Pre Contract

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Maga Engineering (pte)Ltd
01. INTRODUCTION TO THE TRAINING ORGANIZATION

1.1 Establishment and the function of the organization
Mga Engineering (Pte) Ltd is a one of the leading construction firm (contractor) in
Srilanka. I.e. the recent Awards Winner of construction Excellence. In addition to
contractor work, now they design some structural, shoring and other required design. Future it
will become as a design and built firm. During last decades it has shown a huge improvement
in their competitive market as a construction firm. In the early stage mga was involved in the
manpower supply only. But now they are the proud structural main contractor of massive civil
engineering projects in Srilanka. And more importantly now they are getting works more
frequently. Not only that, they are the proud contractor of some massive building, road works,
drainage systems, concrete supply (Batching plant), mechanical systems and also leasing
company.
Projects
Batching plant
Galle
Control workshop
Rajagriya
Department of Civil Engineering
Project
Gampola
Leasing structure
Katunayake
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Main functions of organization:

1. Work as a main contractor
2. Work as a sub contractor
3. Operate sub contractor for some special work
4. Operate the concrete batching plants for their own purposes and supply the ready mix
concrete to other construction.
1.2 Some current projects of mga engineering (Pte) Ltd
Kandy shopping complex
900 million Rupees
Kandy car park
470 million Rupees
Road project (southern province)
>1000 million Rupees
Vocational Training Centre-Narahenpittea 180 million Rupees

Mixed Development Project Bambalapitia
BIA Cargo Building project
550 million Rupees
550 million Rupees
1.3 Some recent past projects of mga engineering (Pvt) Ltd

As a main contractor
Lanka Apollo Hospital
700 million Rupees
Millennium Information Technology Malambe
450 million Rupees
Eden Hotel Beruwala
250 million Rupees
Light house Hotel Galle
200 million Rupees
Blue water Hotel Wadduwa
250 million Rupees
Sin
168 million Rupees
Hotel Kalutara
As a sub contractor
QEQ project Port-Authority
300 million Rupees
AES Kelaanitissa
300 million Rupees
Gampola Bridge
85 million Rupees
Mahiyangana road and bridge
350 million Rupees
Taj Exotica hotel Wadduwa
168 million Rupees
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All these projects are massive projects; mainly massive projects are done by mga.
This give a clear idea about mga engineering (pte) ltd is one of the leading construction firms
in Srilanka,
1.4 Organizational structure of the Mga engineering (Pte) Ltd

Even though Maga engineering (Pte) Ltd has done massive work, they have a large number of
staff with them and very talented and the efficient, experience. Brief chart is shown below.
Chairman / managing director
Finance
director
Director
operation
Director
administration
Dir, engineering
(planning & dev)
Dir.eng
design&con
Assistant
accountant
Coordinating
engineering
Estimating
dept, planning
General Manager
Administration
Finance
department
Driver orators
General administer
Stores
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Site organization chart

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GREATER GALLE WATER SUPPLY PROJECT

Nature of the Work
This is also one of major project of Maga. Normally the Galle area felt drinking water
problems. Previously here no any water supply system took over. So that national water
supply and drainage board under take this project to solve this problems. This project has
many components such as
1. Construction of intake structure and low lift pump house at Wackwella
2. Construction of water treatment plant
Areator
Flash mixture
Clarifier focculator
Sand filter
Sldge drying beds
Recoverypit
3. Construction of Ground Reservoirs.
Clear water reservoir
3000 m3
Hapugalla reservoir
12000m3
Kowulhena
reservoir
7000m3
Halloluwagada reservoir
7000 m3
Mahagoda reservoir
3000 m3
4. Laying of transmission main
Water treatment plant to Hapugala reservoir 1.1km
Water treatment plant to Mahagoda reservoir 4.3.km
Hapugala reservoir to Kowulhena reservoir 9.4 km
Kowulhena reservoir to Halloluawagoda reservoir 10.1 km
5. Laying of main distribution system

The main Reservoir is in Hapugala area. that include pump house system also. From
there, the water is pumped to other reservoirs. Other reservoirs are constructing in Mahagoda,
Kowlhele, and Kallolugoda. Intake plant has been constructing in Wackwella by Maha. The
treatment plant of water supply project has been constructing in Hapugala by the Access
Company. Maga constructing distribution line also. Two sections is Distribution line 1 and
distribution line 2.
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GING GANGA
800mm
INTAKE
600mm
AREATOR
600mm
FLASH MIXTURE
450mm
(2 line)
450mm
CLARIFIER
FOCCULATOR
450mm
(2 line)
450mm
SAND FILTER
150mm
SLDGE DRYING
BEDS
RECOVERYPIT
600mm
400mm
CLEARWATER RESERVOIR
3000M3
350mm
Back wash
800mm
HAPUGALA RESERVOIR
12000M3
THROUGH
SALINITY BARRIER
400mm
MAGAGODA
RESERVOIR 3000M3
600mm
KOWLHENA RESERVOIR
7000M3
500mm
HALLOLUWAGODA RESERVOIR
7000M3
FLOW CHART OF GREATER WATER SUPPLY PROJECT

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PROJECT DETAILS
Project
:-Greater Galle Water Supply Project

kowlhena Ground reservoir
Client
:-National Water Supply Board
Main contractor
:-KOLON-SAMSUNG CONSORTIUM
Kolon Eng. & const.co.Ltd
SAMSUNG Coporation
Consultant
:-CEYWATER CONSULTANTS (PVT) LTD
Sub Contractor
:- Maga Engineering (Pvt) Ltd.&

Access construction &
CML Edwards Construction
Source of water
:- Gin-ganga
Design Demand
:- 32000 Cubic meters per day (7.1 million populations)
Type of contract
:-Design,Build & Turnkey Contract
Contract No.
:-P&D/GREATER GALLE/W/DBT/2000/01
Total cost
:-Rs.96, 163,190.96
Project start date
:- 01 July 2002
Project finished date
:-09 may 2005
Kowlhena Ground Reservoir

I engaged in Kowlhena reservoir for two months training periods. That time the main
structural work had been completed. The following sub works are going on:
In & Out Hume pipe laying.
Painting & tiling work for Chlorination house and Guard

room.
Reservoir roof slab dolomites & metal laying.
Entrance Road work.
Drainage line around the reservoir.
Security fencing work.
Curb stone line with disk drain.
Fixing of entrance steel gate.
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EXCAVATION
Before a foundation can be laid it is necessary to excavate a trench of the required
depth and width. Initially survey was done to establish the level in the whole area to quantify
the excavation. Level was measured for each and every square of grid on middle and edges of
square. Bulk-excavation need to be done up to bottom of the screed of basement slab.
Excavation quantify was calculated from the existing levels and excavation bottom level.
Excavation was done 1m below the ground level. Excavation was difficult and time
consuming using man power
For small area excavation, man power was used. Excavation areas were kept under moist
conditions to minimize dust pollution in the site.
Machinery & Equipment used for bulk excavation
Excavator
JCB site master
Tractor
Disposal of earth
All excavated bad soils were disposed off site by using tractor. Sometime excavated
soil was reused for back filling work. Disposal area was kept wet while spreading of earth.
Blondish stone removing
First tried to remove the blondish stone by manual but, could not remove. After that
drilling hammer and air compressor were used to remove but, whole stone could not remove.
Then large bucket excavator and breaker were used to remove that stone. This excavator was
brought by low bed transport.
Backfilling
Over excavated areas were back filled with suitable materials selected from the
excavation. Those approval fill material was deposited in layers of max.300mm or less, as can
be thoroughly compacted with rollers, vibrator. No layers were deposited until the previous
layer has been compacted to the satisfaction of the engineer, and also no filling of excavation
were commenced until these had been approved and measured by the engineer. Compaction
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was done until the soil gets its required properties (dry density, etc).proctor compaction test
was done
Machinery & Equipment used for backfilling & compacting
Tractors
JCB site master
Excavator
Roller
Vibrating rammer
Field Density Test by Sand Cone Method

After the compaction of each layer the density achieved in the
field should be determined. In the site sand cone method can be done to determine the
density of the compacted fill material.
In the sand cone method small holes are made at several places in the compacted
layer. The weight of the soil removed can be measured. The volume of the hole can be
obtained by filling the hole with sand (density of the sand is known). Then the density of
the soil can be calculated.
The standard proctor compaction density value can be compared with the field
density. Field compaction density is usually specified to be above 98% of the standard
proctor compaction test in the laboratory for sub base and ABC materials layers. If not
further compaction is necessary.
Calculation for Degree of Compaction
Volume of the hole
= Weight of sand in the hole

Density of the sand used
Wet density of the soil = Wet soil in the excavation hole

Volume of the hole
Dry Density of the excavated soil

Wet Density * 100

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(Moisture content of the soil + 100)
Degree of Compaction
= Dry Density of the Excavated soil *100

Lab Maximum Dry Density
Procedure
A hole about 6 wide and 6 deep was dug into the compacted soil.
The soil was removed from the hole was weighted.
The jar was weighted before the filling the hole.
A cone and jar apparatus containing special fine-grained uniform sand was placed over
the hole, and hole was filled with sand.
The jar was weighted again after filling the hole.
Sample from the soil was taken and weighted
Then completely dried and weighted again (the amount of water lost, divided by the
dry weight gives the moisture in the soil)
Calculation
Weight of can +sand 1
=W1
Weight of can +sand 2
=W2 (after filling)
Weight of sand
=W1 W2
Bulk density of sand
= D (Known)
Volume of funnel
= V1 (known)
Volume of hole
= (W1 W2)/D V1 =V2
Weight of can +soil from hole
= M1
Weight of can
= M2
Weight of wet soil
= (M1 M2)
Bulk density
= (M1 M2)/V2 =D2
Weight of can
=w1
Weight of can +wet soil
=w2
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Weight of can+ dry soil

=w3
Weight of wet soil
=w2-w1
Weight of dry soil
=w3-w1
Weight of water
=w2-w3
Moisture content
= (w2-w3)/( w3-w1)
Dry density
=D2/ [1+ {(w2-w3)/ (w3-w1)}]

Dry density
Max
Density
Moisture content
Optimum
Moisture content
From this degree of compaction can be calculated


Screed (Lean) concrete

Grade 15 (1:3:6)/40 mm aggregate size concrete is normally used for screed concrete.
But, grade 20(1:2:4) /20 mm aggregate size concrete was used .first screed concrete bottom
level was measured after that top level was marked in steel rod by using level instrument
(sometime theodolite ) . Before the concreting, water cured. Then there was concreted. Screed
concrete thickness was 75 mm.
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Waterproofing
Water proofing member was fixed above the screed concrete top. It is fixed to prevent
water movement towards the structural inside. There is different kind of water proofing
system.In my site polythene was used for water proofing membrane.
FOUNDATION
Foundation is the lowest part of a structure .which a building rests and its purpose
is to safely the load of a building to a suitable sub soil. Generally, foundations are placed
below the ground level to increase the stability of a structure or a building.
The objectives of providing foundation
To distribute and transmit the total load acting on the structure to a larger are of
underlying support.
To prevent excessive settlement and differential settlement of the structure.

To provide stability to the structures against many disturbing forces e.g. wind, rain,
earth quake etc.
Principal types of reinforced concrete foundations
1. Strip foundation
2. Isolated or pad foundation
3. Raft foundation
4. Combined foundation
5. Piled foundation
Strip foundation
Reinforced concrete strip foundations are used to support and transmit the loads from
heavy walls. Tensile reinforcement is therefore required in the lowest face of the strip with
distribution bars in the second layer running longitudinally.
Normally, weak concrete (grade 15 (1:3:6)/40 mm agg) is used for blinding concrete
but, in my site grade 20 concrete (1:2:4/20 mm agg) was used for blinding concrete.
Normally, grade 20 concrete (1:2:4/20 mm agg) is used for reinforcement concrete. But, in my
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site grade 35 (1:1:1) concrete was used because water pressure is most. 600 mm height
concrete layer was placed. 16 mm rebar is used in 2 layers with 100 mm space in each
other. The rebar should not to touch the water bar.
Isolated or pad foundation
This type of foundation is used to support and transmit the loads from piers and
columns. The most economic plan shape is a square but if the columns are close to the site
boundary it may be necessary to use a rectangular plan shape of equivalent area. In my site
every pad foundation was square.
Normally, weak concrete (grade 15 (1:3:6)/40 mm agg) is used for blinding concrete
Combined foundation
Having a square base is not always possible. If the structure has a wall on the
boundary of the site the columns would be located eccentrically, if conventional isolated bases
were employed. One method of overcoming this problem is to place the perimeter columns on
a reinforced concrete continuous column foundation in the form of a strip. The strip is
designed as a beam with the columns acting as point loads which will result in a negative
bending moment occurring between the columns requiring top tensile reinforcement in strip.
Normally, weak concrete (grade 15 (1:3:6)/40 mm agg) is used for blinding concrete.
Raft foundation
The principle of any raft foundation is to spread the load over the entire area of the site.
This method is particularly useful where the column loads are heavy and thus requiring large
bases or where the bearing capacity is low , again resulting in the need for large bases, there
are three type of raft foundation such as
Solid slab Raft foundation

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Beam and slab Raft foundation
Cellular Raft foundation
Solid slab Raft foundations are constructed of uniform thickness over the whole raft
area, which can be sometimes wasteful since the design must be based on the situation
existing where the heaviest load occurs.
Normally, weak concrete (grade 15 (1:3:6)/40 mm agg) is used for blinding concrete.
REINFORCED CONCRETE
Concrete is strong in compression, but weak in tension
Steel is very strong in tension.
Concrete is much cheaper than steel

Therefore, concrete is used to resist compressive loads, but steel has to be
incorporated into concrete wherever tensile loads are likely to occur. Because steel is
so expensive, the designer has to keep the quantity of steel to a minimize.
Steel and concrete can be used in combination because:
Upon hardening, concrete bonds firmly to the steel.
Concrete and steel expand and contract at the same rate under temperature changes.
Concrete has a high resistance to damage by fire and thus protects the steel, which is
easily damaged by fire.
Types of stresses
The following are the principal type of stress, which develop in structural members:
(1)Compression
Compressive stresses tend to cause concrete to crush.
(2)Tension
Tensile stresses tend to cause concrete to stretch and crack
(3)Shear
Shear stresses tend to cause sliding between adjacent sections of concrete
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BOND AND ANCHORAGE

A good bond between the concrete and steel must be, achieved.
Bond can be increased with:
Clean bar
Deformed bars
High strength concrete
Thorough compaction of the concrete
Reinforcing steel has to be extended beyond the region of tensile stress to develop satisfactory
bond strength. If there is not enough room to extend a bar, a bend or hook is used to develop
bond with the concrete.
REINFORCING STEEL
Types of Reinforcing Steel
Hot-rolled plain round bar (Structural grade).
Hot-rolled deformed bar (Structural grade)
Cold-worked deformed bar (CW bars).
Hard-drawn wire,
Reinforcing fabric (made from hard-drawn wire),
In our site hot rolled plain round bar (mild steel) and hot rolled deformed bar (Tor
steel) were used.It is important to be aware of the different types of reinforcing steel, how to
identify them and where to use them. In schedules, R for round is mild steel in the form of
plain smooth bars.
T or Y denotes steel, which has a ribbed appearance and may be twisted. This is
used to be known as high tensile steel, which is called as tor steel or yield steel.
Tor steel
Tor steel is produced in the form of cold hoisted deformed bars for concrete
reinforcement and available almost all standard diameters, ranging from 6mm to 50mm.but in
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our site we used (10-32) mm bars. For all reinforcement work tor steel was used and its
strength is 460N/mm2.
Mild steel
Mild steel is soft carbon steel and it contains (0.2-0.5) percentage of carbon. This can
be easily cut and bend. In addition, its strength is 250N/mm2. Therefore, it is mostly used for
column stirrups and beam stirrups. In our site the 6 and 10 mm diameters bars were used.
Naming reinforcement bars
Reinforcement on details drawings is described by a coding system to simplify
preparation and reading of the details.
For example: - 25T20-65-125B1
25
- No of bars
- Type of steel (T-tor steel & R-Mild steel)
20
-Bar diameter in mm
65
-Bar mark
125
-Spacing
B1
- Bottom (position)
Abbreviations used
B1
- Bottom reinforcement
B2
- Distribution bars in bottom net
T1
- Top reinforcement
T2
- Distribution bars in top net
C/C
- Center to center
ALT -Alternatively
Weight of tor steel
1m tor steel weight is calculated approximately below the equation.
Weight = diameter / 162.162
Diameter is in mm
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Weight is in kg/m
Bar type
Weight (kg/m)
T10
0.616
T12
0.888
T16
1.579
T20
2.466
T25
3.854
T32
6.313
T40
9.864
Lapping of two bars

Normal length of the full bar is 12 mm. if the reinforcement bar is exceeding 12 mm
then provided lapping. It is carried out according to the standard specification. The designed
lap length in our site is 50 *, where is bar diameter.
Example:(1.)
Lapping
T20
T20
Lapping length = 50 *
= 50* 20
= 1000 mm
(2.)
T32
Lapping
T20
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Lapping length =50 *
= 50* 20 (small bar diameter)

= 1000 mm
Crank of bar
Y
X
Y: X =1:10
Before accepting deliveries of reinforcing steel, always check the following:
Type of steel is correct.
bar sizes are correct
Any damage to the bars
Any sign of bar corrosion.
Do not accept any steel, which is not satisfactory.

