B. G. Shirke Construction Technology Pvt. Ltd...

Civil Division
B. G. Shirke Constructio n Technology Private Limited (BGSCTPL), formerly known as B. G. Shirke & Company, was established in 1944 by its Founder Chairman, Mr. B. G. Shirke. BGSCTPL is a multidisciplinary civil, mechanical and electrical engineering organizatio n having internation al technology tie-ups and over 12,000 workforce. It is a vibrant, dynamic and integral part of modern India, significantly contributing

to industrial, economic and social progress. BGSCTPL also plays an active role in protecting and preserving the countrys ecosystems its forests and waterways. Company is well established in the civil engineering field for over 65 years. The Mission to Industrialize Civil Engineering in the gigantic effort to provide affordable, high quality mass housing has already been achieved with Herculean efforts and unique unflinching dedication. BGSCTPL is endeavouring to spread and entrench Industrialized Civil Engineering Technology throughout the country for the good of all. BGSCTPL also pioneered and patented the 3-S system in India a system using partial pre-cast structural components, such as dense concrete hollow core columns, dense concrete partially pre-cast beams, lintels, staircases, etc., and Siporex blocks and slabs to achieve strength, safety and speed. The Company has so far executed more than 2,00,000 dwelling units using 3 S system, both in India and Overseas, in all types of climatic conditions and heavy rainfall areas. At present, it executes very large housing, industrial and commercial projects in India on Turnkey Lumpsum Basis by the use of proven prefab products and/or also by the conventional methods and materials. It also undertakes projects on Tunkey Lumpsum Basis including Planning, Designing and Execution. 3 S system of building construction has been used successfully for high-rise residential buildings upto 25 storeys. BGSCTPL has also expertise in design, fabricate and erection all types of heavy steel structures, shuttering and centring. Of late, to move with times, BGSCTPL has diversified in infrastructure developments

and completed two road projects on NH-4 between Pune-Satara-Kolhapur, part of a Golden Quadrilateral and one road project at Panvel. BGSCTPL has developed expertise in construction of Highways, Bridges and Marine Structures as well.

Over the years, BGSCTPL have acquired the expertise in the field of construction in the following areas using Conventional as well as prefab technology and resources.

Mass Housing Projects Residential Multistoried Buildings Commercial Buildings Industrial Buildings / Sheds IT Parks Roads Bridges, Flyovers, Underpasses Sports Facilities / Complexes Hotels, Auditoriums Airports

Our registration in highest/unlimited special class/category with many organization and track record of repeated orders from many vendors endorses our reputation and capabilities.

Public Works Department (PWD) Maharashtra, Karnataka, Andhra Pradesh and Tamilnadu Military Engineering Services (MES) Brihanmumbai Muncipal Corporation (BMC) Pune Municipal Corporation (PMC) CIDCO of Maharashtra Ltd. Maharashtra Housing & Area Development Authority (MHADA) Pimpri Chinchwad Municipal Corporation (PCMC) Pimpri Chinchwad New Town Development Authority (PCNTDA) Karnataka Housing Board (KHB) The Singareni Collieries Co. Ltd. (SCCL) Maharashtra State Electricity Board (MSEB) Delhi Development Authority

Integrated Management System (IMS) We are IMS registered organization, which covers ISO 9001:2008, ISO 14001: 2004 and OHSAS 18001:2007 for Quality, Environment, Health and Safety. Det Norske Veritas (D.N.V) Certification B.V. , The Netherlands, has awarded IMS Certification. Our scope of certification is Design, Development and Construction of mass residential, Commercial, Industrial buildings and Infrastructure works like roads, bridges, flyovers, culverts. Grading Certificate We have received GRADING CERTIFICATE from investment information & Credit Rating Agency (ICRA)/ Construction Industry Development Council (CIDC) assigning CR2+ grading which indicates Strong Contract Execution Capacity with respect to contracts with values upto Rs. 500 crores and aggregate values of work to be executed within a year of upto Rs. 1400 crores.

Properties
Light Weight Thermal Conductivity Fire Resistance Strength Colour, Texture Workability Moisture Content Water Vapour Permeability Thermal Expansion Specific Heat Melting Point Sound Transmission Chemical Properties Solubility in Water Light Weight: Go to Top The standard nominal dry density for all Siporex products is 550 kg per cubic meter. Blocks of nominal dry density 450 kg per cubic meter can also be manufactured. This light weight property will give

the following savings : - Size of foundation and other concrete elements of the building , if any , will be reduced . - Foundation depth, excavation and backfill will be reduced. - Number of trailers required to transport siporex materials is much less than those required to transport ordinary precast panels. - Erection work can be carried out without the use of heavy equipment.

