Preface

Civil Engineering is a significant field of Engineering. It is designing, constructing and

maintaining the product world request. It makes the life of human beings more comfortable.
Therefore, industrial training is very important to comprehend work environment and future
engineering profession. As a part of the graduate diploma course, in order to gain practical
knowledge and to understand the application of theoretical studies in industries, we are required
to make a report on our industrial training. So this report is prepared for the completion of three
months industrial training at Lotus Tower project Colombo and Residential Project at Chitra lane
Colombo 5. The structural consultation and project management was conducted by Civil and
Structural Engineering Consultants (Pvt.) Ltd.

In this report I have included mainly three chapters, the first chapter describes about the
training establishment. This includes the vision, mission, type of business, details of projects
involved, management and administrative style and etc.

The next chapter includes my training experiences at the establishment. In this chapter I
have explained about the work done at the site, problems encountered and solutions given. And
also the information about office practices, quality controlling methods, tests followed at the site,
and documents involved in site actions has been described.

The last chapter is the conclusion of the report. It includes what I gained during the training
period, weaknesses identified, the suggestions for improvement and etc.

Thank You,

Kusal Thennakoon.

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Acknowledgement

I take this opportunity to thank everyone who has helped me in every way during my
industrial training period.

I specially thank to the management of the IESL College of Engineering particularly to all
the lecturers and the staff of NAITA industrial training division who arranged me to obtain this
remarkable opportunity. And I would like to thank Mr. D.Weerathunge and Eng. I Dayarathna, the
training coordinators of IESLCE for organizing me the training program and appointing me as an
apprentice in the Civil and Structural Engineering Consultants (Pvt.) Ltd.

I would like to convey my gratitude for Eng. Shiromal Fernando, who was one of the
leading structural engineers in Sri Lanka and Eng. Shyanaka Dhananjaya, Eng. Ravindu
Hettiarachchi, Eng. Ashan Jayalath and Eng. Tharin Sumithraarachchi for the support given during
my training period. And also I would like to thank the staff of the project, where I gained a lot of
knowledge and experience in structural civil engineering and constructions. And I wish to thank
them for making this great opportunity available for me which made my training a great success.

I dedicate my heartiest gratitude to my parents, who gave me courage and provided me

everything possible to make my training a success. Also I would thank to all of my friends who
helped me to make this success and finally I wish to thank everybody.

Kusal Thennakoon.

150941

Department of Civil Engineering

IESL College of Engineering

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Table of Contents
Preface.......................................................................................................................................................... ii
Acknowledgement ...................................................................................................................................... iii
Table of Contents ....................................................................................................................................... iv
List of Figures............................................................................................................................................. vi
Abbreviations ........................................................................................................................................... viii
1. CHAPTER 01: Introduction .............................................................................................................. 1
1.1. Nature of the establishment........................................................................................................... 1
1.2. Vision ............................................................................................................................................ 2
1.3. Mission.......................................................................................................................................... 2
1.4. Services ......................................................................................................................................... 2
1.5. Ongoing Projects ........................................................................................................................... 4
1.6. Administrative strategies and management style .......................................................................... 5
1.7. Details of the projects involved .................................................................................................... 6
2. CHAPTER 2: Training Experience................................................................................................. 12
2.1. Tiling ............................................................................................................................................... 12
2.1.1. Technical details ................................................................................................................. 12
2.1.2. Equipment used in tiling ..................................................................................................... 13
2.1.3. Tiling Procedure.................................................................................................................. 14
2.2. Moisture Correction for Aggregates in concrete ............................................................................. 17
2.2.1. Laboratory procedure for moisture check ........................................................................... 18
2.3. Rebound Hammer Test ................................................................................................................... 19
2.3.1. Test procedure ..................................................................................................................... 20
2.4. Formwork ........................................................................................................................................ 22
2.4.1. Formwork for columns........................................................................................................ 22
2.4.2. Formwork for beams ........................................................................................................... 26
2.4.3. Formwork for slab............................................................................................................... 28
2.4.4. Striking of formwork .......................................................................................................... 29
2.4.5. Quality control for formwork .............................................................................................. 30
2.5. Site Documents ............................................................................................................................... 32
2.5.1. Bill of quantities (BOQ) ...................................................................................................... 32

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 2.5.2. Letter of Acceptance ........................................................................................................... 34
2.5.3. Tender document................................................................................................................. 34
2.5.4. Drawings ............................................................................................................................. 36
2.5.5. Request for Acceptance (RFA) ........................................................................................... 37
2.5.6. Document review report (DRR) .......................................................................................... 38
2.5.7. Request for clarification (RFC)........................................................................................... 38
2.5.9. Non-Conformity Report (NCR) .......................................................................................... 40
2.5.10. Monthly report .................................................................................................................... 41
2.5.11. Daily record ........................................................................................................................ 41
2.5.12. Daily timeline...................................................................................................................... 41
3. CHAPTER 3: Conclusion................................................................................................................. 42
References .................................................................................................................................................. 43

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List of Figures
Figure 1 – CSEC Logo ..................................................................................................................................... 1
Figure 2 – TRCSL Logo ................................................................................................................................... 7
Figure 3 – Moratuwa University Logo ......................................................................................................... 7
Figure 4 – CEIEC Logo ................................................................................................................................ 7
Figure 5 – Lotus Tower................................................................................................................................. 8
Figure 6 – Plan view of the site..................................................................................................................... 9
Figure 7 – Circular staircase view................................................................................................................ 10
Figure 8 – Site Outlook ............................................................................................................................... 11
Figure 9 – Technical details of the tile brand.............................................................................................. 12
Figure 10 – Laser levelling instrument ........................................................................................................ 13
Figure 11 – Levelling bar ............................................................................................................................ 13
Figure 12 - Scraper ...................................................................................................................................... 13
Figure 13 – Square trowel ........................................................................................................................... 13
Figure 14 – Tile cutting machine ................................................................................................................. 13
Figure 15 – Rubber mallet........................................................................................................................... 13
Figure 16 – Surface prepared for tiling ....................................................................................................... 14
Figure 17 – Level peg .................................................................................................................................. 15
Figure 18 – Setting out lines of nylon threads ............................................................................................ 15
Figure 20 – Plastic pieces to maintain grooves ........................................................................................... 16
Figure 19 – Tile Curing ................................................................................................................................ 16
Figure 22 – Tiled area .................................................................................................................................. 16
Figure 23 – Changing batch quantities of concrete .................................................................................... 18
Figure 24 – Sample weighing for test ......................................................................................................... 18
Figure 25 – Rebound hammer .................................................................................................................... 19
Figure 26 – Cleaning the concrete surface ................................................................................................. 20
Figure 27 – Rebound hammer test for a wall ............................................................................................. 21
Figure 28 – Rebound hammer test for a column ........................................................................................ 21
Figure 29 – Setting out lines ....................................................................................................................... 22
Figure 30 – Survey hole ............................................................................................................................... 22
Figure 31 - Kicker......................................................................................................................................... 23
Figure 32 – Detailed drawing for column formwork .................................................................................. 23

