Industrial Training Report (Construction Sector)

7/26/2019 Industrial Training Report (Construction Sector)

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INDUSTRIAL TRAINING REPORT II

TRAINING ORGANIZATION : SANKEN CONSTRUCTION (PVT) LTD

PERIOD OF TRAINING : FROM : 26/10/2015 TO : 03/01/2016

FIELD OF SPECIALIZATION : CIVILENGINEERING

H.M.HASAN

E/11/146


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ACKNOWLEDGEMENTS

I would like to convey my gratitude to the Industrial Training and Career Guidance Unit (ITCGU),

Faculty of Engineering, University of Peradeniya, National Apprentice and Industrial Training Authority

(NAITA) and the Sanken Construction (Pvt) Ltd for providing me the opportunity to have industrial

training experience in my field of study.I am pleased to be trained in Sanken Construction (Pvt) Ltd one of the largest functioning body

construction sector in Sri Lanka. My thanks go to the Project Manager Engineer Mr Nalin Senadeera for

being the greatest support and guidance during the period of my industrial training. I must also thank

Technical officer, Mr Kalpana and Engineer Mr Sampath and Assistant Engineering Mr Piyarathna for

their effort in the fields to guide me towards the proper technical experience.

Finally I would like to add all the technical officers and staff who helped me immensely to make my

training a success.


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CONTENTS

Acknowledgements i

Contents ii

List of Figures iii

List of Tables iv

List of Abbreviations v

Chapter 1: INTRODUCTION 1

1.1 A Brief Account About the Training 1

1.2 A Description About The Establishment 1

1.3 Account On The Project 3

Chapter 2: RESOURCES OF THE CONTRACTOR 4

2.1 Concrete Mixing plant (Batch plant) 4

2.2 Workshop 5

2.3 Laboratory 5

2.4 Machinery 6

2.5 Human Resources 9

Chapter 3: CONSTRUCTION 10

3.1 Introduction 10

3.2 Construction of columns 11

3.3Construction of beams and slab 12

3.4 Brick work 14

3.5 Plastering 15

3.6 Puttying 15

3.7 Painting 16

3.8 Tile Installation 16

Chapter 4: WASTEWATER TREATMENT 17

4.1 Soakage pit 17

4.2 Seepage Bed 18

Chapter 5: PROBLEMS ENCOUNTERED 19

Chapter 6: CONCLUSION 20


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LIST OF FIGURES

Figure 1.1 Organizational structure 2

Figure 2.1 Concrete Mixing plant (Batch plant) 4

Figure 2.2 Concrete Cube Testing Machine and Test cubes 5

Figure 2.3 Truck Mixer 6

Figure 2.4 Backhoe loader 6

Figure 2.5 Excavator 7

Figure 2.6 Jumping Jack compactor and Walk-behind roller 7

Figure 2.7 Electric drill 7

Figure 2.8 Circular power saw 8

Figure 2.9 Bar cutter 8

Figure 2.10 Sander 8

Figure 2.11 Water bowser 9

Figure 3.1 Lap length & Crank length of a column 11

Figure 3.2 Formwork of beams and slab 12

Figure 3.3 Reinforcement for beams and slab 12

Figure 3.4 Concreting beams and slab 13

Figure 3.5 Setting out for brick work 14

Figure 3.6 Construction of brick walls 14

Figure 3.7 Plastering 14Figure 3.8 Puttying 15

Figure 3.9 Tile Installation 16

Figure 4.1 Soakage pit construction 17

Figure 4.2 Seepage Bed Dimensions 18

Figure 4.3 Perforated Distributer Pipes and its Layout dimensions 18

Figure 5.1 Heavy Rainy day in the site 19


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LIST OF TABLES

Table 3.1 Sticking time of formwork 13


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LIST OF ABRIVIATION

Abbreviation Description

ITCGU Industrial Training and Career Guidance Unit

NAITA National Apprentice and Industrial Training Authority

SKPA Relocation of Thangalle prison to Eraminiyaya Angunakolapalassa (SKPA) Project


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Chapter 1: INTRODUCTION

1.1A Brief Account about the Training

This report holds detailed aspects of the industrial training I obtained in the Sanken Construction (Pvt)

Ltd for a period of 10 weeks commencing from 26thof October 2015 to 3rdof January 2016 through the

National Apprentice and Industrial Training Authority (NAITA) and the Industrial Training and Career

Guidance Unit (ITCGU), Faculty of Engineering, University of Peradeniya as a six credit and non-GPA

course followed in the Department of Civil Engineering, University of Peradeniya.

