COSMOPOLITAN HOMES SDN BHD

64, JALAN CHOW THYE & OFF JALAN BURMA,

GEORGETOWN, 10050, PULAU PINANG

NURSYAHIRAH BINTI TAJUDDIN

DF160104

SEMESTER 3 / SESI 2018/2019

 INDUSTRIAL TRAINING REPORT

NURSYAHIRAH BINTI TAJUDDIN

DF160104

COSMOPOLITAN HOMES SDN. BHD.

Faculty of Civil and Environmental Engineering

Universiti Tun Hussein Onn Malaysia
 ii

DECLARATION

I sincerely declare that:

1. I am the sole writer of this report.
2. The detail of training and experience contained in this report describes my
involvement as a trainee in the field of civil in structure and architectural.
3. The report is only prepared for my academic requirement and not for
any other purpose.
4. All the information contained in this report is certain and correct to the
knowledge of the author.

Signature :
Name : NurSyahirah binti Tajuddin
Matric No. : DF160104
Date : 10/09/2019
 iii

ACKNOWLEDGEMENT

I would like to express my utmost gratitude to COSMOPOLITAN HOMES Sdn

Bhd for providing me the chance to pursue the civil engineering training as a partial
fulfillment of the requirement for the degree of Bachelor of Civil Engineering with
Honors.
Thank you to my industrial supervisor, Mr. Man Mohan for the help and
knowledge given during the training. Thank you to Universiti Tun Hussein Onn
Malaysia and Faculty of Civil and Environmental Engineering for giving me this
opportunity to study and gain valuable experience upon finishing this industrial
training. A token of appreciation for my faculty supervisor, Dr Goh Wan Inn for the
assistance during the training period. Thank you to my parents, Mr Tajuddin bin
Shaari and Madam Rosni binti Ahmad followed by family members for their moral
support and motivation. Not to forget my friends, who were the best guides,
motivators and teachers I could ever ask. To everyone who were directly or
indirectly involved in the industrial training, thank you.
 iv

ABSTRACT

This report details the tasks and responsibilities given in the duration of the training.
The report also about the technical work regarding civil structure and architectural
work that have been done by the author during the course of the internship in site.
It also shows what experiences the author goes through, as well as the lessons
learned along the way. The main body of the report details all the activities and
knowledge gained through the entire period of internships and a short report. The
report also entails the suggestions and recommendations that can be implemented to
improve the industrial training and management of the company in general.
 v

CONTENTS

DECLARATION ii
ACKNOWLEDGEMENT iii
ABSTRACT iv
CHAPTER 1 INTRODUCTION 1
1.1 Introduction 1
1.2 Introduction to Industrial Training 2
1.3 Mission Industrial Training 2
1.4 Objective Industrial Training 3
CHAPTER 2 COMPANY BACKGROUND 4
2.1 Introduction 4
2.2 Company Background 4
2.2.1 Corporate Information 4
2.2.2 Company's Collections 6
2.2.3 Site Organisation Chart 15
CHAPTER 3 INTERNSHIP ACTIVITIES 16
3.1 Scope of Practice 16
3.2 Quality Assurance and Quality Control Work (QAQC) 16
3.2.1 Cube Testing and Slump Test 17
3.2.2 Brick Masonry Works 22
3.2.3 Plastering and Skim Coat 32
3.2.4 Lintel and Stiffener 37
3.2.5 Post-concrete inspections 41
3.3 Civil and Structure Work (C&S) 43
3.3.1 Pre-concrete Inspections 44
3.3.2 Concrete casting 51
3.4 Mechanical and Electrical Work (M&E) 4
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3.4.1 Mechanical and Electrical Works for a Building

Project 54
3.4.2 Construction Method of External, Exterior and
Outdoor Lighting System. 55
3.4.3 Install a Concealed Electrical Wiring System 56
3.5 Site Machinery 60
3.5.1 Types of Heavy Construction Equipment 60
CHAPTER 4 SUGGESTIONS AND RECOMMENDATIONS 63
4.1 Introduction 63
4.2 Suggestions and recommendations 63
CONCLUSION 65
 CHAPTER 1

