Table of Contents

1. SECTION 1: COMPANY PROFILE. ........................................................................................................... 5

1.1 BACKGROUND ............................................................................................................................... 5
1.2 Mission .......................................................................................................................................... 5
1.3 Vision............................................................................................................................................. 5
1.4 Values ............................................................................................................................................ 5
1.5 Stability ......................................................................................................................................... 6
1.6 Reputation .................................................................................................................................... 6
1.7 Excellence...................................................................................................................................... 6
1.8 Organization Structure .................................................................................................................. 7
1.9 Company Address. ........................................................................................................................ 7
1.10 SOME MAJOR PROJECTS COMPLETEDBY THE FIRM ..................................................................... 8
1.10.1 Water Projects ...................................................................................................................... 8
1.10.3 Roads, Highway & Bridge Projects ........................................................................................ 8
1.10.4 Buildings ................................................................................................................................ 9
1.11 Orientation .................................................................................................................................... 9
1.11.1 The Consulting Engineer. .................................................................................................... 10
1.12 Training Program......................................................................................................................... 10
1.13 Task assignment and Reporting .................................................................................................. 11
1.14 Conclusion ................................................................................................................................... 11
2. SECTION 2: MARLBOROUGH TWO STOREY APARTMENTS PROJECT. ................................................. 12
2.1 Salient Feature of the Project ..................................................................................................... 12
2.2 Detailed Account of the tasks performed by student................................................................. 12
2.2.1 Site Visit............................................................................................................................... 12
2.2.2 Setting Out .......................................................................................................................... 13
2.2.3 Bar Bending Schedule. ........................................................................................................ 13
2.2.4 Drawing Issue Sheet. ........................................................................................................... 13
2.2.5 Design Calculations. ............................................................................................................ 14
2.2.6 Additional Tasks .................................................................................................................. 20
2.3 Civils Work. ................................................................................................................................. 20
2.3.1 Storm drainage.................................................................................................................... 20

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 2.3.2 Road Paving. ........................................................................................................................ 21
3. SECTION 3: CM2 TRANPORT SYTEM LAFARGE PROJECT. .................................................................... 23
3.1 Salient Feature of the Project. .................................................................................................... 23
3.2 Site Visit....................................................................................................................................... 23
3.3 Soil Test. ...................................................................................................................................... 23
3.4 Setting Out. ................................................................................................................................. 24
3.5 Design.......................................................................................................................................... 24
3.6 Foundation design ...................................................................................................................... 25
3.6.1 Pad footing .......................................................................................................................... 25
3.6.2 Combined Footing. .............................................................................................................. 25
3.7 Problems Faced. .......................................................................................................................... 26
4. SECTION 4: MODIFIED SEWAGE TREATMENT PLANT PHASE 1. .......................................................... 27
4.1 Salient Feature of the Project. .................................................................................................... 27
4.2 The General layout of a Biokube system. ................................................................................... 27
4.2.1 Pre-treatment ..................................................................................................................... 27
4.2.2 Biological treatment............................................................................................................ 28
4.3 Concrete Tests. ........................................................................................................................... 28
4.3.1 Slump Test. .......................................................................................................................... 28
4.3.2 Concrete Cube Test. ............................................................................................................ 29
4.4 Formwork .................................................................................................................................... 29
4.5 Concrete pouring. ....................................................................................................................... 29
4.6 Remedial works ........................................................................................................................... 31
4.7 Water tightness test.................................................................................................................... 31
4.8 Weekly Progress Report .............................................................................................................. 33
4.9 Additional tasks. .......................................................................................................................... 33
5. SECTION 5: MODIFIED SEWAGE TREATMENT PLANT PHASE 2. ......................................................... 34
5.1 Salient Feature of the Project. .................................................................................................... 34
5.2 Bill of Quantity ............................................................................................................................ 34
5.3 Specifications Document. ........................................................................................................... 34
5.3.1 Section 1: Preliminary and General .................................................................................... 35
5.3.2 Section 2: Materials ............................................................................................................ 35
5.3.3 Section 3: Earthworks. ........................................................................................................ 36
5.3.4 Section 4: Plain and reinforced in-situ concrete. ................................................................ 36

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 5.4 Preliminary Drawings .................................................................................................................. 38
5.5 Tender Drawing........................................................................................................................... 39
5.6 Construction Drawings. ............................................................................................................... 39
5.6.1 Collection Pipe and Airlift Pumps Layout and detail. .......................................................... 39
5.6.2 Hydraulic Profiles ................................................................................................................ 41
5.6.3 Manholes ............................................................................................................................ 41
5.6.4 Pipe fitting Schedule and reference drawing ...................................................................... 41
5.6.5 Sump 2 layout and details. .................................................................................................. 42
5.6.6 Flow Splitter Box layout and details.................................................................................... 42
5.6.7 UV Station and HEX Drum Filter Platforms ......................................................................... 42
5.6.8 Pile setting out drawing and piling...................................................................................... 43
5.7 Dewatering .................................................................................................................................. 44
5.8 Pouring of Concrete. ................................................................................................................... 44
5.8.1 Curing .................................................................................................................................. 45
5.9 Pipe work installation and pipe fittings ...................................................................................... 45
5.9.1 Pipe Fittings ......................................................................................................................... 45
5.9.2 Pipe Backfilling .................................................................................................................... 47
5.9.3 As-built drawings and record drawings .............................................................................. 47
5.9.4 Pipe test and Biokube Test.................................................................................................. 48
5.9.5 Water Tightness of manholes and sumps ........................................................................... 48
5.9.6 Thrust Block......................................................................................................................... 48
6. SECTION 6: NKULUMANE OUTFALL SEWER. ....................................................................................... 49
6.1 Salient Feature of the Project. .................................................................................................... 49
6.2 Tasks and Responsibilities. .......................................................................................................... 49
6.3 Design Procedures ...................................................................................................................... 50
6.3.1 Layout of the sewer ............................................................................................................ 50
6.3.2 Identifying and locating manholes. ..................................................................................... 50
6.3.3 Design calculations.............................................................................................................. 51
6.3.4 Longitudinal Sections .......................................................................................................... 52
6.4 Final assumptions and comments. ............................................................................................. 52
7. SECTION 7: SEKUKHUNE LEBALELO RESERVOIRS. ............................................................................... 54
7.1 Salient Feature of the Project. .................................................................................................... 54
7.2 Design Calculations. .................................................................................................................... 54

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 7.2.1 Design of Flat Slab Floors. ................................................................................................... 54
7.2.2 Stability of Retaining Walls ................................................................................................. 55
8. SECTION 8: COMPUTER SKILLS AND OVERALL BENEFITS OF INDUSTRIAL ATTACHMENT. ................. 57
8.1 Computer Skills: Introduction ..................................................................................................... 57
8.1.1 AutoCAD .............................................................................................................................. 57
8.1.2 Prokon ................................................................................................................................. 57
8.1.3 Microsoft. ............................................................................................................................ 57
8.1.4 Revit. ................................................................................................................................... 58
8.1.5 Civil 3D ................................................................................................................................ 58
8.2 Overall Benefits of the industrial attachment. ........................................................................... 58
9. SECTION 9: CONCLUSION AND RECOMMENDATIONS. ....................................................................... 60
9.1 Conclusions ................................................................................................................................. 60
9.2 Recommendations ...................................................................................................................... 60
9.2.1 Recommendations to the company .................................................................................... 60
9.2.2 Recommendations to the university ................................................................................... 60
10. List of Tables ................................................................................................................................... 62
11. Table of Figures. .............................................................................................................................. 62
12. Appendix ......................................................................................................................................... 64

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1. SECTION 1: COMPANY PROFILE.

1.1 BACKGROUND

Hydro-Utilities (Pvt) Ltd is an independent firm of local consulting Engineers providing

professional design, engineering and management consultancy services. The firm was
established in 1991 as one of the first indigenous engineering consultants and still operates
today after 28 years of providing first class engineering service. HU team of professionals and
registered engineers are experienced and passionate about the work they do in implementing
practical sustainable solutions to various environmental challenges in our ever-changing
climate. HU prides itself in delivering the best and meeting the clients’ needs without
compromising on quality, time and cost factors. HU has a range of professional services that
cover water resources engineering and management; water and wastewater treatment and
engineering; irrigation and drainage; highway and transport engineering; structural
engineering; geotechnical engineering and surveys; environmental engineering; and project
management.
Hydro-Utilities is a member of:
• ZACE
• ZIE
• ECZ
and is registered with the World Bank, African Development Bank and also in the process of
registering with other international agencies.

1.2 Mission

Hydro-Utilities aims to be a leading engineering consultancy business in the region helping to

make a significant contribution to the quality of lives of millions of people in our country and
beyond.

1.3 Vision

To be a reputable, world-class and professional engineering consultancy business delivering

innovative, sustainable and safe solutions to engineering challenges.

1.4 Values

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 • To act with integrity and honesty.
• To embrace and demonstrate good business ethics in the workplace.
• To be diligent in our approach to quality.
• To continually seek excellence.
• To be client focused and serve the client’s needs first.
• To embrace the principles of environmental, health & safety management and
sustainability.
• To maintain our stability, strength and reputation through teamwork and deliverance.
Hydro-Utilities prides itself in delivering excellence through leading engineering
applications supported by an experienced and well-established professional staff
complement. Our competitive advantage lies in our stability, reputation and engineering
excellence.

1.5 Stability

Hydro-Utilities office has 400 sq. m of office space that is home to the Administration and
Financial Departments, Roads & Highways, Structural & Buildings, Civil, Water &
Environment Divisions. The firm has grown from strength to strength over the years since its
establishment in 1991 and this is largely due to an efficient and effective management team
and support staff. Stability is one of our key strengths and this has been important in the firm
securing significant contracts locally and regionally and maintaining quality and excellence
even during times of past economic challenges.

1.6 Reputation

Hydro-Utilities has established a solid reputation as engineering and management consultant

in Zimbabwe and beyond since 1991. HU’s success is as a result of having a stable foundation,
passionate and dedicated professional staff and the spirit of teamwork. HU sets high standards
and aim to achieve them so as to give clients the best possible solution taking into consideration
all elements of design and sustainability.

1.7 Excellence

Providing engineering excellence is the way to do business. HU appreciates and understands

today’s ever changing technological and human needs, and as such, aim to match that by
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 providing engineering excellence through up to date engineering applications and new
technologies. An experienced team of engineers and technicians are quick to assess and
provide workable and well-thought out solutions to a variety of engineering problems.

