CHAPTER 1 - INTRODUCTION TO THE TRAINING ESTABLISHMENT

In my training period I was trained at Kalutara public market site which was executed
by Central Engineering Services (Pvt) Ltd. (CESL). In this chapter the details of CESL &
CECB are presented.

1.1 Central Engineering Consultancy Bureau (CECB)

CECB is a well-known and well established consultancy firm in Sri Lanka in many
different civil engineering disciplines. After they were established in 1973 they have become
successful consultants in many different disciplines such as;

 Architectural.
 Structural.
 Electrical.
 Irrigation.
 Power Generation.
 Transportation.
 Public Health.
 Geotechnical.
 Environmental. Figure 1.1- CECB logo
 Land Surveying.
 Coastal & Marine etc.

The vision of CECB:

"To be a World Class Engineering Organization"

The mission of CECB:

“To be a World Class Engineering Organization, acquiring excellence in
Engineering, Architecture and Quantity Surveying, utilizing state of the art technology, with
a highly motivated, trained and skilled workforce rewarded appropriately for their
contribution in the optimum use of resources for the maximum benefit to mankind.”

1
1.2 Central Engineering Services (Pvt) Ltd (CESL)

1.2.1 Introduction to CESL

Central Engineering Services (Pvt) Ltd. (CESL) is a fully owned subsidiary of the
Central Engineering Consultancy Bureau (CECB). Though they have established in 16th
December 2003 as a limited liability company they have been actively participated in the
competition of the construction world in 2011. The is providing services to both public and
private sectors through different aspects such as construction of;

 Bridges and tunnels.

 Buildings.
 Water management and drainage systems.
 Land drainage systems.
 Roads and highways etc.
Figure 1.2- CESL logo
The vision of CESL:

To be the unique model for the construction industry in Sri Lanka

The mission of CESL:

Acquire excellence in construction technology and Process innovation with a highly

motivated, trained staff whose contribution is adequately recognized.

With this they have established their name as one of the leading C1 graded
construction firm in Sri Lanka.

1.2.2 Organizational structure

The operation division of CESL is divided into 11 chief operation engineer

sections island wise. They are;

 Western 1 COE section (Battaramulla)

 Western 2 COE section (Jawaththa)
 South COE section (Galle)

2
  Central COE section (Digana)
 Uva COE section (Badulla)
 East COE section (Kantale)
 South East COE section (Ampara)
 Sabaragamuwa COE section (Rathnapura)
 North COE section (Kilinochchi)
 MKDP & Polonnaruwa COE section (Bakamuna)
 Anuradhapura COE section (Puliyankulama)

(In brackets the location of base office is noted)

The organizational hierarchy can be briefly presented in the below manner.

Operation Divisions 11 COE sections

Contracts Division

Managementt system
development division

Training, Research &

Chief executive officer
development division
Chairman & Board of
Directors
Audits FInance Division

Human resurce division

Legal Division

Figure 1.3- Hierarchy of CESL

The hierarchy presented below explains about the organizational structure that we had
at the site.

3
 DGM (Eng. H.
M. T. N.
Dhanawarane)

SOE (Eng. T.
C. S.
Jayaneththi)

OE (Eng. J.
M. M.
Jayasinghe)

AOE(Eng. K.
P. M.
Krishan)

SE (Eng. L. R.
Wijesinghe)

Zone 1 - EA Zone 2 - TA Zone 3 - EA Draughtsma

QS (H. V. SK (Mr. K. R. R.
(Mr. I. B. K. (Mr. A. M. N. (Mr. W. M. L. n(Mr. S. S.
Paranagama) Rathnaweera)
Perera) Perera) Walikanna) Samarathne)

Trainee TO (Mr. H. TA for Trainee (Ms. Trainee (Ms.

TO (M. G.
(Mr.J. A. A. M. S. E. Safety(Ms. A. D. P. D. Di. P. W. U.
Lasantha)
Sankalpa) Bandara) O. De Zoysa) Silva) Madubhani)

DGM - Deputy General Manager SOE - Senior Operation Engineer

OE - Operation Engineer AOE - Assistant Operation Engineer

SE - Site Engineer EA - Engineer Assistant

TA - Technical Assistant QS - Quantity Surveyor

TO - Technical Officers (Supervisors)

Figure 1.4 – Hierarchy of the Site Staff

Here I joined at the very initial stages of the construction hence I could be able to join
the organizational hierarchy in an effective manner. When I am about to finish my training
period technical officer Mr. H. M. S. E. Bandara joined the staff.

1.2.3 SWOT analysis of CESL

To gain an understanding about the current position and potential of the firm we could
undertake a SWOT analysis.

4
Strengths of CESL

As the main three core strengths of CESL we can identify these factors.

 They have established their name as one of the leading constructor in Sri Lanka.
As per today CESL has actively played its part in construction industry in
island since 2011. On the other hand CECB the parent company has
established its name since 1973. Obviously CESL can shine due to its parent
firm’s goodwill also. On the other hand CESL is C1 graded construction frim.

 They have a set of motivated, well experienced and skilled set of human resources.

When numbers are concerned they have;

 50 civil engineers
 7 electrical engineers
 5 mechanical engineers
 38 engineering assistants
 14 draughtsman
 67civil technical assistants
 80 QS technical assistants
 Since CESL is a semi government organization the government projects have a
greater chance of winning the new government projects.

Weaknesses of CESL

CESL is a semi government organization. Although they practice very efficient

management policies there could be some issues in efficiency and the wastage in the
engineering operations since CESL is not totally profit motive.

Also In my experience CESL had to rely on other concrete suppliers since they do not
have their concrete plant nearby. The lack of resources is another weakness of CESL.

Opportunities of CESL

In the present context the construction industry is at its peak. In different civil
engineering aspects the new projects are undertaken in a very rapid manner. Hence obviously
CESL has greater opportunities to maintain its reputation today.

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Threats of CESL

The main threat that CESL is facing is the competitive rivalry today. Other than
CESL there are many constructors who graded as C1. Companies listed below can be
identified as main competitors for the company.

 Access engineering (Pvt) Ltd.

 CML-MTD construction Ltd.
 I. C. C. (Pvt) Ltd.
 K. D. A. Weerasinghe & company (Pvt) Ltd.
 K. D. Ebert & sons (Pvt) Ltd.
 Maga Engineering (Pvt) Ltd.
 Sanken Constructions (Pvt) Ltd.
 Sierra Constructions (Pvt) Ltd.
 Subasinghe contractors and earthmovers
 Tudawe brothers (Pvt) Ltd.
 V. V. Karunarathne & company

Strengths Weaknesses
• Reputation • Possible wastage
• Human Resources • Possible inefficiencies
• Government Projects • Lesser resources

CESL
Opportunities Threats
• Emerging construction industry • Competition from Rivals

Figure 1.5 – SWOT analysis of CESL

According to the SWOT analysis we can see that the company in an admirable
position as far as the current situation is concerned.