INTRODUCTION

1.1 Introduction

Industrial training were introduced to cater for the curriculum of undergraduate students
in Universiti Tun Hussein Onn. This program is compulsory for all students to improve
their technical knowledge and skills as well as to adapt to the work environment they will
enjoy after graduation.
Industrial Training is important for students as it provides initial exposure and
opportunities to gain real experience in the structure and architectural work at site. This
industrial training aims to enable the learning theory studied during lectures to be applied
as well as possible as early inventories before entering the workplace. This industrial
training is a trial period set by the UTHM to evaluate the students' ability and intellectual
level in practicing all aspects of knowledge learned in the classroom.
In addition, this industry training is also aimed at providing opportunities for
students to enhance their experience. For example, steps and processes in structure work.
I also emphasize to be honest, trustworthy and dedicated to the company, in accordance
with the rules and policies set by the company while working to symbolize
professionalism values in the work. Additionally, industry training has given me a bit of
an emphasis on how to act in accordance with work procedures related with civil and
structure work, mechanical and electrical work and architectural work in site building, so
that each workflow is in accordance with each procedure and quality set by the company.
This industry training program benefits me. Throughout this industrial training
program, I can see how real is the situation of a career as a civil engineer in the realm of
 2

reality. I have learned a lot of new things and how to do something carefully according
to the requirements.
Industrial Training or internship is to expose students to real work of environment
experience and at the same time, to gain the knowledge through hands on observation and
job execution. From the industrial training, the students will also develop skills in work
ethics, communication, management and others. Moreover, this practical training program
allows students to relate theoretical knowledge with its application in the manufacturing
industry.
In conclusion, through this training I was able to gain new insights and more
comprehensive understanding about the real industry working condition and practice.

1.2 Introduction to Industrial Training

Industrial training set by the university for me is for 10 weeks beginning on 1st of July
2019 until 6th of September 2019. Industrial Training is one of the things that must be
taken by all students. This means that industrial training is one of the prerequisites for
graduating students. This is to meet the learning needs which will provide students with
the ability to practice the theories they are learning. This industrial training also aims to
ensure that learning theories learned during lectures can be applied as well as possible as
early inventories before entering the realm of work.
The briefing on industrial training was given by faculty industry training supervisor
Dr Nur Shaylinda Mohd Zin regarding the ongoing industrial training. This is because,
to ensure that all students who undergoes industrial training can deliver good and quality
work performance. This briefing covers the start of the selection process for undergoing
industrial training until the completion of industrial training. During the briefing I was
informed about the format of the Industrial Training Report which should be provided.

1.3 Mission Industrial Training

The main goal of this industry training is to give me the opportunity to learn the real reality
of a civil engineer profession. After undergoing almost 2 months of industrial training,
many of the things I have earned in preparation for entering the realm of work soon. The
 3

program aims to test the ability of students to demonstrate talent in the field of work that
will soon be involved.
Over the periods, all the knowledge devoted by all the engineer here is very useful
for me in preparing to become a professional civil engineer soon. Indeed, Industrial
Training is a program that helps a lot and benefits the students as we prepare for the work
environment.

1.4 Objective Industrial Training

Among the main objectives of this industry training are:

1. Provide exposure to real site engineer professions in the realm of work.
2. Provide opportunities to communicate and collaborate with professionals from
various fields.
3. To gain experience working within a professional organization.
4. Build creativity, technical skills, interpersonel and communication skills.
5. Establish and strengthen relationships with off-campus professionals.
6. This industry training program gives many benefits to the students. Through this
program, students can feel themselves and see for themselves how the actual
situation they are involved in. Problems and challenges faced by students help
students prepare for the outside world in their own field. Experience through which
students teach students to overcome and deal with the problem professionally.
 CHAPTER 2

COMPANY BACKGROUND

2.1 Introduction

This chapter will explain the background of the company Cosmopolitan Homes Sdn. Bhd.
including the organizational structure, property development and involvement in the
industry. Besides that, this chapter is a summary on the weekly activities done during the
industrial training. The daily task is documented in the log book.

2.2 Company Background

2.2.1 Corporate Information

Registered Name : Cosmopolitan Homes Sdn. Bhd.

R.O.C Registration : 868141-D
Business Address : 64, Jalan Chow Thye, off Jalan Burma,
10050, Georgetown,
Penang
Telephone No. : 04 2281008/2289001
Telefax No : 04 2281007
E-Mail Address : cosmo_homes@yahoo.com
DIRECTORS : Mr Bon Tan
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COSMOPOLITAN HOMES SDN. BHD. thrives on exciting challenges in developing

parcels of land into livable, green homes and creating a legacy. They perform by building
a tradition for future generations, where ’our home is your home’ concept and developing
projects that speak for themselves, making owners take pride in its quality homes of repute
and values. As a member of Real Estate and Housing Developers' Association (REHDA),
they ardently focus on improving not only quality of design, planning and construction,
but also quality of life and sustainable development potential. The main purpose of
Cosmopolitan is to construct growth for our stakeholders, build the brand, and create a
strong employment future for all proactive and progressive employees, not forgetting a
conducive environment to nurture innovative employees to realize their fullest potential.