1.8 Organization Structure

Eng T. Mpala
(MD)

Mrs Madida
(HR Manager)

Mrs R. Mugaba
(Receptionist)

Mr M. Chimanga Mr. Gwende Eng. T. Kasirori

(Site Agent) (Draftsman) (Design supervisor)

Mr. G. Jokonya and Mr. C. Takavarasha

(Graduate Trainees)

Mr K. Chinyerere and Mr K. T. Kujinga

(Attachees)

Figure 1-1: Organogram

1.9 Company Address.

HEAD OFFICE
140 Nelson Mandela Avenue
P O Box 5947, Harare, Zimbabwe
E-mail: hydrohre@mango.zw
Tel: +263 4 795252 /729788/ 737721
Fax: +263 4 795252
BRANCH OFFICE
Suite 5 Princess Court
Corner S. Parirenyatwa/L. Takawira
P O Box 3025, Bulawayo, Zimbabwe

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 E-mail: hydrobyo@mango.zw
Tel: +263 9 75895 / 68424
Fax: +263 9 77959

1.10 SOME MAJOR PROJECTS COMPLETEDBY THE FIRM

Hydro-Utilities Consulting Engineers have worked on and completed a wide range of major
civil, structural and environmental projects for clients both in the private and public sectors.
Some of the projects completed are detailed below: -

1.10.1 Water Projects

1.10.1.1 Pungwe – Mutare Water Supply and Pipeline Project.

Hydro-Utilities completed the civil design and supervision of this significant water supply
project for the City of Mutare. This scheme enabled the withdrawal of 0.7m³/s of raw water
by gravity from Pungwe River via a 4.3 km tunnel and 70km pipeline to augment City of
Mutare’s water supply system. SKANSKA were appointed Principal Contractors.

1.10.1.2 Magunje Water Treatment Works.

As Project Engineers and supervisors, Hydro-Utilities led the design and construction of a
350m³/ hour water treatment plant to provide potable water for the town of Magunje and
surrounding areas. This African Development Bank funded project included a 6000m³
water storage reservoir and distribution network
1.10.2 Municipality Housing Projects

1.10.2.1 Bulawayo’s Cowdray Park Housing Project

Previously, Cowdray Park’s 1200 housing units had no sewage disposal systems or at most
dilapidated infrastructure. On this project Hydro-Utilities provided design services for the
installation of a new sewage collection and conveyance system along with associated
sewage treatment ponds. Today, the housing suburb is transformed and enjoys a fully
functional sewage treatment system.

1.10.3 Roads, Highway & Bridge Projects

1.10.3.1 Harare Drive Missing Link Highway Project.

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 To complete the ring road around Harare, City of Harare embarked on a project to construct
the missing 8km road link from Second St/ Golden Stairs junction to Borrowdale Road
junction. Hydro-Utilities were appointed design engineers and project supervisors. This
project is strategic for Harare in that the dual carriageway helped reduce traffic congestion
leading into the city center and also boosted trade and local business between the west and
east regions of Greater Harare. The project was commissioned in 2000.
1.10.3.2 Popoteke River Bridge Project
A Ministry of Transport funded project that involved constructing a road bridge over the
Popoteke River on the Chatsworth – Gutu Road. Hydro-Utilities were appointed design
engineers following a successful technical and financial proposal.

1.10.4 Buildings

1.10.4.1 Belmont Industrial Park, Bulawayo

This Zimbabwe Electricity Supply Authority (ZESA) funded project involved the
structural and civil design of a new industrial park complex for Bulawayo in the Belmont
area. Hydro-Utilities were appointed Project Engineers.
1.10.4.2 Lupane University
Carried out the detailed structural designs for all proposed buildings within the university.
The project included tender document preparation and contract management.
1.10.4.3 Harare Water Supply II
Kunzwi Water Development Corporation - Hydro-Utilities engaged in a joint venture with
Interconsult, Brian Colquhoun, Hugh O’Donnell and Partners, Ncube Burrow and Centro
Project for the design services required for construction of a dam and design and
construction of a water treatment plant to supply water to Harare, Chitungwiza, Norton and
Ruwa. The project also involved design of an irrigation scheme.

1.11 Orientation

During orientation the author was firstly welcomed into the organization and introduced to all
the members of staff. He was shown he’s working area and around the organization’s premises.
The author was then the structure of the organization so that it becomes clear who he reports
to and was also told to follow the chain of command if any problems are encountered. The
student was taught how to obtain make reports, how to file drawings or obtain those required

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 whatever the case might be and to put project files in their appropriate filing cabinets according
to their given order of reference. He was also shown how to operate machines like the
photocopier and plotter. The student was given files of the ongoing project files to read so that
he familiarizes himself with the projects. The student was also given a task to practice standard
detailed drawings, reinforcement detailing, bar mark and shape codes for bending schedules.
During the first weeks of attachment, the student attended a short course called ‘The Consulting
Engineer’, presented by Engineer T. Mpala, as part of the induction to the organization. Below
is a summary of what the student leant from the course;

1.11.1 The Consulting Engineer.

Consulting engineering is a professional service that provides independent expertise in

engineering, science and related technical areas to governments, industries, developers and
construction firms. A consulting engineer provides service and sells his time, and intellectual
knowledge. The consulting engineer is supposed make things work for example from the
Architect to construction. A consulting engineer is supposed to show effectiveness, efficiency
and be innovative. Consulting is mostly design. Below is a list of design sources a consulting
engineer should use to gain knowledge;
a. Design Manuals (e.g. Interconsult Manual, Process Design Manual for small
wastewater works etc.)
b. Software Programs (AutoCAD, Prokon etc.)
c. Internet (academic search engines, You Tube, etc.,)
d. Friends and peers.
e. Ask Seniors.
f. Standards – Standards Association of Zimbabwe

1.12 Training Program

The training program covers from August 2018 to end of May 2019. Below is the list of
scheduled tasks given to the student
• Design calculations including bar bending schedules and reinforcement detailed drawings.
• Drafting Structural layout drawings.
• Civils drawings including water and waste water reticulation drawings, and road sections.

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 • Site visits and site meetings.
• Site supervision.
• Writing meeting minutes and progress reports.
• Drawing issue sheets.

1.13 Task assignment and Reporting

The author would be given a task by the project leader and would report directly to him for
checking. The author used a log book to report the work and duties that he carries out per week
during the attachment period. The logbook was to be signed by the supervisor after every
month as confirmation that what was written was true.

1.14 Conclusion

Industrial attachment is a necessary requisite part of the degree program because it gives the
student an opportunity to familiarize with and gain much needed industrial exposure and
linking theoretical items learnt at school and the actual industrial processes in industry.

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2. SECTION 2: MARLBOROUGH TWO STOREY APARTMENTS
PROJECT.

2.1 Salient Feature of the Project

Project Name: Marlborough Lifestyle Apartments.

Client: Homelux Property Developers (Pvt) Ltd.
Contractor: Homelux Property Developers (Pvt) Ltd.
Duration of Project: 8 months
Project Site Location: The project site is situated about 13km northwest Harare City Centre
at number 58 Marlborough Drive, Marlborough.

Project Scope Details.

• Carrying out the detailed structural designs for seven double storey blocks of residential
apartments, including the main entrance, within the housing complex.
• Carrying out road design and its associated storm water drainage.
• The project also included tender document preparation and contract management.
• Additions and alterations of the existing house to make two semi- detached apartments.
• Water reticulation system for the complex.
• Sewer reticulation system for the complex.
• Design of 2.4m high brick front boundary wall.

2.2 Detailed Account of the tasks performed by student.

2.2.1 Site Visit

The design team which included the author were given a tour by the resident engineer around the
site to identify matters that would affect the contractor during construction which included the fact
that there was a powerline near area where guard house was situated, setting out one block was
going to be difficult as it was to be constructed where currently there was an existing swimming
pool and impact of the tree that was located near another block. During the site visit the author
was tasked with writing the minutes of the meeting. In the meeting there was a discussion of the
need of erecting informative signboards and also demarcating safety signs and boundary restriction
tape on areas that might impose human danger. The use of premix concrete for the construction of
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all the concrete structures was suggested by the design team as this would save time and space, the
use of premix means then a laboratory for concrete cube testing would need to be constructed on
site. There was also a suggestion that speed bumps be placed on the main road in front of the
construction site for the safety of the workers. The existing septic tanks had to be decommissioned
as one had collapsed.

2.2.2 Setting Out

The author was part of the team tasked with checking the setting out of one block. After the site is
handed over to the contractor, the operations carried out are clearing the site, setting out the
building then establishing the datum level. Setting out is the process of developing the physical
positions of corners and walls of a building, and it’s done by transferring dimensions from the
layout plan to the ground. The setting clearly defines the outline of the excavations and the center
line of the walls, so that the construction can be carried out according to the plan. The method that
was used for setting out in this project was the peg or rope method. To confirm if all measurements
were correct the author had to check if the diagonals measured exactly the same. Where there was
a difference in the measurement, the back pegs were adjusted as per dimension.

2.2.3 Bar Bending Schedule.

During industrial attachment the author was required to provide a bar bending schedule for most
of the design calculation and reinforcing detailing he was tasked with. Bar bending schedule is a
list of reinforcement bars for a given reinforced concrete work item, and is presented in a tabular
form for easy visual reference. Table of bar bending schedule summarizes all the needed
particulars of bars – diameter, shape of bending, length of each bent and straight portions, angles
of bending, total length of each bar, and number of each type of bar. This information is a great
help in preparing an estimate of quantities. Bar bending schedule provides details of reinforcement
cutting length, type of bends and bend length. Attached in the Appendix is a bar bending schedule
for Marlborough block C and the detailed drawing.

2.2.4 Drawing Issue Sheet.

The author was tasked with writing drawing issue sheets for this all the projects he has worked on.
A drawing issue sheet is a list of drawings in any given project and a record of when revisions
were issued, to whom and in what form.

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 2.2.5 Design Calculations.