6
CHAPTER 2 - TRAINING EXPERIENCE

2.1 About the project

The project is to build the

Kalutara Public Market as a
supermarket which contains more
than 130 stalls in two stories and
a multi-purpose hall. This is a
design and built contract in
between the client Urban
Development Authority (UDA)
and the contractor CESL. The
budget is approximately Rs. 200
million. This is a consideration
under Mega Police project. The
building is a U shaped one Figure 2.1 – Banner of the Project
covering approximately 1300 m2.
This building consists with;
 35 vegetable stalls
 20 fish stalls
 60 groceries
 23 stalls which are not decided the purpose yet.
 Toilet blocks in both floors separated for male, female & differently abled people
 A lift
 Multipurpose hall at 3rd floor.
As a special feature this building has a 1500 mm level difference for same floor level.

Figure 2.2 – Elevation view of the project

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2.2 Management of the construction works

When I began my training period since there was only concentrated substructure
works all the staff members were involved in those activities. After some time when the
things get much complicated the management came up with three different zones with
assigned set of people. (Refer Annex.1) Each zone was looked after by a senior technical or
engineer assistant with supporting junior staff member (Explained in organizational hierarchy
in Figure 1.4.)

2.3 My responsibility and assigned work

Before they came up with the division of different zones I involved in critical
activities as per instructions of site engineer. After the zone division came up I was
responsible for activities in Zone 2 with a senior technical assistant. But I was always given
the freedom to observe any activity going on the site as per my wish.

Also I was to supervise the activities in night shift until 12 pm in every other week
with a senior engineer assistant.

Especially on Sundays and Poya days which the senior staff members were not
present I was responsible for the activities at the site including management of labor.

2.4 Progress of the project during the training period

The overall progress of the project at the beginning of my training period and at the
end of my training period can be concluded zone wise in the following manner.

Table 2.1 – Progress of the project

At the beginning At the end

Ground floor block works had

Tie beams had been concreted. been completed. Plastering had
Some columns had been been completed. Rendering also
Zone 1 concreted. almost completed.
Backfilling had been partially 1st floor block woks had been
completed. partially completed.
Roof beams had been fully

8

Footings and column shafts in
between tie beams and footings
Zone 2
had been concreted.
Backfilling had been started.
Excavation for footings had been
Zone 3
started.
The pictures below will show the progress made during the training period at different
zones.
At the beginning of the training period
Figure 2.3 – Site at beginning
At the end of the training period
Figure 2.5 - Site at end
completed. Steelworks of roof
had been started.
2nd floor slab had been concreted.
Ground floor block works had
been almost completed.
Plastering had been started.
1st floor slab and roof beams had
been concreted.
Block works on ground floor had
been almost completed.
Block works on 1st floor had been
started.
Figure 2.4 - Site at beginning
Figure 2.6 - Site at end
9
 So I got the opportunity to supervise and observe each and every activity which was
undertaken during this period.

2.5 The work I did during the training period

During the period I got the chance to supervise various activities such as;

 Concrete mixing;
o Hand mixing
o Machine mixing
o Ready mix concrete (once I got a chance to visit Sierra concrete plant,
Beruwala)
 Test cube casting & slump test.
 Excavations.
 Backfilling.
 Preparation for screed.
 Reinforcement, form working, concreting & curing of;
o Footings
o Part of the column shaft in between footings and tie beams
o Tie beams
o Columns
o Floor concrete
o Lift well
o Beams & slabs
o Roof beams
 Rubble works
 Block works
 Plastering & rendering
 Steelworks for roof structure
 Water proofing of lift well
 Scaffoldings
 Chemical anchoring

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Other than the supervision activities I did the following things in my training period.

 Setting out of columns with total station.

 Rechecked the setting out with tape.
 Setting out of block works with tape.
 Used level machine for;
o Marking 1000 level of columns
o Installing level pegs for floor concreting and screeds
o Checking the level of the soil before concreting
o Taking spot levels of slabs and tie beams.
o Leveling the slabs & beams and roof beams.
 Prepared checklists for;
o Reinforcement of footings, columns, beams, slabs etc.
o Form working of them.
o Concreting of them.
o Block works.
o Plastering

In this chapter I have presented below my experiences in details, the work I

supervised and the problems encountered with the remedial actions we took.

2.6 Concrete mixing

During the training period we used ready mixed concrete for elements where fairly
large concrete volumes are needed. In other cases where several footings, screeds, columns
were to be concreted we mixed concrete manually. The concrete mixer was only available on
several days during my training period due to its mechanical issues.

2.6.1 Mix proportions of concrete

According to ICTAD specifications we used the following mix proportions to mix

concrete for different items.

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 Table 2.2 – Mix proportions of concrete

Grade Cement: Sand: Metal

G 15 1: 3: 6
G 20 1: 2: 4
G 25 1: 1.5: 3
G 30 1: 1: 2

We used a gauge box which was made for half a cement bag. But in some cases we
measured the sand and metal quantities with number of shovels. For that we used the
following relationship.

One cement bag = 5 cement pans = 10 cement shovels

For screeds we recommended 1: 3: 6 cement: sand: metal concrete mix. Due to the
roughness of the sand (larger particle size) laborers claimed that it would be difficult to level
the concrete. Hence in most cases we used 1: 3: 5 or 1: 3: 4 concrete mixtures.

The main problem we faced with concrete mixing was the difficulty of controlling the
water cement ratio i. e. the water content. We tried to maintain the water cement ratio at its
lowest but due to the workability issues sometimes we had to increase the water content up to
a point where the w/c ratio exceeds 0.6. We didn’t use any plasticizer at site. So when we mix
concrete with hand we used mix proportions which give higher grade than the required grade
to allow the deviations.

Also at site there was sea sand and river sand. We always used river sand for concrete
mixing.

2.6.2 Hand concrete mixing

First we got cement and sand mixed.

Then we added metals and water and remixed
it.

Figure 2.7 – Hand mixing

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2.6.3 Machine concrete mixing

Before starting mixing the concrete we washed

the inside of the mixer with grout. Then we put metal
into the mixer with some water. Then only we added
cement and sand respectively. Then we added some
water if required. Than the hand mixing this was better
as far as controlling water content is being considered.
Because of some issues we faced I realized that the
rotational speed of the mixer is very important for a
good concrete mix. At the beginning of using the Figure 2.8 – Machine mixing

machine the speed was higher than the suitable speed so the mixing was considerably poor.

2.6.4 Ready mix concrete

In my training experience I checked concreting of grade 25 & grade 35 concrete.

Grade 35 was for a slab which the jacks should be removed shortly. Specifications of the
concrete were slightly different from supplier to supplier. (Refer Annex. 2 for a delivery
note)

 Type of cement OPC.

 Retarded for 4 hours.
 Max coarse aggregate size 20 mm.
 Target slump and tolerance was depending on the suppliers’ specifications I received
120 ± 20 mm, 130 ± 30 mm etc.

Once I got the chance to visit the concrete plant at Beruwala, Sierra Ready mix. There
I saw how they batch the concrete.