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Figure 33 – Verticality measurement.......................................................................................................... 24
Figure 34 – Sketch of verticality measurement .......................................................................................... 24
Figure 35 – T Jack ........................................................................................................................................ 24
Figure 36 - Plywood board fixed with 2”×2” timber frame ........................................................................ 24
Figure 37 - Setsquare and steel tape .......................................................................................................... 25
Figure 38 – Marking rod .............................................................................................................................. 25
Figure 39 – Chad locks ................................................................................................................................ 25
Figure 40 – Steel Jacks ................................................................................................................................ 25
Figure 41 – GI pipes..................................................................................................................................... 25
Figure 42 – Beam bottoms .......................................................................................................................... 26
Figure 43 – Beam bottom fixed to the column formwork .......................................................................... 26
Figure 44 – Fixed beam bottoms ................................................................................................................ 27
Figure 45 – Prop supports for slab .............................................................................................................. 28
Figure 46 – T Jack support........................................................................................................................... 28
Figure 47 – Using spirit level ....................................................................................................................... 28
Figure 48 – Slab supported on U jacks and 4”2” wooden planks ............................................................... 28
Figure 49 – Slab formwork .......................................................................................................................... 29
Figure 50 – GI pipe supports for slab .......................................................................................................... 29
Figure 51 – Minimum period for striking of formwork ............................................................................... 29
Figure 52 – Application of formwork releasing agent ................................................................................ 30
Figure 53 – Pocket in column formwork ..................................................................................................... 31
Figure 54 – Sponge at construction joints .................................................................................................. 31
Figure 55 – Cement grout leakage control method .................................................................................... 31
Figure 56 – Bill Of Quantity document ....................................................................................................... 33
Figure 57 – Letter of acceptance ................................................................................................................ 34
Figure 58 – Content of tender document ................................................................................................... 35
Figure 59 – RFA document .......................................................................................................................... 37
Figure 60 – DRR document ......................................................................................................................... 38
Figure 61 – RFC document .......................................................................................................................... 39
Figure 62 – EOR document ......................................................................................................................... 39
Figure 64 – NCR Document ......................................................................................................................... 40
Figure 63 – NCR document ......................................................................................................................... 40

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List of tables

Table 1 – Ongoing project details………………………………..………………………………11

Abbreviations
BOQ - Bill of Quantities

BSR - Building Schedule of Rates

CEIEC - China Electronics Import and Export Cooperation

CIDA - Construction Industry Development Authority

CSE - Civil and Structural Engineers

CSEC - Civil and Structural Engineering Consultants

DRR - Document Review Report

DT - Document Transmittals

EOR - Engineers’ Observations/Recommendations

EPF - Employer Provident Fund

ETF - Employer Trust Fund

FIDIC - Interantional Federation of Consulting Engineers

ft2 - Square feet (area measurement)

GBCSL - Green Building Council of Sri Lanka

GI - Galvanized Iron

HSR - Highway Schedule of Rates

L - Liters

LCMC - Lotus Construction and Management Consultants

viii`
m - Meters (length measurement)

m2 - Square meters (area measurement)

MEP - Mechanical Electrical Plumbing

mm - Millimeters

MPa - Mega Pascal (strength measurement)

NAITA - National Apprentice and Industrial Training Authority

NCR - Non Confirmity Report

OPC - Ordinary Portland Cement

PPC - Pozzolana Portland Cement

RFA - request for Acceptance

RFC - Request for Confirmation

SSD - Saturated Surface Dry

TRCSL - Telecommunication Regulatory Commission of Sri Lanka

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1. CHAPTER 01: Introduction

CIVIL AND STRUCTURAL ENGINEERING CONSULANTS (PVT.) LTD.

Figure 1 – CSEC Logo

1.1. Nature of the establishment

Civil and Structural Engineering Consultants (Pvt.) Ltd, more commonly known as ‘CSE
Consultants’ is consultancy firm comprising some of the prominent Structural Engineers in the
industry. The main objective of CSE is to maintain high level of quality in the services involved
and to be the trend setter in the industry through innovation, state of the art technologies and
excellence in engineering. The CSE has completed over 100 projects within a short period of time
since establishment. These projects include most of the major constructions within the country.
This success implies the potential of the dynamic team of the company.

The Civil and Structural Engineering Consultants (Pvt.) Ltd has partners in the industrial field.
Mainly Green Building Council of Sri Lanka, Structural Design Institute and the Lotus
Construction and Management Consultants which helps CSE to become a pioneer company in the
civil engineering field.

CSE is Honorary Chaired by Prof. Priyan Mendis; a world renowned Structural Engineer who
has been a consultant for many prestigious and landmark projects across the globe including Burj
Kalifa, the world’s tallest building. He is a former Discipline Head of Civil Engineering at the
Department of Infrastructure Engineering, University of Melbourne, Australia.

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 The Managing Director Eng. Shiromal Fernando is one of the leading structural engineers in
Sri Lanka, who has been structurally designed many high-rise buildings including the tallest
building in Sri Lanka. He is the present Country Representative for ‘Council on Tall Buildings &
Urban Habitat (CTBUH)’, the apex body of tall building professionals across the globe and a
Director at Green Building Council of Sri Lanka.