Mission

To set high quality standards and values in property development through innovative and
inspired architectural designs while making significant development contributions
socially and economically.

Vision

To be a key developer of high repute that delivers sustainable values to stakeholders.

Investing in Future

Moving forward, they aim to become an exemplary developer, venturing into an extensive
portfolio of high-rise residential, mixed commercial developments, townships and
business parks. Apart from featuring state-of-the-art technology, their developments are
planned with an emphasis on green initiatives and environmental responsibility. Not only
do they build inspiring landmarks, their passion and dedication for property development
are to make a positive impact on the people and the community.
 6

Strength Through Growth

Focusing on residential and commercial property development, the company has gone
from strength to strength, amassing a range of quality properties. Their expertise and
commitment to quality is recognized and assessed by CONQUAS® BCA, Singapore, in
one of their many projects, Ardmore Residences. Cosmopolitan is strongly positioned to
achieve further growth in the near future and respond immediately to new opportunities
by continuing to develop 'build for life'. Thus creating environments that move in tandem
to the way we live now and change the way we live for a better tomorrow.

2.2.2 Company’s Collections

Completed Project:
1. Admore Residence

Figure 1: Admore Residence overview.

Overview:
Ardmore Residence is strategically located in rapidly growing township of Jelutong. It
boasts of modern facades and functional interior spaces that radiate class and elegance.
These sophisticated homes are spacious enough to fit 3 generations under one roof.
Notable Features:
 5 bedrooms (1 master bedroom, 2 junior master bedrooms and 2 large bedrooms) 1
ground floor utility room en-suite bathrooms attached to every bedroom
 7

 Enclosed open air courtyard at ground floor that allows to cultivate a landscaped
garden or pond within the home which can be viewed from dining, living area and
master bedroom
 Spacious balconies on first and second floor
 All bedrooms can accommodate Queen size beds
 Master bedroom with courtyard view
 Alarm system installed to each unit
 13.8' high ceiling heights on ground floor, 12' on 1st and 2nd floor
 800 x 800 (2'8” x 2'8”) quality floor tiles for living & dining area
 Conquas Score of 80.2, setting a standard for the industry in term of construction
quality.

Project Summary:
 Description : 3 Storey Luxurious Residences
 Location : Jelutong, Penang, Malaysia
 Tenure : Freehold
 Land Area : 20' x 76' & 20' x 73'
 Built-up Area : 3300sf onwards
 Total units : 46
 Facility : Swimming Pool, Gymnasium, Children's Playground, Foot
Reflexology Pathway,BBQ Area, Free WIFI at Lounge, Function Room,
 Round-the-clock CCTV Surveillance & 24-hour Guard House
 Completion Date: 2014
 8

Figure 2: Admore Residence site plan.

2. Parklane Residence

Figure 3: Parklane Residence

Overview:
Situated in the fast growing township of Bukit Mertajam, in between Jalan Maju & Jalan
Berjaya. Parklane Residences is easily accessible from the North-South Expressway as
well as the new Kulim-Butterworth Interchange. With amenities such as school, markets,
hawker centre & shops at close vicinity. Parklane Residence is one of the most convenient
& prominent neighborhoods around.

Notable Features:
 Located at flood free area – 12m above sea level
 High quality materials used with good workmanship
 Highly usable room space for cozy & comfortable living
 Column free car porch can accommodate at least 2 cars. High ceiling height for
better ventilation
 Living, dining area & bedroom are fully tiled with 2 sq. ft. x 2 sq. ft. tiles
 Mortise lock at main entrance for better security
 4 bedrooms & 3 bathrooms, 2 balconies

Project Summary:
Location: Bukit Mertajam, Penang, Malaysia
Tenure : Freehold
Facility: Badminton court, tai chi corner, reflexology path & children’s playground
 9

Note: OC Obtained

i. 3 Storey Bungalow R83

Figure 4: 3 storey bungalow R83

Description: 3 Storey Bungalow R83
Land Area: 5715sf
Built-up Area: 5488sf
Feature:
 7 bedrooms (1 master bedroom,4 bedrooms, 1 maid room & 1 guest room) with
attached bathrooms and 4 balconies
 Spacious roof top garden can be converted to bedroom, landscaped garden,
washing area, BBQ corner & etc.
 Living, dining and bedrooms are fully tiled with 2sf x 2sf tiles.
 Car Porch can accommodate 2 cars.