2.2.5.1 Design a restrained slab spanning in two directions.

The author was tasked with the design of the first-floor slab. For this task he considered
the largest panel for his design. The panel he chose was 6.438m x 4.03m. The first step
was to determine the loadings carried by the slab. The author first designs the slab as a
250mm thick as specified by the architectural drawing, then he designed the reinforced
concrete slab using slab thickness of 200mm to check if was suitable. Sources used were
BS8110, textbook McGinley Reinforced Concrete Design. The student was also tasked
with reinforcement detailed drawings and bending schedule.
The calculation of the two-way slab is as follows.
𝑙𝑦
• Check 𝑙𝑥 < 2 is a two-way slab

• BS 8110 contains tables of coefficients (𝛽𝑠𝑥, 𝛽𝑠𝑦, 𝛽𝑣𝑥, 𝛽𝑣𝑦). The maximum
design moments per unit width of rectangular slabs of shorter side 𝑙𝑥 and longer
side 𝑙𝑦 are given by;
𝑚𝑠𝑥 = 𝛽𝑠𝑥𝑛𝑙𝑥 2 ……………………………………………. (equation 1)
𝑚𝑠𝑦 = 𝛽𝑠𝑦𝑛𝑙𝑦 2…………………………………………… (equation 2)
where;
- 𝑚ѕх maximum design ultimate moments either over supports or at mid-span on
strips of unit width and span 𝑙х
- 𝑚ѕу maximum design ultimate moments either over supports or at mid-span on
strips of unit width and span 𝑙y
n total design ultimate load per unit area = 1.4𝑔𝑘 + 1.6𝑞𝑘

Figure 2-1:location of moments (Arya,1994)

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 Similarly, the design shear forces at supports in the long span direction, υsy, and short span
direction, υsx, may be obtained from the following expressions;
• Check for Deflection (clause 3.4.6, BS 8110)
After calculating the reinforcement, the author checks that the deflections under working loads
do not adversely affect either the efficiency or appearance of the structure. According to Design
of structural elements, however, it is rather difficult to make accurate predictions of the
deflections that may arise in concrete members principally because the member may be
cracked under working loads and the degree of restraint at the supports is uncertain. Therefore,
BS 8110 uses an approximate method based on permissible ratios of the span/effective depth.
The procedure for checking deflection is as follows;
𝑎𝑐𝑡𝑢𝑎𝑙 𝑠𝑝𝑎𝑛
a. Calculate the Actual span/effective depth ratio =𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑑𝑒𝑝𝑡ℎ

∅
𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒 𝑑𝑒𝑝𝑡ℎ, 𝑑 = ℎ − − 𝑐𝑜𝑣𝑒𝑟
2
b. The basic span /effective depth ratio is determined from Table 2.1

Table 2-1 basic span/effective depth ratio (BS8110-1-1997,Table 3.9)

Support conditions Rectangular section Flanged beams with

𝑏𝑤
≤ 0.3
𝑏

cantilever 7 5.6
Simply supported 20 16
Continuous 26 20.8

c. The design service stress in the tension reinforcement in a member may be estimated
from the equation:
5 𝐴𝑠, 𝑟𝑒𝑞
𝑓𝑠 = ∗ 𝑓𝑦 ∗
8 𝐴𝑠, 𝑝𝑟𝑜𝑣
(477−𝑓𝑠)
d. 𝑀𝑜𝑑𝑖𝑓𝑖𝑐𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 = 0.55 + 𝑀 ≤ 2.0
120(0.9+ )
𝑏𝑑2

e. Check if Permissible span/effective span (modification factor*basic span/effective depth

ratio)> Actual span/effective depth ratio.
• Check for Shear (clause 3.4.5, BS 8110)

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 The design shear stress, υ, at any cross-section can be calculated from:
𝑉
𝑣=
𝑏𝑑
Where,
V design shear force due to ultimate loads
b breadth of section.
d effective depth of section.
The design concrete shear stress can be determined using Table 3.11. The values are in
100𝐴𝑠
terms of the percentage area of longitudinal tension reinforcement ( ) and effective
𝑏𝑑

depth of the section (d). The table assumes that cube strength of concrete is 25 N/mm². For
other values of cube strength up to a maximum of 40 N/mm², the design shear stresses can
1
𝑓𝑐𝑢3
be determined by multiplying the values in the table by the factor ( ).
25

Figure 2-2 : Check for shear (Table 3.7 BS8110-1-1997)

The calculations, bending schedule, reinforcement detailed drawings and the tables used are
attached to this document in the Appendix.

2.2.5.2 Reinforced Staircase Flight and Landing Design.

The author was tasked with the design of a staircase to provide means of movement from the
ground floor to the first floor of the structure. Staircase is to consist of a number of steps with
landings at suitable intervals to provide comfort and safety for the users. The definitions of some
technical terms, which are used in connection with design of stairs, are given below:

a. Tread or Going: horizontal upper portion of a step.

b. Riser: vertical portion of a step.

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 c. Rise: vertical distance between two consecutive treads.
d. Flight: a series of steps provided between two landings.
e. Landing: a horizontal slab provided between two flights.
f. Waist: the least thickness of a stair slab.
g. Soffit: the bottom surface of a stair slab.

Figure 2-3: Stairs main technical terms

The Architectural drawings showed that the staircase has a cranked slab landing. This type is
constructed as a bent slab spanning from landing to flight and to landing with no side supports.
This type of construction only used when the landings cannot gain support each side of stair. The
loadings are steps, finishes and imposed load. The calculation to find the load for the waist is
shown below. The calculation for the flight and landing is shown below.

2.2.5.3 Staircase foundation layout and details.

The author was tasked with drawing the staircase foundation layout and details. The type of
foundation used is for the staircase is shallow foundation. This foundation is constructed for single
column and also called as pad foundation. The shape of individual footing is square and is used
when loads from structure is carried by the columns. Size is calculated based on the load on the
column and safe bearing capacity of soil.

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 Figure 2-4: Complete staircase Figure 2-5: Staircase foundation

2.2.5.4 Roof Beam Design

The author was tasked with the design, reinforcement detailing and bending schedule of a roof
beam for one block of the Marlborough complex. The design was to be used for all the other 6.
The roof beam is connected to the roof slab to prevent separation during rebound. Reinforced
concrete beam is to be designed to carry transverse external loads. The loads cause bending
moment, shear forces and in some cases torsion across their length. Moreover, concrete is strong
in compression and very weak in tension, thus, Steel reinforcement used to take up tensile stresses
in reinforced concrete beams. The challenges the author faced was the determination of loads.
Roof sheeting to be IBR. Assumptions made are:

i. IBR is 0.58mm gauge, Density = 4.334kg/m2

ii. Roof insulation to be alububble, Density=12kg/m3, 4mm material thickness.
iii. Roof live load= 0.4kN/m2
iv. Design steel Grade is 43, Design strength, Py=275Nmm/2.
v. Insulation on 76*50mm pipe purlins at 750mmc/c.
• Self-weight of concrete per area covered =24kN/m2
• Assuming C section Purlin [100*50*15*2.0].
• Self-weight of Purlin=3.6*9.81=0.035kN/m.

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Since walls are not a good structural element, roof beams are used to prevent cranks from the roof
and to uniformly distribute the load from the roof. The roof was designed as a continuous beam.
According to BS8110-1:1997, 3.4.3 Uniformly-loaded continuous beams with approximately
equal spans: and shears. Table 2.2 may be used to calculate the design ultimate bending moments
and shear forces, subject to the following provisions:

a. Characteristic imposed load (Gĸ) may not exceed characteristic dead load (Qĸ).
b. Loads should be substantially uniformly distributed over three or more spans.
c. Variation in span length should not exceed 15% the longest.

Table 2-2: Design ultimate bending moments and shear forces (BS8110-1-1997, Table 3.5)

At outer support Near middle At first interior At middle of interior At interior supports
of end span support spans
0 0.09Fl -0.11Fl 0.07Fl -0.08Fl
0.45F - 0.6F - 0.55F

NB: 𝑙 is the effective span and F is the total design ultimate load (1.4Gĸ + 1.6Qĸ) which is
F=w*span

0.7𝑙
Effective flange width= 𝑏𝑤 + 5

Where 𝑏𝑤 is the beam width= 230mm.

Minimum steel reinforcement, As, min = 0.13% Ac

If 𝑀𝑢𝑙𝑡𝑖𝑚𝑎𝑡𝑒 > 𝑀𝐷𝑒𝑠 no compression reinforcement is required.

2.2.5.5 Design of an Axially loaded Column.

According to Arya (1994), The design process simply involves making sure that the design load
does not exceed the load capacity of the column, i.e. Load capacity ≥ design axial load

Where the column is required to resist a predominantly axial load, its load capacity is given by,
Load capacity = design stress × area of column cross-section.

𝑙𝑥 𝑙𝑦
A column is said to be short if < 15 or 𝑏 < 15
ℎ

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Where; - 𝑙𝑥 is the effective height of the column in respect of the major axis (i.e. x-x axis)

-𝑙𝑦 is the effective height of the column in respect of the minor axis.

-𝑏 is the width of the column cross-section.

- ℎ depth of the column cross section.

The check above showed that the column was short.

Design of short braced axially loaded column calculation procedure;

• The ultimate load that can be supported is taken as,

N = 0.35fcuAc + 0.67Ascfy

• To take account of the area of concrete displaced by the reinforcement the equation for a
rectangular section is taken as

N = 0.35fcubh + Asc(0.67fy-0.35fcu)

• For the design to be approved 𝑁𝑑𝑒s(design ultimate axial load on column) <𝑁𝑢𝑙𝑡(ultimate
axial load on column).

2.2.6 Additional Tasks

Design of window lintels, one-way slab, pad footing, detailed drawings and bending schedules

2.3 Civils Work.

2.3.1 Storm drainage

The author was asked to come up with Marlborough Catch pit Schedule and to draw the
longitudinal section for the catch pit. The catch pit schedule contains 2 junction boxes
which are points were two or more pipes meet and a catch pit is essentially an empty
chamber with an inlet pipe and an outlet pipe set at a level above the floor of the pit. Any
sediment carried by the system settles out whilst in the Catch-Pit, from where it can be
periodically pumped out or removed.

Procedure for doing task:

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 • Identifying the positions of the Catch pits, junction box and the main line from the site
layout drawn by the engineer on the topographical map.
• Writing down the ground levels and lengths of pipes
• Assuming the first catch pit to be 1m deep.
• Using Excel to calculate the IL using 1:200 as the slope.
• Plotting longitudinal section on AutoCAD.

Catch pit long section is attached in the Appendix

2.3.2 Road Paving.

The student was tasked with drawing a typical pavement section for the complex and to draw
standard drainage details. Paving is a composite structure whose thickness and construction are
directly related to the type and intensity of traffic and loads to be carried, and the bearing capacity
and permeability of the subgrade, therefore for the design the student suggested brick pavement
for inside the car pathway and parking area inside the complex, and to provide tar outside the gate
were the road connects with the municipal road.

Procedure used to perform task.

• Taking section from 2 different parking areas, roadway and outside the gate.
• Calculating the gradient of the section.
• Determining the Curb size in the table attached in the appendix. H5 curb was used.
• Drawing the cross section as shown below.
• Same procedure used to draw the other 3 cross sections
• Showing were the cross section was taking on the road layout diagram.

Stages involved in paving

1. Excavations
Top soil was excavated to an average depth of 150mm to avoid plant growth and deposited
at dumping area. Shallow trenches were excavated in any type of ground along line of curb.
2. Formations
The formation or construction of the subgrade begins after the clearing and grubbing phase.
The formations consist of the subbase, the base and the pavement.

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a) Subgrade.
The subgrade which must ultimately carry the pavement load, should be undisturbed soil or
compacted fill, since it also receives moisture from infiltration, it should be sloped to drain.
Insitu subgrade material scarified and compacted to 93% MOD AASHTO density.
b) Base 1
The base is the foundation of well graded aggregates that transfers the pavement load to the
subgrade. It also prevents the upwards migration of capillary water. 150mm base tested and
approved crusher run SG3 quality material compacted to 96% MOD AASHTO density
c) Base 2
The base is the foundation of well graded aggregates that transfers the pavement load to the
subgrade. It also prevents the upwards migration of capillary water. 150mm base tested and
approved river sand SG3 quality material compacted to 96% MOD AASHTO density.
d) The pavement
Flexible pavement was used for this project. To restrain the horizontal movement of the paving
material concrete edging was used. The pavement receives the traffic wear, protects the base,
and transfer its load to the base structure. Interlocking Paver Bricks were to be used pavers for
the pavements.
The road section is attached to the Appendix.

