence a tidy place .

CNC profiled moulds gives accuracy in the shape of precast pieces and uniform for

entire batch of casting.

Grooving arrangement is done with the help of hydraulic profiler, which is

uniform and gives match-casting type accuracy.

No Curing involved , hence tidy work environment.


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It overcomes almost all disadvantages of Wet-casting.

The Concept is quite versatile and can be used for a large variety of precasting we

do in projects (Some of the culverts as big as 6.0m X 4.0m are also being done

elsewhere).

Pipes are also cast with similar concept and is covered under BIS.

Since the technology is quite versatile, can be used for any shape of the

precasting.


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Pre-Cast Foundations

KKSPmanufacturesPre-cast Foundationsystems forfixing

poles, transformers orutility boxes. Thesefoundation systems aretough, andeasy to

install. They require nomessy collection ofmaterials on site.


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Cable Trenches and U sections

Wemanufacturepre-castconcrete cable trenches alongwith covers ofvarious sizes tobe usedforlayingofcables.This is the clean, convenient,

andmost effectiveway oflaying cables and avoids therepeateddiggingofland torepairor add the cables on thesameroot. They areveryconvenient and necessary forallfactories, 5 starhotels,Multiplexes, andmultistorybuildings andmajorprojects


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BoundaryWallPanels.

KKSPmanufactureready toinstallpanels forboundarywalls or temporary roomconstructions.

They arevery economical,reusable & easy toinstall.

They are aesthetically goodhas morelife than brickwalls.


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kksp box culvert dial project

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