Thermal Conductivity: Go to Top The thermal conductivity ( k ) for completely dry Siporex is 0.144 W/m deg C. This is reflected in considerable saving of electricity consumption and improving indoor confort. Other savings are also achieved by using Siporex Blocks when replacing a 30 - 35 cm thick sandwich wall by a single 20 cm thick Siporex wall . This can reduce the size of R.C. beams, columns and foundations and will give more living space. The most economical use of Siporex for normal two or three storey structures is to use the structural wall, floor and roof panels and slabs.

Fire Resistance: Go to Top Siporex is an inorganic material and therefore incombustible . It provides a fire resistance value which meets American, British and German codes. As an example, 15 cm thick siporex wall has a fire resistability of seven (7) hours in accordance with ASTM standards. It is ideal for fire walls and also for fire protection of structural steel.

Strength: Go to Top In relation to its weight, Siporex has a high compressive strength. Following are the strength constants for Siporex material : Compressive Strength = 35 kg/cm2 Tensile Strength = 6 kg / cm2 Modulus of elasticity = 16000 kg/cm2 Shear Strength = 2 kg/ cm2

Colour, Texture: Go to Top Siporex is greyish white. The surface is even. At the wire cut surface, the macro pores are invisible. Milling of the jointing surfaces after the steam curing, makes the pores visible.

Workability: Go to Top Siporex can be worked like wood . One can saw, nail and drill in Siporex. There are several suitable Sipurex tools available for this purpose. When nailing in Siporex special types of nails should be used, which give a good anchorag. Moisture Content: Go to Top Siporex products have a moisture content of 25 - 40 % of its weight when the material is delivered. As with all concrete products Siporex will dry out until it reaches equilibrium with the moisture content of surrounding air. In this state it will reach a moisture content of 2 % -

6 % within one year from erection. As with all other concrete finishes slabs and walls should receive protection against water penetration, for external walls this can be a single coat decorative coating. Water Vapour Permeability: Go to Top The diffusion coefficient for Siporex is approximately 0.15 * 103 g/m.h. Pa { 0.02 g/m.h. mm Hg.) Thermal Expansion: Go to Top The coefficient of linear expansion is 8 x 10-6 per deg. C, which is rather lower than that of dense concrete. Specific Heat: Go to Top At the normal equilibrium moisture content, the specific heat is 1.0 1.1 kJ/ kg deg. C ( 0. 24 - 0.26 kcal/ kg deg. C. ) Melting Point: Go to Top Siporex starts to sinter at about 1.000 deg. C and melts at 1,1001,200 deg. C. Certain physical transformations occur, at lower temperature, therefore, Siporex is not suitable for use in constructions which are going to be exposed to high temperature, e.g. kilns, stoves, chimneys etc. Sound Transmission: Go to Top Sound insulation is the principle method of controlling both airborne and impact sound in buildings and is normally expressed in terms of sound reduction. Sound reduction is defined as the ratio of sound energy at its source to that at any other location and is expressed as decibels ( dB ). It is important to note that the scale of decibels is logarithmic-an increase of 10 dB means a reduction of sound to one tenth, 20 dB a reduction to one hundredth etc. The sound reduction factor provides a means of assessing the relative efficiency of different materials and forms of construction as sound insulators.

In many European countries the sound reduction factor is described as SRI -Sound Reduction Index. In America, the term used is STC Sound Transmission Class. Siporex meets the appropriate standards for sound insulation in house buildings, and helps to protect against production noise in industrial constructions.

Chemical Properties: Go to Top Like ordinary concrete, Siporex is alkaline and does not chemically attack other building materials. Due to the porosity of Siporex all metal fixings into Siporex should be of non corrosive materials or protected against corrosion. Suitable fixings are available for use with aerated concrete from all the major fixings suppliers. Solubility in Water: Go to Top The vital components in Siporex are water insoluble . However, like most building materials, Siporcx contains small amounts of water soluble salts, which have no influence on the strength and resistance . Under severe conditions, they can appear on the surface as efflorescence. The fomation of efflorescence is mainly a matter of repeated wetting in combination with very bad drying conditions . Under normal drying conditions, it hardly ever occurs.