Figure 2.9 – Control panel at plant Figure 2.10 – Ingredients at plant

13
 Figure 2.11 - Batching Figure 2.12 – Truck at site

2.7 Test cube casting and slump test

2.7.1 Test cube casting

Normal practice was casting 4 cubes per 20 m3. If we choose a truck to cast cubes
minimum 3 cubes should be casted. Molds are filled in three layers each compacted with 35
blows. Immediately after filling a mold I labeled them stating;

 Truck number
 Cube number
 Grade
 Date

Here I supervised
especially the number of
blows per layer
carefully. If the slump
showed a deviation
those trucks were given
the priority.
Figure 2.13 – Labeled cubes Figure 2.14 – Casting cubes

14
2.7.2 Slump test

We checked the slump for each and every concrete

truck. The slump cone should be filled in three layers each
compacted with 25 blows. Here also I carefully checked the
number of blows. In my experience all the grade 25 concrete
trucks showed acceptable slumps which were within the
specified tolerable limit. Only in grade 35 concrete I observed
considerably deviated slumps. When the target slump was
specified as 140 ± 20 mm I received trucks with 75 mm slump
& 180 mm slump. After discussing with senior engineers we
accepted them but informed that immediately to the plant
Figure 2.15 – Testing slump
manager.

2.8 Excavations

Mainly for the footings we

excavated the soil by JCB excavators. We
added 300 mm for either side of the footing
as working space and decided the size of the
excavation. Setting out was carried out with
Total Station. First we installed 4 pegs to
indicate the four corner points. That was
decided by keeping a margin of 300 mm Figure 2.16 – Excavating for footings
from the edge of the relevant footing. Then we drew the square with lime powder. Then only
we asked JCB excavator
operator to continue the
work. We excavated
holes approximately 1
m from the existing
ground level.

Sometimes we
found the parts of the
Figure 2.17 – Breaking older Figure 2.18 – Cutting older bars
previous structures in
concrete

15
some excavations. Then without removing the entire structure as a whole we cut and removed
the relevant part which was a hindrance to the newer work.

2.9 Screeds for footings

After the excavation and compaction of soil was completed first we got the soil
leveled and compacted using tamping rammer (Wacker). Then with the total station we
marked the four corners of the screed with a margin of 100 mm from the margin of the
footing. After that we install four level pegs closer to the corners. The level was decides in a
manner such that the thickness of the screed is 50 mm. We laid a gauge 1000 polythene on
the soil and made the formwork using 2x2 timbers.

Concrete mix proportion for screeds was Grade 15; 1: 3: 6, cement: sand: metal. After
applying concrete we got a mason to level the concrete according to the level pegs installed.
Curing was carried out using wet gunny bags after the setting of the concrete.

Figure 2.19 – Polythene laying Figure 2.20 – Leveling screed concrete

Figure 2.21 – Concreted screeds Figure 2.22 – Curing of screeds

16
Special case of screed

Above mentioned process was the normal procedure. But there was a special case. We
had obtained the space only after demolishing the existing old structures. At one location we
found a part of existing concrete basement. So we did not have to remove that concrete and
concrete a screed again. So what we did was we got the rest of the soil compacted with
Wacker and leveled the rest of the area aligned to the concrete surface with quarry dust and
re-compacted with wacker. We concreted a screed only for the area which the concrete
surface was not there.

Figure 2.23 – Compacting soil beneath Figure 2.24 – Compacting quarry

screed dust & leveling

Figure 2.25 – Finished special screed

2.10 Pad footings

At the site we prepared footings with different sizes varying from 900x900x250 mm3
to 2800x2800x450 mm3.

17
 For reinforcement of the footings first we cut and bent bars into U shapes. T12 @ 150
mm was the specification. The dimensions of the bars were determined by reducing the
covering of 50 mm. We bent starter bars of relevant column also.

First we did the setting out of the column and the footing on the screed with Total
Station. Then we fixed the form work on it. Then we placed the reinforcement cage and
placed covering blocks of 50 mm in an appropriate manner. The main difficulty I came across
was the covering. At some instances I had to get some bars deformed to gain 50 mm
covering. After that we placed the reinforcement cage of column starter bars according to the
setting out and supported it.

When concreting them we used a metal sheet so that concrete will flow into the form
work without segregating the materials. We used porker vibrator to compact concrete. After
setting the concrete we cured them with wetted gunny bags.

Figure 2.26 – R/f & Form work of footing Figure 2.27 – Concreting of footing

2.11 Column shaft between footing and tie beams

Normal column shaft was 300x300 mm2 in all over the

structure. But in this part we designed the columns shaft as 350x350
mm2 since the covering was 50 mm. Stirrup was 250x250 mm.
Since the tie beam depth is 450 mm we determined the height of the
column shaft in this manner. First we marked the tie beam top level
on the reinforcement of column. Up to 500 mm below the mark the
column shaft should be concreted. 450 mm is for beam and 50 mm
was for column pocket.
Figure 2.28 –
Concreting of shafts

18
 Again a setting out for the column on the footing was to be done. Then the formwork
was fixed. We drove a nail to indicate the height of the concrete. All the column shaft parts
were concreted manually with 1: 1.5: 3 mix proportions. Importantly before concreting we
applied a thin grout layer to ensure the bond.

2.12 Tie beams

Throughout the structure the tie beams the

design specification was similar. So we asked the
subcontractors to cut, bend and bind in such a
manner that the specification is satisfied along with
the rules of the laps. That means the laps of the top
reinforcement should be in the middle of two
columns and that of the bottom reinforcement should
be closer to the column, in 1/3 of the span of the
beam. Also the lap length should be 800 mm at least.
(50D = 50x16 = 800). However in both lap lengths Figure 2.29 – Typical tie beam
and lap locations there were some instances a detail
rectification is needed. When there is an issue we bound a third bar so that the effect of the
issue will be mitigated. Tie beam stirrups were designed for covering of 40 mm. So the
stirrup dimension was 220x370 mm2.

Then the form work was fixed. Since all the tie beams were not to be concreted as a
whole we had to keep starter bars at some places. Then the beams were locked using form
ties approximately 750 mm – 1000 mm center to center. Adequate supports were also
provided to ensure the rigidity. Here we mainly concerned about the width of the beam and
the grout tightness. At the places where starter bars were placed sponge were used to cover
the voids. On other places mortar was used.

Before concreting we cleaned the inside of the formwork. Then we applied a thin
grout layer into column pockets. During the concreting compaction had to be supervised. We
had to keep eye on the formwork for any potential leakages. At one point there was a severe
leakage which was immediately rectified. After concreting the beams were cured using
wetted gunny bags for 7 days.

19
 Figure 2.30 – R/f of tie beams Figure 2.31 – Form working of tie beams

Figure 2.32 – Concreting of tie beams Figure 2.33 – Curing of tie beams

2.13 Backfilling

Mainly among the columns shafts and tie beams backfilling was required. JCB
excavator and hoe excavator is used for filling the soil. The hoe excavator was for the back
filling among tie beams where the 1st floor had been concreted before backfilling. After
approximately leveling the soil manually we used roller compactor and tamping rammer
(Wacker) to compact the soil. We got the soil compacted layer by layer each the thickness
was approximately 6 to 8”. Before compacting we removed solid debris such as bricks, stones
etc. to ensure the uniform compaction effort. Those derbies were abundant due to the
demolition of the previous structures. Also the parts of trees and other vegetation and wood
pieces were to be removed also. Normally we applied 20-25 roller compactor travelling
effort. Wacker was used at the edges of the concrete where the roller compactor was not
effective.