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3. SECTION 3: CM2 TRANPORT SYTEM LAFARGE PROJECT.

3.1 Salient Feature of the Project.

Project Name: CM2 Transport System Installation SOW

Client: HEMS Engineering.
Contractor: A & Sons Construction.
Duration of Project: 1 week.
Project Site Location: Lafarge

Project Scope Details.

• With reference to technical information provided, recommend the best erection
sequence and methodology.
• design of 7 concrete plinths for the structure and bucket elevator civil.
• Produce a setting out drawing.

3.2 Site Visit.

Before the project had started, the student was part of the design team who went to visit the site
for a general appreciation and survey the site. This site visit at LAFARGE CEMENT ZIMBABWE
LIMITED included inductions and medicals. Medical checkups were to make sure if we were
physical fit to enter the cement plant. The induction was a short course which had topics which
included Site layout, Hazards, Accident/incident reporting and the need for Personal Protective
Equipment. The induction was to ensure that the general safety requirements are appreciated.

3.3 Soil Test.

The author was not part of the team carrying out soil tests but he had an appreciation on how it
was done. Since the site was a cement plant, the cement fines plus the water from rain had hardened
about 400mm above the top soil layer, therefore before the soil test there was concrete breaking to
get to the soil layer. A hammer drill machine was used to break the concrete. For convenience sake
and to save time, the soil test was taken after setting out had been done, which meant the hardened
concrete at all the footing positions had been removed. Soil samples were taken from two
difference positions.

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Auger boring method was used to get samples. The equipment used for Auger boring is shown in
Fig. 3.1. According to Aroka (2004), Soil auger is a device that helps in advancing a bore-hole
into the ground. These are used is cohesive and other soft soil above water table. Hand operated
augers are used up-to a maximum depth of 10 m and power-driven augers are used for greater
depths. Boring is done by pressing the auger into the ground and rotating it with the handle at the
top. As soon as the auger is filled with soil, it is taken out and soil is removed from the blades.
Samples obtained are disturbed samples.

Figure 3-1: Auger Bore

3.4 Setting Out.

The author was part of the team onsite tasked with checking the contractor’s setting out on site.
The author noticed that the method that was used for setting out was the rope method the same
with the one which was used for Marlborough Lifestyle Apartments. To confirm if all
measurements were correct, the team checked if the diagonals measured exactly the same. Where
there was a difference in the measurement, the back pegs were adjusted as per dimension.

3.5 Design.

The student was tasked with the design of the foundations which included pad footings, combined
pad footing, reinforcement detailing and bending schedules. The student used the software Prokon
and AutoCAD, Design of structural elements and Mosley to complete the tasks given. The
supervisor would check the student’s completed task and corrections were made before issue of
construction drawings.

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3.6 Foundation design

3.6.1 Pad footing

Ground =design load plan area < bearing pressure capacity of soil.

Since the settlement of the structure occurs during its working life, the design loadings to be
considered when calculating the size of the base should be taken as those for the serviceability
limit state (i.e. 1.0Gk + 1.0Qk). The calculations to determine the thickness of the base and the
bending and shear reinforcement should, however, be based on ultimate loads (i.e. l.4Gk + 1.6Qk).

Pad footing design procedure used;

a. Calculate the plan area size of the footing using the permissible bearing pressure and the
serviceability limit state loads.
Design axial load,𝑛 = 𝐺𝑘 + 𝑄𝑘
b. Calculate the bearing pressure associated with the critical loading arrangement at the
ultimate limit state.
c. Plan area of base.
𝑁
𝐴𝑏 =
𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑜𝑓 𝑠𝑜𝑖𝑙
d. Determine the design load, N, using the ultimate loads.
e. Check if the ultimate moment> design moment
Where the ultimate moment,𝑀𝑢 = 0.156𝑓𝑐𝑢𝑏𝑑 2
If check is okay no compression reinforcement is required.
f. Determine the reinforcement areas required for bending using ultimate loads
g. Check for punching, face and transverse shear failures.

3.6.2 Combined Footing.

These are two columns close together their footings combined to form a continuous base. The
calculation is similar to that of a pad footing. The loadings were taken from the schedule provided
by the client. The shape of this footing was a rectangle and the loads from the structure were carried
by the columns. The author used Prokon for the calculation. In the prokon software the author had
to enter the loadings, ultimate load coefficients and the dimensions of the foundation.

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The output data of Prokon has required reinforcement area, bar size, deflections, bending schedule
and reinforcement detailed drawings.

3.7 Problems Faced.

i. The location of one pad footing was close to the base of a steel column. This was realized
during concrete breaking. The solution was to join the bases.
ii. Delays to start construction and to meet the deadline due to soils test which took 2 weeks.
iii. The construction site location was directly under the cement production Kiln which caused
the area to have a lot of cement dust.

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4. SECTION 4: MODIFIED SEWAGE TREATMENT PLANT PHASE 1.

4.1 Salient Feature of the Project.

Project Name: Modified Sewage Treatment Plant Phase 1.

Client: Borrowdale Brooke Estate.
Contractor: ESOR Zimbabwe
Project Site Location: Borrowdale Brooke Estate, Harare.

Project Scope.

• Design of a 4-compartment concrete tank.

• Project Management.

4.2 The General layout of a Biokube system.

Figure 4-1: Biokube Section.

4.2.1 Pre-treatment

• The system requires a Septic tank which is used as a pre-treatment for settling particles and
storage of sludge.
• The function of the Buffer tank is to even out fluctuation to allow a stable timed inflow to
the system.
• Pre-treatment is the first stage of BOD removal.

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 4.2.2 Biological treatment

• Submerged aerated filters (SAF) is the heart of the biological treatment.

• Clarifier ensures low SS by settling biological sludge.
• Bio-sludge continuously removed to the septic tank.

4.3 Concrete Tests.

4.3.1 Slump Test.

The author was present onsite when the slump test was carried out. The test was done before
pouring the upper half of the concrete tank. Premix concrete from Scribante (Pty)Ltd was used. A
concrete mixer truck with boom pump was used for pouring concrete. The slump test was to test
of the workability of concrete. Workability of concrete is the ability to work with concrete. The
workability of concrete is affected by the amount of water in the mix. Too much water can make
concrete weak. Not enough concrete can make the concrete too hard to work with. The slump test
was carried out on site before the concrete was poured in place. A sample was taken from the
concrete mixer for each batch.

Procedure for the slump test used.

• Place the cone on a level waterproof base.

• Place your feet on the holding down lugs.
• Place 75mm of concrete in the cone and tamp 25times.
• Repeat this action 3 more times until the cone is full and screed off the top.
• Gently lift cone from the concrete.
• Area cone beside concrete and put tamping rod across the top of the cone.
• Measure down from bottom of tamping rod to top of concrete.
• The measurement is the slump of the concrete.

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Figure 4-2: True Slump

4.3.2 Concrete Cube Test.

The author was also observed the taking of concrete cube test samples from the concrete mixer. A
concrete cube is a sample cube having each dimension of 150 mm. The 6 cube molds are filled
with concrete used in works. The cubes cast are cured for 7 & 28 days and the compressive strength
of cubes is determined at the end of 7 days & 28 days by testing it on compression testing machine.
Compressive strength is the ability of material or structure to carry the loads on its surface without
any crack or deflection. A material under compression tends to reduce the size, while in tension,
size elongates. The cube test results are attached in the Appendix.

4.4 Formwork

Formwork (shuttering) in concrete construction is used as a mold for a structure in which fresh
concrete is poured only to harden subsequently. The formwork used for the Borrowdale Brooke
project was steel formwork. This consist of panels fabricated out of thin steel plates stiffened along
the edges by small steel angles. The panel units can be held together through the use of suitable
clamps or bolts and nuts. The panels can be fabricated in large number in any desired modular
shape or size. Steel forms are largely used in large projects or in situation where large number
reuses of the shuttering is possible. The student was on site for the installing shutters before
pouring concrete and dismantling after curing the concrete.

4.5 Concrete pouring.

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The author was tasked with monitoring the concrete pouring of the upper half of the structure. Pre-
mix concrete from Scribante was used. A Boom Pump truck was used for pouring concrete. During
pouring of concrete the author noticed that the contractor was spilling some of the concrete due to
poor workmanship and notified the site engineer as this was causing wastage of concrete and will
lead to an increase in cost. During pouring, a Poker vibrator was used all around the wall to
compact the concrete and eliminate the voids, the vibrations help to allow air bubbles to escape.
The vibration of concrete is important to achieve consolidation of the concrete mix which often
results in a homogenous concrete. In this case, there was improper vibration and poor
workmanship and the fact that the concrete was not fluid enough to flow to all corners led to
honeycombing.

Figure 4-3:Formwork fixing Figure 4-4: Concrete Pouring using Boom pump

Figure 4-5: Concrete Curing Figure 4-6: Stripping of shutters

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4.6 Remedial works

Due to the improper use of the poker vibrator and poor workmanship the tank was discovered to
have honeycombing and cracks. The contractor was instructed to carry out the remedial works for
the concrete structure at his expense. The contractor suggested that he was going to use the Non-
Shrink Grout and Vandex Plug for waterproofing because it can be used underwater. Non-Shrink
Grout applied as pressurized grout and gravity grouting. The student was instructed to research on
these sealants to determine if they were suitable considering the site conditions, for example the
fact that the site had a high water-table and determining other cost-effective solutions. He
suggested Silicone sealer but due to its un-availability the contractor used Vandex Plug as a sealant.
The student was part of the team tasked with daily site visits to assess the remedials works for each
chamber, make recommendations and to document in a notebook the points with the cracks and to
make progress reports. The areas with defects were identified by being rough. The contractor had
to excavate 6metres deep to expose the whole structure to allow the remedial works to be done
outside. The remedial works and repair works carried out included the following scope of works:

• Sealing of all cracks.

• Chipping of loose aggregates caused by honeycombing.
• Cutting of tension bars (dolly wire) from the walls.
• Sealing of all leaks.
• Application of Non-shrink grout to chipped and exposed areas.
• Placement of a level screed to allow for appropriate placement of BioKube Bioreactors.
• Stone rubbing to smoothen the inside of the chambers.

Pressure Grouting.

Penetration Grouting is mainly used to fill joints or fractures in rock or large pore spaces in order
to strengthen the existing mass and eliminate movement or waterflow, without disturbing the
formation. Pressure grouting was used to seal deep cracks especially at the edges of the base slab
of the tanks. A pump for grouting and a grout mixer were used at this stage. Before pumping the
grout, a plank shutter on the wall so that the grout does not spill out.