Cleaning reinforcement
A wire brush was used to remove all loose rust and scale. Mud, form oil, paint etc, can
be removed by a solvent which is not oil based, e.g. petrel. If the steel is rusted, remember the
following point
Loose, flakey or soft rust must be removed, as it will prevent the concrete bonding to
the steel.
Heavy corrosion reduces the effective size of reinforcement, and an engineers advice
should be sought before using it.
Very light rust causes no problems and it can even improve the bond between steel and
concrete.
Stacking Reinforcement
The following points should be remembered when stacking reinforcing steel on a job site
Stack it off the ground, to protect it from mud.
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Stack it conveniently according to size and length.
Ensure that each bundle is correctly labeled with waterproof tags.
Bending reinforcement
Probably the simplest device for beading bars up to 12mm in diameter is a 3m
length of pipe whose internal diameter is slightly greater than the diameter of the bar. This
method can be used when the bends are simple and the quantity is not great.
For general work up to 20 mm diameter bar, simple hand, operated machines are
available. These machines consist of a flat sleet plate on which is fixed a bending pin around
which the bar is bent.
When bar is bended, the following point should be noted
Bar must be bent accurately to the dimensions shown on the bending schedule.
Otherwise, the cover may not be obtained when the steel is positioned in the structure
fixed.
Bars should be bent cold with a slow and regular movement.
Never heat cold worked bars.
Do not heat other bars without an engineers approval.
If bars have to be heated, do not exceed a cherry red colour.
Never cool heated bars by quenching in water.
If steel has been bent and then straightened, it should not be bent again at the same
point or near the same point.
Fixing Reinforcement
Reinforcement must be securely fined in the formwork so that the bars tire not
displaced by workers walking on them or by the placement of concrete. It is essential for the
safety of a structure to ensure that the correct size, shape and grade of reinforcement is used,
and that the reinforcement is fixed accurately and securely in the position specified. It is
essential that the concrete cover specified in the drawing is obtained in the order to protect the
reinforcement from rusting or chemical attack.
Where bars cross or where there is a lapped splice, bars should be tied together with
either soft iron wire (tie wire) or specially made wire ties( bag ties).The most suitable size of
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wire is 1.6 mm diameter (do not use wire less than 1. 25 mm diameter). Bag ties can be
obtained in various lengths, but 150 mm is suitable for most purposes.
In our site, 1.6 mm diameter tie wire was used. This tie wire one roll was 25 kg .this
wire was cut four pieces for 10, 12,16 mm and three pieces for 20, 25,25mm. Bars were tied
double.
For 10 ,12 , 16 mm, one piece

approximately is 300mm
For 20, 25, 32 mm, one piece

approximately is 400mm
Important checks, during the reinforcement work are :
Check whether spaces of each reinforcement bar were in correct or not.(vertically&

horizontally)
Check weather availability of spacer bars of beams in required spacing.
Binding should be tightened properly.
Covering should be maintained.
In the case of double net , (such as in the case of a base) stools are used between the
two nets to get required space between them.
Under the bottom net cover blocks were used in required density to maintain the
bottom cover.
Laps can not be placed continuously.
REINFORCEMENT SCHEDULES &ARRANGEMENT

(1)Base slab
When rebar arrange for base slab, main bars and distribution bar (secondary
bars)should be considered. smallest span bars are main bars. Longest span bars are
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distribution bars (secondary bars).In bottom, main bars should be below the distribution bars.
In top, main bars should be above the distribution bars.
(top)
Main bar
Main bar
distribution bar
distribution
(bottom)
When main bars or distributions lap, crank is not necessary. we should not lap more
than 50 % of the bars at the same cross section.
First line bar (FF)
Second line bar (NF)
Stools
Stools are used to separate the top reinforcement mesh and bottom reinforcement
mesh. Those should strength enough to bear the load without changing the gap of two layers.
12 mm or 16 mm bars are used to make the stools.
Stool height
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Stool height = slab thickness-(top (main bar diameter +distribution bar diameter) +
bottom (main bar diameter +distribution bar diameter) + (2*cover))
(2) Column
A column is a vertical member carrying the beam and floor loading to the foundation
and is a compression member. Since concrete is strong in compression it may be concluded
that provided the compressive strength of concrete is not exceeded no reinforcement will be
required. For this conditions must exist:
Loading must be axial.
Column must be short, which can be defined as a column where the ratio of its
effective height to its thickness does not exceed 12.
Cross section of the column must be large.
The minimum number of main bars in column should not be less than four for
rectangular columns and six for circular columns.
A minimum main bar diameter 12 mm.

The several shapes (square, rectangular, circular and L shaped) columns are used in
construction.
Stirrups for column
To prevent the slender main bars from buckling and hence causing spalling of the
concrete, links or binder are used as a restraint.
These should be at least one quarter of the largest main bar diameter.
Pitch or spacing not greater than twelve times the smallest main bar diameter.
All bars in compression should be tied by a link passing around the bar in such away
that it tends to move the bar towards the centre of the column.
Main bar
Binder
Binder
Main bar
Column with 4 main bars
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L shape column with 7 bars
Circular column
Strater bar
anchorage
Base slab
Column Elevation
Column plan
In column bar schedule, crank is important . The slope of the inclined portion of a
cranked bar should be 1 in 10. crank the upper bars to extend the lowest bars. Starter bar
should be bended inside base slab. This anchorage length is 50 *.
e.g. column bar diameter 32 mm
crank
crank length=10*32=320 mm
anchorage length= 50 *
=50*32
=1600 mm
(3) Beam
400
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In beam bar schedule, crank is important . The slope of the inclined portion of a
cranked bar should be 1 in 10. Anchorage length of beam depend on the beam height. E.g. if
beam height is 400 mm and cover 50 mm , anchorage length is 250 mm. This anchorage
length may be different. This anchorage length is no specific limitation.
In lightly loaded beams where compression reinforcement is not required. maximum

shear stirrups spacing is 0.75*d. where d is the effective depth of the member.
In more heavily loaded beams where compression reinforcement is required,
maximum shear stirrups spacing is twelve-time size of smallest compression bar. The stirrups
should be at least one quarter the size of the largest compression. Minimum clear spacing of
stirrups should be 75 mm, to enable a vibrator to be inserted.
*
*
*
*
In continuous beam lapping should be avoided in *point such as in top, lapping

should be avoided in support point and in bottom, lapping should be avoided in mid span.
Because, that points are in tension. Bars are important member in tension
Tension bar
Tension bar
Hogging moment
Sagging moment
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Bending moment diagram
Tension
Compression
Compression
Tension
Hogging moment
sagging moment
In continuous beam, hogging moment and sagging moment are due to loads. In top of
the beam, tension is in hogging moment point and compression is in sagging moment point.
In bottom of the beam, tension is in sagging moment point and compression is in hogging
moment point. Tension bars are used in tension points in top of the beam. such as Tension
bars are used in top of the beam in support point .Tension bars are not used in bottom of the
beam. When beam main bars spacing is greater than 250 mm, tension bar is used.
(4)Wall
Vertical bars
Horizontal bars
When vertical bars or horizontal bars lap, crank is not necessary. we

should not lap more than 50 % of the bars at the same cross section.U bars are used to
maintain correct cover and to place bars in correct position. U bars are same diameter.this may
be as the horizontal or vertical.
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Corner bar details in wall
T junction bars details in wall
Opening bars details
L - Shaped bars are used in T junction and corner of the wall to avoid bursting or
cracking. Reinforcement in inner face should extend to outer face.
Nominal diagonal reinforcement should be provided in both faces around all openings
in a wall. If the walls are opening as shown above, the above detail can transmit only about
25% of the walls flexural capacity. Then, it is better to use hair pins .which has a higher
moment carrying capacity.
COVER BLOCKS
Reinforcement work cover block is very important part. Cover block is used to maintain the
space between shuttering and bottom of the reinforcement. Using grade 25 concrete with
6mm chips cover blocks (spacer) will be made as the given sizes. They are made up cement
:sand : chips = 1:1:1.
All formwork of reinforcement were supported on cover blocks. So that the
reinforcement can be completely enclosed by concrete and thus protected against corrosion
cover blocks may also be needed at the sides of the reinforcement to maintain the correct
distance from the side shuttering.
Covering sizes were specified in the drawings. Covering sizes are depend on,
1. Weather condition
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2. Fire resistance
3. Grade of concrete
A part of binding wire was placed inside the cover block at construct level to tie with
reinforcement, otherwise it may move away from the exact location.
In our site 50 mm cover block was used in all places.
EXAMPLE:
T20-1-210
T20-2-210
450mm
T20-3-210
T20-4-210
Column footing
Length = 27450 mm
Width = 2750 mm
Height = 450 mm
Cover = 50 mm
2650 mm
Main bar
200
200
Main bar length=2750-(2*cover)=2750-(2*50)=2650 mm

No of main bars
(27450-2*cover)/210=(27450-2*50)/210= 130.24=131
Therefore no of main bars = 132 (131+1)
Distribution bar
5550
200
12000
11800
200
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11800
12000

5550
200
200
distribution bar length=27450-(2*cover)=27450-(2*50)=27350mm
No of distribution bars
(2750-2*cover)/210= (2750-2*50)/210= 12.62=13
Therefore no of distribution bars = 14 (13+1)
Bars are in top and bottom
2/132/ T20
2650
200
200
2/14/ T20
12000
2/14/ T20
5550
200
2/14/ T20
11800
200
Structure Bartype Barno spacing No
column
Cutting
Total
Total
of
length
length
weight
T20
210
bar
264
(mm)
3050
(m)
799.1
(kg)
1970.58
T20
210
28
12000
336.0
828.58
T20
210
28
5750
161.0
397.03
T20
210
28
12000
336.0
828.58
footing
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Formwork
Introduction
This is temporary structural system, which provides casing to enable wet concrete to
attain the shape required. Formwork provides
1. Strength
2. Smoothness
3. Stiffness
4. Good shape at the concrete face
There are many objectives to be considered in selection of formwork
Concrete finish
Cost
Reuse
Logistics
Productivity
The concrete formwork and its labours are one of the highest profit risk area for the
contractor.
Additional requirements for good formwork
1. Joint should be simple
2. Must be easy to strip after concreting
3. Timber should not be too dry/ too wet (moisture content 15- 20%) with the surface
coated with mould oil
4. formwork economy in the design of structures
Use the same size column
At the formwork erect, consider the materials and methods will be required to
make and the removal
The formwork shall withstand and worst combination of the following loads
Total weight of formwork , reinforcement and concrete
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Construction loads including dynamic effects of placing , compacting and
Construction traffic
Wind loads
Materials used for forms
Coated and uncoated plywood 4 *8 with 12 mm thick
GI pipe 48.6 mm diameter *2.4 mm thick
Timber bearer 100 mm*100 mm
coupler
Procedure
4 * 8, 12 mm thick plywood decking across 48.6 diameter * 2.4 mm thick pipes at
200 mm centers and spacing 1200 mm is placed across 100 mm * 100 mm timber bearers, is
supported by height adjustable vertical shores by Nppon Beatty. these shores are located in
rows at 1200 mm centers and 750 mm spacing , in each row . they are braced for lateral
stability in two directions at right angles, using 48.6 mm diameter GI pipes placed diagonally
and fixed together using GI pipe clamps. After erecting this arrangement, they are properly
leveled.
Details about shores
Type VS- 2
Closed height 2110 mm
Fully extended height 3480 mm
The safe working loads for axial loading are 20 KN in closed position and 15 KN in the fully
extended position
Total weight of the unit 13 16 kg
Material High-tension steel
Lowest tube diameter 60.5 mm
Upper tube diameter 48.6 mm
Top plate fork and flat
First, all the shores are adjusted roughly to required level, which is measured from off
lines. Then 100 mm* 100 mm bearers and 50 mm * 50 mm timber, 50 mm diameter GI pipe
are put after plywood is placed on that. Finally, they are properly leveled.
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Coupler
To brace the shores for lateral stability in two directions at right angles, using 48.6 mm
diameter GI pipes fixed together with GI pipe couplers. Swivel, rectangular couplers are used.
The key factors concreting the workman ship of false work
The false work is used in accordance with the design , in particular as regards quality
of components, and setting out
Tolerances ( 3 mm)
All connections are properly constructed
There is adequate safe access and working space
The base should be satisfactory
The vertical member of the structure should be located centrally on the sole plates on
base plates and fork head if size 100 mm
High tensile pin is commonly used but in some pins replaced by reinforce bars
Props should be erected as plump as possible ( 1.5 )
Over extension of the screw, supporting the fork head must be avoided ( 300 mm)
Provide edge protection to all open side and holes in the decking as well as properly
constructed access to the working area to be prevent accidents
When concreting
Free fall of concreting is not allowed
Heaping of concrete within small area is not allowed and avoided
Prevent the shock loading
On the slab, materials should only be stored in areas designed by the engineer
Forms for columns

The column boxes are made of coated plywood (12 mm) sheets. In which two
Sides are cut to width of the column and other two are cut to the width plus 124 mm . which is
for fixing 2*2 timber and twice the thickness of the plywood sheets. Already there sides are
fixed together and put it correctly along the setting out line, then closed other site properly.
They are tied using by separator, P-cones and supported by telescopic props and chains.
Finally it was plumped using 200-off lines of the columns edges.
Vertical GI pipe space
200-300 mm
Horizontal GI pipe space
600 mm
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Space between slap and first GI horizontal support 200 mm
Column formworks are subjected to greater lateral pressure. Because of, its small cross
section area compared with the height. So column boxes must have tight joint to withstand
that high pressure. And also blowhole is made at the bottom to clean the inside surface before
concreting.
Baffle wall with column
Formwork for this component also similarly erected up to 600 mm from upper surface
of base slab, so that the height of kicker for wall will be 600 mm throughout from the upper
surface of the slab
It is to be noted that the portion of the baffle wall directly connected with the main
periphery wall will not be constructed at this stage, which will be done along with the
construction of main periphery wall. Inner lengths of baffle walls, which are commencing
from expansion joints, are erected under the present stage.
Forms for walls

Wall thickness is maintained throughout the board by separators. This is easier then
column formwork arrangements. Wall is concreted part approximately 4 or 8 according to
their need (retaining wall 8 700 mm RC wall 4). For next lift of formworks sponge is placed
between earlier concreted surface and new formwork, which is to be concreted to give proper
bond prevent leakage of concrete.
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Form work for wall

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P- Cones
This is the old model Japanese system formwork arrangement and P-Cones types. 40
mm and 50 mm size P-Cones used according to load carrying capacity required. i.e. 50 mm is
used to bear where the high force occur.
Pee cone plan view
Rubble ring or welded

Metal plate
Form tie
Separator
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Form panel
50 mm pee cone
Pee cone details
Preparation of formwork
Before concrete is placed, the formwork should be cleaned of all dirt and construction
debris. All surfaces are coated with approved mineral mould oil.
12 mm plywood
50 mm*50 mm timber
Form tie
225 mm
48 mm Gi pipe
500 mm
Pipe support
(Adjustable)
500 mm
500 mm
100 mm*100 mm
Hard wood
500 mm
400 mm
Expansion joint
300 mm
100 mm*100 mm timber

