KEIHIN FIE FACTORY PROJECT

PRESENTATION ON

DRY WALL CONCEPT

(FOR TOILET)

PREPARED BY :- Sunil M. &

Tushar G.

INTRODUCTION
PLAN

ACTION

DO

CHECK
ACHIEVME
NT

COMPARISI
ON

CONCLUSIO
N

PDCA CYCLE
PLAN

:-

DO

:-

To complete the toilet in speedier way.

Why? & How?.
Drawing preparation , Finalize schedule.

CHECK :-

Material Availability, Construction method, To Check

Quality Assessment Standard.

ACTION :-

Actual usable toilet construction for site office

GENERAL CONSTRUCTION TECHNIQUE IN INDIA

(WET WORK-FOR TOILET)

Underground piping
Grade slab casting
Wall marking
Dike wall concreting
Block work with stiffener column and beam concreting
Tile marking on wall
Lining wall concreting
Waterproofing
Plastering
Tile laying on wall
Ceiling work
Flooring
Sanitary fixing

(Attribution Analysis of
Wet wall)
Environment

Slow Schedule.
Quality.
constructionTile groove not
Curing for
n aligned, Bent
block & plaster
tile, Floating on
work, Chipping
surface
Delay in
for MEP
Not proper Cohanding over
services
ordination with
in project
MEP cause
chipping and
repairing work.
Poor workman
Wastage of
ship for tiling
material.
work.

Manpower.

All of you sum

up
the
All to
of delay
you sum
project
up to delay the
project

Dirty
Workplace

Material.

PLAN :-

PLAN :- TARGET SET BY KEIHIN PROJECT TEAM

No block work

No plaster work

No painting work (if required only washable paint)

TO ACHIEVE THE ABOVE TARGET DRY WALL
CONCEPT TO BE
IMPLEMENTED.

PLAN :- DRY WALL CONCEPT

(FOR TOILET)

Probably first time in Shimizu India.

Sample mockup done at temporary site office.

This sample mockup shown to designer and owner.

After approval by designer and owner, The same to be implemented

for main factory office.

If the implementation is satisfactory, will be followed in future

projects in Shimizu India.

SAMPLE BOARD FOR

TOILET

SAMPLE BOARD FOR

TOILET

PLAN :- CONSTRUCTION PROCESS OF DRY

WALL

(FOR TOILET)

Drawing
In total co-ordination with M&E including fixture details.
Underground piping work
To be done as per co-ordination drawing.
Grade slab work to be done with rebar anchorage for dike
wall.
Wall layout marking
Dike wall concreting
Aluminum/LGS partition work
Marking to be done on wall for pipe location.
Pipe arrangement
MS lining wall to be framed with piping to be properly
attached to MS lining wall.
Wainscot granite cladding.
Wall cladding to be done in cement board/PVC panels.
Ceiling work
Flooring work
M&E fixtures.
POINTS TO BE CONSIDERED:
Samples (including M&E) selection to be done before
drawings are prepared.
Pipes pressure check should be done before wall cladding.
Required anchors for sanitary ware to be fixed before wall
cladding.

DO :-

DO :-

DO :- CO-ORDINATION DRAWING

DO :- DETAILS

DO :- DETAILS

DO :- DETAILS

DO :-

DO :-

WALL ELEVATIONS

DO :-

WALL ELEVATION

CHECK :-

CHECK :- Material Feasibility

Adhesive for Granite Pasting on Plywood / Cement

Board
Our product, Araldite Standard is an
adhesive that is one of the world's
strongest bond. The distinct feature
of the product is its versatility. It can
Bond almost anything to anything,
like metal, glass, plastic, ceramic,
wood, marble, granite, rubber and
many more. The product is well suited
for plastics like PTFE, HDPE, silicon
rubber and many others. Another
feature of the product is that it
prevents sagging and does not cause
anyCost
shrinkage
after
curing
: - 124
Rs/Sq.mt.

Consumption :- 0.155kg/Sq.mt.

CHECK :- Material Feasibility

Adhesive 3M tape for fixing
PVC board

Cost : - 700 Rs/Sq.mt.

Consumption :- 5m/Sq.mt.

Silicon for fixing

aluminium & L section on
joints of PVC board.

Cost : - 20 Rs/Sq.mt.
Consumption :- 25ml/Sq.mt.

CHECK :- Material Feasibility

BOQ +
40%.

BOQ +
60%.

=BOQ

BOQ +
54%.

=BOQ

BOQ +
45%.

BOQ +
40%.

BOQ +
27%.

BOQ +
47%.

CHECK :- Material Feasibility

BOQ +
53%.

=BOQ

=BOQ

BOQ +
12%.

BOQ +5%.

BOQ 600%.

CHECK :- REQUIREMENTS
(FOR TOILET)

Requirement of..
1) Safety Gadgets,
2) Tools,
3) Components,
4) Material,
5) Consumable material,
6) Equipment,
7) Method statement,
8) Quality- Acceptable criteria.

ACTION :-

Method Statement (Urinal).

ACTION :-

Underground piping work with

water fill test

Casting of Grade Slab & Dyke wall

Waterproofing on slab on Grade and

then protection Concrete done

After that Fixed Aluminum section

frame of 62mm X 38mm
26

Method Statement (Urinal).

ACTION :-

PPR piping work before MS framing

Pressure testing done for PPR line

Mock up & marking done for inlet

and outlet pipe location

Referred this marking for fixing of

MS frame vertical support
27

Method Statement (Urinal).

