INDUSTRIAL TRAINING REPORT II

TRAINING ORGANIZATION

: SANKEN CONSTRUCTION (PVT) LTD

PERIOD OF TRAINING

: FROM : 26/10/2015 TO : 03/01/2016

FIELD OF SPECIALIZATION : CIVIL ENGINEERING

H.M.HASAN
E/11/146

ACKNOWLEDGEMENTS
I would like to convey my gratitude to the Industrial Training and Career Guidance Unit (ITCGU),
Faculty of Engineering, University of Peradeniya, National Apprentice and Industrial Training Authority
(NAITA) and the Sanken Construction (Pvt) Ltd for providing me the opportunity to have industrial
training experience in my field of study.
I am pleased to be trained in Sanken Construction (Pvt) Ltd one of the largest functioning body
construction sector in Sri Lanka. My thanks go to the Project Manager Engineer Mr Nalin Senadeera for
being the greatest support and guidance during the period of my industrial training. I must also thank
Technical officer, Mr Kalpana and Engineer Mr Sampath and Assistant Engineering Mr Piyarathna for
their effort in the fields to guide me towards the proper technical experience.
Finally I would like to add all the technical officers and staff who helped me immensely to make my
training a success.

CONTENTS
Acknowledgements

Contents

ii

List of Figures

iii

List of Tables

iv

List of Abbreviations

Chapter 1: INTRODUCTION

1.1 A Brief Account About the Training

1.2

A Description About The Establishment

1.3 Account On The Project

Chapter 2: RESOURCES OF THE CONTRACTOR

2.1 Concrete Mixing plant (Batch plant)

2.2 Workshop

2.3 Laboratory

2.4 Machinery

2.5 Human Resources

Chapter 3: CONSTRUCTION

10

3.1 Introduction

10

3.2 Construction of columns

11

3.3 Construction of beams and slab

12

3.4 Brick work

14

3.5 Plastering

15

3.6 Puttying

15

3.7 Painting

16

3.8 Tile Installation

16

Chapter 4: WASTEWATER TREATMENT

17

4.1 Soakage pit

17

4.2 Seepage Bed

18

Chapter 5: PROBLEMS ENCOUNTERED

19

Chapter 6: CONCLUSION

20

ii

LIST OF FIGURES
Figure 1.1

Organizational structure

Figure 2.1

Concrete Mixing plant (Batch plant)