Department of 2400
Civil mm
Engineering
C/C
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Wall formwork
For the key concreting vertical surfaces are prepared with the sharp cut of the original
ground. RRM was arranged places where ground condition is disturbed.
Formwork of the wall foundation was provided at the outer face of the foundation slab
that is inner face was covered by the previous concreted base surface. Along the wall line ,
wall kicker was arranged supporting the formwork with rebar .the kicker height is 150 mm
and at the wall center water bar was kept in positions by using water bar chips and wires so
that it was centered on concrete surface.
The formwork material is 12 mm marine coated plywood sheets for water structure
and supporting system is shown the sketch. To maintain the wall thickness separator were
used with 50 mm pee cone.
For our safe side, and to avoid water leaks through pee cones, rubber washer or
welded metal plate was used whenever fixing reservoir wall formworks. formwork for
reservoir walls was arranged as follows
1. 2.4 m 1st step
2. 2.4 m 2nd step
3. 3rd step with roof corbel
Removal of formworks
Formwork should not be removed until the concrete a sufficient strength to supports
its self weight and any other load transferred. Form should be eased out carefully in order to
prevent the load being transferred suddenly to the partly hardened concrete.
Walls and columns (unloaded)
12-18 hrs
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Tie beams (not load transfer)

24 hrs
Slap
21 days
CONCRETE
Concrete is a mixture of cement, fine aggregate, coarse aggregate and water. Two
essential properties of the hardened concrete are durability and strength. Both properties are
affected by the voids or capillaries in the concrete which are caused by incomplete
compaction or by excessive water in the mix.
According to the code BS 8110 the concretes are divided in to two classifications. The
first consists designed mixes, where strength is the main criterion specified, the design of
the mix is left to the supplier and compliance is judged on the basis of strength testing. The
second classification is that of prescribed mixes, where the cement content or mix
proportions are specified and it is the duty of the specifier to ensure that the mix specified will
give the required properties, including strength. With prescribed mixes, strength tests are not
used to judge compliance width the specification.
Transporting
Transporting of concrete will be done by 5m3 capacity concrete trucks from batching
plant number of concrete trucks will be increased by considering the volumes to be placed.
Concrete Placing
Placing of concrete will be done by using the concrete pump car and crane and bucket
considering the volume arid site conditions. Requited site test (slump test) will be arranged
for each trust to maintain the quality and cube will be casted for checking the strength of
concrete. Concreting will be started at one corner of the formwork and proceeded diagonally
without creating hardened edges.
Curing will be arranged for 7 days by using the gunny cloths and sprinkling of water.
Important things before concreting
Check the reinforce details , stools, services, cover, dimensions, etc
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Check the levels of formwork, reinforcement
Check the reinforcement at all intersection whether the bars, links should securely tie
together with 1.6 mm soft iron wire .whether end of the wires must not point towards
the face
Check the support of the form work and construction joint key
Check the surface (roughened joint surfaced which has to concreting) using
compressor
Wet the surface, formwork just before concreting
Check along construction joint whether properly chipped or not
Slump of the concrete
Concreting In Adverse Weather

No concreting will be allowed to take place in the open during storms or heavy rains.
In places where such conditions are likely to occur the contractor is to arrange for adequate
protection of the material, plant and formwork so that the work may be proceed under proper
cover. Where strong winds are likely to be experienced additional precautions to ensure
protection from driving rain and dust shall also be taken. During showery weather the
contractor shall ensure that work can be concluded at short notice by the provision of stop
ends. On no account shall work be terminated before each section between one stop end
another, is complete. Adequate covering shall be provided to protect newly placed concrete
from the rain.
Concrete at Night or in the Dark
Where approval has been given to carry out concreting operations at night or in places
where daylight is excluded, the contractor is to provide adequate lighting at all points where
mixing, transportation and placing of concrete is in progress.
Concreting in high Temperature
When the temperature of the concrete at the time of placing exceeds 32 0C, it may be
necessary for the contractor to take precautions, such as shading of aggregate stockpiles,
machinery, moulds and mixed concrete from the direct rays of the sun, cooling of the mix
constituents, machinery, reinforcement and moulds, and restricting the transportation time to a
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practical minimum. The necessity for such precautions will be determined by the Engineer in
relation to the other factors affecting the heat of hydration, such as the characteristics of the
mix constituents, the nature of the particular pour and the method of curing to be adopted.
HANDLING CONCRETE
When handling concrete the following are to be avoided:
Delay
Drying Out
Segregation
As soon as the cement and water are mixed and concrete begins to harden and it does so more
quickly with:
High concrete temperature (so keep the concrete cool in hot weather)
Low water-cement ratio.
Hot, dry, or windy weather conditions,

if it hardens too much it may rot be possible to properly place and compact it in the
forms, Throw the batch, out rather than try to doctor it. Never add water to hardened concrete.
There must be no delays in transporting, placing and compacting
Form B I 9(M) requires that t h e concrete be placed and compacted within the following
times from charging the mixer
Temperature32 C or less
Temperature greater than 32 C
Mixed on Site
45 mins
30mins.
Ready-mixed
I hour
45 mins.
No concrete with a temperature greater than 35 C should be placed in the job.
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However, the supervisor should appreciate that from time to time specifications are
altered. So on each new job he should check the Job Document to ensure himself that there
have been alteration of which he is unaware
Compacting
The object of compacting concrete is to ensure that maximum density is obtained,
and that no gaps are left between the concrete and the surfaces of the reinforcing steel and
formwork. A5% loss of compaction can result in a 30% loss of strength.
Proper compaction results
Maximum strength
Sound, watertight concrete
Sharp detail at concrete
Good surface appearance
Good bond with steel reinforcement
Sound protective cover for the steel reinforcement
The different method of compaction can be used such as
Hand compaction by rodding or tamping
Immersion vibrators (also known as internal or poker vibrators)
External form vibrators
Surface vibrators (vibrating screed boards)
Spinning (used only for concrete pipes and hollow circular piles)
Hand compaction
Rodding or tamping by hand can only be used for very small quantities of concrete
with a slump of 50-100mm. it may be used only for compacting minor works such as pipe
heads and not on bridges or culverts.
Immersion vibrators
This type of vibrator may be
mechanically driven by a petrol engine,

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Air-driven from a compressor and
Electrically driven by small electric motor.
These machines have the following advantage

They are one of the most effective methods of compaction.
The engines are small and lightweight thus enabling vibrators to be readily moved
about the job.
Relatively low purchase, running and maintenance cost.
Relatively easy to handle heads up to 70mm in diameter.
Wide range of heads to cover the wide variety of job conditions.
When vibrating the concrete certain procedures must be followed.
(a)Vibrate the concrete evenly
(b)Insert the vibrator vertically
(c) If more than one layer of concrete is being placed in the one operation, allow the vibrator
to penetrate right through the layer into the previous layer
(d)
Withdraw the vibrator immediately motor begins to collect on the surface. This can
take from 5-10 second.

(e)
Withdraw tile vibrator slowly (not faster than 100 rout per second) to allow the hole
left by the vibrator is close up.

(f)
Work systematically, inserting tile vibrator at points about 500 poor apart (this will
vary with different consistencies of concrete and different sizes of vibrating head).
(g)
Avoid using the vibrator to push tile concrete along the forms. the concrete should be
shovelled to its correct position if necessary.

(h)
Do not allow the vibrator to touch the forms as a sand streak may result or the form
may be damaged.
(i)
Normally the vibrator will be operating for about two thirds of the concrete is being
placed, though this time varies depending on the Characteristics of the mix and the
dimensions of the section being poured.
(j)
When placing concrete in floors or deck slabs, it may be necessary to tilt the vibrator
provided it is not used to push the concrete.

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Previous layer
Previous layer
Incorrect
Still plastic
Correct
Previous layer
Incorrect
Incorrect
Previous layer (Still plastic)

Correct
Incorrect
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Correct
Incorrect
Poker using method
CURING
Reasons for curing
Correct curing is very important in order to get the maximum strength, water tightness and
wear resistance. The two things needed to provide conditions favorable for continued
hydration are
Adequate moisture
A favorable temperature
Loss of water from the surface of the concrete can cause hydration to cease, thus
preventing strength development. It can also cause shrinkage, which results in surface
cracking.
Low temperatures also cause hydration to slow down, and it is necessary to keep the
temperature well above freezing.
Advantage of curing
Increase the impermeability of concrete
Increase the durability of concrete
Continuous curing from the time the concrete is placed helps to ensure a hard, dence
surface and the risk of crazing and dusting
Curing methods
Concrete can be kept moist by a number of curing methods. in our site gunny cloths
were used for water curing.
Length of Curing Period
Form B19 (M) states that slabs shall be kept moist for at least 14 days, and other
concrete surfaces for at least 7 days.
Preventing plastic shrinkage cracks
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This type of cracking comes times occurs soon after the concrete has placed. Plastic shrinkage
cracking is usually associated with hot-weather concreting. The following will increase
evaporation of surface moisture and therefore the possibility of plastic shrinkage cracking:
High concrete temperature
High air temperature
Low humidity
High winds
High strength, low slump concrete containing large amounts of cement.
To minimize the possibility of shrinkage cracking the following simple precautions should be
taken:
Dampen the aggregates if they are very dry (but don't forget to allow for this
additional moisture
when adding tile water to the concrete).
Avoid delays in transporting, placing and compacting the concrete.
Erect wind breaks.
Cover the concrete with wet covers or curing compound as soon as possible.
If cracking does occur before initial set, it should be rectified by hand working
followed by proper Curing.
FIXING WATER BARS

The sketchers of the fixing method of all type of water bars (Rear- guard type and
center bulb type) we enclosed.
BUT JOINT OR WELDING METHOD
Fixing clips or welding method to be arranged
Tools required - welding blade and anchoring clips.
INSTALLATION
Placing of water bars
Placing will be executed in accordance with the drawing on which the water bar profile and
the position required is marked level differences, bends, junctions, etc should be carefully
considered before placing.
Centrally placed water bars
(a). Fixing to reinforcement

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Fixing clips are attached to the ends of the water bar. The fixing clips simplify the fixing of
water bars to the reinforcing steel by means of tying wires and thus ensure the water bars are
not displaced during concreting.
(b). Fixing to formwork
Formwork may be used. In this method allow one half of the water bar out and other half will
be casted. Water bars clamped between formwork.
PLACING THE CONCRETE
The water bar performs its function only if both sides are well embedded in the
concrete. The accumulation of coarse aggregates (honey combs) should be avoided around the
water bar to be fixed firmly.
Placing of fresh concrete near the water bar requires core, as otherwise it will be
forced from its position by the pressure of the fresh concrete that is ends will fold up. To
present this the same concrete pressure must be present on both sides of the water bar.
CONCRETING THE SECOND STAGE
The water bar end will be checked for honeycombing and repaired if necessary. Bounding
agent will be wed for the concrete surface.
WELDING
Water bars are made form thermoplastic PVC and therefore allow an easy on site
welding. The ends are heated with welding blade mail the PVC melts (without burning or
charring). The welding blade is removed and molten ends are immediately pressed together.
The welded joint will be inspected after it has cooled.
VIBRATING OF CONCRETE EAR THE WATER BAR
Care will be taken to ensue that concrete is well placed and compacted around the
water bar area.
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Wall Kickers
Proposed Details of the Kicker
(1)Height of the Kicker
According to section 5.7 of BS 8007: 1987, the height of the kicker should be at least 75
mm.
R.D. Anchor suggests on pages 17 & 82 of his well known book entitled, Design of Liquid
retaining Concrete Structures , that the height of wall kicker should be between 100 to 150
mm.
In view of providing firm grip to wall formwork, we propose, the height of wall kicker should
be 100 mm.
(2)Shape of Kicker
R.D. Anchor states in his aforementioned textbook, if rebates are provided at construction
joints, cracks are formed invariably.
According to him, the most appropriate kicker is only a rectangular up stand without any
fillet and the free surface of the concrete must be finished to a compacted level surface.
We also prefer to introduce a rectangular up stand without any fillet as the wall kicker.
(3)Width of Kicker
Since the outer face of the external wall is inclined inwards, the width of the kicker at the upper
surface is slightly less than that at the lower end. The inner angle of inclination of the outer face
of the wall is 86.70 and the width at the upper surface of the kicker is 5.8 mm less than that at
the bottom therefore the width of the kicker at the bottom is 750 mm [wall thickness]. But the
width at the upper end of the kicker is 385 mm.
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Removing of pee cone
Pee cone was removed after someday concreted.
Then that area was cleaned properly.
Motor was applied into the area (cement : sand = 1: 1)
White cement mixed with water and applied above the motor (this is applied for
colour)
Top of the roof

200 mm pebble layer
50 mm benching concrete
4 mm water proofing membrane
Roof slab
Water proofing membranes are used to prevent water movement towards the inside of
the structure. There are different kinds of the water proofing membrane
(e.g.
Xypex).
Roof slab concrete was grade 35 and benching concrete was grade 20. benching
concrete is used to protect the water proofing membrane from its failure by external
activities.
Pebble layer is used to prevent heat installation (dolomite).
Leakage checking
After finished reservoir construction, reservoir was filled by water.
Checked water level for 7 days on morning and evening
Found out leakage in some place
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First, that area was chipped after that water plug (one type of cement) mixed with
water .then applied in that area.
Test for concrete
Slump test
Cube test
Slump test
The workability of concrete is the ease with which it may be placed and
compacted. The slump test is used to indicate the likely workability of a concrete mix.
Concrete is tested to control workability (consistency). The consistency of the concrete is
checked by means of slump cone. The slump test measures the consistency of concrete. It is a
simple means of ensuring that the concrete on site is uniform.
Once the slump of a particular concrete mix has been determined, the slump test
indicates whether or not the materials in different batches are still being mixed in their correct
proportions. If the slump alters from batch to batch, it is most probable that the water content
is varying from batch to batch. However, variation in slump can also be caused by alterations
in aggregate grading or cement content.
Standard slump cone
The apparatus are used in testing such as
(100 mm*200 mm*300 mm)

100m
m
300 mm
200mm
The mould shall be of a metal other than brass and aluminum of at least 1.6 mm.
(or 16BG) thicknesses. The top and bottom shall be open and at right angle to the axis of the
cons. The mould shall have a smooth internal surface. It shall be provided with suitable foot
piece and handles to facilitate lifting it from the moulded concrete test specimen in a vertical
direction as required by the test. A mould provided with a suitable guide attachment may be
used.
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Pointed steel rod: (The tamping rod shall be of steel or other suitable material, 16 mm
in diameter 600 mm long and rounded at one end
A rule or meter tape
Scoop
Smooth flat plate: The base plate shall be of steel or other suitable material, smooth
rigid and with non-absorbent surface.
The test must be carried out on a level non-absorbent surface. The inside surface of
the cone must be clean and free from hardened.
Procedure of this test

In first of all the inside of the slump cone was moistened.
The cone was hold in place on the prepared level surface by placing a foot on each
foot rest.
The cone was filled for three layer, each about one-third of volume, by scooping
concrete from sample.
Each layer was rod exactly 25 times by steel rod. Make sure that the rod penetrates
to the layer beneath each time, and that the strokes must be distributed over the
surface.
Top surface was stroked off by the rod so that the cone was exactly filled
Any surplus concrete was removed from around the base.
The cone was lift carefully but firmly straight up so the concrete was allowed to
subside. Then the cone was placed invert alongside the concrete and the rod was
placed across the top of it.
A rule (meter tape) was used to measure the amount of concrete has subsided.
Slump
Note: if the concrete collapses sideways when the cone is lift, repeat the test.
Allowable slump range is different to every grade of concrete.
Grade of concrete
allowable slump range