1.2A Description about the Establishment

Sanken Construction is an ICTAD C1 Graded (Highest Rank) company, with ISO 9001:2008 QMS

Certification.2013 : Sanken Construction certified with OHSAS 18001:2007 Certification.2014 : Sanken

Construction is in process to obtain ISO 14001:2004- EMS Certification

The functions performed by the Sanken Construction (Pvt) Ltd consist mainly on Construction

Contracts, Property development, Ready-mix concrete, Hiring of Scaffoldings, Design & Build,

Consultancy, Hiring & leasing of machinery, Trading of Products & Materials, Piling, Skill training &

Management.

1.2.1 Vision

Tobe Sri Lankas premier construction service provider

1.2.2 Mission

To provide a quality professional service exceeding customer expectations by the effective utilization of

all resources, with the best practice of the industry


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1.2.3 Organizational Structure

Project Manager

Seinear Q.S

Q.S Main Bill

Q.S Extra Work

Asst. Q.SPlaning Manager

Q/A Manager

M and E/SaftyManager

Site Manager

Drawing Incharge Draftmens

Engineer RebarIncharge

T.O

Engineer inLandscape,Water

Proofing

T.O

Engineer Zone 1Incharge

Asst. EngineerBuilding Incharge

T.O



Trainee BuildingIncharge



T.O BuildingIncharge

Engineer DetailingIncharge

Engineer Finishing

Incharge

T.Os

Asst. Engineer

AdministrativeOfficer

Store keepers

Timekeeper

ConcreteSupervisor

Safty Officer

M & E Engineer

Figure 1.1 Organizational structure


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1.3Account on the Project

Name : Relocation of Thangalle prison to Eraminiyaya

Angunakolapalassa (SKPA) Project

Location : Eraminiyaya Angunakolapalassa

Area of the project : 58 acres

Amount of the project :Rs.4996 million

Client :Democratic Socialist Republic Of Sri Lanka Ministry of

Rehabilitation and Prison Reforms

Contractor : Sanken Construction (Pvt) Ltd

Consultant : Central Engineering Consultancy Bureau.

Date of commencement : 26thof November 2013

Duration : 22 months

After completion of this project all inmates in Thangalle remand prison and about 1000 inmates presently

detain in Welikada prison will be shifted to the new prison where approximately 2000 detainees can be

conveniently detain. This new prison consists with prison hospital, vocational training center, separate

building for industries, 140 quarters for officers, and quarters for single officers. Moreover it consists of

a playground with 400m track, swimming pool with the length of 25m, indoor stadium and trade complex

to sell prison productions.


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Chapter 2: RESOURCES OF THE CONTRACTOR

In order to foster and promote development of the construction works in the project the contractor shall

have a collection of adequate resources. As a multinational company, Sanken Construction (Pvt) Ltd

also has a set of modern utensils such as:

Concrete Mixing plant

Workshop

Laboratory

Machinery

Human resources

2.1Concrete Mixing plant (Batch plant)

The material such as cement, water, fine aggregate (sand) and coarse aggregate mixed for the preparation

of ready-mix concrete in the concrete mixing plant and it is in the worksite for easy accessibility.Ready

mix concrete is used almost every concreting. Concrete is mixed at batch plant and then transported to

site by truck mixers with rotating drum.

Figure 2.1 Concrete Mixing plant (Batch plant)


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Advantages of ready mix concrete,

Labour associated with mixing concrete is saved.

Reduction in the wastage of basic materials.

Noise and dust pollution created at site is reduced.

Ready mix concrete has better quality.

2.2Workshop

All the maintenance work of the machines used for the construction is done in the workshop allocated

to the contractor. This is situated closer to the project offices in order to serve the project efficiently.

2.3Laboratory

All the tests needed to be done to ensure a standard of work is conducted in the laboratory. This location

established in the site closer to the project office.Mostly 28 & 7 days concrete cube test done for the concrete strength measurements, Slump test

done before put to the formwork in the site.