ii. 3 Storey Bungalow R83A

Figure 5: 3 storey bungalow R83A

Description: 3 Storey Bungalow R83A
Land Area: 4089sf
Built-up Area: 3786sf
 10

Feature:
 6 bedrooms (1 master bedroom, 3 bedrooms,1 maid room) with attached bathrooms
 Living, dining and bedrooms are fully tiled with 2sf x 2sf tiles
 Car porch can accommodate 2 cars
 2 balconies

iii. 3 Storey Bungalow R85

Figure 6: 3 storey bungalow R85

Description: 3 Storey Bungalow R85
Land Area: 3702sf
Built-up Area: 3610sf
Feature:
 6 bedrooms (1 master bedrooms,4 bedrooms & 1 maid room) with attached
bathrooms
 Living, dining and bedrooms are fully tiled with 2sf x 2sf tiles
 Car porch can accommodate 2 cars
 2 balconies

iv. 3 Storey Semi-D

Figure 7: 3 storey Semi-D

 11

Description: 3 Storey Semi-D

Land Area: 3863sf
Built-up Area: 3292sf
Feature:
 6 bedrooms (3 master bedrooms,3 bedrooms) & 5 bathrooms
 Living, dining and bedrooms are fully tiled with 2sf x 2sf tiles
 Car porch can accommodate 2 cars
 3 balconiess

v. 2 Storey Semi-D

Figure 8: 2 storey semi-D

Description: 2 Storey Semi-D
Built-up Area: 2369sf
Feature:
 4 bedrooms (1 master bedroom, 3 bedrooms & 3 bathrooms)
 car porch can accommodate 2 cars
 2 balconies

3. Parklane Residence Deluxe

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Figure 9: Parklane Residence Deluxe.

Overview:
Located in the fast growing township of Bukit Mertajam, in between Jalan Maju & Jalan
Berjaya, Parklane Residences Deluxe is easily accessible from the North-South
Expressway as well as the new Kulim-Butterworth Interchange. Surrounded by
established amenities including education, public services, medical and financial
facilities, Parklane Residence Deluxe is one of the most strategic & prestigious
neighborhoods around.

Notable Features:
 High quality materials used with good workmanship
 Highly usable room space for cozy & comfortable living
 Column free car porch can accommodate at least 2 cars
 High ceiling height for better ventilation
 Living, dining area & bedroom are fully tiled with 2 sq. ft. x 2 sq. ft. tiles
 Mortise lock at main entrance for better security
 4 bedrooms & 3 bathrooms
 2 balconies

4. The Junction Commercial Centre

 13

Figure 10: The Junction Commercial Centre.

Overview:
Sited at one of the most strategic junctions (between Jalan Maju and Jalan Berjaya) in
town, THE JUNCTION is a business opportunity waiting to happen. It is designed with a
showroom shop office Concept in mind; all shop offices at THE JUNCTION are modernly
architecture, column free at the shop fronts, comes with full glass designed windows made
for retail and display. THE JUNCTION comes with 2 types of shop offices. The built-up
area is ranging from 2240sf to 3650sf with a mezzanine floor and double frontage.

Notable Features:
 Great exposure due to the heavy traffic along Jalan Maju
 Easy access to highway and Jalan Kulim
 Next to established retailers like Wah Lee Electronics Group
 Nearby the new Kampung Baru Market, Sentosa Hawker Centre and SMK Bukit
Mertajam
 Population catchments area due to close residential areas

Upcoming project:
1. Urban Suites @ Jelutong (Ongoing)
 14

Figure 11: Urban Suites @ Jelutong

I am now currently involving in this construction project during my internship.
Description : Commercial Services Suites
Location : Jelutong, Penang, Malaysia
Tenure : Freehold
No. of Block : 2 Blocks of Commercial
Indicative Price : RM 4XX,XXX onwards
Facility : More than 40 types of facility
2. Tawar Residence

Figure 11: Tawar Residence.