The main problem in this stage was the difficulty of controlling the moisture content.
At a period there was a severe drought and at another period there was a severe rainy season.
When the soil is too dry we added the water in an arbitrary manner. At rainy season it was
very difficult to control the moisture content. As a preventive action we kept the new soil
mass covered when it is raining.

20
 Figure 2.34 – Filling the soil Figure 2.35 – Compacting the soil

We preceded the backfilling up to the

bottom level of the floor concrete. Here the
main and difficult task was to finish the
backfilling in a manner such that the floor
concrete would have uniform thickness of
100 mm throughout the floor. So initially we
leveled the final loose soil layer keeping 2” Figure 2.36 – Leveled ground with soil &
quarry dust
higher than the required level to allow the
compaction. But at some instances, after
getting the soil layer compacted we realized
that the level is not uniform throughout the
floor. Here we checked the level using the
level machine. So we removed some soil
when there were peaks. For further fillings
Figure 2.37 – Compacting quarry dust
we used quarry dust since compacting a thin
soil layer would result in a poor bonding in between the two soil layers. We wetter the quarry
dust and used wacker to compact them.

There was a larger hole where we could not fill it with soil due to excessive moisture
content at the moment. For that we put quarry dust and got it compacted it with porker
vibrator.

21
2.14 Floor concreting

Thickness of the floor concrete was 100 mm

throughout the floor of the building. But there were a lever
difference between corridors and shops. The level of the
shops is 100 mm higher than that of corridors. To facilitate
that first we had co concrete strips where the level
differences occur.

Then we laid gauge 1000 polythene on the

compacted soil.
On top of that we Figure 2.38 – Concreting
laid BRC R6 200 strips
c/c mesh. Here we
kept a lap of one square where a lap is needed.
Though this is the floor we used 25 mm cover
Figure 2.39 – Prepared floor
blocks instead of 50 mm blocks. If we used 50 mm
cover blocks the mesh would lie on the neutral axis
of 100 mm floor concrete. After that we installed level pegs to indicate the top level of the
floor concrete. We covered them with short conduit pieces for the safety. Also along the
edges we kept regiform strips to ensure the expansion to allow possible movements of the
floor concrete.

When concreting the floor we supervised in a manner such that the concrete will not
form any cold joints. When the next truck did not come to the site at the moment we asked
them not to release the whole concrete mass at once. Until the next truck came we concreted
the floor slowly releasing concrete discontinuously. Since size of the floor is small we did not
have to use Barra emulsion. I drew the pattern of concreting with the number of trucks (pour
pattern diagram). (Refer Annex. 3)

2.15 Columns

First we did the setting out of the columns with

total station. Before starting the formwork of the columns
we concreted 50 mm kickers on tie beams or slabs so that
the formwork can be rigidly fixed according to the setting
Figure 2.40 –A concreted
kicker
22
out.

The major problem we faced here was the lack of the covering. Though the
recommended covering is 25 mm at some instances the bars were on the edges according to
the setting out. At those instances we increased the dimensions in a manner such that the
setting out is not adhered only on the side where there was less
covering. Due to that we got columns with dimensions up to
300x315 mm2 though the recommended size was 300x300
mm2. But we could only increase the column size by 15 mm.
In some cases we had to deform the bars.

In all the columns as per the design there were 4 bars.

Column section was 300x300 mm2 and covering was to be 25
mm. Hence the stirrup dimensions were 250x250 mm2. Cranks
had to be bent before lapping the bars. When we bound
stirrups we instructed to bind in a manner such that the corner
which the lap presents is changing. Figure 2.41–R/f of
columns
At the site we used conventional plywood form
works. Hence we could concrete the column up to 2440
mm (the height of the plywood board) at one time.
When the formwork is fixing also we got the problem
of difficulty to keep the cover blocks. Due to the
practical deviations of the stirrups, the thickness of the
binding wire of the cover blocks etc. when we bound
Figure 2.42–Covering of columns
two cover blocks at opposite sides the total length
exceeded 300 mm. Then we reduced the thickness of the blocks by breaking the cover blocks.

In the form working of columns we

highly concerned about the grout tightness,
rigidity of the supports and verticality. Four
acro jacks for four sides were fixed. Sometimes
we had to use chains also. When there are
spaces which would lead to grout leakage we
inserted pieces of sponge in to them. To check Figure 2.43–Form working of columns

23
the verticality we installed plumb bobs in two directions
and checked the upper and lower gap between the
plywood board and the string before and after
concreting.

Before concreting we applied a thin layer of

grout. Then we concreted the total height in three times
and compacted with porker vibrator. The main problem
we got was the formation of honeycombs. Fortunately
we did not get severe honeycombs. So we broke the Figure 2.44– A honeycomb

loose concrete and covered the patch with construction

grout where honeycombs were present and that remedy was sufficient.

Bulging of the formwork was an issue in only one instance. In that column one of the
2x2” timber rods was weak. So after that we considered about that also.

We could remove the formwork after a day. Then we cured the columns with wetted
gunny bags for 7 days.

Figure 2.45– Concreting Figure 2.46– Compaction of Figure 2.47– Curing of

columns concrete in columns columns

24
2.16 Slabs & Beams

2.16.1 Kickers

At this site I got the chance to

supervise the activities of slabs & beams 4
times. First step was setting the kickers on
top of the columns in required height. We
marked finish 1000 level in all the columns
and informed the subcontractors the distance
between the 1000 level and the top of the
kickers. For the first floor the floor to floor Figure 2.48– Kickers of beams
height was 3000 mm. Since the depth of the
beams were 450 mm and the thickness of the plywood used for form working was 15 mm the
distance between the 1000 level and the top of the kickers was 3000-1000-450-15 = 1535
mm. After fixing kickers also I checked the accuracy with tape. At the toilet block there was
a 225 mm drop which affected some beams. We had to be careful about that also. In column
pockets on one side we kept a space to allow the cleaning in future.

2.16.2 Beam bottoms & side boards

Then the beam bottoms were fixed.

Beam width was 300 mm all over the
structure. The bottoms were strengthened by
two 2x2” timbers at sides and GI pipe in
middle. Acro jacks were set approximately
750 mm c/c. Here the subcontractor was
well experience about those things so we did
Figure 2.49– Beam bottoms
not need to advise them about the adequacy
of supports. Then the side boards were fixed. In that also we had to take care of the details at
the drop.

25
2.16.3 Slab panels

In from working of slab panels we

used 4x4” timber rods at approximately 750
mm c/c and GI pipes 1’ c/c. After setting the
support they laid the boards on top of that.