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Grade 15

100+/-10
Grade 20
120+/-10
Grade 25
120+/-10
Grade 30
120+/-25
Grade 35
120+/-25
Grade 35A
120+/-25
Grade 50
120+/-25
Cube Test
a) Size of Test cubes
The standard size of cube shall be 150 mm*150 mm *150 mm, but may be 100 mm*100
mm* 100 mm. cubes may be used, if the minimal maximum aggregate size does not
exceed 25 mm
b) Compacting test cubes
The test specimen shall be made as soon as practicable after sampling, in such a way as to
produce full compaction of the concrete with neither segregation nor excessive laitance.
The mould shall be filled in layers approximately 50 mm depth and each layer shall be
compacted. After the top layer has been compacted the surface of the concrete shall be
finished level with the top of the mould by means of a trowel.
When compacting by hand, the standard compacting bar shall be used and the storks of
the bar shall be distributed in a uniform manner, over the cross sections of the mould.
The number of strokes per layer, required to produce the specified condition will vary
according to the type of concrete, but in no case shall the concrete be subjected to less than 35
storks per layer for 150 mm.
c) Curing Test cubes
Specimens made on site.
Immediately after they are made, the test specimens shall be stored in a place free from
vibration, under damp matting or other suitable damp material, completely covered with
polythene or other impervious sheeting, at temperature of 20 +- 5 C, for 16 to 24 hours, form
the time of adding water.
If the concrete has not achieved sufficient strength, to enable remoulding to be carried out
within the stated period, the remoulding shall be delayed for a further 24 hours, but this fact
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shall be stated in the text report. During this further period, the specimens shall be stored in
the moist air conditions stated
After moist curing, the specimens shall be marked for later identification, removed form
the moulds and unless required for test within 24 hours, immediately submerged in a water
tank until they are transported to the testing laboratory.
One or more tanks can be used, containing clean water, renewed at least once a month and
maintained at a temperature of 20 +- 2 C on site.While the specimens remain on site, records
of the daily maximum and minimum air and water storage temperatures shall be kept with
maximum and minimum thermometers or with continuous recording instruments.
The specimens, well packed in damp sand or wet sacks and enclosed when necessary
in a polythene bag or sealed container, shall be sent to the testing laboratory, when they are
not less than 3 days, nor more than 7 days old, to arrive there in a damp condition not less
than 24 hours, before the time of test.
On arrival at the testing laboratory, the specimens shall be stored in water, maintained
at a temperature of 20 +- 1 C, until the time of test. The specimens shall not be allowed to
become dry at any time, until they are tested.
Specimens to be tested at 24 hours, shall be stored for this period in the moist air
conditions stated and remoulded just before test
d)General
The characteristic strength of concrete, on which the structural design is based is that, 28
day cube strength below which, not more than 5% of the test results may be expected to fall
In order to get an idea of the quality of the concrete sooner, compressive strength test at 7
days may be used, to test compliance with the specified characteristic strength.
For this purpose, the 7 days strength may be taken to be 2/3 of the 28 day cube strength.
The rate of sampling shall generally be as given below, unless other-wise decided by
the officer In charge.
One sample shall be taken from any one batch, selected randomly to represent an average
volume of not more than 20 cubic meters, 20 batches or of the total quantity of concrete
under consideration for testing, whichever is the lesser volume, but not at a rate less than 1
sample per day per grade.
d) Testing Plan
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Each cube shall be made from a single sample taken from a randomly selected batch of
concrete. The samples shall be taken at the point of discharge from the mixer or in the
case of ready mixed concrete, at a point of discharge from the delivery vehicle.
Number of cubes needed
In site number of cubes is varied according to the main contractor or client
requirement.
0-10 m3 3 cubes in which, 1 cube for 7 day testing and 1 cube for 28 day
10-25 m3 6 cubes in which, 2 cubes for 7 day testing and 2 cubes for 28 day
over 25 m3 9 cubes in which, 3 cube for 7 day testing and3 cube for 28 day
Information about machinery / equipment

Overview
The size of project.
The topography.
Volume of earth to be removed any other detailed influence the choice of type.
In general, the earth moving machines are used for ground leveling and bulk earth
moving whilst the static-type machines are usually operated on specific tasks. In both
civil engineering and building work the initial construction site is often uneven and
requires leveling. The most suitable plants is generally selected moving machines.
Factors affecting equipment selection
Selecting the correct equipment for the job ideally forms part of the construction planning
process. Equipments were choused for this task after analysis of many interrelated factors.
I. The function to be carried out.
II. The capacity of the machine.
III. The cost of method and cost comparison with other method
IV. The limitation of the method.
V. The method of operation :- the distance and direction of travel, speed, and frequency
of movement, sequence of movement, state of ground, etc,
VI. Etc
Used some equipments in site
1. Backhoe (Excavator)
2. JCB
3. Bulldozer
4. Concrete trucks
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5. Pump car
6. Breaker
7. Bar bending, cutting machines
8. Compressors
9. Lorries and trucks (wagon)
Backhoe (Excavator)
Hydraulically operated backhoe is used to have the shape of the excavation curve varied
to suit the situation and allows the limit of the excavation to approach much nearer to the
tracks of the machine due to both arm the bucket are indecently controlled by means of
separated hydraulic rams and also additionally the variable force available with hydraulic
powering gives the machine a much increased capacity.
Used situations
Excavation of large earth materials
Shoring removal, installations
Loading of material into wagon
To place the concrete when absence of crane, pump car but to small area
To lift goods, etc as a small crane
Etc
Wheeled backhoe / Loader (JCB)

Much of the work is done using this machine.
Height (up to -2.9 cm, clear height -3.7m) For trench excavation we used two size buckets
(inter changeable)
Used situation
Excavation of train trenches
Loading of loose material in to wagon
To lift goods as a small crane
As a bulldozer (stripping the top soil, mud, shallow excavation, etc)
Transport the material within short distance
Stock pilling of materials
Etc
Bulldozer
This is very versatile machine and was used frequently. The dozer is normally
operated with a straight blade fixed perpendicular to the line of movement to push the
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material forward or angled to move the soil to the side. Crawler type dozer was used in our
site due to
Give low pressure to the base
Not stability problem then wheel type(uneven surface)
Etc
Used situation
Stripping top soil and clearing vegetation
Shallow excavation
Spreading and grading of soil
Ripping
Concrete trucks
In which fully mixed concrete is loaded into the truck mixer at the batching plant.
During transportation to the site the drum revolving at1-2 revolutions per minute agitates the
mix. On arrival the mix is finally mixed by increasing the drums revolutions to between 10 to
15 revolutions per minute for a few minutes before being discharged. 3-5 m 3 trucks are used.
Mixture drum is inclined 16o.
Lorries and trucks (wagon)
Earth moving trucks are used to transport material not only longer distance but also
within the site. They are usually loaded by an excavator, but sometimes, in exceptional cases
by the JCB also. Actually the choice of system in transporting material form the loading point
depends on many factors including.
a) Site conditions
b) Volume of material to be moved
c) Type of material
d) Time available
e) Road condition
f) Distance
g) Etc
Pump car
The transport and placing of concrete by pump car is an increasingly popular method
because
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a) It is very fast
b) Efficient
c) Little waste of concrete
d) Can prevent the segregation
Etc
Considering points
The speed of the pumping(10-90m3/h)
Should be pump able concrete where slump and sand grading is important
Supply of concrete to the pump should be adequate for the pumps capacity
Maintaining continuously flow of concrete
Breaker
The most common pneumatic tools used in building are the breaker. Which is used
basically for breaking up hard surfaces. This tool needs a supply of compressed air as their
power source.
Steel bending, cutting machine
which is used to bend , cut the reinforce bars. This is one of management planning.
steel yard is in another place and near the site . if the yard is out of the site then we should
have transport facility, time wasting, etc.
Gapugala Batching plant

Gapugala batching plant was temporarily built to supply concrete to that project and
follow Japan standard. This plant supply the concrete to Gapugala reservoir, kowlhena
reservoir, Hallolugoda reservoir, Magoda reservoir , intake and NOH .
Plant cement container
58 metric tones
Water tank
150 letters
Cement
Procedure
First sand is conveying belt to the scale which is controlled automatically by lever
principal.then metal is passing to that it scale after sand conveyer stopped. Automatically
calculatethe total weight (sand +metal) and stop when the required weight passed. Both sand
and metal mix together and pass it to the pan/drum mixture. At the same time cement and
water also come to this pan and stop when the required weight collected . at once 1 m can
able to mix . I.e. for 5m3 concrete preparation, five times is necessary.
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Mixing speed
-20 rpm
-min
For prepare 1 m3, time required
Fully prepared mix is then transported to site using concrete trucks. In plant , one
cube is casted per 30m3 concrete to checking strength and also checked the slump from every
truck concrete mixture . G15, G20 ,G25 ,G30,G35,G50 concrete is prepared to supply . if any
cube fails from its required strength then core test should be done
Grade of concrete
The standard recommended compositions are as follows and Concrete grade was
decided according to the requirement of the structure. The basis and the method of
proportioning of concrete are depending on the grade of concrete and the structural
importance of the members. In this concretes Pozzolith300R, AEA303A and Rheobuild 561
are used as admixtures. Pozzolith300R is to change porosity, AEA303A is to change air voids
and Rheobuild 561 is to change rigidity.
SAFETY PROCEDURE
Which is the important consideration point in construction sites where dangerous
accidents take place ,such as handling of huge machines, electrical works, working at higher
elevation, etc.before happen accident , we should be aware of it . some of those are given
below.
Wear helmet, safety foots, etc always at the site
Wear safety belts when working at higher elevation
Not allow to work underneath when working is going on at higher elevation directly
Provide ladders for the access of the higher elevation
Keep first aid person at the site always
Put safety barriers/ barricades to indicate unsafe areas
Put SAFETY FIRST board
Put safety nets/ fans around the scaffolding
Monitories the electrical supply wires, switches safety
Never use the florescent bulb without safety glass
Etc
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-1.0 INTRODUCTION
I have been appointed to do the training in Tudawe Brothers Limited and I have been
working first 13 weeks at the site Little Sisters of the Poor at Maradana. The site is located
next to St.Josephs College. Then after 9 weeks, I have been working at the site Godagama to
Malamba road project which site office is in Aturugiriya. Head office of the organization is
located at 505/2, Elvitigala Mawatha, Colombo 05.
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1.1 ABOUT THE ORGANIZATION

Tudawe Brothers Ltd. (TBL) is one of Sri Lanka's premier construction engineering
companies, established in 1942 and incorporated in 1947.
Its areas of construction are high rise office complexes, shopping malls, luxury
apartments, industrial estates, educational & healthcare institutes, highways & bridges and
water supply systems. Tudawe Brothers Ltd remains in the field of housing construction
where it has built over 1500 personal housing units, of which approximately 200 comprise
modern up-market apartments.
Given its commitment to excellence, two associates were established to
complementing the work done by Tudawe Brothers Ltd. Tudawe Trading Company Ltd
provides support services related to electrical , air conditioning and fire protection and
Universal Interiors (Pvt) Ltd supplies and installs architectural aluminium systems for
buildings.
Tudawe Brothers Ltd has won construction excellence awards in 1991, 1994 & 2001
and Merit Award by the Institute for Construction Training and Development (ICTAD)
in1996. Also Tudawe Brothers Ltd is the first local company to be awarded ISO 9002
certification for Building Construction & the Manufacture of Ready Mixed Concrete, by an
internationally accredited registrar Det Norske Veritas.
ICTAD grading of the company :
M1 - Building constructionM1 - Highway construction
M1 - Water supply and drainage
M3 - Bridge construction
M5 - Irrigation and land drainage
M5 - Dredging and reclamation
F1 - Finishing trades
EM1 - Electrical and mechanical works under Tudawe Trading Company Ltd.
1.2 ON GOING PROJECTS

1. Malambe to Godagama road project ( Project Cost is Rs. 370 Million )
2. Ambathale to Kaduwale road project (Project cost is Rs. 110 Million )
3. Little Sisters of the Poor (Project Cost is Rs. 409 Million )
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4. Ascon Appartments ( Project Cost is Rs. 247 Million )
2.0 ABOUT THE LSP (BUILDING SITE) ORGANIZATION
2.1 ABOUT THE SITE DETAILS

Site Location
No:204, T.B.Jayah mawatha, Colombo-10
Client
Little Sisters of the poor
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Architect
Arch. H.M.R.B.Herath
Consultants
LSP Design Group & Multi consultancy

services
Contractor
Tudawe Brothers Ltd.
Project Cost
Rs. 409 Million.
Period
15 months.
Table : 2.1 About the building site details
2.2 THE ORGANIZATION CHART
Project Director
Project Co-Ordinator
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Project Engineer
Site
Technical
Supervisor
Engineer
Officer
Planning Engineer
Site Project
Manager
Site Quantity
Quantity
Surveyor
Surveyor
Assistant
SiteSurveyor
Surveyor
Surveyor AssistantStore
StoreKeeper
Keeper
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Figure :2.1
Structure of the organization for the building site
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2.3 JOB FUNCTIONS

Project co-coordinator
1. Reports to project manager
2. Overall planning, co-ordination of site activities, site management and budgeting.
3. Leads a team of engineers, site quantity surveyor, surveyors and quality assurance
co-ordinator.
4. Liaises with client, consultants and local authorities.
5. Attends all client or consultant meetings.
6. Co-ordinates nominated subcontractor activities.
Site manager
1. Reports to project coordinator.
2. Plans and co-ordinates site activities and with the site staff.
3. Monitors work programme and quality control.
4. Liaises with client, consultants and local authorities
5. Attends all client or consultant meetings.
6. Liaises with sub-contractors.
7. Implementation of safety measures.
8. Liaises with nominated sub-contractors.
9. Liaises with manager planning ad development and prepares micro programmes.
10. Preparation of three monthly programme and monitors programme.
Site planning engineer and engineer in-charge

1. Reports to site manager.
2. Checks discrepancies between structural and architectural drawings.
3. Counter checks alignment and levels by surveyor.
4. Checks structural drawings for discrepancies.
5. Liaises with consultant engineer on technical matters.
6. Monitors work progress and quality control.
7. Preparation of shop drawings for temporary works.
8. Preparation of bar bending schedules.
9. Documented and drawing control.
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Site quantity surveyor

1. Reports to site manager.
2. Evaluates and prepares progress payments to sub-contractors.
3. Assist in preparation of the monthly valuation and estimates of variation orders.
4. Prepares material forecasts and weekly requisitions.
5. Verifies material requisitions.
6. Prepares daily reports.
Technical officer
1. Sets out alignment and levels.
2. Checks discrepancies between structural drawings and issues RFI.
3. Counter checks alignment or levels by surveyor.
4. Monitors work progress and quality control by using inspection and test plans.
5. Records daily works and submits to R.E for certification at the end of the day.
6. Act as a member of the site safety committee.
7. Submits of materials for approval from consultants.
8. Maintains concrete cube testing reports.
Supervisor
1. Reports to site engineer or technical officer.
2. Sets out alignment and levels.
3. Labourer supervision and ensuring the quality of works.
4. Counter checks alignments or levels by surveyor.
5. Monitor work progress and quality assurance by using inspection and test plans.
6. Records daily works.
7. Act as a member of the site safety committee.
Site surveyor
1. Counter check setting out or level done surveyors.
2. Monitor progress and quality control by inspection and test plan.
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Store keeper
1. Maintaining stock controls (consumables and nonconsumables).
2. Controls or checks quantity and quality of materials delivered.
3. Ensures adequate inventories and stocks are available to meet the sites planned
activities.
4. Prepares daily and monthly records for materials received at site.
5. Inventory control of plant, machinery and equipment, their usage at site and
maintaining records of repairs and services.
6. Inventory control of nonconsumables.
7. Prepares Good Received Note (GRN).
8. Prepares goods issued note.
9. Prepares transfer notes for materials transferred out from the site.
10. Prepares material reconciliation report.
11. Liaises with purchasing department.
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3.0 FORM WORK

One of the easiest and most obvious ways of judging whether a concrete job is
satisfactory or not is by its finished appearance.
The formwork and the way it is made and used play a greater part in the finished
appearance than anything else. It is made from expensive materials by skilled men and the
total cost of fabricating, erecting and striking formwork is often comparable with the concrete.
Apart from the appearance considerations, formwork usually needs to be used many
times and this can only be done if it is carefully and properly handled, cleaned and stored- be
it of timber, steel or other material-as otherwise time and money will be wasted and the job
will not progress smoothly.
3.1 REQUIREMENTS FOR FORMWORK

o It must be built and erected so that the required shape, size position and finish of
the concrete are obtained.
o It must be strong enough to take the pressure or weight of the fresh concrete, and
any other loads, without distortion, leakage, failure or danger to workmen.
o It should be designed and constructed so that it can be easily and quickly erected
and struck, so saving both money and time.
o It must be able to strike without damage to the concrete or to itself.
o It must be able to handle using available equipment or to be manhandled if
necessary.
o The arrangement of the formwork must provide access for the concrete handling
and placing and, equally important, all the necessary safety precautions relating to
working areas and platforms must be followed.
o Joints between members must be tight enough to prevent grout leakage.
3.2 TIME OF REMOVAL

Form work of beams and slabs should not be removed until the concrete reaches a
sufficient strength to support its self weight and any other loads transferred.
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Forms shall be eased out carefully in order to prevent the load being transferred suddenly to
the partly hardened concrete.
The most common fault with release agents is for too much to be put on: this can stain
the concrete. On the other hand, if not enough is applied, striking is made difficult and both
the concrete and form face can be damaged.
The right amount is thin film applied uniformly by brush, roller or best of all spray. if
by mistake too mush is applied wipe off the excess with a clean rag. Never dilute or mix
different release agents together.
3.2.1 THE MINIMUM PERIOD TO REMOVING FORMWORK

Formwork can be struck when the concrete has gained enough strength to be self
supporting and also to carry any other loads that may be put on it.
The job specification will normally give guidance on when forms can be struck and
these times may be governed by the size and shape of the member, the concrete mix, and the
weather (Table: 3.1).
Part of structure
Period
for
ordinary
Portland
cement without admixtures

Sides of foundations, columns, beams and walls
Undersides of slabs up to 4.5 m span
24 hrs
7 days
Undersides of slabs of above 4.5 m span and
14 days
undersides of beams and arches up to 6 m span.