 15

2.2.3 Site Organisation Chart

DIRECTORS
Mr Bon Tan

PROJECT MANAGER
Mr Man Mohan Singh

ENGINEERS
(ASSOCIATES)
1. Mr Isahak bin Mohd Shariff
(Civil & Structure Engineer)
2. Mr Teoh Yin Zheng
(Architect/Civil & Structure Engineer)
3. Mr Belvin Daniel Raj
(Mechanical & Electrical Engineer)
4. Mr Muhammad Nur Ariff bin Zamhari
(Quality Assurance & Quality Control)

 Main Contractor: China Construction Yang Tze River

 Consultant: Perunding YAA
 CHAPTER 3

INTERNSHIP ACTIVITIES

3.1 Scope of Practice

The scope of practice describes the procedures, actions, and processes that is permitted
to undertake in keeping with the terms of their professional license. During the 10 weeks
of industrial training practice, I was assigned into several task which are:
 Quality Assurance & Quality Control work
 Civil & Structure work
 Mechanical & Electrical work

Under the Quality Assurance and Quality Control work, I was given exposure on
how to check and inspect architectural work. In addition, under civil and structure work,
I was given to check and inspect structural work. Besides, I also need to read and review
C&S and architectural drawings. On mechanical and electrical work, I assist M&E
engineer to check and inspect electrical wiring and water piping system.

3.2 Quality Assurance and Quality Control Work (QAQC)

In QAQC work, the engineer need to develop and determine all standards to perform
inspection and tests on all procedures and oversee all testing methods and maintain high
standards of quality for all processes. Other than that, engineer have to review quality of
all materials at site and ensure compliance to all project specifications and quality and
 17

collaborate with department for all material procurement and maintain quality of
materials. Engineer also need to supervise effective implementation of all test and
inspection schedule and ensure adherence to all procedures and coordinate with various
teams to perform quality audits on processes. Assist with employees to ensure knowledge
of all quality standards and ensure compliance to all quality manual and procedures and
collaborate with contractors and suppliers to maintain quality of all systems.
QAQC engineer also need to manage lifting of all equipment and handle efficient
storage of all hazardous materials and perform quality audits as per required schedule.
Analyse all products and non-conformance processes and evaluate all documents to ensure
maintenance of optimal quality and prepare monthly reports to evaluate performance.
Monitor an efficient system and record for all project activities and analyse all processes
to ensure all work according to quality requirements. Manage all work methods and
maintain knowledge on all quality assurance standards and monitor continuous
application for all quality assurance processes and recommend corrective actions for all
processes.

3.2.1 Cube Testing and Slump Test

Concrete is one of the most widely used building materials in the world, yet people still
find it difficult to take samples correctly and manage the testing and certification process.
Failure to do this can result in the need to spend even more money undertaking
complicated calculations to prove compliance with British Standards or even drilling and
crushing cores to prove design and reliability.
Concrete is used mostly for structural purposes such as foundations, columns,
beams and floors and therefore must be capable in taking the loads that will be applied.
One of the methods of checking its fit for purpose is to carry out a concrete cube test which
measures the compressible cube strength of the concrete and relates directly to the
required design strength specified by the designer. Also is it is usually a minimum
requirement from the client to provide evidence of cube test results to ensure compliance
with the designers requirements.
 18

Taking a Sample (Sampling)

Equipment need:
 A bucket or wheel barrow
 Wooden board / Polythene sheet or similar
 Cube moulds
 Tamping rod or vibrating poker
 Slump cone
 Pen or marker to identify the samples
 Mound releasing agent and brush
 Scoop
 Concrete float
 Tape Measure
 Damp cloth
 Concrete curing tank

Noted that we cannot simply take a sample from the first or last section of the pour, it
would not be a true representation of the batch. The concrete is usually sampled after the
first metre of concrete has been poured to ensure a good sample is taken. As said in BS
EN 12350-1, take a few samples throughout the pour for the best representation of the
batch and make sure to take 150% of what we will need. The sample is taken and used to
make the cubes. The sample must be a good cohesive mix, it may require some mixing
once taken from the concrete batch to be suitable for a slump test and cubes.
Usually a minimum of 3 cubes are taken from each sample. The frequency of
sampling should be identified in client specifications or by the designer. This could be per
batch / load or even per volume poured. Cube moulds sizes are 150mm x 150mm x 15
mm and be made from steel. The cube moulds must be manufactured to the specifications
/ standards of the relevant body, in the UK it is the British Standards Institute to this
specification BS EN 12390-1:2000. Before the concrete is scooped into the moulds, the
moulds must be lightly coated in a mould release agent. This ensures that the concrete
does not stick to the mould and makes it easier to remove the cube. When using a 150mm
mould, the concrete sample is scooped into the mould in 3 equal layers (50mm) and
compacted between each layer. There are various methods to compact the concrete into
the moulds. For this site, they used hand compaction which is by using a compacting rod.
 19