2.16.4 Reinforcement of beams

Figure 2.50– Slab panels

Then the reinforcement of beams

could be started. We gave the prepared bar
schedule to the bar bender. He cut and bent
the bars according to the schedule and
labeled them while the other subcontractor
was doing the form working. They started
binding the bars in the areas where the form
working is completed. Since the Figure 2.51– R/f of beams
subcontractor was skilled we did not have to
tell what bar to bind in each and every instance. But we checked the beams while they were
binding them. In no case there was a mistake in 1st layer of the bars. But in binding the 2nd
layer of R/f, spacing of stirrups, lap lengths (should be 50D); stirrups of the column pockets
etc. had to be rectified in some cases. It was recommended to rectify all the errors before
lowering them.

Once we had to lower the beams before rectifying the mistakes otherwise the
subcontractor who was to do the slab R/f would have to idle. But there were some 2nd layers
which were not bound. So we had to lift the top
reinforcement net of the slab and insert bars at some
instances. At other instance we had to drill the form work
and insert bars. That process took much considerable time
and effort to rectify the issues if we had rectified them
before lowering the beams.

Also there were issues regarding primary &

secondary beams. Since this is not a conventional
Figure 2.52– Primary &
secondary beams

26
rectangular building but a U shaped one in some cases it was difficult to define what the
primary beams are. In fact all the beams had similar cross sectional dimensions of 300x450
mm2. In most cases we selected the beam with the highest weight of reinforcement as the
primary one. But we did not bent joggles at the connections so we could not totally insert the
secondary beams into the primary beams. So we bound them in the manner shown in the
diagram. However then we had to take care of the covering at those inter connections.

2.16.5 Completion of the formwork

Before lowering the beams we fixed

the cover blocks of 25 mm in the bottom of the
beam. Also we pasted masking tape where the
joints of the plywood resented and applied
mold oil all over the inside of the formwork.
Figure 2.53– Masking tape & mold oil
2.16.6 Reinforcement of slab panels

After lowering the beams we could

start the bottom R/f of slab panels. For that
also we gave the prepared bar schedules to the
bar bender and he did his job. Here sometimes
there were no 12 m bars available but the
drawings asked us to use them. In that
occasion our senior technical assistant
Figure 2.54– Completed reinforcement
rectified the bar schedules in a manner such
that the longer bars were replaced by lapping two short bars. Here also we avoided setting the
lap in the middle of the slab panel. When there is a lap in slab panels we placed the bars in a
manner to switch the lap to the other side in
every other bar.

Then the top net of the slab could be

bound. First we laid the distribution bars. On
top of that we bound the specified bars as the
top reinforcement according to the drawing.
Since the distribution bar was always below
the specified top layer and T1, T2 should not Figure 2.55– Electrical works

27
be interchanged there were some conflicts.

After fixing the stools the electrical works could be started.

2.16.7 Beam locking

Meanwhile the beams were locked

using form ties approximately 750 mm c/c.
Here a cross GI pipe was locked with two
2x2” timber rods or short GI pipes at from
tie. The thread bars inside the beam were
covered with ¼” conduit.
Figure 2.56– Locking the beams
2.16.8 Covering

Then we kept cover blocks of 25 mm

to the sides of the beams as required. Since
there were small deviations of the dimensions
of the stirrup it was not easy to place the
cover blocks. Then we used steel rods or a
Betty to deform the stirrup and kept cover
blocks.
Figure 2.57– Keeping covering blocks
Mainly lack of the covering was an
issue at the sides of the beams which the slab R/f U bars
are bound. At some instances we detached the bars and
attached again after keeping the cover. Sometimes we
kept the cover blocks on the tip of the U where covering
was lesser.

To check the top covering we used a gauge of 150

mm (slab thickness). When the covering was not there or
the gauge touched the top net we deformed the bars by
hitting the place by a steel rod or Betty. If possible we
deformed the bars using a dog.
Figure 2.58– Checking top
covering

28
2.16.9 Cleaning the formwork

After completing all the works we had to clean the remaining debris on slab panels
and on beams. There were regiform pieces, plywood pieces, timber dust, leaves, binding wire
parts etc. For the cleaning purpose we used air
compressor, vacuum cleaner, water jet and blower. First
we took the larger debris with hand and the remaining we
washed through the column pockets. After the cleaning is
completed we sealed the column pockets.

2.16.10 Concreting the slab

First we slightly wetted the formwork. When

concreting a special care was taken not to form cold
joints. At column pockets we applied a thin grout layer to
Figure 2.59– Cleaning the
ensure the bond. There were a construction joint, for that formwork
we used Barra emulsion to ensure the bond. I drew the
pattern of concreting by different trucks. (Refer Annex. 4) Compaction was crucial for the
beams and for the column pockets.

Figure 2.60– Concreting the slab Figure 2.61– Construction joint just
after concreting

29
2.16.11 Curing and removal of formwork

After setting the concrete we used wetted

gunny bags to cure the slabs. We cured slabs for
7 days. We removed the formwork of slab panels
only after 14 days and the beam bottoms only
after 21 days. But due to labor efficiency we
tended to remove the entire formwork after 21
days. Figure 2.62– Curing of slab

2.17 Lift well

2.17.1 Lift base

First we prepared the base of the lift well.

There was one footing which we had to cut off the
starter bars for the columns and concrete the rest of
the area as a screed up to the level of the footing.
That issue arose because the design of the lift was
received later. We applied a water proofing sheet
and on top of it we did a cement rendering. On that
we did the setting out.

The reinforcement of the lift well was Figure 2.63– R/f of lift base
consisted with U shaped sections. Using two U bars
we formed a box in one direction and a
same type box was formed in the
perpendicular direction. Then the starter
bars of the walls and 4 corner columns
and the walls were bound.

The formwork was completed

using two 4x4” timber rods at the sides to
facilitate 200 mm thick base. But at the Figure 2.64– R/f and formwork of lift base

corners we had to use plywood because

30
the columns were 100 mm larger in outer side than the lift well.

2.17.2 Lift wall

Since this is two stories building the designers

has only designed the lift wall as a concrete wall only up
to the tie beam level to take the potential thrust from the
earth. That also consisted with U bars inserted from the
tie beams.

But here we had an issue. Only after completing

the work we realized that we have bound the bars
without considering the level of the tie beams. In our
attempt the tie beams had sagged from its middle. So we
had to remove ties, lift the cage with JCB backhoe and

retie them. Figure 2.65– Lifting the R/f

cage
In form working also we had to deform some
bars to gain the required covering. In concreting also we observed that the amount of the
wastage was considerably higher due to the manner that we concreted it.

Figure 2.66– R/f of lift walls Figure 2.67– Concreting of lift walls

31
2.18 Roof beams

The reinforcement, formwork and concreting had similarities with those of tie beams
and the beams. The main issue of supervising the activities was I had to climb the
scaffoldings all the time. We had to manage and supervise the scaffoldings as well in this
scenario.

As per the design the reinforcement of

the roof beams was ideal throughout the
structure. So we prepared bar schedules in a
manner such that the laps of the top layer would
be at the middle of two columns and those of the
bottom layer would be near to a column. Again
we had to check whether that rule is adhered
Figure 2.68– Typical Roof beam
when they
detail
bind the
reinforcement.