Cantilever slabs and beams
21 days
Domes , shells and other structures of special nature
As per written instructions of

engineer in charge.
Table : 3.1 Minimum period for removing form work
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3.3 FORM WORK FOR BEAMS AND SLAB

Form work for beams and slab are generally erected at once. Horizontality of the
beams and slab form work is an important parameter therefore we need to make more
attention on the process of levelling the formwork .In our site we have used a level machine
for levelling the form work of beams and slab (Figure: 3.1).
Floor level
Z
beam
Y
15
staff
4200
Level Machine
Figure : 3.1
Floor level
Levelling the beam and slab form work
X = known height (marked on the column normally 1000 mm level line)

Y = beam height
Z = slab thickness
Therefore while levelling the beam the staff reading should be = 4200 - ( X + Y + 15 )
Therefore while levelling the slab he staff reading should be = 4200 - ( X + Z + 15 )
plywood thickness is 15 mm.
Generally supports (false work) of the formwork raised or lowered to get the required
reading and by this process the form work for the slab and the beams can be easily levelled.
The figure : 3.1 shows the detail description of the form work for the beam and slab.
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4.0 REINFORCEMENT
Reinforcement is used to carry tensile stress as well as compressive stress.
Reinforcement bars carry tensile stress only, where as compressive stress will be carried by
both reinforcement bars and concrete, which is depending on the situation of carrying.
Normally steel bar is used as reinforcement because it has enough strength and both steel and
concrete has nearly the same thermal coefficient. In early days wooden bar was also used for
this purpose.
The reinforcement detail are mentioned in the reinforcement drawing. After that the
following checks have to be done.
1. Spacing
2. No of strips
3. Lap length
4. Starter bars for columns
5. Cover blocks
If there are any construction joints, they should be chipped to bond properly.
4.1 INDICATION OF REINFORCEMENT IN DRAWING

Engineering drawing is a language to communicate with details. Therefore there is a
standard to indicate the reinforcement details in drawings such as,
4Y 16-07-125T
This means that
- No of bars
- Indicate for Tor steel
16
- Indicate the diameter of the bar in mm
07
- Indicate the bar mark
125
- Indicate the distance between two bars
- Indicate the position of the bar (top bar)

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4.2 COVER BLOCKS
Reinforcement work cover block is very important part. Cover block is used to maintain the
space between shuttering and bottom of the reinforcement. They are made up to 1:2 cement
mortar.
All formwork of reinforcement were supported on cover blocks. So that the reinforcement can
be completely enclosed by concrete and thus protected against corrosion cover blocks may
also be needed at the sides of the reinforcement to maintain the correct distance from the side
shuttering.
Covering sizes were specified in the drawings. Covering sizes are depend on,
1. Weather condition.
2. Fire resistance
3. Grade of concrete.
A part of binding wire was placed inside the cover block at construct level to tie with
reinforcement otherwise it may move away from the exact location.
In our site 30mm cover block was used in all places.
4.3 BAR BENDING WORK

In our site usually bar bending is done by bending machine and cutting machine. But for
minor works it can be done manually with the help of cutting lever. Skilled bar benders are
involved in this process. The bar bender did his job according to bar schedule which was
given to him. It includes,
Size of bar
No of bars
Dimensions
Bending length
Crank length position
4.4 PLACING OF REINFORCEMENT

All reinforcement should be placed in correct position as shown in drawing. It should
not be allowed to move when concreting.
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5.0 CONCRETE
Concrete is a mixture of cement, fine aggregate, coarse aggregate and water. Two
essential properties of the hardened concrete are durability and strength. Both properties are
affected by the voids or capillaries in the concrete which are caused by incomplete
compaction or by excessive water in the mix.
According to the code BS 8110 the concretes are divided in to two classifications. The
first consists designed mixes, where strength is the main criterion specified, the design of
the mix is left to the supplier and compliance is judged on the basis of strength testing. The
second classification is that of prescribed mixes, where the cement content or mix
proportions are specified and it is the duty of the specifier to ensure that the mix specified will
give the required properties, including strength. With prescribed mixes, strength tests are not
used to judge compliance width the specification.
5.1 GRADE OF CONCRETE

The standard recommended compositions are as follows and Concrete grade was decided
according to the requirement of the structure. The basis and the method of proportioning of
concrete are depending on the grade of concrete and the structural importance of the
members.
1)
Grade 10 mix
Grade 10 mix is obtained by the following proportion
Cement: Fine aggregate: Coarse
aggregate=1:4:8
Water added (roughly)=32 liters Expected strength= 10 N/mm2
2)
Grade 15 mix
Grade 15 mix is obtained by the following proportion,
aggregate=1:3:6
Water added (roughly)=32 liters
Expected strength=15 N/mm2
Mainly used for screed but not used for reinforcement concrete.
3)
Grade 20 mix
The following proportion obtains grade 20 mix
Cement: Fine aggregate: Coarse aggregate=1:2:4

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Water added (roughly)= 25 liters
Expected strength= 20 N/mm2

Mainly used for screed
4)
Grade 25 mix
The following proportion obtains grade 25 mix,
aggregate: 1:1.5:3
Water added (roughly)=23 liters
5)
Mainly used for walls
Grade 30 mix
The following proportion obtains grade 30 mix

Cement: Fine aggregate: Coarse aggregate=1:1:2
Water added (roughly)=20liters
Mainly used for columns, slabs, and basement of foundation
The above-mentioned proportions of concrete aggregates are based on volume measures. One
bag of cement is 50kg, which is equivalent to 0.035. This cement volume was taken as one
unit volume and other aggregates were then mixed on basis of volume according to the grade
of concrete. To do this task unit volume and other aggregates were then mixed on the basis of
according to the grade of concrete .To do this task unit volume boxes were made which
internal dimensions were 400mm*300mm*250mm. (I .e The volume of unit volume box was
0.035m3). For example for grade 15 concrete mix, 3 boxes of fine aggregates and 6 boxes of
coarse aggregates was added to 1 bag of cement.
Here it should be noted that the relative proportion of fine aggregate to coarse
aggregate is generally kept at a constant ratio 1:2
5.2 CHECKS BEFORE CONCRETING

o Thorough inspection should be made for the formwork by the supervisor before
concreting. The inspection should include,
o Are the loads and wedges secure against loosening due to vibration?
o Has the right number of ties been used and are they in the right places?
o Are all the ties properly tightened?
o Are all inserts, void formers cast-in fixings in the right position and secure?
o Have the stop-ends been properly secured?
o Have all the joints been sealed to stop grout loss?
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o Is the formwork is correctly aligned and levelled?
o Are all the props plumb? And at the right spacing?

o Are the pops and struts properly tightened up and locked?
o Can the formwork be struck without damaging the concrete?
o Has the release agent been applied? is it the right one?
o Is the reinforcement correct?
o Has the reinforcement the right cover? are there enough spacers?
o Are the forms clean and free form rubbish or odd bits of timber or metal? Tie-wire
droppings will cause a stain on the face of the concrete.
o Is there are proper access for concreting and compaction?
o Can any necessary inserts or box outs be done when concreting?
o Is the curing equipment and are covers ready?
The above checks combined with general check on the security and tightness of the forms
can save accident and injury or even loss of life.
5.3 TEST FOR CONCRTE

Normally two types of test were done for concrete in our construction site. They are,
1. Slump test.
2. Cube test.
5.3.1 SLUMP TEST
The slump test is the simplest test for testing workability at the site. The height of the slump is
depending on the amount of water in the mix. The nature of the aggregate also influence to
the slump.
The main apparatus are used in testing,
1. Slump cone.
2. Smooth flat plate.
3. Tamping rod 600 mm long and 16 mm diameter
At first the cone and late were cleaned and the cone was placed on a metal surface. Then the
concrete was put as a three layers and each lager was compacted 25 times with the rod. After
filling three times, the cone was removed immediately and kept that side of the concrete cone
and the rod was kept on the cone. Finally the slump was measured between the top of the cone
and highest point of the concrete. After the finishing the test all the apparatus were cleaned
with water and dried.
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5.3.2 CUBE TEST

This test was carried out to determine the compressive strength of the harden
concrete. Casting the test cubes was made in special mould, which is 150 mm x 150 mm x
150 mm., either site mix or ready-mix, it is very essential to confirm the strength of concrete.
Because the strength of concrete is not only depending on the proportions of cement and
aggregates but also depending on the quality of materials, amount of water added, size of
aggregates etc. The very common and easiest method to test the concrete at site is the concrete
cube test. The concrete cube test was done to the grade 25 concrete (1:1.5:3) the method is as
follows,
5.3.2.1 Preparation of moulds
The standard concrete moulds were checked whether they were clean and dimensionally
correct.
The moulds were detached and their internal surfaces
Then they were again assembled and grease was applied to the internal surfaces.
5.3.2.2 Preparation of cubes
Concrete samples were randomly collected
The first concrete layer was placed into mould (approximately 1/3 height of the
mould)
35 blows were given to that layer
Then the second layer of concrete was placed to the into the mould (approximately 2/3
height of the mould)
Finally the third layer of concrete was placed to the rest of mould and 25 blows were
given to that layer.
Then the top of the concrete surface was smoothened and the location of site were
written on the cube
Similarly 8 cubes were prepared
All the cubes prepared were kept at carefully
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5.3.2.3 Testing of cubes
Next day moulds were removed and all the cubes were fully submerged in water.
After 7 days, cubes were taken from water and 4 cubes were tested for strength After
28 days, the rest of 4 cubes were tested for their strength to find the compressive
strength of
the test cubes, gradually increasing.
Compressive force is applied to each test cubes separately by hydraulic mechanism. The
crushing strength is taken as the compressive strength, which can be directly red from the dial
gauge. Finally the average strength is taken as the compressive strength of the test cubes.
5.4 CONCRETING
Some experienced in the construction of formwork, preferably a tradesman, should
always be standing by when the concrete is being placed. He should have a supply of suitable
materials such as props, bolts etc. to handle dangerous situations. Check cracking, excessive
deflection, level and plump and any movement. Concrete should be deposited at, or as near as
possible to, its final position.
The concrete should be placed in uniform layers. Avoid placing it in large heaps or
sloping layers because there is always a danger of segregation, especially with mixes tending
to be uncohesive.
In walls and columns no layer should be more than about 450 mm thick. With layers
thicker than 450 mm, the weight of concrete on top makes it almost impossible-even with
vibration-to get the air out from the bottom of the layer. In thin slabs compacted by a vibrating
beam, restrict the layers to 150-200 mm. With greater thickness, vibrators have to be used.
Place the concrete as quickly as possible but not faster than the compacting method and
equipment can cope with.
Where a good finish is required on columns and walls, fill the forms at a rate greater
than two metres height per hour. Also avoid delays and interruptions because these will cause
colour variations on the surface.
Make sure that each layer of concrete has been fully compacted before placing the
next one, and that each new layer is placed while the underlying layer is still responsive to
vibration. This will make the layers "knits" together.
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In columns and walls, the placing must be done in such a way that the concrete does
not strike the face of the formwork; similarly, avoid heavy impact against reinforcement, as
the force could displace it.
5.4.1 PLACING OF CONCRETE
The main objective in placing is to deposit the concrete as close as possible to its final
position as quickly and efficiently as you can, so that segregation is avoided and it can be
fully compacted.
Concrete can be transported by a variety of different methods ranging from
wheelbarrows, dumpers and ready-mix trucks to skips and pumps, and though it is obviously
desirable to place the concrete directly into position this is not always possible: for example, it
will seldom be practical to discharge from a dumper or ready-mix truck directly into the top
of a column or wall.
5.4.2 TRANSPORTATION OF CONCRETE

There are various methods are available for transporting concrete, ranging from
wheelbarrows to pumps, and many factors affect the choice:
o the nature of the site
o the ground conditions.
o the size of the job.
o the distance to be covered.
o the heights of loading and discharge.
On many jobs several different methods or a combination of methods may be required, for
example when concrete has to be transported both horizontally and vertically.
5.4.3
COMPACTION OF CONCRETE
After concrete has been mixed, transported and placed, it contains entrapped air in the
form or voids. The object of compaction is to get rid of as much as possible for this unwanted
entrapped air; down to less than 1% is usually the aim.
The amount of entrapped air is related to the workability: concrete with a 75 mm
slump contains about 5 % air, while concrete of 25 mm slump contains about 20 %. This is
why a low-slump concrete requires more compactive effort-either a longer time or more
vibrators compared with a concrete with a higher slump.
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5.4.3.1 Reasons For Removing Air

Voids reduce the strength of the concrete. For every 1 % of entrapped air, the strength
falls by about 5 to 6 %. So a concrete with say, 3 % voids will be about 15-20 % weaker than
it should be.
Voids increase the permeability, which in turn reduces the durability. If the concrete is not
dense and impermeable, it will not be watertight, it will be less able to withstand mildly
aggressive liquids, and any exposed surfaces will weather badly; in addition, moisture and air
are more likely to get to reinforcement and cause it to rust.
Voids reduce the contact between the concrete and the reinforcement and other
embedded metals; the required bond will then not be achieved and the reinforced member will
not be as strong as it should be.
Voids produce honeycombing on stuck surfaces. Fully compacted concrete will be dense,
strong, durable and impermeable. Badly compacted concrete will be weak, non-durable,
honeycombed and porous. The air must be removed.
5.4.3.2 Vibration
By the vibration the entrapped air can be removed. When a concrete mix is vibrated it
is "fluidized", which reduces the internal friction between the aggregate particles. The
fluidization of concrete allows entrapped air to rise to the surface, and the concrete becomes
denser.
5.4.3.3 Vibrators
These are mobile items of mechanical plant used to vibrate (shake) air out of fresh
concrete.
There are 2 major types of vibrators:
o External vibrators (Form vibrators)
o Internal vibrators (Poker/Immersion vibrators)
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Rules for using internal vibrators

1. Make sure you can see the concrete surface. Lights may be required in thin deep
sections.
2. Put the head in quickly. When inserting the poker, allow it to penetrate to the bottom
of the layer as quickly as possible under its own weight. If done slowly, the top part of
the layer will be compacted first, making it more difficult for the entrapped air in the
lower part of the layer to escape to the surface.
3. Insert the head vertically. This minimizes the voids created by inserting the head, and
allows air bubbles to rise up .
4. Do not stir. This only increases the voids.
5. Leave the poker in the concrete for about 10 seconds.
6. Withdraw the poker slowly. The main thing is to see that the hole made by the poker is
closed up; otherwise you will be left with a hole in the finished concrete. If this does
happen-and it is often difficult to prevent if the concrete is very stiff-put the poker
back in near enough to the hold for the next spell of vibration to close it up. For the
final insertion, withdraw the poker even more slowly and move it about to ensure that
the hole closes up properly.
5.4.3.4 Length Of Time Required For Full Compaction

1. As the concrete is vibrated, air bubbles come to the surface. When the bubbles stop it
can be taken as a sign that not much more useful work can be done on the concrete.
The distance of the bubbles from the poker is also a useful guide to its radius of action.
2. Sometimes the sound of the poker can be a helpful guide. When the poker is inserted
there is usually a dropping off in frequency, and when the pitch becomes constant the
concrete is free of entrapped air.
3. The surface appearance also gives an indication of whether or not compaction is
complete. A thin film of glistening mortar on the surface is a sign that the concrete is
compacted, as is cement paste showing at the junction of the concrete and formwork.
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5.5 Curing
When water is added to cement chemical reaction takes place (Hydration of cement),
which results setting and hardening of cement. Mixing water is usually sufficient for the
initial hydration of cement. If however, there is insufficient water in the concrete during
its setting period, concrete cant develop its full strength.
It is generally believed that the cement keeps on hardening for at least one
year. When concrete is laid, its water content is rapidly loss, if insufficient precautions are
not taken. This is due to evaporation occurs in the action of sun, wind and heat generated
during setting of cement. The prevention of such process is known as CURING.
But in sites normally curing will be done for 10 14 days. This is sufficient for
concrete to reach the required strength. It is found that concrete will get strength at an
increasing rate. The percentage increase of strength with respect to duration is listed
below,
Duration
Percentage
3 days
40%
7 days
65%
28 days
100%
3 months
115%
6 months
120%
1 year
130%
Climate conditions and the type of cement used will also affect the curing practice.
Concrete will get more strength at high temperature and low at low temperature. Concrete
should be protected from harmful natural conditions. If proper curing is not taken place,
there will occur shrinkage initially and it leads crack.
There are two methods of curing is available. One is supplying moisture to
concrete and the other is preventing moisture from concrete. But in our site we normally
used the first method.
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6.0 MASONRY WORK