Figure 2.2

Concrete Cube Testing Machine and Test cubes

Figure 2.3

Truck Mixer

Figure 2.4

Backhoe loader

Figure 2.5

Excavator

Figure 2.6

Jumping Jack compactor and Walk-behind roller

Figure 2.7

Electric drill

Figure 2.8

Circular power saw

Figure 2.9

Bar cutter

Figure 2.10

Sander

Figure 2.11

Water bowser

Figure 3.1

Lap length & Crank length of a column

11

Figure 3.2

Formwork of beams and slab

12

Figure 3.3

Reinforcement for beams and slab

12

Figure 3.4

Concreting beams and slab

13

Figure 3.5

Setting out for brick work

14

Figure 3.6

Construction of brick walls

14

Figure 3.7

Plastering

14

Figure 3.8

Puttying

15

Figure 3.9

Tile Installation

16

Figure 4.1

Soakage pit construction

17

Figure 4.2

Seepage Bed Dimensions

18

Figure 4.3

Perforated Distributer Pipes and its Layout dimensions

18

Figure 5.1

Heavy Rainy day in the site

19

iii

LIST OF TABLES
Table 3.1 Sticking time of formwork

13

iv

LIST OF ABRIVIATION
Abbreviation

Description

ITCGU

Industrial Training and Career Guidance Unit

NAITA

National Apprentice and Industrial Training Authority

SKPA

Relocation of Thangalle prison to Eraminiyaya Angunakolapalassa (SKPA) Project

Chapter 1: INTRODUCTION
1.1 A Brief Account about the Training
This report holds detailed aspects of the industrial training I obtained in the Sanken Construction (Pvt)
Ltd for a period of 10 weeks commencing from 26th of October 2015 to 3rd of January 2016 through the
National Apprentice and Industrial Training Authority (NAITA) and the Industrial Training and Career
Guidance Unit (ITCGU), Faculty of Engineering, University of Peradeniya as a six credit and non-GPA
course followed in the Department of Civil Engineering, University of Peradeniya.
1.2 A Description about the Establishment
Sanken Construction is an ICTAD C1 Graded (Highest Rank) company, with ISO 9001:2008 QMS
Certification.2013 : Sanken Construction certified with OHSAS 18001:2007 Certification.2014 : Sanken
Construction is in process to obtain ISO 14001:2004- EMS Certification
The functions performed by the Sanken Construction (Pvt) Ltd consist mainly on Construction
Contracts, Property development, Ready-mix concrete, Hiring of Scaffoldings, Design & Build,
Consultancy, Hiring & leasing of machinery, Trading of Products & Materials, Piling, Skill training &
Management.
1.2.1

Vision

To be Sri Lankas premier construction service provider

1.2.2

Mission

To provide a quality professional service exceeding customer expectations by the effective utilization of
all resources, with the best practice of the industry

1.2.3

Organizational Structure
Q.S Main Bill

Seinear Q.S
Planing Manager

Q.S Extra Work

Asst. Q.S

Q/A Manager

Drawing Incharge

Draftmens

M and E/Safty
Manager

Engineer Rebar
Incharge

T.O

Engineer in
Landscape,Water
Proofing

T.O

Project Manager
Engineer Zone 1
Incharge

Asst. Engineer
Building Incharge
T.O

Engineer Zone 2
Incharge

Site Manager

Engineer Zone 3
Incharge

Asst. Engineer
Building Incharge

Trainee Building
Incharge
Asst. Engineer
Building Incharge
T.O Building
Incharge

Engineer Detailing
Incharge
T.Os
Engineer Finishing
Incharge
Asst. Engineer

Concrete
Supervisor
Store keepers
Administrative
Officer
Timekeeper
Safty Officer
M & E Engineer
Figure 1.1 Organizational structure
2

1.3 Account on the Project

Name

: Relocation of Thangalle prison to Eraminiyaya

Angunakolapalassa (SKPA) Project

Location

: Eraminiyaya Angunakolapalassa

Area of the project

: 58 acres

Amount of the project

: Rs.4996 million

Client

:Democratic Socialist Republic Of Sri Lanka Ministry of

Rehabilitation and Prison Reforms

Contractor

: Sanken Construction (Pvt) Ltd

Consultant

: Central Engineering Consultancy Bureau.

Date of commencement

: 26th of November 2013

Duration

: 22 months

After completion of this project all inmates in Thangalle remand prison and about 1000 inmates presently
detain in Welikada prison will be shifted to the new prison where approximately 2000 detainees can be
conveniently detain. This new prison consists with prison hospital, vocational training center, separate
building for industries, 140 quarters for officers, and quarters for single officers. Moreover it consists of
a playground with 400m track, swimming pool with the length of 25m, indoor stadium and trade complex
to sell prison productions.

Chapter 2: RESOURCES OF THE CONTRACTOR

In order to foster and promote development of the construction works in the project the contractor shall
have a collection of adequate resources. As a multinational company, Sanken Construction (Pvt) Ltd
also has a set of modern utensils such as:

Concrete Mixing plant

Workshop

Laboratory

Machinery

Human resources

2.1 Concrete Mixing plant (Batch plant)

The material such as cement, water, fine aggregate (sand) and coarse aggregate mixed for the preparation
of ready-mix concrete in the concrete mixing plant and it is in the worksite for easy accessibility. Ready
mix concrete is used almost every concreting. Concrete is mixed at batch plant and then transported to
site by truck mixers with rotating drum.

Figure 2.1 Concrete Mixing plant (Batch plant)

Advantages of ready mix concrete,

Labour associated with mixing concrete is saved.

Reduction in the wastage of basic materials.

Noise and dust pollution created at site is reduced.

Ready mix concrete has better quality.

2.2 Workshop
All the maintenance work of the machines used for the construction is done in the workshop allocated
to the contractor. This is situated closer to the project offices in order to serve the project efficiently.
2.3 Laboratory
All the tests needed to be done to ensure a standard of work is conducted in the laboratory. This location
established in the site closer to the project office.
Mostly 28 & 7 days concrete cube test done for the concrete strength measurements, Slump test
done before put to the formwork in the site.