We had an issue in formwork. We placed the

Figure 2.69– Covered rag bolts
bars a bit longer and lock the beams.
cover blocks before locking the beam. Then it was
difficult to maintain the beam width to 300 mm due to
practical imperfections. So at the points where the width
exceeds the limit the prepared thread bars could not be
used to lock the beams. Then we had to cut new thread

Before concreting the beams we had to place the rag bolts and cover the threads with
masking tape to facilitate the steel works for roof in future.

In concreting the beams also we had an issue because the length of the pump car was
slightly inadequate to concrete the beams at far most corner. Then we put the concrete on to a
board near that corner and but the concrete into the beams using shovels.

32
 Figure 2.70 – R/f of roof beams Figure 2.71 – Concreting roof
beams

2.19 Rubble works

At the level difference of 1500 mm, at 300 mm

step level differences, at a rubble stair case and at the
foundations of fish stall at the back of the structures
there had to be constructed rubble masonry retaining
walls or foundations. The strength of the rubble work is
depending entire on the degree of packing of the
rubbles so it depends on the skill of the mason. The
largest rubble work was
at the 1500 level
difference. (Refer Fig.
2.71)

The main problem

we faced here was the lack Figure 2.72 – Details of rubble
of smaller rubble stones to retaining wall
fill the gaps in between the larger rubbles. The masons claimed
that normally a rubble load would consist with smaller stones
also. Here we had to break the larger rubbles into smaller parts
which consumed more time.
Figure 2.73 – Constructing
rubble wall

33
 Also at the initial stages of the construction the sand we had was considerably rough i.
e. consisted with larger size particles. The recommended mortar used for bind the rubble was
1: 5 - cement: sand. Due to the issue we used 1: 2: 3 – cement: quarry dust: sand mortar.

2.20 Block works

After completing the setting out we did not have

to concern about the work that much. Most of the block
works were done by subcontractors. At the site we used
150x190x390 mm3 (150x200x400 units) blocks for the
walls. The masons consistently claimed that the blocks
are too heavy so the construction speed would be lesser.
The weight of a block was approximately 30 kg.

We used sea sand for the 1: 5 – cement: sand

Figure 2.74 – Constructing
mortar. Due to the richness of the shell content of the sea
block work
sad we used the masons tend to increase the
thickness of the mortar joint than 10 mm.
we consistently advised about the joint
thickness.

Near the columns to ensure the bond

other than the thick grout paste we fixed a
Figure 2.75 – Hoop iron at columns
steel L shaped strip (hoop iron fasteners)
once in every 4 layers of blocks. On top of the block we fixed the strip to the column with
concrete nails.

2.21 Plastering

Plastering of the walls were carried out

by subcontractors in most cases. We kept the
gauges for 15 mm plaster referring to the 300
mm off line from the face of the wall at two
points. Those were at the bottom part of the

Figure 2.76 – Plastering

34
wall. For the top of the wall the mason had to keep two gauges using the plumb bob referring
to the bottom gauges. 1: 5 – cement: sand plaster was applied afterwards.

We had to sieve the sea sand for the plastering.

After the process we kept the box bar on the plaster and
checked the perfectness of the plaster using a torch. We
observed whether we can see light from places through box
bar and the plaster.

We used chicken mesh at the connections of beams

or columns with the block work when there is a risk of
detaching especially at the places where concrete surface
and the block work surface are on one plane. We cut
approximately 6” wide strip of the chicken mesh and
attached it to the wall where the connection is present using
concrete nails and washers. Then we applied the plaster on
it.
Figure 2.77 – Chicken mesh
At rainy days there were difficulties of plastering
the walls. At one rainy day two plastered wall parts at the level difference were washed down
by the rain water. Afterwards we used that mortar for ongoing rubble works and block works
with suitable modifications to overcome the higher water content.

2.22 Floor Rendering

On the concreted floor we kept

level gauges using the level machine.
According to the spot levels we
calculated the level of the top of the 25
mm thick rendering from the finish 1000
level marked on the columns. That
means if we have larger level differences
we would keep 15 mm thickness at the Figure 2.78 – Floor rendering

35
point and level the entire floor to that level. But in our case we did not get larger variations
for floor concrete hence we could adhere to the level of 1000-25=975mm.

The main problem we faced was due to the rain water seepage into the building it was
difficult to render the floor. So we first rendered the floor areas at the stalls (higher level). (I
was not able to supervise the lower level of the floor. But if the rain continues we would
probably have constructed a small bump to block the water seeping into the area.)

2.23 Water proofing

In my training experience we did the water proofing for the lift well. The water
proofing consisted with main three phases.

1. Membrane at the basement (under the lift base).

2. Water bar on the lift base.
3. Membrane on the lift walls.

2.23.1 Membrane at the basement

On the screed of the lift base first we

did the setting out for the lift base. According
to that dimensions the subcontractor painted a
thin tar layer. On top of that they heated a 3
mm bitumen sheet and pasted it. On top of that
we applied cement rendering to protect the
membrane.
Figure 2.79 – Membrane at the base

2.23.2 Water bar on the lift base

After concreting the lift base and

before concreting the lift walls we placed a
water bar on the lift base in the middle of the
lift wall. We could paste it with Chemfix glue
but to assure the bond we nailed it at several
Figure 2.80 – Water bar

36
 places to the lift base.

We checked how the water bar will act as a water

proofing material. It will swell by absorbing the water so
that any pores will be sealed while the water tries to
penetrate it. We kept a small part submerged in water to see
how it works. (See Fig. 2.81)
Figure 2.81 – Swollen
water bar

2.23.3 Membrane on the lift walls

After the completion of the lift wall we

could paste the membrane on it. But we had to
excavate around the lift well to increase the
working space. Like the membrane at the
basement here also after cleaning the surface
they painted a tar layer on the area. Then the 3
mm bitumen sheets could be pasted on it by
heating the sheet. The main problem we
encountered here was the moisture content of the
surrounding. So first we had to remove the water
with a piece of sponge. But then we had to allow Figure 2.82 – Membrane at walls

it dry while the subcontractor had to idle a while. To protect the membrane we tried to paste
1” regiform sheets but it was unsuccessful due to the sandy nature of the bitumen sheet.
Hence we kept the regiform sheet next to the membrane and got the soil compacted in a
manner such that the regiform sheet will remain next to the membrane.

2.24 Chemical anchoring

We had to do chemical anchoring for

some design alterations and also for some missed
opportunities to keep starter bars. First we drilled
the holes into the concrete beams to insert the
new bars. The major problem we faced was
some of our attempts ended up with meeting the
Figure 2.83 – Chemical anchoring

37
reinforcement of the beam. Then we had to attempt for the 2nd time also. Then we cleaned the
hole well. The chemical was inserted into the hole and then the bars were inserted. We had to
make sure that the hall was clean and dry. Also it was crucial to make sure the chemical paste
was coated all around the bar.

2.25 Scaffoldings

Mainly the scaffoldings had to be

supervised for the roof beams. Due to the
lack of resources we only completed the
scaffoldings with working plate only for a
little portion. For others we used GI pipes
and the plywood boards on top of it to form a
working space so that we could increase the
space between the adjacent scaffoldings.
Here the labors were skilled so I only had do
Figure 2.84 – Scaffoldings
inform the senior management about the
required resources and manage the team to set the scaffolding fast as per the requirement at
the time.