Made prefabricated MS frame

Weld MS frame to the Support tube and

anchored at bottom

ACTION :-

Fixed horizontal MS support tube to

the Aluminum frame

Checking for plumb, Alignment

and 5mm Top slope
28

Method Statement (Urinal).

Extra supports weld for Urinal

fixing.

After that fixed plywood on the

MS frame

ACTION :-

Cut plywood treated by Anti-termite

Cement Board is fixed with the

help of araldite and screw
29

Method Statement (Urinal).

Layout marking on board to

minimize the wastage.

Fixed with help of araldite and

pop for holding.

ACTION :-

Cut exact size of granite cladding.

Granite fixed as per sequence

made
30

ACTION :-

Method Statement (Wash Basin Counter).

Fixed Aluminum section frame

of 62mm X 38mm

Weld MS frame to the support tube

and anchored at bottom

Fixed horizontal MS support tube to

the Aluminum frame

Applied anti rust paint on touch up

work
31

ACTION :Method Statement (Wash Basin Counter).

Weld 50X50mm angle frame for

counter

Fixed plywood and cement board on

it and marking of basin.

Fixed extra support for basin rest

Cut opening for basin installation and

applied anti termite for cut plywood.
32

ACTION :-

Method Statement (Wash Basin Counter).

Installed basin.

Granite cut and polished

Level of basin adjusted by

fixing M.seal.

Fixed on the Counter

33

PROBLEMS AND OVERCOMES :-

Problems with
Conventional method.
1.

Slow
construction

2. Dirty work
place

3. Co-ordination
with M&E

Overcomes by Dry
wall Method.
To be complete site
office toilet in 45
days with trial
and error.

Because of using
plywood and
cement board we
maintained clean
work place

M&E and wall framing

work carried out
Simultaneously.

35

Problems with
Conventional method.
4. Poor workmanship for tile laying

Overcomes by Dry
wall Method.
Accuracy level high because of
fixing by using of Araldite.
We are using
polycarbonate
sheet, PVC
board and
prefinished
Gypsum Board.

5. Undulation in calcium silicate board false

ceiling & Damage of acoustic grid
ceiling .

6. Delay in handing over of project

Toilet work
complete on
time

36

Difficulties & Precaution.

1.Anchorage of EWC in Drywall.

2.Fixing of bigger size granite peace

on cement board. And variation
in thickness of granite.

3. Use of plywood. (Termite problem)

37

Solution.
1.Drilled & Weld threaded locking nut and bolt
at correct location. Need to take care
while welding cause damage of PVC pipe.

2.Used araldite and pop on surface to hold the

granite piece and For variation of granite,
we used packing fixed with screw on
cement board behind granite and lay
araldite on it.

3. Used pretreated ply woods and taken care

about all cut edges should treated.

38

ACHIEVEMENT :-

After Execution.

After Execution.

After Execution.

After Execution.

After Execution.

After Execution.

k
c
i
th ds.
m ar
m
12 C Bo
PV

After Execution.

Also Followed SHIMIZU standard QCDSE.

Quality of work improved

because
accuracy level is high.
C Cost is high but again it is
profitable due to less construction
period.
D Delivery is very fast because
of good productivity.

Safer due to preassemble

work..
E We are getting clean work
Environment to work and material
wastage is less.

COMPARISION AND CONCLUSION :-

SECTIONS WITH SKIN WALL

SECTIONS WITHOUT SKIN WALL

COMPARISION OF TECHNIQUES
SL.N
O.

PARTICULARS

WET WALL

DRY WALL

Consumption of water

High

Nominal

Recyclable Material

No

Almost

Construction period

Long and slowAround 2 months.

Short and fast- 1.5

months
considered for
trial.

Curing period

Long

Nominal

Repairing/dismantling

Difficult

Easy

Working environment

Initial Cost

Dirty- due to mortar

Clean- to use
work and chipping
Epoxy Adhesive
work.
for tile/granite and
panels to be
screwed.
Low- but due to H/O
getting delayed,
overhead cost
increases.

High- but time

saving, if H/O is
earlier, we will
save money.

COST ANALYSIS BETWEEN BOTH METHODS.

Dry wall Method

Framing; 24%

Internal finishes; 65%

External finishes; 10%

Framing
External finishes
Internal finishes

Wet wall Method

Internal finishes; 41%

Civil work
Civil work; 46%

External finishes
Internal finishes

External finishes; 13%

COMPARISION OF COST

(Rate/Sq.mt)

COMPARISION OF COST

(Rate/Sq.mt)

Total Rate for Wet wall = 4,828.00 +

3845.00
= 8,673.00
Rs/Sq.mt

COMPARISION OF COST

(Rate/Sq.mt)

COMPARISION OF COST

(Rate/Sq.mt)

Total Rate for Dry wall = 5,698.00 +

4,682.00
= 10,380.00 Rs/
Sq.mt

COMPARISION OF COST & PRODUCTIVITY

Rate for Dry wall
Wet Wall
10,380.00 Rs/Sq.mt
Rs/Sq.mt

8,673.00

= 20% Extra Cost

BUT.
By Implementing Dry wall method, We
are able to finish 38 Sq.mt Toilet in 45
days with productivity of 8.79
sq.mt/MD with compare to Shimizu Indias
recent productivity i.e. 5.23 sq.mt/MD.

THANK YOU