Figure 2.2 Concrete Cube Testing Machine and Test cubes

2.4 Machinery
The machinery needed to serve the project will be discussed in this section.
2.4.1 Truck Mixer
Ready-mix concrete transported by truck Mixer. Almost every time Ready-mix concrete used for the
concreting works.

Fig. 2.3. Truck Mixer

2.4.2 Backhoe loader

Backhoe is used for site clearances, light transportation of material, provide shifted materials for
construction work in upper levels and excavation perposes, etc.

Fig. 2.4 Backhoe loader

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

Fig. 2.5 Excavator

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

Fig. 2.6 Jumping Jack compactor and Walk-behind roller

2.4.5. Electric drill
Electric drill contains of removable bit from which drilling can be done. This is used for drill wood,
concrete etc. Bits changed according to the purpose.

Fig. 2.9 Electric drill

2.4.6 Circular power saw

Power saw is an electric machine that is used for cutting wood. It consists of a rotating serrated circular
blade. This is used to cut formworks and adjust door window slashes etc.

Fig. 2.8 Circular power saw

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

Fig. 2.9 Bar cutter

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

Fig. 2.10 Sander

2.4.9 Water Bowser Water is supplied for the site for construction and day today use by bowsers and
separately drinking water also supplied

Fig. 2.11 Water bowser

2.4.10Poker vibrator
Poker vibrator is a machine powered by petrol, and consists of a cable with vibrating edge. Vibrating cable is put
in to green concrete to be compacted it well.

2.4.11 Dump Trucks

Vehicles used for transportation of loose material needed for construction
2.5 Human Resources

Road construction work is most commonly done by unskilled laborers. Workers can specialize in certain
types of work. Diligent and responsible workers are usually promoted to supervisory positions; to train
and supervise other workers.
The types of workers are distinguished using skill levels.
General workers These kinds of workers are necessary to perform general excavation with picks and
shovels and clean the sides of roads for better working environment.
Masonry workers For the building of structures such as culverts, retaining walls, etc.
Machine operators For a better efficient way of finishing up the project work, skillful machine
operators are needed with specific talents in operating the machineries used in the construction
Drivers For transportation purposes, drivers are necessary for a construction project.
Construction supervisors Supervision of the construction work is done by supervisors.
Staff Staff working in the project office for the functioning of the project.

Chapter 3: CONSTRUCTION
3.1 Introduction
Initial survey is conducted and according to the design of the buildings and get approved by the consultant.
After the Site clearance setting out is done. Then following process is followed for the construct a building
and in every finished work approved by consultant for next level. But the works carried out by deferent
buildings in parallel.

Construction Process

Excavation

Foundation

Concrete Structure (Load bearing )

Columns

Beams

Stairs

Slab

Brick work (Non load bearing)

Roofing

Rough Plumbing

Wiring

Plastering

Flooring

Tiling

Painting

Finish Plumbing

Finish Electrical and Lighting

Modifications

10

3.2 Construction of columns

3.2.1 Setting out for columns
Setting out for columns was done accurately using theodolite and steel tape to avoid buckle or fail due
to eccentric loads applied on them. Marking lines was done using marking chord. Columns.
3.2.2 Laying kickers
Kickers were laid in to 75 mm thickness. Plywood sheet boxes were used for its formwork. Curing
kickers was done at least for 7 days.
3.2.3 Reinforcement for columns
Overlapping and cranking main bars and tying stirrups into correct spacing were done according to the
design. Checked whether correct bar type is used, correct spacing were left between stirrups, lap length
and crank length is corrected and good quality reinforcement is used. Column formwork required 30
mm covering blocks are attached.
Lap length (LL) = D2 x 50
Crank length (CL) = (D1 + D2+ 5) x 10

Figure 3.1 Lap length & Crank length of a column

3.2.4 Formwork for columns
Column formwork was fixed to kickers. Formwork done by plywood sheets and their internal surfaces
are covered with form oil. Sponge sheets were placed in joints of formwork to avoid leakage of grout.
After fixing jacks and props and placing cover blocks were done. Then verticality of column formwork
was checked. Checking verticality was done at two edges of each face, to avoid twisting of column.
3.2.5 Concerting columns
Existing surface of concrete chipped and wet with grout in order to have strong bond. Concreting was
done using grade 25 machine-mixed concrete and free fall height of concrete is less than 1200 mm.
Poker vibrator was used for compact concrete well.
3.2.6 Striking column formwork & curing
Column formwork was removed after a day (24 hr) from concreting. Then curing was done for 7 days
applying moist gunny bags.