2.26 Steel works for roof

In my training period I could observe the beginning of the steel works for the roof
including;

 Cleaning the rust of UBs.

 Applying anti corrosive paints for UBs.
 Cutting UBs with grinder.
 Cutting the plates with flames.
 Smoothing the edges of the plates with grinder.
 Drilling the holes for splice plates.
 Welding splice plates.
 Placing the UBs with a crane.

Etc.

38
 We did not have to closely monitor those activities since the subcontractor was very
skilled. All the machineries and equipments were also from the subcontractor. We only had to
inform the details of the work and facilitate them with the required ingredients. Here I was
able to learn only the basic activities since my training period was over before they come to
the major steel works.

Figure 2.85 – Steel works

2.27 Setting out of columns with total station

Mainly the setting out was carried out by the engineer

assistant but I got the chance to mark some of the columns. We
obtained the coordinates of the columns from the footing Auto
CAD drawing.

If the columns were on a vertical or horizontal grid line

we could have mark the relevant lines with total station and then
mark the relevant columns. But due to the U shape of the
building in most cases we had to mark the corners of the column
Figure 2.86 – Setting
for each and every column.
out with TS

39
 The main problem we faced was the lack of visibility. To set the total station we had
to have two known points. We set the TS at one of those points and considered other as the
back sight, then rechecked it by observing that point. So at known point we had to observe
one other known point and the area where the setting out was to be done. In some case we
could not satisfy those needs. Hence we had to mark temporary points to carry out the work.

Also when marking a columns in most cases we could not see all the four points. In
some cases we could only observe two points. In those cases we had to use mason square to
completely draw the column.

2.28 Rechecking the setting out with tape

Though the setting out with TS was trustworthy there might be errors while marking
the points, setting the TS etc. Hence we rechecked the setting out with tape. I printed a
drawing with all the relevant dimensions at the relevant area and checked with the tape
whether the setting out is exactly the same as the drawing.

Except one place I did not find any deviation of the setting out. That error also was
not due to the fault of the TS. The mason had marked a line of a column slightly differently
considering some marks on the concrete while the intentionally marked points were there.

2.29 Setting out of block works with tape

If the total station was available we could easily mark the line. But there was a time
where the total station was not available. Then we had to do the setting out with tape. The
block works on lower ground floor had been completed then the setting out of the adjacent
upper ground floor had to be completed.

First we had to mark the off line on the relevant area. We observed the 300 off line on
the lower ground floor at two different points with center plumb bobs and copied it on the
upper ground floor. Then using that line we could mark all the other relevant lines and off
lines with tape and mason square.

2.30 Use of level machine

I used level machine for different purposes. Some of them are described below.

40
2.30.1. Marking 1000 level of columns
For the formwork of the beams we had to mark finish 1000 level on each and
every column. If the columns to be marked were on a same level with some marked
columns I obtained the reading for 3 columns and got the average to mark on the other
columns. If there is no any column marked on that level I took the reading for 3
columns at a different level and calculated the reading for the relevant columns.

2.30.2. Installing level pegs for floor concreting and

screeds
From the marked finish 1000 level I
obtained the level of the surface of the floor
concrete. For the screeds for footings I calculated
level to ensure the thickness of the screed is not
less than 50 mm. First we installed a piece of bar
and read the difference between the reading at that
level and the required level. I informed the
difference to the labor and he made the change.
Figure 2.86 – Installing
Then I rechecked it. The process was carried out
level pegs
until the correct level is achieved.

2.30.3. Checking the level of the soil before concreting

If the level of the soil is higher than the recommended level the thickness of
the concrete would be reduced. If the level of the soil is lower than the required level
the thickness of the concrete would be higher i. e. we could not achieve the
economical perspectives. Hence it was crucial to level the soil to the recommended
level. I checked the reading of different points and asked the labors to adjust the
relevant amount by removing the soil or by adding quarry dust.

2.30.4. Taking spot levels of slabs and tie beams.

To decide the level of the plaster we had to gain an understanding about the
deviation of the level of the concrete. So I obtained spot levels. (Refer Annex. 5)

41
2.30.5. Leveling the slabs & beams and roof beams.
Thought the subcontractors leveled the slab using a string we leveled the slabs
and beams. After obtaining the reading at marked finish 1000 level I calculated the
reading to be expected at the bottom of the slabs and beams. Then I asked the labor to
invert the staff and keep it vertically and checked the reading. I found deviations up to
20 mm. The main problem I came through here was the lack of visibility due to acro
jacks. Then I had to set the level machine at different places to level different areas.

2.31 Preparing check lists

We prepared check list to ensure the work is up to the required standard without any
features with disqualifying nature. Mainly for reinforcement we concentrated because that’s
where the beams and columns are mostly deviated one from another and that’s where the
mistakes might happen at highest probability. Other than that I prepared check lists for
formworks, concreting, block works and plastering. The checklists covered comprehensively
the possible errors so the method was effective. It required the signature of the technical
officer and the site engineer hence the degree of responsibility is also admirable in the
method. (Refer Annex. 6 for the formats of the checklists)

Especially to gain ISO standards I prepared checklist file appropriately with colour
tags for different zones and two box files separately for ground floor and upper floor
checklists.

2.32 Managing the labors and labor handling

In most cases the site engineer or a senior staff member did allocate the available
laborers to the duties for the day at the beginning of the day. My responsibility was to
supervise the set of activities to make sure the work is up to the required quality. But in some
days especially on Sundays and Poya days I had to allocate the laborers for different duties.

The main problem I encountered in this aspect was the lower number of the laborers.
Not only I but also senior management people had that issue. Especially on the Deepavali
season the Tamil laborers demanded a vacation. So we had to rely on a limited number of
laborers to carry out several different tasks at the same time. That was very frustrating on the
laborers side because switching in between activities in a rapid manner was uncomfortable up

42
to an extent, which was very understandable. So when supervising the activities I had to be
extra careful to make sure the laborers’ level of satisfaction is not harmed.

On the other hand there were some instances where one of the laborers tends to be
idling while others work hard. In those instances I tried my best to convince them to work as
others explaining the unfairness of idling as one of a set.

During these activities I had to be updated as to how the work was going at the
moment, what proportion had we completed from the task, how many laborers were there to
facilitate my task, where were they working and what are they doing at the moment etc.
Senior staff members were directly contacting me for the information.

2.33 Resource management

The store keeper issued the required materials only after receiving a signed note by a
staff member. That note required us to fill these details.

 Date
 Name of the required material
 Quantity of the material
 Name of the laborer who is asking the material and the Signature
 Name and signature of the staff member who is confirming the requirement

I was also entitled to sign the request notes. At some cases a senior member told about
the required quantities. Otherwise in most cases I discussed with the skilled laborer and came
to an agreement.