Masonry is used to construct walls and foundation. Masonry walls may be partition
walls or load bearing walls.
6.1 MASONRY ITEMS

Masonry consists of two items;
(1) Bricks and blocks
(2) Mortar
6.1.1
BRICKS AND BLOCKS
6.1.1.1 Clay Bricks

They are made of firing clay or shale deposits. Normal size of brick 21510265mm
is called work size. The usual size of a brick is such that with one mortar joint to each face the
combination shall be 22511275mm.
Before it is used for construction it should be put into the water at least one hour. If they are
not put into water the bricks would absorb water from cement mixture and this would reduce
in hydration reaction in cement and reduce the strength of walls.
Figure : 6.1
Width
Brick shape
Length
Bed face
Height
Stretcher face
Header face
Width of the brick is governed by the fact that it should be of such a size that a brick
can be easily geld by one hand. Height is governed by firing considerations during
burning.
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6.1.1.2
Blocks
It is a walling unit exceeding in length, with or height the dimensions specified for a
brick. The height of a block work should not exceed either its length or six times its width,
to avoid confusion with slabs and panels.
In solid blocks small holes passing through or nearly through the block do not exceed
25% of its volume. In hollow blocks, holes passing through the unit exceed 25% of its
volume. In cellular blocks do not pass through entirely.
Types of blocks
Front view
Plan view
Solid block
Figure: 6.2
Hollow block
Cellular block
Types of blocks
In our site they have used hollow blocks for the construction of wall (Figure: 5.1). The
sizes that were found in our site are 390*190*200 mm and 390*190*100 mm. As the
strength of the wall increase with size of unit and since there are no practical difficulties in
making a bigger unit. Blocks are made as large as possible. Only restriction is that those
should not be heavier than about 25 kg to facilitate two handed laying.
6.1.2. MORTAR
Mortar generally mixed on volume basis with the help of a gauge box. The mix
proportion of the mortar may vary with the type of individual component whether brickwork
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or block work and with the thickness of the wall ( Table: 6.1 & Table: 6.2 ). In practice the
mixing can be done manually or using a tilting drum.
Type of mortar
Cement
Sand
Location
Cement: sand mortar
Walls above ground level for

225mm thick wall
Cement :sand mortar
Table: 6.1
For walls of 115mm thick.
Mortar for brickwork
Type of mortar
Cement
Sand
Location
Cement: sand mortar
Walls above ground level for 200 and

150mm thick walls
Cement: sand mortar
1
Table: 6.2
For walls of 100 mm thick.
Mortar for block work
6.2 BOND
6.2.1 NEEDS FOR PROPER BONDING
force
oforce
To account for variations in brick dimensions so that verticality and horizontally of
a wall can maintained
o Provide uniform contact force
between adjacent bricks/blocks.
o Exclude rain and dust which may pass through the wall
force
o Make the brick wall a monolithic structural element

Accommodate different strains setup in different directions due to discrete walling units
which make the wall by a weak mortar which can undergo large strains with microcraking.
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Figure : 6.3
stress distribution in a masonry wall.
Bond is the interlacement of bricks produced when they lap those immediately above or
below them. An unbounded wall with its continuous joints has little strength and stability
since load is not distributed evenly (Figure: 6.3). Strength of such a wall is also not
uniform and exceedingly weak at a continuously vertical joint.
6.2.2
SOME IMPORTANT TYPES OF BONDS
6.2.2.1 Stretching Bond

brick thick walls only = 113 mm only.
Figure : 6.4
Stretching bond
A
B
A
B
Plan of A
Plan of B
6.2.2.2 Heading Bond

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1 brick walls only = 225 mm
A
B
A
B
Plan of A
Plan of
B
Figure : 6.5
Heading bond
6.2.2.3 English Bond

For 1 brick,1 bricks ,2 bricks . thick walls.
This consists of alternate courses of headers and stretchers(Figure : 6.6).
A
B
A
A
B
A
Plan view of A
Plan view of B
Figure : 6.6
English bond
6.2.2.4 Flemish Bond
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This consists of alternate stretchers and headers in every course. This
considered to more attractive than English bond and is used to limited extent in
Srilanka(Figure : 6.7).
A
B
A
B
A
B
Plan view of
A
Plan view of
B
Figure : 6.7
Flemish bond
6.2.2.5 English Cross Bond

This differs from the English bond in the position of the stretcher in alternate courses. This is
also considered to be more attractive than English bond (Figure : 6.8).
`
A
A
B
A
C
B
A
Plan view of
A
Plan view of
B
Plan view of
C
Figure : 5.7
Flemish bond
Figure : 6.8
English cross bond
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6.3 WALL CONSTRUCTION

For the construction of wall we have to give more attention for the verticality and the
alignment of blocks.
In our site before start to construct the wall the lines were marked by the labourers who
are doing the setting out procedure. These lines were normally marked easily from the grid off
lines. By using a plumb bob those lines were transferred to the beam level (upper level) and
they tied a string between the top and the bottom markings by hammering nails.
By the above procedure or work the verticality of the wall can be easily maintained. This
is really reduce the work load that is on the masons. Because according to the string they can
easily built up the wall more quickly using a straight edge without any difficulty. Using a
plump bob for each and every block is really a time consuming work so by the above
procedure we can increase the speed of the work ( Figure : 6.9).
String
Gauge box
Figure : 6.9
Construction of wall
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6.4
Lintel
The lintel work means that a reinforcement beam kept between the block (or brick) work
where the opening will be provided.
The lintel is provided to take the bearing load affected by the overlaying block (or
brick) work. Generally it will be pre-casted at the site and then will place in the correct
position if the opening is small. Otherwise by using the shuttering work it will be casted. In
my site litel was casted by using shuttering works. The structural arrangement of lintel is
shown as follows,
Lintel
Opening
Figure: 6.10
Lintel arrangement
6.5 PROBLEMS AND THE EXPERIENCE ENCOUNTERED

1.
Size of bricks and blocks are different. That was hard to construct the block or brick
wall with design thickness. When select the bricks must considered the sizes.
2.
Before using any bricks or blocks for any construction work those should be soaked
into the water. Because if those are too dry they will absorb the water from the mortar
and then the water content of on the mortar will reduce and then we could not be able
to get proper bond between the blocks or bricks.
3.
For constructing the wall vertically our site engineer suggested to tie a string between
the soffit and the floor ( Figure : 6.9 ). Because checking the plump line using a plump
bob for each and every block is really a time consuming procedure. To increase the
work speed the site engineer suggested that procedure. But some of the masons are not
quite happy with that. Because they do not like to change the procedure for their work.
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7.0 PLASTERING
The function of plastering is protection of wall and the appearance of the building.
Various types of plasters are used. In our site cement plaster was used. Ratio of mixture of the
cement plaster is 1:5 cement, sand. Thickness of plastering is 15mm.
Plastering was the art of covering to surfaces with a plastic material to
obtain an even, smooth, regular, clean and durable surface.
The principle objects of plastering were,
To provide a true, even, smooth and finished surface to the work and improve the
appearance.
To protect the surfaces from harmful effects of atmospheric influences
To cover defective workmanship.
To cover up unsound and porous materials.
To give suitable ground for white wash, co lour wash, distemper or paint.
Plastering conceals defective workmanship and covers up unsound and cheap quality
material. Often, plastering was required to provide a satisfactory base for decorating the
surface by whitewashing, color washing, distempering or painting. External plastering also
termed as rendering was done with the object of improving the resistance of the surface to
rain water penetration and other atmospheric influences.
The following factors affected the selection of the type of plaster to be used:
1. Availability of binding materials.
2. Desired durability and finish.
3. Atmospheric conditions to which the plaster would subjected.
4. The place where the plaster is going to be used lime whether on exterior surfaces or interior
surfaces.
The plastic material or plaster was made by working together a mixture of building material,
which was cement, lime or clay, fine aggregates (usually sand) and water. Certain additives
were sometimes added to improve its adhesiveness, durability and luster. When cement was
used as the binding material, the plaster was termed as cement plaster and when lime was
used as the binding material, it was called lime plaster. Sand normally forms the greatest
proportion of the constituents of a plaster. Sand controls the shrinkage, porosity, strength and
adhesive properties of plaster. Fine sand was often recommended for plastering and it should
be so graded that it has not pass by more than 5% through a sieve of 100 mesh ( b.s. sieve ).
Used sand were clean, sharp and free from deleterious matter. Normal tap water was used to
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add. Depending upon the availability of the materials, the choice of plaster for any particular
location, was governed by the rainfall, weather conditions and the finish desired.
7.1 LIME SLURRY

Using slaked line and water to a consistency of slurry by mixing in a tub or a
bucket makes lime slurry. This slurry is used for obtaining a smooth finish for internal walls.
It is done by letting this slurry flow over the plastered surfaces ( commonly referred to as
floating ) and then making a smooth finish by toweling with wooden float. As with the case
with lime it takes time for hardening and adequate care is not taken this finish is bound to get
damage.
PROBLEMS AND THE EXPERIENCE ENCOUNTERED
1.
Before plastering wall has to curing by the water. Because avoid present voids
between wall surface and motor. But our site they did not consider about that.
2.
In corridor walls, plaster tags have to put together. Otherwise after finishing work
sometimes walls were not same line. That is not good appearance. But our site several
times they did not consider about that.
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8.0 TILING
Tiling is generally done to get a nice appearance to the internal part of a building. Tiling
work can be divided into mainly three types. There are wall tiling, floor tiling, and staircase
tiling. They are available in different sizes. For our site tiles were brought from Lanka wall
tiles and Royal ceramic. During in our training period they were doing only wall tiles work.
8.1 WALL TILES

Wall tiles are usually done on to the bath room walls. The process of wall
tile is given below,
For placing the wall tiles the procedure is given below,
. Setting out was done on the cleaned surface.
. All tiles were placed in a water bucket for some time (15- 20 minutes) before placing the
tile.
. Then cement mortar was applied to the surface. Tiles were aligned properly.
. After that cement grout was applied to the tile according to the tile colour.
Wall tiles sizes

Length
= 152mm
Wide
= 152mm
Thickness = 6mm
8.2 TILE CUTTING

While tiling sometime we need required sizes. Therefore we have to cut the tiles
to achieve the suitable size. For this purpose special type of cutting tools are available in use,
for example,
1. Scaiber _ widely used for linear cutting.
2. Wheel cutter _ mainly used for wall tile for line cutting.
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9.0 ABOUT THE ROAD PROJECT ORGANIZATION

GODAGAMA TO MALABE ROAD PROJECT
9.1 ABOUT THE STE DETAILS
LOCATION
Malambe to Godagama Road Project.
CLIENT
Road Development Authority.
CONSULTANT
Roughton International (U.K),

Engineering Consultants Ltd (Sri Lanka),
Asphalting (Pvt) Ltd (Sri Lanka).
CONTRACTOR
Tudawe Brothers Ltd.
COMMENCEMENT
01 02 2002
COMPLETION
30 04 - 2004
PROJECT COST
Rs. 370 million.
FUNDED
Asian Development Bank (A.D.B).
ROAD LENGTH
11.3 km
Table : 9.1 About road site details
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9.2 SITE ORGANIZATION CHART

PROJECT MANAGER
Quality control
Project
Quantity
Surveyor
Surveyor
Site
Manager
Laboratory
Assistant
Accountant
Project
Enginee
r
Assistant Surveyor
Quantity
Surveyor
Store
Keeper
Assistant Engineer
Lab
Technician
Assist store
Keeper
Work shop Foremen
Technical Officer
Trainees
Figure : 9.1
Draught person
Supervisor
Structure of the organization for road site.
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10.0 HIGHWAY CONSTRUCTION

A highway is a hard surface made on an embankment for easy transport of
goods and passengers by vehicles. Usually a highway connects two stations. In addition to
connect two stations it will have serve a lot of people around the road.
10.1 A GOOD HIGHWAY SHOULD HAVE THE FOLLOWING

QUALITIES.
1. It should be straight as much as possible.
2. It should be short as much as possible
3. It should have easy curves
4. It should have low gradients
5. It should have strong foundations
6. It should have good sight distance.
10.2 HIGHWAY CONSTRUCTION CATOGARIES

Construction of highway is divided into three categories
a. New constructions
b. Re-constructions
c. Stage-constructions
10.2.1 NEW CONSTRUCTION
This is meaning that the highway is constructing from initial stage to connect two
stations.
10.2.2 RE-CONSTRUCTIONS
Any improvements or constructions works done in already made highway
constructions.
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10.2.3 STAGE CONSTRUCTIONS

The construction works are carried out in stages.
Ex:
Stage1 -Constructing structures such as stage drain, culverts, bridges and retaining
Walls
Stage2
- Preparing sub base
Stage3
- Metaling and taring.
10.3 ALIGNMENT
Marking the position of the highway on the ground is known as alignment.
Alignment or
locations of the highway comprises of the following two components,
1. Horizontal components:
It includes the straight path, curves and horizontal deviations
2. Vertical components:
It includes verticals curves, verticals gradients and etc.
Both these components play a vital role in determining the alignment of a road. After
careful study of the area. Except in flat areas due consideration has to be given to the grade as
it will be difficult to use a road having very high grades. Once the road is aligned and
constructed. It becomes it, due to high cost of construction and increases in value of ad joints
land.
10.4 FACTORS THAT AFFECTED THE LOCATION OF NEW

HIGHWAY
1 Shortest length
2 Low gradient
3 Easy curves
4 Good sight distance
5 Adequate drainage
6 Least earth work
7 Easy river crossing and railway crossing
8. Material requirement
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11.0 ENGINEERING SURVEYES FOR HIGHWAY

LOCATION
In a highway project, before finalizing the alignment of a highway or road engineering
surveys are to be carried out, the surveys may be completed in the following four stages,
1 Map study.
2 Reconnaissance surveys.
3 Preliminary surveys
4 Detail surveys.
11.1 MAP STUDY

If the topographic map of the area is available, it is easy locate the likely
routes of the road. If the map is not available the area photographs will be taken for this
purpose. On these maps main features of the area like rivers, hills etc. after studying these
maps in the office carefully the probable alignment can be located on the map keeping
following points in view.
a. Alignment should avoid ponds, lakes, valleys, inhabited area etc.
b. In case of a hill road, it should pass through a mountain pass.
c. For crossing a river, curved path should be avoided. The road should cross the
river at right angle.
11.2 RECONNAISSANCE SURVEYS

It is quick and without instruments survey. In this survey only
very simple instrument like abbeys level, tangent clinometers and barometer etc may be used.
Some of the details to be collected during reconnaissance are,
I. Terminal points and approximate length of the proposed road
II. Traffic conditions and design standards such as gradient, radius of the curves etc.
III. Drainage facilities provided such as number and type of cross drainage structures,
natural flood level and natural ground water level along the suggested route.
IV.General characteristic of the area such as type of soil, observation of geological
features, valleys, ponds, rivers, hills, permanent structures, marshy land.
V.Availability of construction materials
VI. Transport facilities available.
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VII. Approximate cost per km of the route
11.3 PRELIMINARY SURVEYS

It is approximate or rough type of survey conducted to have
fair idea of the surrounding areas. This type of survey generally is done with the help of a
plane table, compass, chain or steel tape. To have idea of earthwork approximate levels are
also taken at different points.
11.3.1 THE MAIN OBJECTIVES OF THE PRELIMINARY SURVEYS AS FOLLOWS

To survey the different alternative alignment proposed for the highway on the basis
of reconnaissance survey and to collect all necessary details of topography,
drainage and soil etc.
To compare the merits and demerits of different proposed alignment.
To estimate the quality of the different alternative proposals.
To workout cost of the different alternative proposals.
To select and finalize the best alignment from all considerations.
11.3.2 LOCATION AND DETAILED SURVEY