When using a 150mm mould, each layer compacted is tampered using a certified
compacting rod /bar, 35 tamps per layer is required. Once the 3 layers have been tampered,
tap the side of the mould with a hammer. Tampering and tapping removes trapped air in
the concrete and allows compaction of the sample. Once complete, the concrete is levelled
off using a concrete float or trowel to give a smooth surface flush with the top of the
mould. Each layer is filled and vibrated till no more bubbles are on the surface of the layer,
this is repeated for the 3 layers. It is very important not to over vibrate the layers as it may
lead to segregation / disruption of the concrete mix.
For labelling purposes, it is very important to uniquely identify each of the cubes
(and moulds) and to record where they have come from. Usually companies will have a
process of labelling or tracking the cubes, which is for this site, they used paper sticker
label. After that the cubes should be covered with a damp cloth and a plastic sheet and
stored in dry environment at a temperature range of 20 ± 5 degrees. The concrete cubes
are removed from the moulds between 16 to 72 hours, usually this done after 24
hours. Make sure the cube ID is transferred to the cube from the mould before placing
into a curing tank. The curing tank needs to operate at a temperature between 20 ± 2
degrees and provides a moist environment that allows the cubes to hydrate properly.
Ensure the cubes are fully submersed at all times and record the tank water temperature at
least daily.
In lab testing stage, the cubes are generally tested at 7 and 28 days unless specific
early tests are required, for example to remove a concrete shutter safely prior to 7 days.
For this site, they prepared 3 cubes for every 7 days and 28 days’ sample. The cubes are
removed from the curing tank, dried and grit removed. The cubes are tested using a
calibrated compression machine. This will be carried out internally by competent
personnel or by a certified test house which is TESTECH SDN BHD. The cubes are tested
on the face perpendicular to the casting face. The compression machine exerts a constant
progressing force on the cubes till they fail, the rate of loading is 0.6 ± 0.2 M/Pas
(N/mm²/s). The reading at failure is the maximum compressive strength of the concrete.
The concrete minimum compressive strength will be specified by the
client/designer in a specific format. An example of this is given below:
For concrete C40/50
 20

The 40 is the compressive requirement of 40 N/mm² of a crushed 100m concrete core and
the 50 is a compressive requirement of 50 N/mm² for a crushed concrete cube. Therefore,
using the method of testing using concrete cubes, the tested compressive strength should
be compared to the second number. Once the cubes have reached failure, the shape of the
cube has been altered due to the compression. The failure shape can indicate whether it is
a satisfactory or unsatisfactory failure. The image below shows the various failures of a
cube.

Figure 12: Satisfactory failure of cube specimens

Figure 13: Unsatisfactory failure of cube specimens

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Figure 14: Concrete cube specimen

Figure 15: Calibrated Compressive Machine

Slump Test

Slump Test is a site testing that will always do once the concrete lorry arrived in site. This
is to ensure that the concrete is usable. If the slump test fails to meet the range limit as
dictated in the DO resit order, then the load should be rejected. The method to handle the
slump test is as below:
 22

1. Place the damp slump cone on a flat, hard surface.

2. Fill the cone with the concrete sample in three stages. Once each stage is filled, tamp
the mix with the tamping rod 25 times. After the third tamping the excess concrete
shall be struck off flush to the top of the cone.
3. Lift the mould carefully upwards, to minimise disturbance of the concrete inside.
The concrete will slump.
4. Place the cone next to the concrete slump and measure the difference in height in
mm between the top of the cone and the top of the highest point of the concrete.

Also note what the slump looks like; true (similar shape to the cone), shear (the slump has
sheared in some way), collapse (no resemblance to the original cone). The slump is
normally specified by the designer or may be a specific mix to aid in placement, i.e. a high
slump for a pump mix. Then the slump will be record on the appropriate paperwork.

Figure 16: Shows the slump test that have been done in site.

3.2.2 Brick Masonry Works

Brick masonry is a highly durable form of construction. It is built by placing bricks in

mortar in a systematic manner to construct solid mass that withstand exerted loads. There
 23