2.34 Safety management

The degree of the safety that the site had was considerably admirable but there were
some issues also. In my experience I did not come across a severe accident which caused a
fatal incident. But there were some incidents due to lack of safety. So as a responsible person
I always request the laborers to think about their safety. In most cases I asked laborers to;

 To wear hand gloves in most of the time.

 To wear boots whenever necessary especially when mixing concrete.
 To wear eye protection equipment when they use bar cutter or grinder.

43
  To wear masks when cleaning the chipped concrete for kicker box or cleaning the
drilled holes for chemical anchoring.
 To wear helmets in most of the time.

Here some of the laborers were very reluctant to wear helmets claiming they would
get headache, especially the sub-contractors. So we had to explain them about the importance
of having the safety helmets.

2.35 Exposure to plant, equipment and machinery

During the training period I got the chance to observe and supervise the various
plants, equipments and machineries. Some of them are listed below with the purpose that was
used at the site.

 JCB excavator to excavate pits for footings, moving the materials such as sand,
cement bags, metal, cement blocks etc. from the place where stored to the place where
there were to be used them at the moment.
 Hoe excavator for the backfilling in between tie beams after concreting the 1st floor
slab.
 Roller compactor to compact the soil.
 Tamping rammer (Wacker) to compact the soil where the roller compactor was not
effective.
 Concrete mixer to mix concrete.
 Porker vibrator to compact concrete.
 Pump cars and concrete trucks to concrete larger masses.
 Bar bender to bend the bars into L, U shapes and to prepare stirrups and stools.
 Bar cutter to cut the bars into required lengths.
 Power saws to facilitate form working.
 Vacuum cleaner, water jet, air compressor, air blower etc. to clean the slab formwork.
 Hammer drill to insert bars into concreted elements for chemical anchoring.
 Hoist to carry materials into 1st floor whenever necessary.
 Sieve machine to sieve sand for plastering.
 Crane to lift the UBs up to the roof.
 Welding plant to weld the steel UB sections at roof.
Etc.

44
2.36 Support from the staff at the site

First I would appreciate the DGM, Eng. H. M. T. N. Dhanawardane and the senior
operation engineer, Eng. T. C. S. Jayaneththi for their kind attention about my training as the
training coordinators. My direct supervisor was the operation engineer, Eng. J. M. M.
Jayasinghe. Under him the site engineer Eng. L. R. Wijesinghe was the closer supervisor for
me as the engineering professional. Apart from that I was directly involved at the site
activities with the technical assistant Mr. A. M. N. Perera who was the senior staff member to
take care of the activities at zone 2. All three members did a perfect job as my supervisors by
explaining the engineering aspects of the undergoing works and by sharing their other
experiences and encountered problems which was related to the work at that moment. Also
they gave me a considerable degree of responsibility only after explaining me about the work
and I gained a sufficient knowledge about the work. The assistant operation engineer, Eng. K.
P. M. Krishan also gave his full support by showing me how to manage with people.

Apart from that the engineer assistant Mr. I. B. K. Perera who was responsible for the
setting out for the building was very helpful for me to practice the level machine and
especially the setting out with total station and with the tape and plumb bobs. Engineer
assistant Mr. W. M. L. Welikanna also helped me to understand the issues at the site by
asking and answering the related questions at many occasions. Technical assistant, Ms. A. D.
O. De Zoysa and the technical officer Mr. H. M. S. E. Bandara was also very helpful for me
to understand the problems and find solutions at the site.

On the other hand Mr. H. V. Paranagama, the quantity surveyor of the site was very
helpful for me to gain an understanding about BOQ, interim bills, RPC rates, BSR etc. The
store keeper Mr. K. R. R. Rathnaweera also gave an admirable support when it comes to
management of resources.

Basically the support from the staff was highly appreciable. Though I was the only
engineering trainee from our university it was not an issue thanks to the friendliness of the
staff.

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CHAPTER 3 - CONCLUTION

3.1 About the training

At the Kalutara Public Market site by CESL as a trainee I was able to observe and
then supervise the activities related to many civil engineering applications. Especially I got
the chance to learn about concreting i. e. mixing of concrete by hand or machine, ready mix
concrete, test cube casting and slump test, compaction and curing of concreted elements etc.
During the training period screeds, footings, tie beams, columns, slabs & beams, floor
concrete and roof beams were concreted. Also I got the chance to learn and supervise the
cutting, bending and binding of reinforcement and the form working of such items.
Meanwhile I was to supervise excavation and backfilling at some areas. Rubble works, block
works, plastering and rendering was also covered in the period. Steel works for the roof were
also started by the time. Other than those things I got the chance to observe chemical
anchoring and water proofing. Labor management was one of the main aspects I got the
chance to learn there.

On the other hand I was to do some setting outs with total station and with tape. On
some instances I checked the accuracy of the setting out also. Level machine could be used
for different purposes including leveling the slabs & beams, leveling soil, obtaining spot
levels etc. Check lists are another important thing I did during the training period.

Considering the different aspects I covered during my training period I could

concluded that during this short 16 weeks period I have got the chance to take the maximum
advantage by being exposed to a wide range of activities.

3.2 Areas of weaknesses

At some times I felt that I should recall what I studied in University. Especially in
reinforcement it was important to know what we learnt at University. Though I was
successful in understanding and managing the activities I hope to recall the design aspects I
learnt further.

It was obvious that as the only trainee form our university who went there it would
take some time to get used to the environment of the organization. I feel that I should be
improved in managing the laborers. Though I did not fail in any activity I feel that I should
learn more how to get the work done while maintaining the laborers’ level of satisfaction at

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higher level. But on the other hand that was an overall issue at the site. The experience I
gained here will help to achieve my target.

3.3 Training at CESL

Clearly the organization did a highly admirable job when it comes to training me. The
support from the staff members including senior engineers and fresh technical officers the
welcome and the willing to train me were honestly appreciable. Senior staff members
consistently asked questions about the work at the moment with the intention of making my
knowledge strong. Non engineering staff members also gave a greater help to understand the
management and financial side of the project.

Due to the higher work load the operation engineer had limited time to spend on the
training diary and the four weeks assessments. But that was highly understandable. Though
he had such a work load he was kind enough to facilitate such needs as well as to make my
knowledge thorough.

I can honestly conclude that I was fortunate to be trained under these staff members.

3.4 How to improve the training

Since the project was two story building I was fortunate to be exposed in to a wide
range of activities. But I was unable to be exposed to piling, complex reinforcement and
formwork design. If we got the chance to be rotated at different sites it would be resulted in a
larger set of experiences. But on the other hand as far as the time to get used to the
organization is being concerned it is questionable whether it would be useful.

If the period was to extend up to 6 months I would have been exposed to the complete
finishing of the site. So in any case I would suggest increasing the training period up to 6
months with the intention of improving the quality of the training.

3.5 Expectation vs. reality

At the beginning of the training period my intention is to gain the maximum in this
limited time period without being demotivated by the fatigue. Obviously I did attend the
work if not for a major event even in weekends and Poya days. Also I was there at night shift
on every other week until 12 pm. But that dedication resulted in gaining a vast area of
knowledge and experiences. I finished my training period as a highly satisfied intern.

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