CSE is now engaged in some of the major and landmark projects in Sri Lanka and overseas.
CSE strongly intends to expand its services in the Civil and Structural Engineering and intends to
be one of the best engineering consortiums in the world and contribute to the development of the
country and world at large.

1.2. Vision

To be resource and knowledge base in the field of structural engineering.

1.3. Mission

Maintain the professional standard for structural engineering, ensuring continued technical
excellence, advancing safety, creativity and innovation across the built environment and promoting
sustainable approaches in engineering solutions, supporting engineers as they protect, influence
and take forward our environment’s conservation responsibility.

1.4. Services

Structural engineering consultancy.

 Structural analysis and design

 Seismic design
 Investigation of alteration and failures
 Structural audit service

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Advanced protective technology for engineering structures.

 Security assessment
 Security planning
 Security system design and management

Green consultancy

 Green building design

 GBCSL Documentation
 Education and training

Other services

 Project management
 Geotechnical engineering

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1.5. Ongoing Projects

The most of the major projects within the country is consulting by Civil and Structural
Engineering Consultants (Pvt.) Ltd. Few of them are mentioned below:

Table 2 – Ongoing project details

Project Location

Lotus tower D.R. Wijewardana Mw., Colombo 10.

No. 39, R.A. De Mel Mawatha,

AVIC Astoria
Colombo 03.

JKH Waterfront Resort No. 130, Glennie street, Colombo 02.

The one (Krrish square) York street, Colombo.

Capitol twin peaks No.24, Staple street, Colombo 02.

No.137, Sir James Pieris Mw.,

Colombo City Centre
Colombo 02.

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1.6. Administrative strategies and management style

CSE Consultants has a working shift of 8 – 12 hours per day depending on the site condition.
The daily shift can be night or morning shift; it is also depending on the site conditions. Every
engineer in CSEC has to work 6 days per week and should have a one holiday per week in the
weekend, the holiday can take according to the workers’ desire; Saturday or Sunday.

If the engineers are working at beyond their normal daily shift the transportation and food cost
will be paid and no overtime payment is given. This is a management technique that can be seen
within the company since they are not paying OT for workers. And the other payments (food and
transportation) excluding the salary should be taken as claims of petty cash from the accounts
department.

The major administrative technique within the site can be seen that, every engineer from each
site should present about the progress of the site in every week on Thursday at the CSEC head
office. The presentations were evaluated by Eng. Shiromal Fernando. Since CSEC is carrying out
larger number of projects within the country it is a suitable and easiest way to have an idea about
the work progress in each site.

As motivational management techniques within the company, it conducts an annual Christmas

party for all employees and an annual sports festival. This is very important to relax their minds
and enhance their health conditions and fitness.

And also Employee Provident Funds (EPF) and Employee Trust Funds (ETF) were given for
every permanent worker within the company. Employer contribution to EPF is 12% from the
salary, employer contribution to ETF is 3% and the employee contribution to ETF is 10% from
the salary.

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1.7. Details of the projects involved

Lotus Tower Project

Lotus tower project is one of the landmark and major project within the country. The
location of the Lotus tower is in Colombo city to the west of Sri Lanka, main road of airport to the
east of Sri Lanka, Colombo harbor in the north and the Beire lake to the south. And the lotus tower
is situated lakeside to the Beire lake. The whole structure is consisting of three main parts tower
base, tower body and the tower mast.

The tower base designed as a Buddhist lotus throne. The total area of the tower base is
19461m2. It is consisting of a basement floor of 5.4m floor to floor height and three floors above
the ground of 5m floor to floor height, which is built enclosing tower body.

The tower body is a cylindrical reinforced concrete structure with the top elevation
263.100m. And also tower body consist of the tower mast of 89.900m, in which the concrete mast
is 27.600m and the steel mast is 59.300m. The tower body has no functional rooms and mainly
consist of structural elements, ducts and the lift.

The tower building is designed to a lotus flower in full bloom. The tower house has an area
of 7537m2. It consists of 8 functional floors: first two floors for mainly broadcast and TV
transmitter room, Third and fourth are mainly banquet halls, Fifth and sixth floors are for guest
rooms, seventh floor is for storage of equipment and observation deck and the eighth floor is
reserved as the water tank room.

The main purpose of the lotus tower; is a commercial comprehensive building integrating
a radio, television transmission, satellite reception, catering and entertainment, shopping,
exhibition, conference, banquet and tourism after establishment. And it will be the first TV tower
in Sri Lanka and the highest in south Asia.

This project is designed to consider the sculpture, aesthetic style, structural mechanics and
the characteristics of the national culture of Sri Lanka. This implies with the full bloom lotus tower
building and the lotus throne tower base, which indicates the thriving, peaceful and developing Sri
Lanka.

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Client : TELECOMMUNICATION REGULATORY COMMISSION OF SRI LANKA.
(TRCSL)

Figure 2 – TRCSL Logo

Project consultancy unit : FACULTY OF ARCHITECTURE UNIVERSITY OF

MORATUWA.

Figure 3 – Moratuwa University Logo

Design and Built Contractor : CHINA ELECTRONICS IMPORT AND EXPORT

COOPERATION. (CEIEC)

Figure 4 – CEIEC Logo

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Total construction area : 26,998m2

Height of the tower : 350m

Approximate project cost :

Project started date and expected finishing date :

The elevation +0.000m of the of the project is equivalent to the 6.050m elevation of Sri Lanka.
The design service life of the structure is 50 years. The structure is a combination of reinforced
concrete structure and steel structure. Mainly grade 35 (C35) concrete is used for structural
elements and grade 50 (C50) concrete is used for the supporting structure of the tower house.

Figure 5 – Lotus Tower

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Residential project at Chitra Lane, Colombo 5.

PROJECT NAME : Proposed Residential project at Chitra Lane, Colombo 05.

EMPLOYER : Asia Broadcasting Cooperation (Pvt.) Ltd.