11

3.3 Construction of beams and slab

3.3.1 Setting out for beams & slab
1000 mm height level of columns was marked on column surfaces. Level instrument was used there.
Level of beam bottom was marked using that level.
3.3.2 Formwork of beams and slab
Beam and column formwork was fixed using plywood sheets, 2 x 2 wooden bars, galvanized iron
pipes, separates, p-cones and form ties. Props were placed at 600 mm x 600 mm distances to support
beam and slab formwork. A U-head or T-head was placed on each prop and then galvanized iron
pipes or 2 x 2 wooden bars were laid horizontally and tied them. Power saw was used for cutting
plywood sheets and then fixed side boards for beams and formwork for slab. Verticality of side boards
and dimensions were checked. Form oil was applied. Form ties, P-cones and separates were placed at
600 mm distance, after laying reinforcement.

Figure 3.2 Formwork of beams and slab

3.3.3 Reinforcement for beams and slab
Steel bars for beam reinforcement were bended and tied above the beam formwork. They were placed
on 2 x 2 wooden bars laid at beam formwork and they were jointed at columns. They were lowered in
to beam formwork after tying cover blocks. Slab reinforcement was laid on slab formwork.

Figure 3.3 Reinforcement for beams and slab

12

3.3.4 Concreting beams and slab

After the Levels checking Concreting slab and beams was done using ready mix concrete. Slump test
and preparing concrete cubes to test compressive strength are done for concrete transferred by each truck
mixer.

Figure 3.4 Concreting beams and slab

3.3.5 Striking beam and slab formwork & curing
The striking time of formwork depends on type of cement, grade of concrete, dimension of the section
and the temperature of the concrete. Minimum striking time for side formwork of beams, under side
formwork of slabs according to its span is mentioned in table 2.1. Curing was done for slab and beams
for 7 days using moist gunny bags and water ponding.
Table 3.1 Sticking time of formwork
Type of formwork

Striking time

Side formworks of beams, columns or walls

24 hrs

Slab formwork up to 4.5 m span

7 days

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

14 days

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

21 days

Cantilever slab and beams

21 days

13

3.4 Brick work

Walls were constructed by burnt clay bricks using 1:5 cement sand mortar. External walls were constructed
into 225 mm thickness and internal walls into 112.5 mm thickness.

3.4.1 Setting out for brickwork

Above figure elaborates how setting out lines should be marked for brickwork. Two offset lines should
be marked on either sides of brick wall. When the wall plaster is done, correct measurements can be
taken from those offset lines. 25 mm allowance should be left on both sides of a door or an opening.

Figure 3.5 Setting out for brick work

3.4.2 Construction of brick walls
None load bearing type masonry brick wall is used to build the walls. English bond is used for walls as
considered to be strongest bond. 1:5, Cement sand is used for bonding mixture. One skilled labour and
a mason can build more than 800 brick wall in a day (8h) work but due to inconsistency of brick
dimensions and cement mixtures, water amount they build around 600 to 700 brick wall in a day (8h)
and also height of a brick wall constructed is limited to maximum of 1.5m Mortar layers should be 10
mm in thickness but practically it was higher than that. That causes to over consumption of cement and
sand for brick work than the designed. Bricks should be wetted with water before use in brick work.
The blocks should not be wetted before use. Verticality of walls is checked with the plumb bob and
straight edge.

Figure 3.6 Construction of brick walls

14

3.5 Plastering
Cement to sand 1:5 mixture is used for plastering work. Water appropriately used for proper mixture
and usability. Plumb bob and spirit level and feather edges are used and got a good finishing. After few
more days the wall preparation (cleaning) was done

Figure 3.7 Plastering

3.6 Puttying
After the plastering work, 1st coat puttying done and kept for drying and then second coat of puttying
done and kept to dry. To puttying stainless steel Trowels and Skimming Spatulas and for get a good
level of finishing Feather Edges are used. Then sanding was done by using 180 grit sandpapers for
further finishing.