Design
General Design Princilples Structural System General: Siporex is a structural material approximately less than one qurarter the weight of conventional concrete. The siporex system consists of various prodcut types: wall panels, floor/roof slabs and lintels, which can be combined to form a load bearing structure. By using this system costly labour and material intensive in situ concrete structures of columns, beams, floor and roof slabs can be eliminated. This fact makes it particularly suited for the construction of buildings, up to three stories. The width of the units in the Siporex system is in accordance with the international modular standard of 60cm. Thickness and length of the units can be selected to suit requirements of each particular project. Therefore, the Siporex system offers a high degree of flexibility which can be easily adopted to various design requirements. Figure below shows how the component parts of the Siporex system fit together to form the complete structure

The figure below shows sample Siporex shop drawings based on customer's architectural drawings.

Design Princilples: Go to Top Before commensing the architectural design for a project, the following guidleines should be noted: 1. The maximum span of Siporex panels is 6m. This means that the maximum clear span between the load bearing walls should not exceed 5.8m. The distance between the other non-load bearing is immaterial. If the clear span is more than 5.8 then steel / concrete beams, supported on steel / concrete columns, should be used to support the roof slabs. Upper wall panels should be supported by lower wall panels. Direct support on floor slabs is not allowed. Where unsupported walls can not be avoided in order to achieve

2.

3.

maximum economy either an intermediate steel beam can be used or non load bearing lightweight dry wall construction used on the slab. The foundation should be made high enough such that the wall panels will not absorb moisture from the ground.

Structural System: Go to Top Siporex buildings are designed based on the box system principle. All Siporex walls which carry floor or roof loads act as shear walls and are required to resist lateral forces due to wind or seismic loading. The vertical wall panels have grooves along their edges which form joints when erected. These joints receive 8mm tie-bars from the footings and at the top, connecting the lower wall with the one above. As they penetrate the ring bond beams, a strong connection will be provided between the vertical and the horizontal structures. These joints (3.3 x 5cm) are grouted and they are able to transfer shear forces from one panel to the other. In this way a rigid structure is formed which is able to resist lateral forces due to high wind loads or seismic forces. It has been noted that Siporex buildings are very resistant to earthquake forces. The roof and floor slabs have a tongue and groove as well as a notch at the top to be reinforced with a 8 mm dia bar and grouted with cement - sand motar. This provides the possibilty to transfer shear forces from one panel to the other and cosequently eliminates differential deflections.

Range of products
Products -> Reinforced Panels

Vertical Wall Panels (WV)

WV are reinforced units, for load bearing applications as either external or internal walls

Details...

Floor & Roof Slabs (FS & RS)

FS & RS can be used in all types of buildings, e.g. housing

Details...

Horizontal Wall Panels (WH)

WH are used in boundary walls and non-load bearing cladding for steel

Details...

Lintels (LW & LB)

Lintels are used as load bearing members over the window

Details...

Products -> Reinforced Panels -> Vertical Wall Panels (WV)

WV are reinforced units, for load bearing applications as either external or internal walls in a wide variety of low and medium rise buildings. They can also be used as non load-bearing cladding for steel or concrete

framed structures. They may be of single or double reinforcement. Longer panels have double reinforcement.

The table below shows the maximum length of WV with single reinforcement. Longer panels have double reinforcement.

Wall units are milled along their edges to standard profiles and may be chamfered or fluted on one or both faces. Figure below shows the shape and size of the milling. Below table gives a guide to the permissible vertical load.

Products -> Reinforced Panels -> Floor & Roof Slabs (FS & RS)
FS & RS can be used in all types of buildings, e.g. housing, industrial, commercial and educational. The units are milled along their edges to provide tongue and groove and a grouting groove on top. The bottom longitudinal edges can be chamfered giving an attractive V-shaped joint pattern on the ceiling.The figure below shows the milling shapes and sizes of the floor/roof slabs.

The figure below gives a guide to the permissible load bearing capacity of slabs of different thicknesses related to the span.

Reinforcement in Siporex panels is located in standard positions as shown in the figure below. Holes and slots for services can be cut anywhere in areas up tp 70mm on either side of a joint between 600mm wide units. Small holes for pipes can be drilled between the reinforcement bars. Advice should be obtained from the technical department on possible locations of such holes. Larger openings require special arrangement of the reinforcement which should be obtained before manufacturing. Floor and roof slabs must never be cut to reduce the length of the panel. Floor and roof slabs are designed for simple supports.