PROJECT MANAGER : Lotus Construction and Management Consultants (Pvt.) Ltd.

CONSULTANT : Pan Arch (Pvt.) Ltd.

CONTRACTOR : L.H. Piyasena and Cooperation (Pvt.) Ltd.

PROJECT COST : Approximately Rs. 500 million

DATE OF COMMENCEMENT : 10th March 2017

DATE OF COMLETION (EXPECTED) : 10th September 2018

This residential building is a five storied building with a basement and a roof top. The total
building is coordinated according to a grid system, where horizontal grid is from 1-12 and the
vertical grids are from A-J (figure 6). The foundation type of the building is pile foundation. And
the building is standing on 52 bored piled.

Figure 6 – Plan view of the site

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 The structure is a reinforced concrete structure, basically grade 30 (C30) concrete is used
for concreting structural elements and concrete of grade 35 (C35) with integral water proofing
admixtures is used for the construction of water retaining structures. And all walls are constructed
using solid bricks.

The level of the basement is -1900 and the basement level is mainly used for car parking.
The car park consists of 21 parking slots with 2 car washing areas. And also the basement level
consists of the pump room, water sump (capacity 1000l), electrical panel and generator room. The
total floor area of the basement is approximately 8000 ft2.

The ground floor is at the level of +1400. At the level of +500 the car pouch is located and
the ground floor is lifted 900mm above the car pouch level. The ground floor is mainly consisting
of an office area, lounge area, dining area, cinema, kitchen, store, food store and the main staircase.
The total floor area of the ground floor is approximately 8770 ft2. The floor to floor height between
ground floor and the first floor is 6m. And between the ground floor level and the first floor level,
the staircase landing level and the intermediate floor level is located. The staircase landing is at
the level of +4400 and the intermediate floor level is +4250 between grids F and H.

The main staircase of the building is designed and constructed as a circular staircase with
two flights and a staircase landing of area 250 ft2. The rise of the staircase is 158mm and the going
is 310-430mm because of its circular shape.

Figure 7 – Circular staircase view

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 The level of the first floor is +7400, and the floor to floor height is 4.5m. The first floor is
mainly reserved for entertainment. And according to client’s requirement, the first floor consists
of a swimming pool of length 16650mm, breadth 5325mm and a depth of 1.2m, an open verandah,
dancing floor, billiard area, gymnasium, a studio and a spa. The total floor area of the first floor is
approximately 9230 ft2.

The level of the second floor is +11900 and the level of the third floor is +15900, and the
floor to floor height is 4m in both level. Second and third floor are mainly consisting of bedrooms,
where a single bedroom is with an attached bathroom and a closet. Second floor has six number
of bedrooms and the third floor has four number of bedrooms with the master bedroom. The floor
area of the second floor is approximately 6450 ft2 and the third floor area is approximately 6525
ft2. Another main feature in the third floor is, that it consists of an open sky area from the dome in
the roof terrace and the shrine room.

The roof terrace level is at +19900 and the perimeter of the level is with a 3.2m height
guard wall. The main feature in the terrace area is that it consists of a glass dome to get additional
sunlight to the open area in the third floor. And also this level has a possible area for solar panels,
water sump (1000l) and sculpture. The total floor area of this level is approximately 5900 ft2.

Figure 8 – Site Outlook

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2. CHAPTER 2: Training Experience
2.1. Tiling

Tiles are basically used for interior design, usually tiles are made up of ceramic and granite tile
can also be seen. Comparing to other rendering methods tiling is advantageous since it has less
maintenance and also it is healthy and long lasting. In lotus tower project tiles were used in floors,
walls and for the skirting. The commercial areas are tiling with an unglazed polished porcelain tile
and the bathroom areas are tiling with a skid resistant tile.

2.1.1. Technical details

The tile brand used was MONALISA. The nominal size of the tile is 600mm×600mm and the
thickness is 10mm. The tile used is a grade A, it has a higher strength and using for commercial
areas, for example; shopping complexes and airports. The manufacturing method is dry pressed
(ISO 13006:2012) with less than 0.5% water absorption and the bending strength is greater than
35 MPa.

Figure 9 – Technical details of the tile brand

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2.1.2. Equipment used in tiling

Figure 11 – Levelling bar Figure 10 – Laser levelling

instrument

Figure 12 - Scraper Figure 13 – Square trowel

Figure 15 – Rubber mallet Figure 14 – Tile cutting machine

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2.1.3. Tiling Procedure

Surface preparation

 Construction was started after the MEP works were done.

 Then the surface was levelled with a screed concrete.
 Then the substrate was cleaned and the surface was wetted for one day.

The surface was wetted, because if not the surface will absorb water from the tile bed mortar so
the required strength may not achieve.

Figure 16 – Surface prepared for tiling

Setting-out

 According to 1m finishing floor level, using the infrared the finishing level of the tile was
marked.
 Then using nylon threads, the setting out lines were produced. The nylon threads were
fixed between two level pegs, that used to define the finishing level.

14`
 Figure 18 – Setting out lines of nylon threads Figure 17 – Level peg

Construction procedure

 After the surface preparation and the setting out, the prepared wet surface was applied with
dry cement. This is in order to enhance the bond between tile bed and the concrete surface.
 Then cement sand mortar in the ratio of 1:3 was spread and levelled on the surface to an
approximate thickness of 30mm.

The cement sand mortar bed was prepared in order to make an ideal surface for tiling and to ensure
the protection of water proofing layer (if any) or any other layers below the surface of tiling.

 Then a cement bonding layer of approximately 10mm thickness was applied at the back of
the tile and then placed at the correct position.
 Then using the rubber mallet and plastic cross pieces, a groove of 2.5mm was maintained.

The tile groove was maintained in order to avoid the cracks occurred due to thermal expansion.
The groove size is depending on the exposure condition. For example; at lotus tower, internal tiles
were maintained with a groove of 2.5mm and external tiles in tower house area was maintained
with a groove of 10mm.

15`
  Then the surface was cured once a day for 7 days.

Figure 20 – Tile Curing Figure 19 – Plastic pieces to maintain grooves

Finishing

 Initially the groove must be cleaned with air compressor.