Figure 3.8 Puttying

15

3.7 Painting
After the puttying Filler coat applied and patch work done. For patch worked areas sanding and
application of filler coat was done.
3.8 Tile Installation
1:5, Cement: sand mixture is used for the tile bedding preparation and appropriate water amount is used
for workability. After placing the bedding up to given level, kept it for one day and damped the surface
to reduce suction to avoid debonding the tile mortar and bed.
Tiles are soaked in clean water more than 30min (to prevent drawing water from cement mortar and get
debonding).
Cement water mixed mortar is used as adhesive and placed it ait on the back side of the tile it is fixed by
using tapping method tile was placed onto uniform position. Then level of tile was checked using spirit
level and plastic spacers are used to get the proper spacing. Finally grout was spread by using a soft
trowel and excess grout removed and tile surface was cleaned.

Figure 3.9 Tile Installation

16

Chapter 4: WASTEWATER TREATMENT

4.1 Soakage pit
In the beginning of soakage pit construction the earth was excavated using backhoe loader up to required
level and C25 grade concrete laid for screed and formwork and reinforcement work began for base and
covering blocks are placed then C25 grade ready-mix concrete was placed then 1st stage and 2nd stage
reinforcement, covering and formworks and soakage holes (100mm PVC pipes) kept and concreted
according to the stage. Finally the slab reinforcement and formwork and coverings are placed according
to drawings and concreted. In every stage the pokering and curing was done.

Figure 4.1 Soakage pit construction

17

4.2 Seepage Bed

Firstly the located place excavated 8000mm below the ground level. Dimensions and geotextile laying
are shown below and 70mm drop was maintained between longitudinal ends.

800mm

6m

Figure 4.2 Seepage Bed Dimensions

300mm was filed with metal type 20mm-40mm layer was laid. Then six 160mm diameter perforated
distributer pipes are laid with pipe axis to axix span is 1000mm and 1st and 6th axis to embackment is
500mm.

Figure 4.3 Perforated Distributer Pipes and its Layout dimensions

After that 200mm same rock type placed and the geotextile cover folded to get a 5000mm lap to avoid
water infiltration from above. On top of this 250mm sandy soil placed then 50mm of normal soil placed
up to the Ground level.

18

Chapter 5: PROBLEMS ENCOUNTERED

Heavy rain delayed most of works.

Identification of weather pattern early and prepare accurate time schedules will help to perform well but
project like this its impossible to maintain works like excavation only in dry period because the parallel
works of different buildings with limited resources in a remote area like Angunakolapalassa. Hence
building a proper drainage system is the way to overcome this effects by reducing the waiting time to
drain water.

Figure 5.1 Heavy Rainy day in the site

Less resources delayed the works.

This mainly occurs in the finishing stages of most buildings arrived in same period. The inefficient
management of resources and delays in resource arrival to the site. This can overcome very easily by
proper and direct communication and make the schedule of buildings arrival of finishing stages are little
different from buildings to building.

19

Chapter 6: CONCLUSION
During my training period of 12 weeks I was able to gather a good experience in building construction
and it helped me to understand what is happening on the site apart from the theoretical aspects. In the
site, I gained practical, technical knowledge and experience regarding situations of the working site and
how to overcome the difficulties and also got supervision and communication skills within the site. The
industrial training is important and valuable experience as an apprentice in the field of Civil Engineering.
The engineers in the site induced and guided me to go with the process in progress. The management of
conflicts occurred between staff and labors or in between them, arrangement of facilities to support the
work proposed, adjustment for the scarce resources and labors, taking decisions depends on the forth
coming problems and avoidance of unnecessary work to reduce the cost. Not only that, by exposing to
the field I was being got to know the people from various organizations, and this environment helped
me to express my interest, intensions and suggestion Finally confident to state that the training I got is
more than I really expected to get and I hope that the future undergraduates coming for the internship
will find their training even more beneficial to their future career.

20