The minimum permissible end bearings are:

for L <= 4000mm

50 mm each side

for L > 4000 mm

60 mm each side

Products -> Reinforced Panels -> Horizontal Wall Panels (WH)

WH are used in boundary walls and non-load bearing cladding for steel or concrete framed structures, particularly for industrial buildings. The wall panels are milled along their edges to standard profiles and may be chamfered or fluted on one or both faces, Fig Below shows shapes of milling:

Products -> Reinforced Panels -> Lintels (LW & LB)

Lintels are used as load bearing members over the window and door openings in all kinds of walls. Maximum obtainable lengths (free spans) in meters for lintels of various design loads and thicknesses are shown in the

table below.

The minimum permissible end bearings are:

for L<= 2400 mm

200 mm each side

for L> 2400 mm

300 mm each side

Due to the special reinforcement arrangement, lintels must never be cut.

Products -> Blocks -> Blocks

Test Paragraph

Siporex blocks are used as load bearing and non-load beaing walls. It is also used as thermally insulating roof tiles and as hordi blocks. Following are the standard dimensions in cm:

- Block : 60 x 25 thickness (Nominal dry density is 550 kg/m3)

- Hordi Blocks : 60 x 37.5 x thickness is multilple of 2.5 cm. On the request, other possible dimensions may be produced.

For hordi blocks the dimension of 37.5 cm is the nominal dimension. Blocks are produced with alternate actual dimensions of 37 cm and 38 cm. No stocks of hordi blocks are kept at the factory. If hordi blocks are required two or three weeks should be allowed for manufacturing. The density delivered to site will vary according to the drying time that has passed since manufacture and the local climatic conditions.

Erection
Guidlines For Estimating Erection Costs Of Siporex Panels Auxiliary Materials Handtools and Equipments Erection Procedure Repair to Siporex Panel Guidlines For Estimating Erection Costs Of Siporex Panels. Erection Manpower: 3.0 - 3.5 Manhours per m3 Siporex for residental construction is a good average figure. The figures covers erection of the structural superstructure on the prepared foundation base ( level + or - 1cm) and includes grouting of wall and roof joints as well as repair work, to make the surface suitable for application of finishes. The figures also include the preparation of the normal ring beam behind rebated wall panel upstands:

Erection: 1 Crane operator 2 erectors 1 panel preparation man 2 assistant erectors for general site work, grouting, repair work, dowel drilling etc. Type of crane: Mobiel telescopic crane, 1040 ton range depending on reach needed. Crane hours: approx 0.5 hours per m3 of Siporex. Cost of Auxiliary Materials and Consumables: SR - 20 - 30 per m3 of Siporex panels. The figure includes cost of repair mortar, glue, sand-cement grout mortar, concrete for normal size ring beams on rebated panels, plastic wedges, nails, ring beam reinforcement, fixings etc. Cost of a larger ting beam requiring formwork shall be calculated separately. Major steel fixings and steel beams are not included.

Note: Above data should be considered as general guidelines only. They are not a substitute for a careful evaluation of actual requirements of each

project and a detailed bill of quantities. the data supplied are based on LCC's own experience and are correct to the best of our knowledge. However, no guarantees of any kind can be given as individual projects may vary a great deal.

Auxiliary Materials, Hand Tools and Equipments: Auxiliary Materials: Go to Top

Sand - Cement grout to fill joints between wall panels- consumption 45 kg/m3 Siporex Glue - Consumption 6kg/m3 Siporex Repair Mortar - Consumption 6kg/m3 Gesol consumption 0105 liters/m3 Dowels 5.5 dia x 250 mm long - used as stiches to connect wall panels - 2pcs / wall panel. Plastic wedges - to support the wall panels temporarily - 2 pcs / wall panel. Galvanised nails 75mm, 100mm, 125 and 150mm. Siporex sandpaper Masonry nails Reinforcement Rebar Tying wire Spacer blocks ( concrete) Concrete

Handtools and Equipments: Go to Top

Erection Procedure: Go to Top R.C. foundation should be cast with a smooth and levelled surface. This saves a lot of work in leveling the tops of the wall panels later. Layout out of walls panels should be marked on the foundation using chalk lines and ensuring that any overhang has been allowed for on the periphery of the foundation. Steel dowels of 8mm dia connecting the wall panels to the foundation, are either placed in their positions before casting the foundation or placed in a drilled hole of 4cm dia in the foundation and then grouted. Another alternative is to make a hole of 8mm dia

and fix the steel dowels using Hilti C10 or equivalent. These dowels are placed at each wall panel joint.