 Then the tiling grout was applied into the grooves.
 Finally, the tiles were cleaned with an approved tile cleaner.

Figure 21 – Tiled area

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2.2. Moisture Correction for Aggregates in concrete

Aggregates used in concrete contains water as a thin film around its surface and also inside
pores within aggregate particles. The moisture correction is important since, the excess water in
aggregates will add a considerable amount of water to the concrete, if the pores in aggregates are
not saturated, it will absorb water from the concrete and also since the concrete was batched
according to weight of ingredients, this will reduce the amount of aggregates added to the concrete
so it will ultimately effect the strength of concrete. Therefore, the moisture correction is done for
aggregates in concrete, in order to determine the correct amount of water and aggregates that has
to be added in to the concrete.

Concrete has two types of aggregates; coarse and fine aggregates. From these two types
fine aggregates contribute more water as moisture water to the concrete. The moisture in
aggregates can be represented as;

Oven dry : All moisture in aggregates removed by heating.

Air dry : All moisture removed from the surface, but the internal pores are partially
filled.

Saturated surface dry : All pores filled with water and no film of water on the surface.

Wet or moist : All pores are completely filled with water with a film on the surface.

The most suitable moisture type is saturated surface dry aggregates (SSD). If the moisture type is
oven dry or air dry, since it is not saturated it will absorb water in concrete and if the moisture type
is wet or moist it will add more water to the concrete. Both the cases ultimately effect the strength
of concrete. So the water in excess of saturated surface dry condition can be defined as moisture
content.

This cannot be accurately identified due to practical reasons; weather condition, constant change
of material stock and etc. So in calculation of batch quantities of aggregates and the total water
requirement of the mix, the mass of water added to the mix was decreased and the mass of
aggregates was increased accordingly.

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2.2.1. Laboratory procedure for moisture check

In laboratory, the total moisture content was determined by oven dry method. (Ref: BS 812: part
109: 1990)

 Initially an aggregate sample was taken. (Approximately 200g)

 Then the sample was weighed. (m1)
 Then the sample was dried at required temperature for few minutes according to standards.
 Then the final mass of the sample was weighed. (m2)

𝑚1 − 𝑚2
𝑀𝑜𝑖𝑠𝑡𝑢𝑟𝑒 𝑐𝑜𝑛𝑡𝑒𝑛𝑡 = × 100%
𝑚2

Since the oven dried condition was considered, in the calculations the actual water absorption rate
of aggregates was deducted from the calculated moisture content in order to obtain the moisture
content at saturated surface dry condition. So accordingly water requirement was reduced and the
aggregate requirement was increased when batching.

Figure 23 – Sample weighing for test Figure 22 – Changing batch quantities of

concrete

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2.3. Rebound Hammer Test

The rebound hammer test is a non-destructive test that used to determine the compressive
strength of a certain structural element. The main testing method of compressive strength for
concrete is cube test. Generally, there are 8 cubes casted, depending on the volume of the concrete.
From those 8 cubes, 2 cubes each are used for 7 days, 14 days and 28 days’ compressive strength
test, additional 2 cubes were casted, to test within 56 days if the above strengths were not achieved.
If the 56 days’ strength is also not achieved for the particular strength class, then the next step is
to conduct non-destructive tests.

Mainly there are two types of non-destructive tests to check the quality of concrete; rebound
hammer test and the ultrasonic test.

The rebound hammer test measures the concrete quality and indicates as surface hardness. This
is an approximate estimation of the strength of concrete. This test can be done on wet or dry
concrete surface, using the graph in manufactures’ instruction. The reading is depending on the
position of the hammer, vertical or horizontal. Therefore, according to the reading of the
instrument corresponding compressive strength value can be read using manufacturers’ graph or
the chart provided.

The basic principle of rebound hammer is that, the rebound of an elastic mass depends on the
hardness of the surface against which the mass impacts.

Figure 24 – Rebound hammer

Figure 25 – Cleaning the19`

concrete surfaceFigure 26
– Rebound hammer
2.3.1. Test procedure
 Initially the instrument was checked for its anvil according to manufacturers’ instructions.
 Then the concrete surface was cleaned using the rough stone provided. (figure 26)

This is to make sure the hammer is not impacted with the grout layer on the concrete surface.

Figure 27 – Cleaning the

concrete surface

 Then a cage was drawn in order to represent the testing area. (figure 27)

At least 9 readings should be taken Figure

from28a –particular
Reboundarea.
hammer
This is because of the test is sensitive
test for a wallFigure 29 –
to the presence of aggregates and Cleaning
voids underneath the plunger,
the concrete surface so to get accurate results we have
to get at least 9 readings and take the average of it.

 Then the anvil of the hammer was pressed against the wall and the lock was released.
 After that the anvil was pressed against the wall again by applying more force until
hammering sound occurs. In this case the rebound hammer should be kept normal to the
concrete surface, to have accurate results.
 Then the lock was pressed and the reading was noted.
 Likewise, the above procedure was repeated for 9 places in the testing area.
 Then the average value of the results was compared and analyzed with the grade of concrete
in the particular structural element.

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Figure 33 – Rebound hammer test for Figure 30 – Rebound hammer test for
a wall a column
The test was done at the site AVIC Astoria according to British Standards (Ref: BS 1881
part 202: 1986). This test also known as Schmidt hammer, impact hammer or sclerometer test.
Figure 34 – Rebound hammer test for Figure 31 – Setting out linesFigure 32
a columnFigure 35 – Rebound – Rebound hammer test for a column
hammer test for a wall

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2.4. Formwork

Formwork is a mold used to shape and support the concrete until it gains sufficient strength to
carry its own weight. The British standard code of practice for formwork is BS 5975 2008:2011.
Basically formwork can be classified in to two categories; temporary formwork and permanent
formwork.

In temporary formwork the materials used can be removed and reused after concrete gains its
sufficient strength. But in permanent formwork, the material cannot remove and reuse. The type
of formwork is depending on the location of application. At the site a permanent formwork of
cement blocks was used for the tie beams at ramp area.