4.7 Water tightness test.

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After the remedial works the structure had to go under a water tightness test from the instruction
from the consulting engineer to test for leaks. The term ‘water tightness’ although descriptive, is
not sufficiently for the purposes of a contract specification. Some loss of liquid is inevitable due
to evaporation or slow diffusion through the concrete and also through fine cracks. Fine cracks up
to 0.2mm heal autogenously as water percolates through the cracks and dissolves calcium salts
from the cement. The design team came up with the methodology for the water tightness test. The
student was part of the team tasked with supervising the water tightness test.

Methodology

• The structure is tested by filing with water and measuring the level over a period of time.
• The concrete in the structure must be allowed to attain its design strength before testing
commences, and all outlets must be sealed to prevent loss of water through pipes, overflows
and other connections.
• The structure should also be cleaned.
• The structure is slowly filled to its normal maximum operating level. If the structure is
filled too quickly, the sudden increase in pressure is likely to cause cracking.
• A tank should be filled over a period of three days.
• BS 8007 limits the rate of filling to a uniform rate of not greater than 2meters in 24hours.
• To allow the concrete to become completely saturated with water, a stabilizing period is
allowed after filling has been completed.
• If it is obvious that there is no leakage through cracks after some days, it may be possible
to commence the record test somewhat earlier.
• The level of water is measured and recorded for seven days. The level should be recorded
at four positions to guard against errors.
• In assessing the results of the water level readings during the test, allowance must be made
for these variations. A method of achieving this is to moor watertight containers 80% filled
with water at points on the surface.

Acceptance

A water test will enable a net loss of water to be measured due to leakage and further absorption
into the concrete structure. The maximum acceptable limit may be taken as 1/1000 of the average

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depth of the water. BS 8007 recommends a value of 1/500 of the average water depth or 10mm or
another specified amount.

Figure 4-7: Water tightness Test

4.8 Weekly Progress Report

The author was tasked with writing the weekly progress reports for the Borrowdale Brooke MSTP.
The author had to go to site every Friday to take a record of the weekly progress report. The Weekly
progress report is a summary of the weekly objectives, and of all work done during a week and
how these activities contributed to the completion of a task or a project, or how each one brings
the team closer to the achievement of their targets. It also includes major equipment on site, site
challenges, schedule of activities to be performed during the next reporting period and also site
pictures.

4.9 Additional tasks.

• Weekly Site Meetings

• Progress reports.
• Steel tonnage calculations.
• Concrete Volume.

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5. SECTION 5: MODIFIED SEWAGE TREATMENT PLANT PHASE 2.

5.1 Salient Feature of the Project.

Project Name: Modified Sewage Treatment Plant Phase 2.

Client: Borrowdale Brooke Estate.
Contractor: ESOR Zimbabwe
Project Site Location: Borrowdale Brooke Estate, Harare.

Project Scope.
• Design of ancillary works for the new on-site sewage treatment plant that include two sump
chambers, flow split chamber, drum filter platform, UV Station housing, manholes and
connecting pipework for the Borrowdale Brooke Estate in Harare to treat raw sewage
draining from the estate to acceptable effluent discharge standards.
• Project Management.

5.2 Bill of Quantity

The author was tasked with helping with writing a BOQ for the (Put example from Brooke). The
Bill of Quantities is a document prepared by the cost consultant that provides project specific
measured quantities of the items of work identified by the drawings and specifications in the tender
documentation. The quantities were measured in number, length, area, volume, weight and time.
BOQ was prepared using tender drawings. The BOQ was issued to tenderers for them to prepare
a price for carrying out the works. The BOQ assists tenderers in the calculation of construction
costs for their tender, and, as it means all tendering contractors will be pricing the same quantities,
it also provides a fair and accurate system for tendering. The contractor tenders against the bill of
quantities, stating their price for each item. This priced bill of quantities constitutes the tenderer's
offer. As the offer is built up of prescribed items, it is possible to compare both the overall price
and individual items directly with other tenderers' offers, allowing a detailed assessment of which
aspects of a tender may offer good or poor value. This information can assist with tender
negotiations.

5.3 Specifications Document.

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The author was tasked with writing a Specifications Document. This Specification was for the
Contract to be made with ESOR for materials to be used in the construction and due completion
of the Modified Sewage Treatment Plant. The Works involved in the contract are to be carried out
in accordance with Specifications, Bills of Quantities and Drawings included in this Contract
Document. The author used specification documents from previous sewage treatment plant
projects and he had guidance from his supervisor Engineer T Mpala. Construction specifications
are the details for the work that needs to be completed in a construction project. These details
include information such as materials, the scope of work, installation process, and quality of work.
A summary of the sections of the document are as follows.

5.3.1 Section 1: Preliminary and General

This section includes

• The Description of works covered by the contract.
• Part of Site Available to Contractor.
The operations of the Contractor shall be confined to the area of and immediately adjoining
the Works included in this Contract
• Control of Labor and Security
The Contractor shall be responsible for the control and discipline of his employees while
on site and is advised to provide adequate security for all materials on site awaiting
incorporation in the Works.
• Setting Out
The Contractor shall read and understand all the necessary construction Drawings. The
Contractor shall consult with the Engineer regarding any clarifications on any information
indicated on the Drawings prior to carrying out all the necessary steps for the setting out of
all constructional Works on site.
• Protection of Existing Services and Infrastructures
In carrying out the Works, the Contractor shall observe due care to prevent damage to
existing service installations and infrastructure. Any damage to such existing Services and
infrastructure shall be repaired at the Contractor’s own expense.

5.3.2 Section 2: Materials

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 • General.
All goods and materials shall be of the best quality and obtained from an approved supplier.
• Samples
Fair and representative samples of all materials to be used in the work shall be submitted to
the Engineer for his approval e.g. cement, pipes etc. wherever practicable, at least three
weeks before it is proposed to use the materials.
• Packing
All goods are to be carefully packed to prevent damage during transit.
• Unloading
The Contractor shall exercise care and be responsible for the loading and unloading of all
materials and shall make his own arrangements, at his own expense, for the safe storage of
all materials on site for which he alone will be responsible.

5.3.3 Section 3: Earthworks.

• Definition of Earthworks
Earthworks shall include all excavations, filling, embankments and forming, whatever may
be the materials and for whatever purpose they are required, and all other Works contingent
upon or relating to excavations as required by the nature of the Contract, as described in the
Specification and as shown on the Drawings.
• This section also included the specification for site clearance and the type of excavation to
be used. Backfilling specification and method of compaction. The contractor shall carry out
all dewatering necessary to keep excavations dry.

5.3.4 Section 4: Plain and reinforced in-situ concrete.

• General Code of Practice.

Materials
• Cement
The cement shall be used within six weeks of manufacture and each batch of cement
delivered shall be stacked separate from the previous batches and a record of date of
manufacture of each batch shall be kept.
• Aggregates

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 The aggregates used must comply with SAZ’S 190. The cleanliness of the aggregates shall
be to the Engineer’s approval.
• Reinforcement
Reinforcement shall conform to B.S 4449, B.S 4482, B.S 4483 and ZISCO specification
RSK 2075 and twisted to comply with B.S 4461. The reinforcement shall be cut and bent
in accordance with B.S 4466.
• Aggregate
Each type of aggregate shall be stockpiled on a hard-smooth surface and kept separate from
the other aggregates.
Concrete Manufacture and Placing
• Concrete Mixes.
The Contractor may elect to use either a prescribed or designed mix subject to the prior
approval of the Engineer and as stated on the drawing.
- Prescribed Mixes.
A prescribed mix shall be proportioned to reach the required strengths and durability as
stated on the Drawings and specification.
- Designed Mixes
The proportion of a designed mix shall be calculated by a recognized testing laboratory
nominated by the Contractor to reach the required strengths and durability as stated on the
Drawings.
• Trial Mixes
The Contractor shall produce laboratory-designed mixes for the various concrete grades. He
shall submit results obtained from tests on trial cubes and aggregates, together with the mix
proportions, the origins of the aggregate and other recommendations made by the laboratory
for the Engineer’s approval all before any concrete Works commence.
• Method of Mixing
All mixing shall be done by mechanical mixer. The mixers shall be kept in good working
order and be thoroughly cleaned at the end of each pour
• Slump Tests
Slump tests shall be carried out in accordance with B.S 1881 at regular intervals during
mixing and at the request of the Engineer.

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 • Cube Crushing Tests
At least one set of six test cubes shall be made from each pour. The cubes and their curing
shall be in accordance with B.S 1981. Two cubes of each set shall be crushed at an age of
7, 14 and 28 days. The crushing tests are to be carried out by an approved laboratory.
Concrete for cubes must be taken from the mold directly after pouring and before any
vibration has taken place.
• Transporting
Runs or gangways for concrete transporters and main runs for foot traffic shall not be
supported or allowed to bear on the fixed reinforcement.
• Placing
The concrete shall be placed within 30 minutes of water being added. It shall be transported
and placed in such a manner that no segregation takes place. Addition of water to the mix
after dispensing is not permitted.
• Compaction
Poker vibrators shall be used for all concrete compaction. Each insertion of the Vibrator
shall be vertical and within 0,5m of the previous insertion and it is to be withdrawn slowly.
The vibrators are to be kept clear of the formwork and shall not be used to move the concrete
laterally.
• Curing
The concrete shall be kept in a permanently wet state for the minimum period of 7 days.
Methods of curing concrete shall be to the prior satisfaction of the Engineer.

5.4 Preliminary Drawings

The author was part of the design team tasked with producing preliminary drawings for this project.
Preliminary drawings were the initial set of sketches, drawings and plans used to convey concepts,
designs, and ideas between clients, design professionals, and project stakeholders. These drawings
also showed the general process flow diagram for the sewage treatment plant. Preliminary
drawings serve the purpose of communicating and establishing an understanding and direction of
a project between the client and the design team. Preliminary drawings help visualize ideas among
the different parties involved. The preliminary drawings serve to move projects forward and
initiate cost estimates, feasibility studies and other analysis. Although preliminary drawings help

38 | P a g e
 establish a common understanding and vision of a project, they were not intended as specifications
for construction or engineering purposes. Instead, preliminary drawings establish the basis for
more specific plans that will ensue.

5.5 Tender Drawing.

The author was part of the design team which was responsible for producing tender drawings. A
tender is a process of obtaining a suitable contractor to do the works. Tendering is the process of
choosing the best and cheapest company to supply goods and services by asking several companies
to make offers for supplying the goods and services. Initiating step of a tendering process in which
qualified contractors are invited to submit sealed bids for construction or for supply of specific and
clearly defined goods or services during a specified timeframe. The tender process is designed to
ensure that the work to be done for client is given out in a fair way. The student was part of the
design team tasked with the drawings to be used for Tender.