Nylon offset lines shoud be used to ensure outside line of panels is maintained. Aluminium straight edge should be set to line and level to inside face of the wall panels. The longest elevation with least number of openings and the farthest reach should be selected. This ensures that correct signals can be given to the crane operators and sight lines are maintained between operator and erector. Siporex glue martar is used as a bed for the wall panels. In saudi Arabia and the gulf countries the Siporex glue bed also acts as the only D.P.C required. Wedges are used for temporary support of wall panels, and allow fine adjustment for plumb. Corner elements are erected first and carefully positioned and bedded on glue mortar. Panels are erected as per mark numbers shown in Siporex shop drawings. Working to a fixed straight edge for alignment, the wall panels are lifted by a lifting hook and placed in position and checked for plumb. The top edges are also aligned and are steadied by temporary wall braces at every 3 rd or 4 th panel. Dowels of 5 mm dia x 250 mm long are used as stitches to connect the top joints between the wall panels.

The tightly fit together wall panels are grouted by thoroughly wetting the grooves with water and then pouring in a fluid cement-sand grout ( 1:3 ) or pouring in Siporex grout, and then positioning steel dowels for the next storey panels. Note that Siporex products should always be well wetted with water before applying any other materials (e.g. glue, repair mortar, grout, plaster,...etc.)

Lintels are placed on top of window and door openings used a lintel grab. They are supported on and connected to wall panels. Panels supported by lintels are connected to these lintels by steel bars. Floor or roof slabs are lifted with a grab and carefully positioned with specified end bearing, on levelled wall panels. Minimum 50 mm side bearing is required on walls parallel to span. Tongue and groove joint faces provide a firm connection between the units which ensure the stability of the building.

The notches formed between the floor or roof slabs are concreted along with the ring/bond beams, after placing all the connecting and continuity steel bars. Any damages are repaired and any spaces between the panels are filled flush with repair mortar. After repair and setting of the repair mortar, the repaired areas and the joints are rubbed down with sand paper to give smooth surfaces.

Repair to Siporex Panel: Go to Top Damage to Siporex panels may be repaired on site subject to certain limitations. Siporex units which are structurally defective and unfit for the purpose for which they are designed must not be repaired but should be rejected and replaced with sound units.

Broken panels must be rejected. A broken panel is a unit which due to fracture on its lower face (tension side) or through breakage and/or fracturing of the bearing faces at the ends is no longer able to fulfill its structural functions for which it has been designed. Panels with transverse cracks which extend through the thickness of the slab should be rejected. Slabs with hair-line cracks which do not penetrate to the tensile reinforcement will normally be suitable for use. damage which exposes extensive parts of the reinforcement cannot be repaired. Panels with major damage to the bearing surface which exposes cross bars on the tensile steel should not normally be repaired.

Spalling to face of panel can be repaired if maximum dimension of repair is 30 cm and depth is less than 1/4 of the total panel depth. Spalling to edge of panel can be repaired if maximum dimension of repair is 30 cm and maximum depth is 20cm.

Elcetro Mechanica l
Chases and Penetrations Conduits can be chased easily into Siporex wall panels, but steel bars should not be cut. Panels with large cut-outs must have the reinforcement specially designed around these cut-outs. Panel board recesses can be provided neatly and economically by using a lining panel to avoid large recesses in the external wall. Pipe runs can be accommodated at design stage to avoid unplanned cutting. Typical diagrammatic sections of a Siporex house with electrical and plumbing works are shown in the figures below which show also a typical section of a chased wall.

Finishes
Before applying finishes, damages should be repaired and chases and openings should be made good. The most Economical form of finish can be obtained by having V-joints between wall panels. This should be properly laid down over the faade at the design stage. Many other methods of finishing can be used with Siporex. Floors and Roofs The figure below shows suggested arrangements for floor and roof finishes. Soffits of floors and roofs should be made with visible V-joints, which can be sprayed with Serpospack (two coats) either smooth or textured finish. For wet areas such as kitchens and bathrooms, Serpo hard should be used. There are many alternative finishing systems that can be used with Siporex. Suspended ceiling systems can also be used which are normal below bathrooms to conceal waste pipe runs.

Walls Joints between wall panels should be taped with fiberglass tape unless the joints are of Vshape. For internal walls, it is suggested to use one layer of Serpospack Normal and one layer of Serpospack fine which gives a very smooth surface as a base for painting or wall papering. Where required, the second coat may be applied with a textured finish. Also, glass cloth e.g. SCANDATEX, or wall papering can be used. For external walls, where Siporex panels have exposed V-joint, two coats of Serpocoat textured finish are recommended. Where Siporex panels have plain joints, one coat of serpohard (2mm 4mm) external plaster followed by two coats of Serpocoat are recommended. For external block walls, Serpoprime (5mm 20mm) should be used instead of Serpohard.