And also formwork can be classified according to the material type used; for example: timber,
steel, plywood, aluminum, plastic and etc. The material type of formwork is depending on the
project type, quality, clients’ requirement and other factors. At the site (Residential project),
plywood formwork in traditional method was used.

2.4.1. Formwork for columns

 Before the formwork placement the reinforcement was checked and the bottom surface of
the column was chipped and applied with bonding agent (Barra emulsion – 157D primer)
in order to enhance the bond between fresh concrete and casted concrete.
 Then the setting out lines were marked using theodolite, for this purpose survey holes
(figure 29) were used and for each column 200mm offset (figure 30) was provided. The
offset was provided in order to check the verticality and the accuracy of the position of the
column.

Figure 39 – Survey hole Figure 36 – Setting out lines

Figure 40 - KickerFigure 41 – Survey 22`

Figure 37 – Survey holeFigure 38
hole – Setting out lines
  Then the kicker was provided as the base of the column according to the setting out lines
of the column. The kicker is helpful to stop bleeding while concrete pouring.

Figure 42 - Kicker

 Then the formwork was erected.

The formwork box was prepared using 15mm thick plywood, then it was supported and fixed by
using galvanized iron pipes and chadlocks. Then the steel jacks were provided from all sides for
additional support to avoid the movement of formwork while concreting. Further details were
provided in the detailed drawing.

Figure 43 – Detailed drawing for column formwork

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Figure 44 – Verticality measurementFigure 45 – Detailed drawing for
column formwork
  Finally, the column formwork was checked for its verticality at least from three points
(figure 34) before and after concreting. And if there is any deviation it was adjusted by
hammering. The allowable tolerance was ± 2mm.

Figure 49 – Sketch of verticality Figure 46 – Verticality measurement

measurement

Figure 47 – Sketch of verticality

Figure 50 – T JackFigure 51 – Sketch of measurementFigure 48 – Verticality
Equipment used for column
verticality formwork:
measurement measurement

Figure 55 - Plywood board fixed with 2”×2” Figure 52 – T Jack

timber frame

Figure 53 - Plywood board fixed with 2”×2”

Figure 56 - Setsquare and steel tapeFigure 57 - timber frameFigure 54 – T Jack
Plywood board fixed with 2”×2” timber frame

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 Figure 70 – Steel Jacks Figure 67 – GI pipes

Figure 71 – GI pipesFigure 72 – Steel Figure 68 – Beam bottomsFigure 69 – GI

Jacks pipes

Figure 64 – Chad locks Figure 61 – Marking rod

Figure 65 – Steel JacksFigure 66 – Chad Figure 62 – Chad locksFigure 63 – Marking

locks rod

Figure 58 - Setsquare and steel tape

Figure 59 – Marking rodFigure 60 - Setsquare and

steel tape
25`
2.4.2. Formwork for beams

Procedure :

 Initially the beam bottom fixing level was marked on the column, according to the 1000mm
reference line from the structural floor level and the beam depth. Then the column
formwork was fixed up to the marked level. (figure 43)
 Then the beam bottom was prepared. (figure 42)

The beam bottom was prepared according to the beam thickness. A plywood sheet was cut
according to required length and breadth, then a 2”×2” wooden frame was fixed to the plywood
sheet and finally a GI pipe of diameter 50mm was fixed at the center. This was done in order to
stiffen the formwork such that it can withstand the weight of concrete.

Figure 73 – Beam bottoms

 Then the beam bottom was fixed to the column formwork initially done.

Figure 74 – Beam bottom fixed to the

column formworkFigure 75 – Beam
bottoms

Figure 76 – Beam bottom fixed to the

column formwork

igure 77 – Fixed beam bottomsFigure 78

– Beam bottom fixed to the column
26`
formwork
  Then the steel jacks were provided at regular intervals along the beam.

The steel jacks were provided at regular intervals of 2ft for longer span beams (<2m) and at 3ft
interval for longer span beams (>2m). These steel jacks were provided in order to have the rigidity
of the formwork to carry the weight of concrete. The spacing interval should be determined
according to a detailed design for the formwork considering approximate load that will applied
and the maximum bearing capacity of steel jacks. But at the site it was done in general practice.

Figure 79 – Fixed beam bottoms

 Then the sideboards for the beams was fixed, the side boards at the perimeter beams were
Figure 80for
fixed after rebar fabrication – Prop supportsoffor
the easiness slabFigure 81
construction. The– side boards were attached
Fixed beam bottoms
to each other with form tie and thread bars along the cross section. This was done in order
to avoid movement of side boards while concreting.

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2.4.3. Formwork for slab
Procedure :

 In slab formwork, initially the supports were fixed at the required heights in regular
intervals.

At the site the floor difference between first and second floor is 4.5m, so the supports were
provided with steel jacks and scaffoldings erected one on another. To extend supports up to the
required height T jacks were used at the bottom. The length of a T jack (figure 35) at the site was
2ft, that means it can extent up to 2 feet. But in order to have proper stiffness to the support the
extended height was limited to 1-1.5 ft.

Figure 85 – T Jack support Figure 82 – Prop supports for slab

 Then at the top of supports U jacks were fixed and a 4”×2” wooden plank was placed on
Figure 86 – Using spirit levelFigure 87 – T Figure 83 – T Jack supportFigure 84 –
the shorter span of the slab panel and fixed using nails. The horizontal level was maintained
Jack support Prop supports for slab
using the spirit level. (figure 48)

Figure 91 – Slab supported on U jacks and Figure 88 – Using spirit level

4”2” wooden planks
28`
Figure 89 – Slab supported on U jacks
and 4”2” wooden planksFigure 90 –
Using spirit level
Figure 92 – Slab formworkFigure 93 – Slab
  Then GI pipes with diameter 50mm and with required lengths were laid on top of wooden
planks (4”×2”) along the longer span direction of the slab panel.
 Then a 15mm thick plywood board was placed on top of GI pipes and fixed to the beam
sideboard using nails. And after fabrication of reinforcement the slab and beam formwork
was levelled using leveling instrument and levelling staff, according to 1000mm reference
level and floor to floor height.