The alignment finalized on the basis of preliminary surveys is
to be located on the ground by establishing centre line by driving pegs at 20 m intervals. After
this operation the detailed survey is carried out for collecting information for the following
works.
Design of the highway
Preparation of construction plans.
Estimate earthwork.
Work out of the cost project.
11.4 DETAIL SURVEYS

To carry out levelling survey, temporary benchmarks are generally
fixed at intervals of about 300 meters. The cross section levels are taken up to the desired
width at intervals of 10 meters or at closer intervals where slopes change abruptly.
All river crossings, valleys etc are surveyed in detail up to considerable distance on either
side.
All-important topographical features should be noted in detail and plotted.
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Information regarding existing hydraulic structures such as culverts, bridges should be
gathered.
12.0 ROAD CONSTRUCTION MATERIALS
12.1 INTRODUCTION ABOUT THE MATERIALS

In this project is also included with road network improvement Project. There are several
layers are laid. About that layers are given below the table.
Layer
Surfacing C/W
Shoulder
Minimum Overlay
Base Course
Sub Base
S.S.G
SBST
GB
GS
GC
S.S.G
C/W
A/C
Thickness
Type
50
A/C
20
SBST
150
GB
200
GB
250
GS
130
GC
Table : 12.1 Introduction about the materials
- Single Bitumen Surface Treatment

- Granular Base course
- Natural Gravel or Similar Approved
- Gravel Soil or Similar approved
- Selected Sub Grade
- Carriage Way
- Asphaltic Concrete
12.1.1CROSS SECTION OF THE ROAD

Carriage way : 3.7 m
Shoulder
: 1.8 m
Carriage way
Shoulder
3%
3%
0.3
1.8
3.7
Invert level
5.5
6.7
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Figure :12.1
Cross section
12.2 ROAD CONSTRUCTION OPERATIONS

1. Clearing & Grubbing
2. Road way excavation in the all classes other than rock requiring blasting and part
refill
3. Rock excavation
4. Type material fill
5. Sub base construction type material
6. Aggregate Base Course
7. Tack coat
8. Prime coat
9. Asphalt concrete surfacing
In our training period we have seen only Sub base construction,
Aggregate Base Course, Prime coat and Asphalt concrete surface works.
12.3 SUB GRADE

The material shall be suitable material obtained either from excavation cut or from
approved borrow areas. No aggregate in the materials shall be greater than two thirds of the
layer to be compacted.
Degree of compaction: Top 150mm should be more than 95% MDD
Lower layers should be more than 93% MDD.
The rate of compaction test for every 500 sqm.
MDD is indicated Maximum Dry Density.
12.3.1 SELECTED SUB GRADE
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Materials used for selected sub grade shall be naturally occurring soils or gravels
and shall not include highly plastic clays, silts, peat or other organic soils or any soil that is
contaminated with topsoil, vegetable or other deleterious matter.
SL properties No.
Test method
Selected sub grade
Liquid Limit not to exceed

Plasticity Index not to
AASHTO
T90
T90
40
15
Exceed
Maximum dry density
T180/BS1377 test 14
1650
Not less than (kg/m3)

4 days soaked CBR at 93%
T193
15
MDD not less than (%)

Table : 12.2 Requirements of sub grade materials
12.3.2 FAILURE OF SUB GRADE
The failure of sub grade may be attributed due to the following two causes.
Inadequate stability
Excessive stress application
The inadequate stability of the sub grade may be attributed due to the following factors,
Inherent weakness of the soil itself.
Excessive moisture in the sub grade.
Inadequate compaction of the sub grade.
12.4SUB BASE
The materials used for sub base shall be naturally occurring or blended gravels and sands
or mixtures there have and shall not include highly plastic clays, peat or other organic soils or
any soil that is contaminated with top soil vegetable and other deleterious matter.
The completed sub base shall contain no aggregate.
Degree of compaction > 98% of MDD.
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Test method
SL properties No.
Sub base
AASHTO
Liquid Limit not to exceed

(%)
Plasticity Index not to
exceed(%)
Maximum Dry Density not
Less than (kg/m3)
4 days soaked CBR at 98%
T90
40
T90
12
T180/BS1377 Test 14
1750
T193
30
MDD not less than (%)
Table : 12.3 Requirements of sub base materials.
Grading Requirements for Sub Base Materials
Sieve size (mm)
50
37.5
20
5
1.18
0.3
0.075
% Passing
100
80-100
60-100
30-100
17-75
9-50
5-25
Table :12.4 Grading requirements for sub base materials
12.4.1 FAILURE OF SUB BASE

Failure of sub base takes due to the following reasons,
Inadequate strength or stability
Loss of cohesion or binding action
Loss of materials
Inadequate thickness of wearing course
Use of improper or inferior materials
Crushing of base course
Lack of lateral support for the base course
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Following are the main reasons for the inadequate strength or stability of the sub base
Improper mix proportion
Inadequate thickness of the sub base
Use of soft variety of stone aggregates
Poor quality control during construction period
12.5 AGGREGATE BASE COURSE (ABC)

After the edge treatment the base materials shall be laid for the road.
Aggregate Base Course is a mixture of various sizes of aggregates and quarry dust in it.
Normally aggregates of 37.5mm, 28mm, and 20mm are included.
In this project the thickness of the ABC layer is 200mm. The motor
grader is used to laying ABC. Normally the road has a cross fall of 3% from the center the
motor grader can be used to blade the road as required.
After placing it shall be compacted well using the rollers and the compaction shall be
tested.
Degree of compaction > 98% of MDD.
12.5.1 COURSE AND FINE AGGREGATE

Course aggregate substantially retained on the 4.75mm sieve and
fine aggregate substantially passing 4.75mm sieve.
The course aggregate shall be crushed rock from an approved
quarry and the fine aggregate shall either be crusher fines or river sand.
They shall be free from weathered, soft, laminated or elongated
pieces, deleterious matter and shall be free from clay and excess dust.
For course aggregate used for asphalt concrete surfacing and seal
coat surface treatment shall have a lost angles abrasion value not greater than 40%.
Fine aggregate used for road bases and surfacing shall either be
crusher fines or river sand.
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12.5.2 METHOD OF SELECTING MATERIAL

Aggregate Base Course material shall be selected according to the
following requirements.
Grading Requirements for ABC Materials

Percentage Passing
Sieve Size
Nominal Size (mm)
37.5
28.0
20.0
50.0
100
100
37.5
95-100
100
28.0
100
20.0
60-80
70-85
90-100
10.0
40-60
50-85
60-75
5.0
25-40
35-55
40-60
2.36
15-30
25-40
30-45
0.425
7-19
12-24
13-27
0.075
5-12
5-12
5-12
Table : 12.5 Grading requirements for ABC materials
12.6 PRIME COAT

This work shall consist of an application of a prime coat on a base or sub base
newly constructed using gravely soil, stabilized soil or aggregate prior to laying of a surface
dressing or a surface course, so as to provide a proper bond between the layers and also to
serve as a protective measure for the base or sub base.
12.6.1 PREPARATION OF SURFACE

The layer to be primed should be cleaned of all loose and deleterious material by means
of a rotary broom or hand brooms. The brushing force should be sufficient to dislodge all
adhering material without damaging the pavement surface. Clay and other foreign material
should be removed by hand. The exposed surface should be kept moist up to the time of
spraying.
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12.6.2 APPLICATION OF PRIME COAT

Prime Coat should be applied at the instructed rate after trials and temperature
defined in (Table : 12.6) by means of a bitumen distributor for large areas and by hand lance
and nozzles for small and inaccessible area so as to achieve an even distribution of the prime
coat over the surface. At the start and end of each run building paver or other approved
material shall be spread over the surface to ensure a clean joint between adjacent runs and to
protect adjacent surface and also to permit the distributor to build up sufficient speed so that
at the start of each run the distributor shall be travelling at the correct speed for the instructed
application rate. There should be no leakage or drips of oil, diesel or bituminous material from
the distributor.
The total width of primed surface should be 300mm wider than the specified
width of the final surfacing and the edges of the prime shall be parallel to the centre line of the
road.
The indicative rate of spread of bituminous material for the prime coat should be in
the range of 0.5 to 1.5 litters per square meter.
Prime Coat Type
Temperature (Degree Celsius)
MC 30 or 45% Cut back bitumen
40 70
55 90
75 - 110
Table : 12.6 Relationship between prime coat and temperature
Sieve Size
4.75
2.36
1.18
0.6
0.3
0.075
Percentage Passing (By mass)

100
80 100
60 95
30 80
20 55
10 30
Table : 12.7 Grading Envelope for Sand for Prime Coat
12.7 TACK COAT
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This work shall consist of an application of a tack coat to an existing pavement
prior to construction of a surfacing, so as to provide a bond between the two layers.
Penetration grade bitumen:
The penetration grade bitumen used for road construction and refining petroleum
shall derive maintenance work.
12.8 ASPHALTIC CONCRETE SURFACING

This work shall consist if furnishing materials, mixing at a central mixing
plant, and spreading and compacting asphaltic concrete wearing course on an approved base
course as and where shown on the drawings and as instructed by the Engineer. The wearing
course will be typically of 50 mm thickness as specified.
12.8.1 PREPARATION OF EXISTING SURFACE

Where asphaltic concrete surfacings are laid over newly constructed
aggregate bases, prior to construction, the surface shall be cleaned of extraneous matter and
applied with a prime coat. Where asphaltic concrete surfacings are laid on existing
pavements, the surfaces of such pavement shall be corrected to the required width and profile
as instructed. All potholes, ruts, depressions, and damaged edges shall be corrected.
12.8.2 WEATHER LIMITATIONS

The bituminous mix shall not be laid during rainy weather or when the
surface on which it is laid is damp or wet.
12.8.3 ASPHALT LAYING PROCEDURE

The Asphalt mix shall be laid immediately after transporting, by means of
approved mechanical self powered pavers. They shall be capable of spreading, finishing and
providing initial compaction to the mix so that, the surfacing can be finished to the required
lines, grades, levels, dimensions, and cross sections intended, either over the entire width or
over such other partial widths as may be practicable.
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The bituminous mix, after spreading, finishing, and initial compaction by the
paver, shall have a smooth surface free of irregularities causes by dragging, tearing or
gouging.
In narrow widths and in restricted areas where the paver cannot operate, the mix
may be manually laid. In which case, care shall be taken avoid segregation. Manually laid
strips shall be rolled at the same time as the paver laid work.
12.8.4 COMPACTION PROCEDURE

Immediately after the mix has been spread as struck off, the
surface shall be checked and any irregularities adjusted. Rolling shall commence as soon as
the material will support the roller without undue displacement or cracking. The mix shall
then be thoroughly and uniformly compacted by rolling, according to the sequence of rolling
as given below,
1. Transverse joints.
2. Longitudinal joints, where applicable.
3. Outside edge.
4. Initial or breakdown rolling.
5. Second or intermediate rolling.
6. Finish or final rolling.
The speed of the roller, shall not exceed the limits given below the table.
Type of Rollers
Breakdown
Intermediate speed
Finish speed
Steel Wheeled Rollers

Pnumatic Tyred Rollers
Vibratory Rollers
speed (km/hr)
3
5
5
(km/hr)
5
5
5
(km/hr)
5
8
-
Table : 12.8 Relationship between rollers and their speed
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Industrial Training
13.0 SPECIAL EQUIPMENTS

13.1 PNEUMATIC TIRED ROLLER
The pneumatic tired roller is recommending to be used on asphalt surface treatment.
The resilient tyres on these rollers force the aggregate firmly into the asphalt binder without
crushing the particles. It is also widely used on asphalt pre- mix paving in combination with
tandem steel rollers. The most popular type of pneumatic-tyred roller for road maintenance is
the self propelled smooth tread tyred roller with 3 or 4 wheels at front and, 4 or 5 wheels at
rear.
The front wheels are always mounted on oscillation axles and on some models are the front
suspension constructed with hydraulic pressure equalisation which provides a kneading
action allowing the wheels to follow the contour of the surface and provide better
embodiment. The front and rear wheel sets are installed in a staggered position providing an
overlap in the gaps between the wheels.
The water sprinkler system for tyres and tyre scrapers are normally included. Most models
are provided with a tyre inflation system, either a hose for manual operation or with automatic
tyre inflation, adjustable from the drivers seat. Enabling the driver to increase or decrease the
tyre pressure during operation.
13.2 BACKHOE
This type of machine is the one that is most commonly used machine by the
contractors for excavating basements, pits and trenches. This is also called the backhoe.
Discharge is by raising the bucket in a tucked position and emptying the spoil through the
open front end into the attendant haul unit or alongside the trench. Output varies from 60
bucket loads per hour, and this depends on the nature of the excavation area.
13.3 FACE SHOVEL

This excavator operates best from a flat prepared surface to work above the tracks against an
excavation face. It serves only to loosen and load material and is mostly used in quarrying and
road cuttings. In our site they used for spreading sub base and ABC and move that materials
from one place to another place.
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13.4 MOTOR GRADER

Many earthmoving projects require the final ground to be accurately finished. So that the
surface is smooth and level without undulations and ridges. Although a skilful driver using a
bulldozer can in many instances achieve adequate results, the grader has been specifically
developed for trimming the sub grade, sub base, ABC surface on the roads and road cuttings.
It is self transporting and supported on two or three axles.
Methods of working with the Grader
The blade can be used in several positions for:
Levelling and trimming on the horizontal, with the mould board central or swung out
either to the left or right. If the mould board is set at an angle on plan, the material will
roll off the blade to form a windrow. However, with the blade at right angles to the line
of movement, then only spreading or trimming is obtained.
Levelling and trimming to the slope and vertical face.
Forming ditches the mould board is angled both on plan and in the vertical and set
such that the blade just protrudes beyond the outside line of the wheels nearest to the
ditch to be shaped. A windrow is formed along the top of the ditch. The ditch is
depended gradually, trimming off a layer at a time, keeping the nearside wheels in the
ditch.
Back filling along trenches. The action is similar to that for producing a windrow.
13.5ASPHALT PAVER FINISHER

A paver finisher is a machine for laying asphalt for road construction to
give accurate depth, even levelling and good surface finish before rolling.
We can use Paver for sub base or ABC work. But our site they have not used. But it is
compared to the motor grader method, is found more suitable, because,
1. Better and easier respect of levels, both longitudinal and transvers.
2 . Improved homogeneity of the plant prepared mix.
3. Uniform pre-compaction.
4. Improved adherence of asphaltic courses.
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Industrial Training
The paver can easily handle asphalt and all asphalt mixes, coated and uncoated materials,
crushed stones and dry lean concrete, in fact all road making materials other than wet
concrete.
This is the equipment used for paving road surface with asphalt. The paver should
be capable of spreading finishing and providing initial compaction of the asphalt mix. It
should be able spread the mix to correct lines, grades levels, dimensions and cross section
intended, either over the entire width or part of widths as case may be.
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14.0 SPECIAL TESTS

14.1 ATTERBURG LIMITS DETERMINATION
This test consists of two parts.
1. Liquid Limit determination
2. Plasticity Limit determination
14.1.1 LIQUID LIMIT DETERMINATION

From the selected material a sample about 100g, which passes through 0.425mm
sieve was taken.
The sample was mixed with distilled water on the glass plate.
A portion of the mixture was placed in the cup and levelled with the use of the
spatula.
With the use of the grooving tool the levelled mixture was divided along the
diameter through the center of the hinge.
By rotating the handle of the machines number of blows were be given until the
two parts comes in to contact.
A small quantity of the mixture was removed by the grooving tool was placed in a
container and weighted.
After that it was be dried in the oven and weighted.
Then moisture content was calculated as shown in the attached test report.
Above test shall be carried out for four samples. (For two samples no. of blows <
25, for the other two samples blows >25)
Liquid Limit is the moisture content corresponding to the water contest of 25
blows.
14.1.2 PLASTICITY LIMIT DETERMINATION
Selected material sample was mixed with distilled water on the glass plate until it can
be rolled and it shall be rolled between the hand and the glass plate.
When it comes to a thread with a diameter less than 3mm the soil shall be kneaded
together and was rolled again. This should be done until the thread shows signs of
cracks and further could not be rolled.
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Industrial Training
The cracked threads were put in to a container and weighted.
Then it was be dried in the oven and weighted.
Test was being carried out for two samples and moisture content can be determined.
The average moisture content of the two samples is the plastic limit.
From the results of the above two tests plasticity index can be acquired.
Plasticity Index = L.L P.L
14.2 SIEVE ANALYSIS TEST