5.6 Construction Drawings.

Construction Drawing are used to provide a graphic representation of what is to be built. The
working drawings and specifications set a framework to ensure everything is clearly defined and
in full compliance with all building regulation requirements.

5.6.1 Collection Pipe and Airlift Pumps Layout and detail.

i. Collection pipe is to be used for collection effluent from the BioKube chambers to sump 1.
The author was tasked with drawing this detail. The designs were suggested are as follows
a. A channel with a grating on top.
b. Manholes from each Biokube chamber outlet.
Manholes were to be used as collection points. Bricks were to be used for the
construction of manholes. The manholes were to be constructed at a gradient for
effluent to flow to sump 1. This design was not used because it was to increase the
number of structures and also a better way of collecting effluent was suggested. The
detail is showed below;
c. The design used is shown in the diagram below. A layout is shown below

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 Figure 5-1:Collection pipe layout and details

Figure 5-2: Collection pipe fixing on site

ii. Airlift pumps are to be used for transferring RAS from the Biokubes to existing MH before the
septic tank via a 110mm diameter PVC pipe. The author was also tasked with the determination
of the pipe invert levels by providing a minimum depth of cover of 300mm and slope of 1:200
for the collection pipe layout, and a gradient of 1:60 for the airlift pumps, and also drawing
longitudinal sections using the calculated invert levels. For calculating the invert levels and
drawing long-sections, the student used Excel and AutoCAD software respectively. For
drawing the long-sections the student used examples from Hydro-Utilities previous projects.

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 5.6.2 Hydraulic Profiles

The author was tasked with drawing the hydraulic section of the whole sewage treatment plan
system. The student used invert levels of pipes to draw the hydraulic section on AutoCAD.
According to Metcalf and Eddy Hydraulic profiles are created for three reasons:

i. To ensure that the hydraulic gradient is adequate for the wastewater to flow through the
treatment facilities by gravity.
ii. To establish the head requirement for the pumps where pumping will be needed.
iii. To ensure that the plant facilities will not be flooded or backed up during periods of peak
flow.

5.6.3 Manholes

MH are access points required for testing, inspection and cleaning. Manholes differ from
inspection chambers in that they are deeper(>1m) and can be entered if necessary, the author was
tasked with calculating MH invert levels, cover levels and MH depths using the previously
calculated values of the collection pipes and invert levels and existing MH details. All MH were
designed to be 300mm above ground level.

CL= GL+ 300mm

Depth = CL – invert level.

The author was tasked with determining of the invert levels of MHs that connect the buffer
chamber and sump 1outflow pipes to the river downstream and adding all these details to the
general layout drawing. All the amendments had to be clearly shown onto the drawings so that the
contractor can easily interpret the drawing.

5.6.4 Pipe fitting Schedule and reference drawing

The author was tasked with writing a pipe fitting schedule for all the phase 2 works. A pipe fitting
schedule is a list to show all the fittings including the typical detail, pipe material, number of
fittings and general notes. The pipe fitting schedule included spigot pipes, Tee piece, reducers and
puddle flange. The author leant that flange adopters are used to connect pipes of different material

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and also that a Puddle Flange is put inside the concrete wall to prevent leakages. The author
suggested that there be a pipe fitting schedule for each layout drawing and adding a pipe fitting
reference drawing to make it clear where each fitting is supposed to go. The author used the
catalogues from Pro Plastics and examples from previous Hydro-Utilities projects for determining
the correct way to represent the pipe fitting details.

5.6.5 Sump 2 layout and details.

A pump sump is a concrete pit used to collect effluent from the Biokube chambers to be pumped
using a submersible pump to the flow splitter box or the dam. For the pipes that go over the sump
wall a 100mm wide x10mm thick Galvanized steel anchor strip is to fix the pipe onto the wall so
that there is no movement. Strip is to be bolted to concrete wall with M20 (Grade 8.8) anchors (1
bolt on either side of the steel pipe). The author was tasked with adding the channel section detail
on top of the sump wall. The channel section is to be fixed on top of the wall using a base plate
and bolts. The author also had to draw AutoCAD drawings showing how cross-sections of how
the channel-section is to be fixed and supported on to the sump wall. The channel-section cross-
section drawing is showed below.

5.6.6 Flow Splitter Box layout and details

A flow splitter box is an engineering structure used to divide flow into two or parts. Its purpose is
to control flow or for flow equalization from the sump 1 to the HEX Drum filter. The HEX Drum
filter can only treat influent at a rate 40m³/hr. The author was tasked with calculating the invert
levels for the nozzle which is to be used to transport effluent from 1 chamber to the next and
correctly showing the information on the AutoCAD drawings. The author also had to correctly
position the inlet and outlet pipes so that there won’t be back flow. Although the author did not
design the Flow splitter box, he was tasked with writing drawing the reinforcement detail and bar
bending schedule for its walls.

5.6.7 UV Station and HEX Drum Filter Platforms

A UV station is the final treatment point for the effluent. The UV station is to disinfect bacteria
from water. UV destroys harmful microorganisms without adding chemicals or odor to water. The
aim of the Hex Drum Filter is to reduce the BOD of the influent wastewater to a given level of
purification, such that on discharging to the receiving water, the treated waste will not have

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detrimental effects on the environment. The author was tasked with the design of slabs using the
load from each respective device and also the design of ground beams, using the loads from the
slab plus the dead load the respective device. The beams will be sitting on top of piles. For design
the student used the steps from BS8110 part 1. The student also had to draw the reinforcement
detailing on AutoCAD and its respective bending schedule.

5.6.8 Pile setting out drawing and piling

Borrowdale Brooke has a high-water table, Hydro decided that pile foundation be used for this
project. The contractor, Esor is a specialist in piling and was given the contract to design the pile
and to pile at specified pile positions. The author was tasked with the pile setting out drawing. The
author used the existing concrete structure as a reference point to locate the pile locations and mark
the positions on the site general layout and site layout plan. All measurements were to the center
of the pile. A pile is a type of deep foundation that transfers building loads to the earth farther
down from the surface than a shallow foundation does to a subsurface layer or a range of depths.
A bore pile rig was used for piling. Although the student was not involved in designing the piles
he was on site during piling. The piles were tested for strength using a pile integrity testing system.

Figure 5-3: Pegs for pile setting out

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Figure 5-4: Sump 1 Piling

5.7 Dewatering

The Borrowdale Brooke Site has a high-water table therefore dewatering systems were routinely
used to provide temporary reductions in ground water levels for structures extended to below
groundwater level. The site required continuous dewatering to allow for ease of construction. The
contractor used a submersible pump to dewater the inside and around the tanks. The author would
observe how the contractor would dewater the area. The contractor had to be first prime the pump
before pumping. Priming was to force air out of the pump and create a vacuum, allowing water to
move through it once the pump is powered on. The water was filled into the pipe using a bucket.
When there was no electricity for pumping the second method used for dewatering was a rope and
bucket. The third method used for dewatering was an excavated v-section drainage channel located
5 meters from the concrete tank allow for movement near the tanks and to keep the excavations
for phase 2 works dry.

5.8 Pouring of Concrete.

The author was involved in the checking of reinforcement placement and a site instruction had to
be issued before concrete pouring. The design team had to check steel drawings against relevant
civil drawings and bending schedules. There was a discrepancy with the reinforcement for the flow
splitter chamber. The solution was to increase the wall thickness from 150mm to 200mm. The
concrete used for this project was pre-mix. A concrete mixer was to transport concrete to site. The

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author was tasked with the supervision of pouring concrete for the flow splitter box and sumps,
beams and slabs. For each of these structures a toggle joint was provided. A 50mm x 50mm plank
was put in place to create the construction joint. The construction joint’s purpose was to join the
concrete wall and the slab. Before pouring concrete for the flow splitter walls the concrete joint
has to be clean and an appropriate sealant had to be placed before pouring. During pouring of the
walls the contractor had to make sure that the pipes don’t move from their installed positions. For
each batch of concrete mix there was a slump test.

Figure 5-5: Steel fixing for the flow splitter box

5.8.1 Curing

After pouring and compaction, concrete was allowed to cure. Curing of Concrete is a method by
which the concrete is protected against loss of moisture required for hydration and kept within the
recommended temperature range. Curing will increase the strength and decrease the permeability
of hardened concrete. A curing practice involves keeping the concrete damp or moist until the
hydration of concrete is complete and strength is attained. Curing of concrete should begin soon
after initial setting time of concrete or formwork/shuttering is removed. The method used for
curing the concrete chambers was water curing. It was done by spraying or sprinkling water over
the concrete surface to ensure that the concrete surface is continuously moist. Moisture from the
body of concrete is retained from evaporating and contributes to the strength-gain of concrete.

5.9 Pipe work installation and pipe fittings

5.9.1 Pipe Fittings

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 a) PVC TRP Pipe Flared End and TPRP Bocking ring to connect T piece and existing flanged
puddle flange for the collection pipes.
b) Drains pipes to connect.
The spigot end of a fitting has the same outside diameter as pipe. The common female
connection of PVC fittings is referred to as the socket or hub, and the spigot end of a fitting
can be inserted into a Hub or Socket. A connection between two sections of pipe, the straight
spigot end of one section is inserted in the flared-out end of the adjoining section; the joint is
sealed by a caulking compound or with a compressible ring.
c) Equal Tee Socket for solvent welded joints
A Socket Weld is a pipe attachment detail in which a pipe is inserted into a recessed area of
a Valve, fitting or flange.
d) Flexible Coupling
A flexible coupling is used to connect two shafts, end-to-end in the same line. The purpose
is to compensate for small amounts of misalignment and random movement between the two
shafts. Flexible couplings can accommodate varying degrees of misalignment up to 3° and
some parallel misalignment.
e) Flange Adaptor
They are used to connect dissimilar pipes. Pipe adapters may have either male or female IPS
threads on one end and the opposite gender on the other end, which needs to be welded or
soldered onto a smaller pipe. Flange adaptor helps us in introducing valves and flanged
fittings or connect to existing flanged pipework. It acts as a layer that connects between
devices having different designs, sizes or materials, and allows them to be fitted or to function
together.
f) PVC Pipe Reducer
Pipe reducer is a kind of pipe fitting that joins two pipes of different diameter.
Uses of pipe reducer:
A pipe reducer serves the two basic purposes:
• Changing the piping diameter
• Handling the expansion, misalignment or vibration problem.
g) Tee Piece

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 Pipe Tee is a type of pipe fitting which is T-shaped having two outlets, at 90° to the
connection to the main line. It is a short piece of pipe with a lateral outlet. Pipe Tee is used
to connect pipelines with a pipe at a right angle with the line. Pipe Tees are widely used as
pipe fittings. They are made of various materials and available in various sizes and finishes.
Pipe tees are extensively used in pipeline networks to transport two-phase fluid mixtures.
h) End Cap.
Pipe caps act as protective device and are designed to protect pipe ends of various shapes.
The main purpose of using pipe caps is to waterproof the connections. They are also used to
close the ends of hydraulic or pneumatic pipes and tubes. They are used in the plumbing
apparatus of domestic, commercial and industrial water supply lines, machinery and
processing equipment etc. They are also fitted on water pump lines with the sole purpose of
removing air blocks. Pipe caps are highly demanded as an important category of pipe fittings.
i) Pipe valves
Pipe valves are mechanisms or devices to regulate or control the flow of liquid or gas within
a pipe. While some valves are used to regulate the rate of flow, there are others that are used
to stop it completely in order to prevent flooding or allow repairs to be made.