are several types of bricks and number of mortars which can be used to construct brick
masonry. The bond in brick masonry, which adheres bricks together, is produced by
filling joints between bricks with suitable mortar. Special cautions shall be
practiced while mortar is mixed and placed since it greatly affects the performance
and durability of masonry structure.
Bricks may be classified according their uses as follows, bearing in mind
that it is sometimes possible for a brick to come under more than one heading:
i. Facing bricks
Facing bricks are intended to provide an attractive appearance. They are available
in a range of brick types, colours and textures. Some may not be suitable in positions
of extreme exposure. Some facing has engineering properties.
ii. Common bricks
Common bricks are suitable for general building work not chosen for its appearance.
These are bricks for ordinary work that is not exposed to view, for example walls
that are to be plastered or built underground.
iii. Engineering bricks
Engineering bricks are hard burnt bricks that are very dense. They have a minimum
compressive strength and minimum water absorption. They are not chosen for their
appearance. There is no requirement for colour. These are bricks suitable for ground
works, manholes and sewers, retaining walls or as a ground level damp proof course
to free-standing walls and situations where high strength and situations where high
strength and low water absorption are the most important factors.
iv. Special bricks
A wide variety of bricks are available in special shapes or sizes, to blend or contrast
with most facing bricks. Squints are an example. They are manufactured to special
shapes that enable the brick layer to build angled corners at 45 degrees or 60 degrees.
They are used to reduce the thickness of a wall and still maintain the face texture of
the wall or remove the sharp corners from a brick wall or pier.
 24

General characteristics of good bricks:

The essential requirement for building bricks are sufficient strength in crushing, regularly
in size, a proper suction rate and a pleasing appearance when exposed to view.
i. Size and Shape: The brick should have uniform size and plan, rectangular surface
with parallel sides and sharp straight edges.
ii. Colour: The bricks should have a uniform deep red or cheery colour as indicative of
uniformity in chemical composition and thoroughness in the burning of the bricks.
iii. Texture and Compactness: The surface should not be too smooth to cause slipping
of mortar. The brick should have pre-compact and uniform texture. A fractured
surface should not show fissures, holes grits or lumps of lime.
iv. Hardness and Soundness: The bricks should be so hard that when stretched by a
finger nail no impressions is made. When two bricks are struck together, a metallic
sound should be produces.
v. Water Absorption: Should not exceed 20percent of its dry weight when kept
immersed in water for 24 hours.
vi. Crushing Strength: Should not be less than 10 N/mm2
vii. Brick Earth: Should be free from stones, cankers, organic matters, saltpetre, etc.

Advantage of bricks:
These are the advantages of bricks:
i. Uniformity is size and shape. Therefore, it can be easily laid in masonry.
ii. Unlike stone brick does not dress. Therefore, there is no reduction time and labour.
Moreover, skilled labour is not needed.
iii. Bricks are cheaper than the stones. Though same quantity of brick cost more than
same quantity stone. More expenditure is consumed on processing of tone masonry,
such as breaking of stone into smaller size and dressing.
iv. Smaller in size and lighter therefore less effort is required while building brick
masonry.
 25

Disadvantages of bricks:
These are the disadvantages of bricks:
i. Bricks are less durable than stone.
ii. Plastering is required.
iii. Alkalis and salts present in the brick earth have hygroscopic properties. They absorb
moisture from the air and creating a damp and unhygienic condition.

Mortar:
Mortar is a workable paste used to bind construction blocks together and fill the gaps
between them. The blocks may be stone, brick etc. Mortar is a mixture of sand, a binder
such as cement or lime, and water is applied as a paste which then set hard. Mortar can
also be used to fix, or point masonry when the original mortar has washed away. Masonry
mortar is composed of one or more cementitious materials, clean well-graded masonry
sand, and sufficient water to produce a plastic workable mixture. Types of mortar used in
masonry work:
Figure 17: Mortar masonry
 Cement mortar in a concrete mixer.
 Lime mortar
 Cement-lime mortar
 Lime-surkhi mortar
 Mud mortar

Bonding of bricks:
Bonds in brick work on account of their uniform size and shape, the bricks can be rise to
different types of bonds. Bonding is essential because it eliminates continuous vertical
joints both in the body as well as in the face of the wall and also imparts strength to the
masonry. Defective arrangement of bricks reduces the strength and durability of the
structure. The choice of the bond is influenced by the situation, function and thickness of
the wall.
 26

i. English bond:
The strongest English Bond consists of alternating course of stretchers and headers. A
quarter bond is maintained by incorporating queen closers in every second course. English
bond is generally used in one brick walling.
ii. Flemish bond:
Flemish bond consists of alternating headers and stretchers along each course with the
headers centred on the stretchers above and below.
i. Single Flemish bond:
 Combination of English bond and Flemish bond.
 In a course, facing is Flemish bond and backing is English bond.
 Cannot be adopted in walls having thickness less than one and half brick.
 Provided for the attractive appearance of the Flemish bond.
 Slightly stronger than Double Flemish bond.
ii. Double Flemish bond:
 Each course presents the same appearance both in the face and back of the
wall.
 Every course consists of headers and stretchers alternately.
 Best suited for consideration of economy and appearance.
 This type of bonding is comparatively weaker than English bond.
iii. Stretcher bond:
Stretcher bond is the commonest bond used today and the least interesting in appearance.
It can be made more interesting by laying a course of different coloured bricks or to lay
such bricks to form a pattern on a wall.
 Stretcher bond wall
 Stretcher bond wall with piers
 Stretcher bond piers
 27

Figure 18: Bricks bond pattern.