Figure 97 – GI pipe supports for slab Figure 94 – Slab formwork

2.4.4. Striking of formwork

Figure 98 – Minimum period for striking of Figure 95 – GI pipe supports for
formworkFigure 99 – GI pipe supports for
At the site, the removal of formwork is done according to structural
slabFigure 96 – engineers’ specifications,
Slab formwork
slab
after analyzing compressive strength results of the concrete for the particular structural element.
And according to British standard specifications (BS 8110: part 1 1997 – table 6.2) the minimum
period of striking of formwork is depending on three factors (figure 51);

Figure 100 – Minimum period for striking of formwork

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Figure 101 – Application of formwork releasing agentFigure 102 – Minimum
period for striking of formwork
  Type of structural element: The time of removal of formwork for slabs, beams and columns
are different from each other, since it varies according to the size of the structural element.
 Type of cement used: The type of cement may be ordinary Portland cement (OPC) or
Pozzolana Portland cement (PPC), according to the cement type used in concrete the
hardening process varies. So the formwork striking period also varies.
 Surface temperature of concrete: Hydration process of concrete has an exothermic reaction
and at higher temperatures the rate of hydration is higher. There is a temperature gradient
or a temperature difference in concrete, between the center of the structural element and
the surface of the structural element. In order to keep a uniform hydration rate throughout
the concrete of the particular structural element, the temperature gradient should be
reduced. This can be done by increasing the temperature at the external surface of the
concrete structural element. So by keeping the formwork, it will reflect back the emitting
heat radiations for the concrete and will increase the temperature at the surface. So there
will be a uniform hydration occurs throughout the whole structural element and it will
achieve the required strength on time. Such that the surface temperature has an effect on
the period of striking formwork.
2.4.5. Quality control for formwork
 The dimensions of beams and slabs should be checked according to detailed drawings.
Allowable tolerance is ± 2mm.
 Application of formwork releasing agent. This is important to ensure the quality of concrete
work after hardening and also it makes the formwork panels reusable. At the site a grease
and diesel mixture of 1:1 is used as the formwork releasing agent.

Figure 103 – Application of formwork releasing agent

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Figure 104 – Pocket in column formworkFigure 105 –
Application of formwork releasing agent
  Reusable formwork panels are not allowed to use more than 2-3 times and the formwork
panel quality was checked visually for its cleanliness and quality before concreting.
 The free fall height should be maintained while concreting, so in column formwork, it was
done for 2 stages and at 1.5m height a pocket was made in the formwork in order to
maintain free fall height.

Figure 106 – Pocket in column

formwork
 Joints should be checked whether there is any possibility of leakages of cement grout
and if there is any, should be treated with wet cement bags or sponge. At the site to
Figure 107 – Sponge at
avoid grout leakage a sponge layer at construction joints were used.
construction jointsFigure 108 –
Pocket in column formwork

Figure 109 – Cement grout leakage

Figure 112 – Sponge at construction joints
control method

Figure 110 – Bill Of Quantity

Figure 113 – Cement grout leakage control documentFigure 111 – Cement grout
methodFigure 114 – Sponge at construction 31` leakage control method
joints
2.5. Site Documents

Site documents are involved in document management process in a site. Document

management is the process of handling of documents in order that the information can use
effectively and efficiently during the project period and also after the project. It is a document to
prove any construction activity occurred within the site. It is important to keep an orderly and
complete set of documents or records, it will save time, cost and energy.

It is engineers’ responsibility to manage the documents correctly; how and what are the
documents that should be managed, from who to whom the documents should be addressed, what
is the process of submitting and transmitting a document and etc.

2.5.1. Bill of quantities (BOQ)

BOQ is the document that has itemized supplies, materials, labor and etc. in tendering of a
construction project. It is very useful in cost planning and cost estimation of the project. The BOQ
document is made according to standard method of measurements (SMM), the method of
preparation of BOQ has 2 components; taking-off and working-up.

Taking-off is the measurement of dimensions and the completion of the description

according to drawings and specifications. And working-up is followed by an abstract sheet which
categorize similar items together.

A typical BOQ contains :

 Item No : Item is categorized according to type of work, for example;

concrete work, reinforcement work and etc.
 Description : It is the description of finished work item, this description
should be based according to provided drawings and specifications.
 Quantity : Description has a quantity allocated according to measured
dimension according to detailed drawings.
 Unit : Each item has a unit according to its measurement as in
description. It can be a linear, square, metric measurement or just a number.

32`
 Rate : Rate is the price per unit given by the contractor. The rate is
decided according to schedule of rates issued by CIDA. (Building schedule of Rates –
BSR or Highway Schedule of Rates – HSR)
 Amount : Amount = Quantity × Rate, which gives the total amount for
the item described.

Figure 115 – Bill Of Quantity document

Figure 116 – Letter of acceptanceFigure 117 – Bill Of

Quantity document

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2.5.2. Letter of Acceptance

Letter of acceptance is the legal document or the contact between client and the contractor.
This describes about the scope of work and handing over to the contractor, and the acceptance of
the contractor with responsibilities. This document is signed by both the parties with the witnesses.

Figure 118 – Letter of acceptance

2.5.3. Tender document

Figure
The tender document is the 119 – which
document Content
theofcontractor
tender will prepare the bids and carry
documentFigure 120 – Letter of acceptance
out and complete the project work accordingly. This document details all the requirements of the
project and explains all the rights and duties of the main parties involved in the project, that is
client and the contractor.

A tender document contains :

 Form of tender : this is the formal offer to construct, complete and maintain
the project according to contract documents.
 Tender notice and conditions : this describes about the terms and conditions which
the work should be carried out according to CIDA or FIDIC specifications.
 Form of agreement : the formal agreement between client and the contractor in
execution of work.

34`
 General specifications : this gives more information about the drawings and the
BOQ.
 Bill of Quantities (BOQ)
 Drawings : Describes the details of work and scope of work in sketches.