5.9.2 Pipe Backfilling

Regardless of the type of pipe material, proper handling of backfilling operations is important to
provide a good protection to the pipe and to avoid undue settlement of the backfilling materials.
Backfilling involves two operations, deposition and compaction. The backfill material was a good
soil which did not contain any rock. During backfilling bedding material (sand) was placed over
the pipe, enough to cover the sewer pipe then gravel and there was compaction. Sand used as
backfill material so that if the pipe leaks sandy soils allows the water to have a pathway rather than
clay soil which allows minimum movement of water which will cause the pipe to clog this in turn
leads the pipe to burst.

5.9.3 As-built drawings and record drawings

On building projects, it is common for changes to be made during construction because of

circumstances that emerge on site. As a result, it is common for as-built drawings to be prepared,
either during the construction process or when construction is complete, to reflect what has actually
been built. The contractor made markup changes to the ‘final construction issue’ drawings on-site

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using red ink, and these were used by the consultant team to create record drawings showing the
completed project.

5.9.4 Pipe test and Biokube Test

Pipe test was done to check if the plumbing was watertight. At the same time the Biokube pumps
were tested. The test was done by switching the system on and checking for leaks.

5.9.5 Water Tightness of manholes and sumps

Our Manholes were pre-casted concrete. Manhole lift holes and grade adjustment rings were sealed
with non-shrinking mortar. Inlet and outlet pipes were joined to the manhole with a casketed
flexible watertight connection that allows differential settlement of the pipe and manhole wall to
take place. Manhole frames, grates and covers were installed in such a manner as to prevent
infiltration of surface or ground water between the frame and the concrete of the manhole section.

5.9.6 Thrust Block

Thrust block were provided at some bends, where there was change in direction. Thrust blocks are
meant to prevent pipes from being moved by forces exerted within the pipe arising from the
internal pressure of the pipeline or the flow of water hitting bends, tapers and closed or partially
closed valves by transferring the resultant thrust force at a bend to the undisturbed soil behind the
thrust block. The size of a thrust block is dependent upon the deflection of the flow and the head
of water inside the pipe.

Figure 5-6: Thrust Block provided at bend

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6. SECTION 6: NKULUMANE OUTFALL SEWER.

6.1 Salient Feature of the Project.

Project Name: Nkulumane Outfall Sewer.

Client: Bulawayo City Council
Contractor: ESOR Zimbabwe
Project Site Location: Nkulumane, Bulawayo.

Summary of project
The City of Bulawayo intends to improve and upgrade the water supply and sewerages services
in the city with the aim of contributing to the improvement in health and social wellbeing of
its population. The proposed project’s emphasis is on rehabilitating and enhancing the water
supply system and contributing to environmental improvement through rehabilitation of
sanitation infrastructure. The CoB, with support from the African Development Bank intends
to improve the sewer drainage capacity, rehabilitate waste water treatment facilities. In terms
of sewerage services, the city is plagued with collapsed sewers due to aging infrastructure,
thereby limiting sewer drainage capacity, and is in need of rehabilitating the city’s waste water
treatment facilities. Currently, the 80Ml/day expected to be treated; only 30% is finding its
way into treatment facilities with 70% being discharged directly into streams and rivers.
This project is part and parcel of the Bulawayo Water and Sewerage Services Improvement
Project (BWSSIP). Currently the existing sewer outfall is being rehabilitated due to the regular
overflows and sewer stoppages

Project Scope.
Hydro-Utilities was to provide designs and drawings of the proposed outfall sewer.

Outfall Sewer
A sewer that receives wastewater from a collection system or from a wastewater treatment
plant and carries it to a point of ultimate or final discharge in the environment.

6.2 Tasks and Responsibilities.

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 The author was tasked with designing sewer line 3 and the sewer main line 4. For these two
lines he had to provide,
a. Draw sewer longitudinal sections.
b. General layout which shows the manhole number GL, CVL, IL depth, pipe length, pipe
size and gradient.
c. Manhole schedule which included manhole details such as manhole size and manhole
cover type. The manhole size values were extracted from Table 6.1.
d. Standard Manhole details.

The author was instructed to mirror the existing line in the design. Line 3 has a total of 14 manholes
and is 1 kilometer long. The main line 4 is 3.8 kilometers long and has a total of 59 manholes. The
(BWSSIP) provides the pipe sizes for the proposed line.

6.3 Design Procedures

6.3.1 Layout of the sewer

The surveyor provided a detailed Topographical Survey with contours and a list of the existing
manholes with their invert and cover levels. The scale for the survey plan is 1m :1000units.
Contours are to provide ales detailed but more visual representation of the area. According to A.
Bannister, the topographical survey shows the natural and manmade features of the area. Using
Civil3D, the author had to offset 3.5 meters from the existing line to the side which he thought
would be easy to excavate and construct the manholes. For example, main sewer line 4 was offset
3.5 meters to the left because to the right there some sewers connecting to the existing line therefore
will have to be removed for the construction of the proposed line.

6.3.2 Identifying and locating manholes.

Locate manholes at;

• Changes in direction;
• Changes in slope;
• Changes in size
• heads of runs;

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 • At pipe junctions.
• Every 100m and each manhole was given an identification number which clearly shows its
line and which manhole intersects with the main line 4. In larger pipes, where man-access
is possible (although undesirable), the spacing of manholes may be increased up to 200m.

6.3.3 Design calculations.

Use Civil3D and the surveyor’s topographical survey to create an alignment and draw
ground profile view. From the profile view we get the ground levels at manhole locations
and the pipe lengths can then be measured as to be the length between manholes. We then
Export the Civil3D model drawing to AutoCAD. Most of the design calculations are done
using the excel spread sheet. MS Excel was also used to calculate the coordinates to be
used for plotting the CVL and ILs. The formulas are written in such a way that when you
change a value in the excel sheet table about it automatically changes the value of the
coordinate. The values of the gradients are determined by comparing with the values of the
existing outfall sewer line. The student would adjust the gradients so that the assumptions
below are satisfied.
Formulas to input in MS Excel for Table
a. Depth= CVL - IL
b. CVL=GL+30Omm
c. 𝐼𝐿2 = 𝐼𝐿1 -(Distance/gradient)

Assumptions made in calculations;

i. CVL should be 300mm above GL.
ii. Manhole is 100m with a few exceptions of manholes which are 110m.
iii. minimum cover depth of 600mm from the ground to the crown of the pipes as
shown in Table 6.2.
iv. Minimum depth of manholes = 300mm (manhole height above GL) + 600mm
(minimum cover) + Pipe diameter.

Purposes of Manhole.

a. They are used to carry out inspection, cleaning and removing obstruction in the sewer line.

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 b. Manhole allows joining of sewers or changing the direction of sewer or alignment of sewer
or both.
c. They allow the escape of considerable gases through perforated cover and thus help in
ventilation of sewage.
d. They facilitate the laying of sewer line in convenient lengths

Table 6-1: Manhole sizes (Sanitation Manual-Design procedures 5,1990)

Nominal Diameter Nominal Diameter

of sewer(mm) of Manhole(mm)
150 900
225 1050
300 1050

Table 6-2: Manhole minimum cover ( Sanitation manual-Design procedures 5,1990)

Location of sewer Minimum cover to crown of sewer pipe (mm)

Pipeline servitude 600
Road reserve 900

6.3.4 Longitudinal Sections

A Long Section is a profile view of a surface along a particular route, which plots elevation against
the distance along the route. The long sections were to show the general profile of the pipe lines,
for example if the pipe appears above ground in some areas, and to show the excavation depths.
Using the calculated coordinates in MS Excel, the student would use NOTE++ to create a table so
that the coordinates will be easy to plot. Using the excel table the students would just edit the
AutoCAD drawing to add the required details for each manhole. The longitudinal section and
layout drawing for line 3 are attached in the Appendix.

6.4 Final assumptions and comments.

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 • A number of the manholes especially along line 4 are blocked and the invert levels could not
be inferred from the survey data that we received from the Surveyor. As such we were unable
to reliably replicate the existing sewer line.
• The proposed sewer lines have larger pipe sizes and, in some cases, have been placed deeper
than the existing lines to allow for minimum cover of 600mm to the crown of the pipes. This
in turn making the manhole inverts slightly deeper.
• We have also added additional manholes along lines exceeding 100m in length. This has been
done to allow for the serviceability of the sewer lines. Some of the pipe grades are almost flat
and as such are prone to sedimentation of waste when flows are very low e.g. in periods of
water rationing. It is there necessary to allow for easy maintenance of the sewer system in the
event of a blockage.
• All Manholes have been placed 300mm above ground level to prevent surface runoff, which
often has silt and debris, from entering the sewer system. It was noted in the existing system;
some manhole was below finished ground level making them prone to blockage.

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7. SECTION 7: SEKUKHUNE LEBALELO RESERVOIRS.

7.1 Salient Feature of the Project.

Project Name: Sekhukhule Lebalelo reservoirs.

Project Site Location: Sekhukhule District municipality, Limpopo Province, South Africa.
Project Scope: Design of 2ML reinforced concrete reservoir. HU to provide layout drawings
and detailed drawings.

7.2 Design Calculations.

7.2.1 Design of Flat Slab Floors.

The flat slab is defined in BS8110: Part 1, clause 1.2.2.1, as a slab with or without drops,
supported generally without beams, by columns with or without column heads. The drop
panels are effective in reducing the shearing stress where the column is liable to punch
through the slab and they also provide an increased moment of resistance where the
negative moments are greatest. The student was tasked with designing a flat slab whose
use is too close of the reservoir. Two-thirds of the amount of reinforcement required to
resist the negative design moment in the column strip should be placed in a width equal to
half that of the column strip and central with the column. The design calculations are
attached to this document in the Appendix.

Figure 7-1: Flat slab with drops division of panels (BS8110-1-1997, figure 3.12)

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 Table 7-1:Division of moments between strips (BS8110-1-1997, Table 3.18)

Design moment Column strip Middle strip

Negative moment 75% 25%
Positive moment 55% 45%

7.2.2 Stability of Retaining Walls

The author was tasked with checking for sliding, overturning, bearing capacity failure and
design moments for the base slab of the reservoir. A retaining wall may fail in any of the
following ways:
• It may overturn about its toe.
• It may slide along its base.
• It may fail due to the loss of bearing capacity of the soil supporting the base.
• It may undergo deep-seated shear failure.
• It may go through excessive settlement.