Figure 2.2 Concrete Cube Testing Machine and Test cubes


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Fig. 2.3. Truck Mixer

Fig. 2.4 Backhoe loader

2.4Machinery

The machinery needed to serve the project will be discussed in this section.

2.4.1 Truck Mixer

Ready-mix concrete transported by truck Mixer. Almost every time Ready-mix concrete used for the

concreting works.

2.4.2 Backhoe loaderBackhoe is used for site clearances, light transportation of material, provide shifted materials for

construction work in upper levels and excavation perposes, etc.


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Fig. 2.5 Excavator

Fig. 2.9 Electric drill

2.4.3 Excavator

Excavator used to the excavate earth up to the required level.

2.4.4 Compactors

The jumping jack compactors and Walk-behind rollers are used for compacting perposes in the site.

2.4.5. Electric drill

Electric drill contains of removable bit from which drilling can be done. This is used for drill wood,

concrete etc. Bits changed according to the purpose.

Fig. 2.6 Jumping Jack compactor and Walk-behind roller


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Fig. 2.8 Circular power saw

Fig. 2.9 Bar cutter

Fig. 2.10 Sander

2.4.6 Circular power saw

Power saw is an electric machine that is used for cutting wood. It consists of a rotating serrated circular

blade. This is used to cut formworks and adjust door window slashes etc.

2.4.7 Bar cutter

Bar cutter is also an electric machine from which steel bars can be cut efficiently.

2.4.8 Sander

Wooden surfaces are grinded using sander. This also is an electric machine


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Fig. 2.11 Water bowser

2.4.9 Water Bowser Water is supplied for the site for construction and day today use by bowsers and

separately drinking water also supplied

2.4.10Poker vibrator

Poker vibrator is a machine powered by petrol, and consists of a cable with vibrating edge. Vibrating cable is put

in to green concrete to be compacted it well.

2.4.11 Dump Trucks

Vehicles used for transportation of loose material needed for construction

2.5 Human Resources

Road construction work is most commonly done by unskilled laborers. Workers can specialize in certain

types of work. Diligent and responsible workers are usually promoted to supervisory positions; to train

and supervise other workers.

The types of workers are distinguished using skill levels.

General workersThese kinds of workers are necessary to perform general excavation with picks and

shovels and clean the sides of roads for better working environment.

Masonry workersFor the building of structures such as culverts, retaining walls, etc.

Machine operators For a better efficient way of finishing up the project work, skillful machine

operators are needed with specific talents in operating the machineries used in the construction

DriversFor transportation purposes, drivers are necessary for a construction project.

Construction supervisorsSupervision of the construction work is done by supervisors.

StaffStaff working in the project office for the functioning of the project.


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Chapter 3: CONSTRUCTION

3.1Introduction

Initial survey is conducted and according to the design of the buildings and get approved by the consultant.

After the Site clearance setting out is done. Then following process is followed for the construct a building

and in every finished work approved by consultant for next level. But the works carried out by deferent

buildings in parallel.

Construction Process

Excavation

Foundation

Concrete Structure (Load bearing )

Columns

Beams

Stairs

Slab

Brick work (Non load bearing)

Roofing

Rough Plumbing

Wiring

Plastering

Flooring Tiling

Painting

Finish Plumbing

Finish Electrical and Lighting

Modifications


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3.2 Construction of columns

3.2.1 Setting out for columns

Setting out for columns was done accurately using theodolite and steel tape to avoid buckle or fail due

to eccentric loads applied on them. Marking lines was done using marking chord. Columns.

3.2.2 Laying kickers

Kickers were laid in to 75 mm thickness. Plywood sheet boxes were used for its formwork. Curing

kickers was done at least for 7 days.

3.2.3 Reinforcement for columns

Overlapping and cranking main bars and tying stirrups into correct spacing were done according to the

design. Checked whether correct bar type is used, correct spacing were left between stirrups, lap length

and crank length is corrected and good quality reinforcement is used. Column formwork required 30

mm covering blocks are attached.

Lap length (LL) = D2 x 50

Crank length (CL) = (D1 + D2+ 5) x 10

3.2.4 Formwork for columns

Column formwork was fixed to kickers. Formwork done by plywood sheets and their internal surfaces

are covered with form oil. Sponge sheets were placed in joints of formwork to avoid leakage of grout.