Figure 121 – Content of tender

document

Figure 122 – RFA documentFigure 123

– Content of tender document

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2.5.4. Drawings

At the site there are three types of drawings; architectural, structural and shop drawings.
All drawings should be approved by the relevant responsible person; structural engineer,
architecture, resident engineer before the commencement of the specific work at the site.

The shop drawings are the re-edited drawings from the architecture or the structural
engineer, made by the contractor in order to avoid practical issues and for ease of construction.
The shop drawings received from the contractor should be compared with the approved structural
or architectural drawings and the alterations should be approved by the resident engineer.

36`
2.5.5. Request for Acceptance (RFA)

Any type of document related to site activities made by the contractor should be approved
by the consultant. So the documents to take approvals should be submitted to the consultants as an
RFA document, then it will be checked and a status was given; approved, re-submit or nor
approved. For example; method statements, cube strength reports and etc.

RFA document contains the reference number, details of addressed person, name, signature
and the designation of the requested person, subject of work, work category; structural,
architectural and etc., carbon copy for other involved parties and comments and approval.

Figure 124 – RFA document

Figure 125 – DRR documentFigure 126 – RFA

document

37`
2.5.6. Document review report (DRR)

Document review report is the document which replies the RFA document by the
consultant. This document gives the status for the RFA document as approve (A), approved with
comments (B), re-submit (C) or rejected (D).

Figure 127 – DRR document

2.5.7. Request for clarification

Figure(RFC)
128 – RFC documentFigure 129 – DRR
document
This document is from contractor to the project management consultant requesting
clarification or information about a particular construction work at the site. This document is
attached with relevant drawings. The response of the consultant should be noted and the signature
of both the parties, consultant and the contractor should include.

38`
 Figure 130 – RFC document

2.5.8. Engineering Observations/Recommendations (EOR)

Figure 131 – EOR documentFigure 132 – RFC document
This document refers to observations of the engineers at the site. If a particular work carried
out in a wrong way according to engineering aspects, this document is used to inform the
responsible parties about the activity with recommendations.

Figure 133 – EOR document

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Figure 134 – NCR DocumentFigure
135 – EOR document
2.5.9. Non-Conformity Report (NCR)

This document is used to inform the responsible parties about any activity which is altered
from the procedure stated in the method statement. The responsible party, mainly the contractor
should give reasons for alterations or re-do the activity according to the approved method
statement. If not the payment for the particular activity can be hold or release a percentage of
payment until the work is accurately completed.

At the site, the anti-termite treatment was done without proper compaction of soil according to the
method statement. So the contractor was informed through an NCR document and hold the
payment for the activity.

Figure 139 – NCR document Figure 136 – NCR Document

Figure 140 – NCR document Figure 137 – NCR documentFigure 138 – NCR
Document

40`
2.5.10. Monthly report

Monthly report is the document which summarize the activities of the month and represent
the progress of the month. This document includes the scope of work, work progress; RC work
progress, brick work progress, man power of the month, cube strength results, weather chart, cash
flow chart, status of RFA, status of inspections, received drawings, document transmittals, site
issues identified and site photos.

This document is very important in identifying reasons for delay of work, alterations with
the work program and etc. and also with this document the parties involved in the project can have
a better idea about the site activities. The copy of this document is sent to each party involved in
the project; client, project manager, contractor and etc.

2.5.11. Daily record

Daily record has information about the man power at the site on particular date, weather
record, work done at the site on the particular date, man and machinery on particular date,
documents received on date, and etc. This should be transmitted from contractor’s project manager
to the consultant engineer. This document records are important for the other documents like
monthly report, daily timeline and etc.

2.5.12. Daily timeline

This is also similar to daily record but contains more information. This consist of daily
work record, weather record, progress of work, work program, machinery details at the site and
site photos of particular works done at the site. And additionally it contains problems identified at
the site, work carried out by consultants and comments on special activities during the date. A
copy of this document is sent to the client and other relevant parties involved in the project. This
is basically a document which confirms project management consultants’ work and site conditions
to the client and other parties involved in the project.

This document is very important in post-examination of work records and to analyze the
site works according to the work program at the site.

41`
3. CHAPTER 3: Conclusion

The twelve weeks in industry for training was very important for me to gain a lot of practical
knowledge in the civil engineering field. It was a good experience and I had the chance to apply
what I learned from theory in the practical field. This report is explaining about the experience and
knowledge that I have gain in my industrial training period.

This is the second report of the second in-plant training of the coarse, in first training I was
able to cover civil engineering aspects related to buildings on contractor side and on the second
training I was able to take the knowledge of buildings on consultant side. Most of the experiences
I get in my second training was the application of the knowledge gain from the first training. And
this report includes the new things I learnt at sites in my second training.

The most significantly it is a great opportunity to have my training in Civil and Structural
Engineering Consultants (Pvt.) Ltd., since I was able to deal with most popular and leading
structural engineers of the country, was able to gain knowledge about civil engineering software
like AutoCAD, ETABS, MS project and etc. and trainees of the company were given two training
sites within the 12-weeks of training.

And also a special weekly presentation session was conducted at the head office premises for
the trainees, and this session was evaluated by most renowned engineers in the company. This
presentation session was a great opportunity for trainees to enhance the presentation skills and also
it was a platform to share all our knowledge at different sites within the country at the same place.

A 24-week training is not enough for a civil engineering student to cover all the fields in the
discipline, but after 24-week training period I have become a more confident and responsible
person in civil engineering field. Finally, I am very glad to finish my second training period and
the report of the that in a successful manner. Again I would like to thankful to everybody who
supported me to complete this task.

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References
 A.M.Neville. (2010). Concrete Technology. Essex, England: Piersen Education Limited.

 Blackledge, G. F. (2002). Concrete practice. London: British Cement Association.

 Civil and Structural Engineering Consultants (Pvt.) Ltd. Retrieved from csec.lk:
http://www.csec.lk

 Royal Charter UK. (2006). Bs 8110 - Structural use of concrete. In J. Grainger, & S.
Wilson, Part 1: Code of practice for design and construction (pp. 1-155). London: British Standards
Institution.

 Lecture notes

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