Figure 7-2: Failure of retaining wall: (a) by overturning; (b) by sliding;(c) by bearing capacity
failure

Check for Overturning.

∑ 𝑀𝑅
𝐹𝑆𝑜𝑣𝑒𝑟𝑡𝑢𝑟𝑛𝑖𝑛𝑔 =
∑ 𝑀𝑜

Where

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∑ 𝑀𝑅 = sum of the moments of forces tending to overturn about point toe.

∑ 𝑀𝑜 = sum of the moments of forces tending to resist overturning about the toe.

Check for sliding along the base.

𝐹𝑆 ∑𝐹 Where, ∑ 𝐹𝑅 = sum of the horizontal resisting forces. ∑ 𝐹𝑑 =sum of horizontal

𝑠𝑙𝑖𝑑𝑖𝑛𝑔=∑ 𝑅
𝐹𝑑

driving forces

Check for Bearing Capacity Failure

𝑞𝑢
𝐹𝑆𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 =
𝑞𝑚𝑎𝑥

Where

∑𝑉 6𝑒
𝑞𝑚𝑎𝑥 = (1 + )
𝐵 𝐵

𝑒= the eccentricity of the resultant R

B= width of base

∑ 𝑉 = summation of the weight per unit length of the wall.

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8. SECTION 8: COMPUTER SKILLS AND OVERALL BENEFITS OF INDUSTRIAL
ATTACHMENT.

8.1 Computer Skills: Introduction

The advancement in electronic technology has led to the invention of accurate, fast and
sophisticated computer gadgets and software. In engineering, computers play a pivotal role in the
design and analysis of engineering projects. They are more comprehensible and fast in result
production and enable the user to link raw data to detailed design programs as well as to produce
drawings. During attachment the author was introduced to numerous computer software packages.
However, it was made sure that the author understood the design from the first principles and that
he was able to make manual design calculations before using computer programs. Below is a list
of programs the author was introduced to AutoCAD, Revit, Civil 3D, Microsoft software, Civil
Designer, Prokon. And Note++

8.1.1 AutoCAD

This is a common computer aided design and drafting program. It is a fast, easy and comfortable
approach to drafting. AutoCAD enables one to create drawings within a short period. The author
started by learning AutoCAD’s basic functions like drawing a line, moving, copying, scaling and
giving exact measurements to objects from lectures at University and got to apply the skills and
perfect them with help from his supervisor. The author came to a position of putting together the
knowledge acquired in order to produce complex drawings and use AutoCAD 2018 and 2019. In
order to enhance the AutoCAD skills acquired the author was tasked to produce drawings for the
longitudinal profiles, layout drawings, reinforcement detailing, pipe fitting schedules, manhole
schedule, pavement sections and standard details of all the projects he was involved in of which
the drawings are attached.

8.1.2 Prokon

The student used Prokon software to calculate the concrete tank deflection, design of a combine
footing and a pad footing.

8.1.3 Microsoft.

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Microsoft Office is a collection of office-related applications. Each application serves a unique
purpose and offers a specific service to its users. The student used Microsoft Word to create
documents for example the specification document. Microsoft PowerPoint to create presentations.
Microsoft Outlook was used to manage email and calendars. The author also used Microsoft Excel
to calculate manhole invert levels, cover levels and gradients.

8.1.4 Revit.

Autodesk Revit is Building Information Modeling (BIM) software for Microsoft Windows, which
allows the user to design with parametric modeling and drafting elements. Building Information
Modeling (BIM) is a new Computer Aided Design (CAD) paradigm that allows for intelligent, 3D
and parametric object-based design. A change anywhere is a change everywhere, instantly, with
no user interaction to manually update any view. The author used this program to produce
structural layout details for Knightsbridge 2 storey apartments. After drawing on Revit the student
would export to AutoCAD.

8.1.5 Civil 3D

AutoCAD Civil 3D software is a design and documentation solution for civil engineering that
supports building information modeling (BIM) workflows. By learning to use AutoCAD Civil 3D,
you can improve project performance, maintain consistent data, follow standard processes, and
respond faster to change. The author used this software to create a longitudinal section model for
the outflow sewer ground levels.

8.2 Overall Benefits of the industrial attachment.

a. Gain valuable work experience

The hands-on work experiences the author received on attachment were invaluable and cannot be
obtained in a classroom setting. He had a chance to apply some of the theoretical knowledge
acquired from NUST in the industry. The author had a chance to learn in the specialized field of
consulting engineering and get a hands-on experience. In addition to learning the specialized skills
of this field, he was able to gain transferable skills such as communication, teamwork, and

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computer proficiency this also helps in preparing in preparing the author to enter the workforce
upon graduation.

b. Explore a career path

Industrial attachment helped the author to realize exactly the career path he was interested to
pursue after graduation. The author had an experience of structural engineering, civils engineering
and project management. Some students begin college with a career path in mind, and end up
changing their minds later on. Taking on an attachment while in college allowed the author to work
in his desired field, helping him decide if the field was right for them.

c. Gain confidence

Industrial attachment helped the author to gain self-confidence. This was because the author was
encouraged to learn and was given an opportunity to apply what he had learned in a safe
environment where mistakes were expected and be corrected rather than learning the hard way in
his first job out of college. The author also gained confidence by attending site meetings and short
courses at ZIE. It also helped him to learn more about himself as a professional, and be more
prepared to make decisions, take the initiative and risks.

d. Network with professionals in the field

Industrial attachment helped the author with the professionals in the industry. The author leant that
attachment is more than just about earning credit, getting a grade, or making money; it’s to provide
an opportunity to learn from the people around you, ask questions, and impress. Because the
professionals you encounter during an internship can be your future colleagues or the connection
to your first job.

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9. SECTION 9: CONCLUSION AND RECOMMENDATIONS.

9.1 Conclusions

Industrial Attachment exposes a student to the real engineering world, it provides a platform for
the student to exercise the theoretical knowledge acquired from college. This period allows the
author to think in other terms as most of the assumption made in class are not applicable and the
values given in examples for designs have to be calculated or obtained from manuals. Industrial
attachment helped the author to work under pressure to meet deadlines. Initially the author could
not put into use the numerous formulae and design procedures as the theory part would at most
instances idealize the concept of any design, but after the attachment period the student can manage
to design water reticulation systems, structural elements, communicate and assist clients and
appreciate the importance of the theory we obtain in class. Among other things the author also
benefited in realizing the importance of team work and good communication skills at work place.
All this would not have been if it were not for Hydro-Utilities Consulting Engineers (Pvt)ltd that
offered the author an opportunity to spend his attachment period with them.

9.2 Recommendations

9.2.1 Recommendations to the company

The following are the student’s recommendations to the company;

• The student should be given a clear and achievable deadline to finish the task.
• To have a clear path of communication for the design team because the student noticed
that if a detail on one drawing changes and is not communicated it would affect other
drawing and will make the design team look disorganized.

9.2.2 Recommendations to the university

The list below is of the student’s recommendations to the university;

• NUST should update the syllabus material as the material leant at school is becoming less
and less relevant to the industry due to technology advancement. The student suggests
software’s like Civil 3D, Prokon, Revit and Civil Designer be introduced to student for ease
of drafting and designing.

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 • The university should introduce more practical courses and site visits so that the students can
familiarize themselves with the engineering practices before going to the industry.
• Encourage the students to join ZIE which will make students network with engineers from
their profession.
• Assessment visits should be increased so as to closely monitor the performance of students
on attachment. This would also help the organization in improving the academic curricula as
they would really know exactly what is required by the Civil engineering industry, thus
producing quality students.
• Introduce students to relevant civil engineering manuals.

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10. List of Tables

Table 2-1 basic span/effective depth ratio (BS8110-1-1997,Table 3.9) ..................................................... 15

Table 2-2: Design ultimate bending moments and shear forces (BS8110-1-1997, Table 3.5) ................... 19
Table 6-1: Manhole sizes (Sanitation Manual-Design procedures 5,1990) ................................................ 52
Table 6-2: Manhole minimum cover ( Sanitation manual-Design procedures 5,1990) .............................. 52
Table 7-1:Division of moments between strips (BS8110-1-1997, Table 3.18) .......................................... 55

11. Table of Figures.

Figure 1-1: Organogram ................................................................................................................................ 7

Figure 2-1:location of moments (Arya,1994) ............................................................................................. 14
Figure 2-2 : Check for shear (Table 3.7 BS8110-1-1997) .......................................................................... 16
Figure 2-3: Stairs main technical terms ...................................................................................................... 17
Figure 2-4: Complete staircase ................................................................................................................... 18
Figure 2-5: Staircase foundation ................................................................................................................. 18
Figure 3-1: Auger Bore ............................................................................................................................... 24
Figure 4-1: Biokube Section. ...................................................................................................................... 27
Figure 4-2: True Slump ............................................................................................................................... 29
Figure 4-3:Formwork fixing ....................................................................................................................... 30
Figure 4-4: Concrete Pouring using Boom pump ....................................................................................... 30
Figure 4-5: Concrete Curing ....................................................................................................................... 30
Figure 4-6: Stripping of shutters ................................................................................................................. 30
Figure 4-7: Water tightness Test ................................................................................................................. 33
Figure 5-1:Collection pipe layout and details ............................................................................................. 40
Figure 5-2: Collection pipe fixing on site ................................................................................................... 40
Figure 5-3: Pegs for pile setting out ............................................................................................................ 43
Figure 5-4: Sump 1 Piling ........................................................................................................................... 44
Figure 5-5: Steel fixing for the flow splitter box ........................................................................................ 45
Figure 5-6: Thrust Block provided at bend ................................................................................................. 48
Figure 7-1: Flat slab with drops division of panels (BS8110-1-1997, figure 3.12) .................................... 54
Figure 7-2: Failure of retaining wall: (a) by overturning; (b) by sliding;(c) by bearing capacity failure ... 55

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 REFERENCES
• Metcalf & Eddy, INC (1991), Wastewater Engineering, Treatment, Disposal and Reuse.
Third Edition. McGraw-Hill, Inc.
• Chanakya Arya, (1994), Design of structural Elements, Third Edition.
• T.J. McGinley and B.S Choo (1990), Reinforced Concrete, Design Theory and Examples,
Second Edition
• W.H. Mosley and J.H. Bungey (1987), Reinforced Concrete Design, Third Edition.
• BS8110 (1997) Structural use of concrete Part 1: Code of practice for design and construction
• BS 4466:1989, Specification for Scheduling, dimensioning, bending and cutting of steel
reinforcement for concrete.
• Sanitation Manual-Design Procedures, SALA Manuals, Specifications and Guidelines.
• Dr. K.R. Aroka (2004), Site Investigations, Pg421, Soil Mechanics and Foundation
Engineering,
• http://www.thepipefittings.com/
• https://theconstructor.org/

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12. Appendix

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