After fixing jacks and props and placing cover blocks were done. Then verticality of column formwork

was checked. Checking verticality was done at two edges of each face, to avoid twisting of column.

3.2.5 Concerting columns

Existing surface of concrete chipped and wet with grout in order to have strong bond. Concreting was

done using grade 25 machine-mixed concrete and free fall height of concrete is less than 1200 mm.

Poker vibrator was used for compact concrete well.

3.2.6 Striking column formwork & curing

Column formwork was removed after a day (24 hr) from concreting. Then curing was done for 7 days

applying moist gunny bags.

Figure 3.1 Lap length & Crank length of a column


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3.3 Construction of beams and slab

3.3.1 Setting out for beams & slab

1000 mm height level of columns was marked on column surfaces. Level instrument was used there.

Level of beam bottom was marked using that level.

3.3.2 Formwork of beams and slab

Beam and column formwork was fixed using plywood sheets, 2 x 2 wooden bars, galvanized iron

pipes, separates, p-cones and form ties. Props were placed at 600 mm x 600 mm distances to support

beam and slab formwork. A U-head or T-headwas placed on each prop and then galvanized iron

pipes or 2 x 2 wooden bars were laid horizontally and tied them. Power saw was used for cutting

plywood sheets and then fixed side boards for beams and formwork for slab. Verticality of side boards

and dimensions were checked. Form oil was applied. Form ties, P-cones and separates were placed at

600 mm distance, after laying reinforcement.

3.3.3 Reinforcement for beams and slab

Steel bars for beam reinforcement were bended and tied above the beam formwork. They were placed

on 2 x 2 wooden bars laid at beam formwork and they were jointed at columns. They were lowered in

to beam formwork after tying cover blocks. Slab reinforcement was laid on slab formwork.

Figure 3.2 Formwork of beams and slab

Figure 3.3 Reinforcement for beams and slab


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Figure 3.4 Concreting beams and slab

3.3.4 Concreting beams and slab

After the Levels checking Concreting slab and beams was done using ready mix concrete. Slump test

and preparing concrete cubes to test compressive strength are done for concrete transferred by each truck

mixer.

3.3.5 Striking beam and slab formwork & curing

The striking time of formwork depends on type of cement, grade of concrete, dimension of the section

and the temperature of the concrete. Minimum striking time for side formwork of beams, under side

formwork of slabs according to its span is mentioned in table 2.1. Curing was done for slab and beams

for 7 days using moist gunny bags and water ponding.

Table 3.1 Sticking time of formwork

Type of formwork Striking time

Side formworks of beams, columns or walls 24 hrs

Slab formwork up to 4.5 m span 7 days

Slab formwork above 4.5 m span & under side of beams up to 6 m span 14 days

Under sides of beams and arches over 6 m and up to 9 m span 21 days

Cantilever slab and beams 21 days


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3.4 Brick work

Walls were constructed by burnt clay bricks using 1:5 cement sand mortar. External walls were constructed

into 225 mm thickness and internal walls into 112.5 mm thickness.

3.4.1 Setting out for brickwork

Above figure elaborates how setting out lines should be marked for brickwork. Two offset lines should

be marked on either sides of brick wall. When the wall plaster is done, correct measurements can be

taken from those offset lines. 25 mm allowance should be left on both sides of a door or an opening.

3.4.2 Construction of brick walls

None load bearing type masonry brick wall is used to build the walls. English bond is used for walls as

considered to be strongest bond. 1:5, Cement sand is used for bonding mixture. One skilled labour and

a mason can build more than 800 brick wall in a day (8h) work but due to inconsistency of brick

dimensions and cement mixtures, water amount they build around 600 to 700 brick wall in a day (8h)and also height of a brick wall constructed is limited to maximum of 1.5m Mortar layers should be 10

mm in thickness but practically it was higher than that. That causes to over consumption of cement and

sand for brick work than the designed. Bricks should be wetted with water before use in brick work.

The blocks should not be wetted before use. Verticality of walls is checked with the plumb bob and

straight edge.