Sieve analysis test is important when grading the materials.
First sample of dry selected material was weighted.
The set of sieves was selected.
Take the sample and pass through the sieves (Starting from the largest
one)
Soil remained at each sieve was weighted and therefore passing

percentage can be calculated.
Sieve analysis test is done for concrete aggregates, ABC material and
asphalt material as well as for soil.
14.3 PROCTOR COMPACTION TEST

In this test, a sample of soil is compacted in a standard container (volume
of the mould is 996 cm3). The container is filled in five layers. Each soil layer is compacted
using a 4.5kg weight, which is lifted through a distance of 450mm and dropped 27 times
evenly over each soil layer.
After striking off the surface of the container, the soil sample is weighted
immediately after the test (wet weight) and then weighted again after drying the soil in an
oven (dry weight). The difference between the wet and dry weights represents the weight of
water that was contained in the soil. The density of the dry soil can now expressed in terms of
kg per cubic meter. The amount of water or moisture may also be expressed as a percentage of
the dry weight.
The procedure is repeated, adding different amounts of water to the soil with each
repetition and the soil weights as well as percentages of moisture are recorded as described
previously.
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Plotting the data on a graph, a curve similar to following graph,

Dry Density
Maximum Dry Density
Optimum Moisture Content
Moisture content (%)

Figure : 14.1
Dry Density Vs Moisture Content
From this curve we can find Maximum Dry Density & Optimum Moisture Content.
14.4 FIELD DENSITY TEST BY SAND CONE METHOD

After the compaction of each layer the density achieved in the
field should be determined. In the site sand cone method can be done to determine the
density of the compacted fill material.
In the sand cone method small holes are made at several places in the compacted
layer. The weight of the soil removed can be measured. The volume of the hole can be
obtained by filling the hole with sand (density of the sand is known). Then the density of
the soil can be calculated.
The standard proctor compaction density value can be compared with the field
density. Field compaction density is usually specified to be above 98% of the standard
proctor compaction test in the laboratory for sub base and ABC materials layers. If not
further compaction is necessary.
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Calculation for Degree of Compaction

Volume of the hole
= Weight of sand in the hole

Density of the sand used
Wet density of the soil = Wet soil in the excavation hole

Volume of the hole
Dry Density of the excavated soil
Wet Density * 100

(Moisture content of the soil + 100)

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Industrial Training
15.0 PROBLEMS AND THE EXPERIENCE ENCOUNTERED

1. Over compaction is not good for the sub base or any other layer. Because if we over
compact to the soil, shear failure will be presented. But they did not consider about
over compaction.
2. Before priming surface has to clean. After cleaning immediately prime coat will be
primed. But our site sometimes after cleaning one or two days they will prime.
3. After priming within 24 hours without being disturbed. So as to allow the prime coat
to fully penetrate the surface unless full penetration. But they did not consider about
that.
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16.0 SAFETY
Unaccepted accident causes pain, permanent disabilities, human suffering or
death. This affects the victim and other working resulting in loss of morale and even a fear of
performing certain tasks. Therefore accident in construction competent, safetyconscious,
supervision, education, discipline, job safety organization, safety device and equipment.
16.1 SAFETY PROCEDURES
All persons must wear safety helmets before enter the site works.
Do not though any heavy things on high level that may cause injuries.
Ensure that there is no danger from live electrical cables or equipment near to work is
carried out.
Goggles and screens must be used when doing the work that might cause damage to
eyes.
Always wear a suitable when doing work that creates dust.
As the nature of the work boots and gallowses must be use.
Keep work area clean
Consider area environment
Power tools were not exposed to rain. They were not used in damp or wet location.
Machineries were not use if there is risk to cause fire or explosion.
Guard against electrical socket
Do not let visitors touch the tools or extension chord.
Store ideal tools
Do not force tools (it will do the job better and safer at rate for which it was intended)
Use right tools
Dress properly
Use safety glasses; also use face or dusk mask if cutting operating is dusty.
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17.0 CONCLUSION
After finishing the Level 3 examination we have to go into the industry as civil
engineers. Without knowing about the industry and practical knowledge we could not be able
to survive as real engineers in future. By considering this University of Moratuwa and NAITA
decided to have an Industrial Training programme for undergraduates after finishing their
Level 3 examination.
While we are in the university we are studying many theories. Even though we are
doing a lot of practicals during the academic year to understand the concepts clearly, certain
things can not be found or can not be learnt as concepts such as labourer management.
Therefore it is necessary to take the Industrial Training as serious and we have to do it
properly. Labourer management is very important for civil engineers because most of the time
they have to deal with the labourers directly or through subcontractors.
Civil engineer should have the ability to coordinate the other labourers or subcontractors to
finish a construction within the limited valuable time period. They must have the ability to
work as a team otherwise they could not meet the target within the allocated time. There may
be conflicts between the different subcontractors about the construction work those should be
solved by engineers to finish the construction within the limited period. These things can be
easily learnt from the industrial training period.
Twenty-two weeks were allocated for our Industrial Training programme. Within that duration
learning everything about the construction was not possible. Because of this reason a trainee
might got the chance only to learn a part of the construction. Normally one particular work is
repeated even for several months .Hence just increase the training period will not be the
solution for the above problem. Therefore it is better if the trainees can be changed
themselves to the other sites of the same organization where other part of the construction is
going on with the aid of the University and NAITA.
The Department of Civil Engineering from University of Moratuwa allocated a staff member
for each and every student during the training period. Therefore the trainee gets supervised by
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that staff member every month and he/she has the chance to speak about their problems
related to their training programme with the staff member.
This type of supervision really motivated us to finish the training successfully.
I feel sad to say ,that in our site mainly road site, most of the staffs were not really
worried about the trainees whether the trainees have got or learnt anything from their training
period. They only aimed on the work that we were done for them and they only wanted to
finish those work in time. In our sites they have not any special programme for trainees we
have to work as a technical officer or sometimes even as a labourer. If the organisation have a
defined programme for trainees, that really will guide the trainees in their learning procedure.
During our training period we were work with several trainees from other institutions.
Their training period is more than two years. But our training period is only twenty-two
weeks. Therefore we have to learn everything within twenty-two weeks. Therefore we have to
work hard in our training period. Otherwise they will defeat us.
Finally I wish to thank the whole staff of University of Moratuwa and
to the staff of NAITA.
116
CONTENTS
1.0 INTRODUCTION...............................................................................................................1
1.1 ABOUT THE ORGANIZATION..................................................................................59
1.2 ON GOING PROJECTS................................................................................................59
2.0 ABOUT THE LSP (BUILDING SITE) ORGANIZATION..............................................60
2.1 ABOUT THE SITE DETAILS.......................................................................................60
2.2 THE ORGANIZATION CHART...................................................................................61
2.3
JOB FUNCTIONS....................................................................................................63
3.0 FORM WORK..................................................................................................................66

3.1
REQUIREMENTS FOR FORMWORK..................................................................66
3.2
TIME OF REMOVAL..............................................................................................66
3.2.1 The minimum period to removing formwork..........................................................67

3.3
FORM WORK FOR BEAMS AND SLAB..............................................................68
4.0 REINFORCEMENT.........................................................................................................69
4.1 INDICATION OF REINFORCEMENT IN DRAWING..............................................69
4.2 COVER BLOCKS........................................................................................................70
4.3 BAR BENDING WORK..............................................................................................70
4.4 PLACING OF REINFORCEMENT.............................................................................70
5.0 CONCRETE......................................................................................................................71
5.1 GRADE OF CONCRETE..............................................................................................71
5.2 CHECKS BEFORE CONCRETING.............................................................................72
5.3 TEST FOR CONCRTE..................................................................................................73
5.3.1 SLUMP TEST..........................................................................................................73
5.3.2 CUBE TEST............................................................................................................74
5.4 CONCRETING..............................................................................................................75
5.4.1 PLACING OF CONCRETE....................................................................................76
5.4.2 TRANSPORTATION OF CONCRETE...................................................................76
5.4.3
COMPACTION OF CONCRETE....................................................................76
5.5 Curing.............................................................................................................................79
6.0 MASONRY WORK...........................................................................................................80
6.1
6.1.1
MASONRY ITEMS.................................................................................................80
BRICKS AND BLOCKS..................................................................................80
II
6.1.2.
MORTAR..........................................................................................................81
6.2 BOND.............................................................................................................................82
6.2.1 NEEDS FOR PROPER BONDING........................................................................82
6.2.2
SOME IMPORTANT TYPES OF BONDS......................................................83
6.3
WALL CONSTRUCTION........................................................................................86
6.4
Lintel............................................................................................................................87
6.5 PROBLEMS AND THE EXPERIENCE ENCOUNTERED........................................87

7.0 PLASTERING....................................................................................................................88
7.1 LIME SLURRY..............................................................................................................89
7.2
PROBLEMS AND THE EXPERIENCE ENCOUNTERED...................................89
8.0 TILING...............................................................................................................................90
8.1 WALL TILES..................................................................................................................90
8.2
TILE CUTTING.......................................................................................................90
9.0 ABOUT THE ROAD PROJECT ORGANIZATION........................................................91

9.1 ABOUT THE STE DETAILS........................................................................................91
9.2 SITE ORGANIZATION CHART..................................................................................92
10.0 HIGHWAY CONSTRUCTION......................................................................................93
10.1
A GOOD HIGHWAY SHOULD HAVE THE FOLLOWING QUALITIES............93
10.2 HIGHWAY CONSTRUCTION CATOGARIES.........................................................93

10.2.1 New construction...................................................................................................93
10.2.2 Re-constructions....................................................................................................93
10.2.3 Stage constructions................................................................................................94
10.3 ALIGNMENT...............................................................................................................94
10.4 FACTORS THAT AFFECTED THE LOCATION OF NEW HIGHWAY................94
11.0 ENGINEERING SURVEYES FOR HIGHWAY LOCATION.......................................95
11.1
MAP STUDY............................................................................................................95
11.2
RECONNAISSANCE SURVEYS............................................................................95
11.3 PRELIMINARY SURVEYS........................................................................................96

11.3.1 The main objectives of the preliminary surveys as follows...................................96
11.3.2 Location and detailed survey.................................................................................96
11.4 DETAIL SURVEYS.....................................................................................................96
12.0 ROAD CONSTRUCTION MATERIALS.......................................................................97
12.1 INTRODUCTION ABOUT THE MATERIALS.........................................................97
12.1.1Cross Section of the road........................................................................................97
12.2
ROAD CONSTRUCTION OPERATIONS..............................................................98
12.3
SUB GRADE............................................................................................................98
III
12.3.1 SELECTED SUB GRADE....................................................................................98

12.3.2 FAILURE OF SUB GRADE.................................................................................99
12.4
SUB BASE................................................................................................................99
12.4.1 FAILURE OF SUB BASE...................................................................................100

12.5 AGGREGATE BASE COURSE (ABC)...................................................................101
12.5.1 Course and fine aggregate....................................................................................101
12.5.2 Method of Selecting Material............................................................................102
12.6
PRIME COAT.........................................................................................................102
12.6.1 Preparation of Surface..........................................................................................102

12.6.2 Application of Prime Coat................................................................................103
12.7 TACK COAT...............................................................................................................104
12.8 ASPHALTIC CONCRETE SURFACING.................................................................104
12.8.1 Preparation of Existing Surface..........................................................................104
12.8.2 Weather Limitations...........................................................................................104
12.8.3 Asphalt Laying procedure....................................................................................104
12.8.4 Compaction Procedure.........................................................................................105
13.0 SPECIAL EQUIPMENTS............................................................................................106
13.1 PNEUMATIC TIRED ROLLER..............................................................................106
13.2
BACKHOE.............................................................................................................106
13.3
FACE SHOVEL......................................................................................................106
13.4
MOTOR GRADER.................................................................................................107
13.5
ASPHALT PAVER FINISHER...............................................................................107
14.0 SPECIAL TESTS...........................................................................................................109

14.1
ATTERBURG LIMITS DETERMINATION.........................................................109
14.1.1 Liquid Limit Determination.................................................................................109

14.1.2 Plasticity Limit Determination.............................................................................109
14.2 SIEVE ANALYSIS TEST.........................................................................................110
14.3 PROCTOR COMPACTION TEST............................................................................110
14.4 FIELD DENSITY TEST BY SAND CONE METHOD...........................................111
15.0 PROBLEMS AND THE EXPERIENCE ENCOUNTERED.......................................113
16.0 SAFETY........................................................................................................................114
16.1
SAFETY PROCEDURES.......................................................................................114
17.0 CONCLUSION..............................................................................................................115
IV
LIST OF FIGURES
Figure :2.1
Structure of the organization for the building site.............................................62
Figure : 3.1
Levelling the beam and slab form work............................................................68
Figure : 6.1
Brick shape........................................................................................................80
Figure: 6.2
Types of blocks...................................................................................................81
Figure : 6.3
stress distribution in a masonry wall.................................................................83
Figure : 6.4
Stretching bond..................................................................................................83
Figure : 6.5
Heading bond...................................................................................................84
Figure : 6.6
English bond......................................................................................................84
Figure : 6.7
Flemish bond.....................................................................................................85
Figure : 5.7
Flemish bond....................................................................................................85
Figure : 6.8
English cross bond.............................................................................................85
Figure : 6.9
Construction of wall..........................................................................................86
Figure: 6.10
Lintel arrangement...........................................................................................87
Figure : 9.1
Structure of the organization for road site.........................................................92
Figure :12.1
Cross section.....................................................................................................97
Figure : 14.1
Dry Density Vs Moisture Content.................................................................111
LIST OF TABLES
Table : 2.1 About the building site details...............................................................................61

Table : 3.1 Minimum period for removing form work...........................................................67
Table: 6.1
Mortar for brickwork...........................................................................................82
Table: 6.2
Mortar for block work..........................................................................................82
Table : 9.1 About road site details...........................................................................................91

Table : 12.1 Introduction about the materials.........................................................................97
Table : 12.2 Requirements of sub grade materials..................................................................99
Table : 12.3 Requirements of sub base materials..................................................................100
Table :12.4 Grading requirements for sub base materials.....................................................100
Table : 12.5 Grading requirements for ABC materials.........................................................102
Table : 12.6 Relationship between prime coat and temperature...........................................103
Table : 12.7 Grading Envelope for Sand for Prime Coat......................................................103
Table : 12.8 Relationship between rollers and their speed....................................................105
VI

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Industrial Training

Maga Engineering (pte)Ltd

01. INTRODUCTION TO THE TRAINING ORGANIZATION

Department of Civil Engineering

Maga Engineering (pte)Ltd

Main functions of organization:

900 million Rupees

Kandy car park

470 million Rupees

Road project (southern province)

>1000 million Rupees

Vocational Training Centre-Narahenpittea 180 million Rupees

550 million Rupees

550 million Rupees

1.3 Some recent past projects of mga engineering (Pvt) Ltd

700 million Rupees

Millennium Information Technology Malambe

450 million Rupees

Eden Hotel Beruwala

250 million Rupees

Light house Hotel Galle

200 million Rupees

Blue water Hotel Wadduwa

250 million Rupees

168 million Rupees

300 million Rupees

300 million Rupees

Mahiyangana road and bridge

350 million Rupees

Taj Exotica hotel Wadduwa

Department of Civil Engineering

168 million Rupees

1.4 Organizational structure of the Mga engineering (Pte) Ltd

Chairman / managing director

Department of Civil Engineering

Maga Engineering (pte)Ltd

Site organization chart

Maga Engineering (pte)Ltd

GREATER GALLE WATER SUPPLY PROJECT

Clear water reservoir

4. Laying of transmission main

Water treatment plant to Hapugala reservoir 1.1km

Water treatment plant to Mahagoda reservoir 4.3.km

Hapugala reservoir to Kowulhena reservoir 9.4 km

Kowulhena reservoir to Halloluawagoda reservoir 10.1 km

5. Laying of main distribution system

Maga Engineering (pte)Ltd

FLOW CHART OF GREATER WATER SUPPLY PROJECT

Maga Engineering (pte)Ltd

:-Greater Galle Water Supply Project

:-National Water Supply Board

:-CEYWATER CONSULTANTS (PVT) LTD

:- Maga Engineering (Pvt) Ltd.&

:- 32000 Cubic meters per day (7.1 million populations)

:-Design,Build & Turnkey Contract

Project start date

Project finished date

:-09 may 2005

Kowlhena Ground Reservoir

In & Out Hume pipe laying.

Painting & tiling work for Chlorination house and Guard

Reservoir roof slab dolomites & metal laying.

Entrance Road work.