Figure 3.5 Setting out for brick work

Figure 3.6 Construction of brick walls


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3.5Plastering

Cement to sand 1:5 mixture is used for plastering work. Water appropriately used for proper mixture

and usability. Plumb bob and spirit level and feather edges are used and got a good finishing. After few

more days the wall preparation (cleaning) was done

3.6Puttying

After the plastering work, 1stcoat puttying done and kept for drying and then second coat of puttying

done and kept to dry. To puttying stainless steel Trowels and Skimming Spatulas and for get a goodlevel of finishing Feather Edges are used. Then sanding was done by using 180 grit sandpapers for

further finishing.

Figure 3.7 Plastering

Figure 3.8 Puttying


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3.7Painting

After the puttying Filler coat applied and patch work done. For patch worked areas sanding and

application of filler coat was done.

3.8 Tile Installation

1:5, Cement: sand mixture is used for the tile bedding preparation and appropriate water amount is used

for workability. After placing the bedding up to given level, kept it for one day and damped the surface

to reduce suction to avoid debonding the tile mortar and bed.

Tiles are soaked in clean water more than 30min (to prevent drawing water from cement mortar and get

debonding).

Cement water mixed mortar is used as adhesive and placed it ait on the back side of the tile it is fixed by

using tapping method tile was placed onto uniform position. Then level of tile was checked using spirit

level and plastic spacers are used to get the proper spacing. Finally grout was spread by using a soft

trowel and excess grout removed and tile surface was cleaned.

Figure 3.9 Tile Installation


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Chapter 4: WASTEWATER TREATMENT

4.1Soakage pit

In the beginning of soakage pit construction the earth was excavated using backhoe loader up to required

level and C25 grade concrete laid for screed and formwork and reinforcement work began for base and

covering blocks are placed then C25 grade ready-mix concrete was placed then 1 ststage and 2ndstage

reinforcement, covering and formworks and soakage holes (100mm PVC pipes) kept and concreted

according to the stage. Finally the slab reinforcement and formwork and coverings are placed according

to drawings and concreted. In every stage the pokering and curing was done.

Figure 4.1 Soakage pit construction


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4.2Seepage Bed

Firstly the located place excavated 8000mm below the ground level. Dimensions and geotextile laying

are shown below and 70mm drop was maintained between longitudinal ends.

300mm was filed with metal type 20mm-40mm layer was laid. Then six 160mm diameter perforated

distributer pipes are laid with pipe axis to axix span is 1000mm and 1stand 6thaxis to embackment is

500mm.

After that 200mm same rock type placed and the geotextile cover folded to get a 5000mm lap to avoid

water infiltration from above. On top of this 250mm sandy soil placed then 50mm of normal soil placed

up to the Ground level.

6m

800mm

Figure 4.2 Seepage Bed Dimensions

Figure 4.3 Perforated Distributer Pipes and its Layout dimensions


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Chapter 5: PROBLEMS ENCOUNTERED

Heavy rain delayed most of works.

Identification of weather pattern early and prepare accurate time schedules will help to perform well but

project like this its impossible to maintain works like excavation only in dry period because the parallel

works of different buildings with limited resources in a remote area like Angunakolapalassa. Hence

building a proper drainage system is the way to overcome this effects by reducing the waiting time to

drain water.

Less resources delayed the works.

This mainly occurs in the finishing stages of most buildings arrived in same period. The inefficient

management of resources and delays in resource arrival to the site. This can overcome very easily by

proper and direct communication and make the schedule of buildings arrival of finishing stages are little

different from buildings to building.

Figure 5.1

Heavy Rainy day in the site


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Chapter 6: CONCLUSION

During my training period of 12 weeks I was able to gather a good experience in building construction

and it helped me to understand what is happening on the site apart from the theoretical aspects. In the

site, I gained practical, technical knowledge and experience regarding situations of the working site and

how to overcome the difficulties and also got supervision and communication skills within the site. The

industrial training is important and valuable experience as an apprentice in the field of Civil Engineering.

The engineers in the site induced and guided me to go with the process in progress. The management of

conflicts occurred between staff and labors or in between them, arrangement of facilities to support the

work proposed, adjustment for the scarce resources and labors, taking decisions depends on the forth

coming problems and avoidance of unnecessary work to reduce the cost. Not only that, by exposing to

the field I was being got to know the people from various organizations, and this environment helped

me to express my interest, intensions and suggestion Finally confident to state that the training I got is

more than I really expected to get and I hope that the future undergraduates coming for the internship

will find their training even more beneficial to their future career.

Industrial Training Report (Construction Sector)

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