Types of Brick Wall:

i. Building to gauge
It is essential to consider the height of the wall when building. Brick layers use a
gauge rod to ensure that the beds of mortar between each brick are uniform and to
monitor the overall height of the wall as each course is laid. Gauge rods are generally
made by bricklayer using timber but they can also be bought in stainless steel.

ii. Racking back and stopped ends

It shows a half brick wall with a stop end and racking back. This method of
construction is commonly used by bricklayers to build plumbing which allow them
to plumb either end of the wall and build to a line in the middle of the wall. This
process is much quicker than building the wall one course at a time.
 28

iii. Return corners

It shows a half brick wall built with a return corner. This means that the wall turns
usually 90 degrees and continuous in another direction. We should notice that the
bond remains unchanged and that the course height remains constant on the return.

Figure 21: Return corners

Brick Masonry Construction Preparations

1. Check the level of the ground using level, theodolite or transparent hose level.
2. Set the layout of the structure.

3. Trace of building axis and wall alignment using gypsum powder, chalk, or similar,
marking the trenches for foundation.
 29

4. After that, install foundation wall, cure foundation for minimum two days before
beginning of brick masonry construction.

5. Distribute bricks in several stacks along project site to cut time and effort later.

6. Wet bricks few hours prior to the work. Not only does this avoid absorbing too much
water from mortar but also improve adherence of bricks and mortar.

Step 1: Setting out the wall and purchase the right amount and type of bricks.

Figure 23: Laser survey used for setting out of the brick wall.

Step 2: Prepare all the materials (bricks, mortar, machineries and tools) that are
needed.
Once mixed the mortar, then can start to lay the bricks, we have to use all the mortar and
strike the joints before quitting. Do not forget to install the ex-met between the brick (at
every 300mm or 4 layer of bricks). The function of the ex-met is as a reinforcement for
the brick. Wet bricks few hours prior to the work. Not only does this avoid absorbing too
much water from mortar but also improve adherence of bricks and mortar.

Figure 24: Ex-met that being install between bricks.

 30

Make guidepost or gauging rods.

With this method, we can ensure our wall’s level. First, take two long wooden boards or
posts and measure out each row of the brick wall, also known as course. Next, mark the
boards where each brick should be, including the mortar lines. It is important to make sure
that we can drive the posts into the ground so that they can be freestanding.

Laying brick
First, move the string line up to where the top of the next course of bricks will be then lays
a bed mortar on top of the first course of bricks, so that it is in a triangle shape. Next, take
a slab of mortar and coat the end of the brick that will be pushed up against the first brick.
Used the trowel to feather through it to create an air pocket for laying the bricks on. We
can use the spirit level to ensure that the bricks are flush and at even height then pushing
on them lightly to make sure that they are perfect. Besides that, we also need to scrape
away any excess mortar away. Then, place mortar on the side of the bricks and lay them
next to each other. Repeat this step until the wall has reached the height that had been set.
Make sure to lay the waterproofing emulsion on the beam or slab at the outer
parameter and toilet brick wall that will expose with water. before start laying brick. This
is to avoid the water from damage the mortar and brick at the bottom layer.

Figure 26: Figure 27: Laying of brick for brickwall

Waterproofing emulsion

Points Considered in Supervising Brick Masonry Constructions

The following points should be observed in the construction of brick masonry:
 Use good quality bricks.
 Ensure that brick courses are perfectly horizontal.
 31

 Verticality of the wall should be ensured by frequently checking with plumb-bob.

 Whenever work is stopped brick masonry should be left with toothed end.
 Use of brick bats should be avoided.
 Raising walls by more than 1.5 m in one day shall be prevented.
 Raise face joints to a depth of 12 to 20mm so as to be used as a key for plastering
or pointing.
 Brick masonry should be regularly cured for 2 weeks.
 The thickness of mortar joints shall be 10 mm both horizontally and vertically.

Types of defect on the brick work:

Figure 28: The mortar not being fill Figure 29: The space between the
properly at the top of the brick wall to brick and the column/ between brick
cover the space between brick and the and beam not being fill properly with
beam. mortar.
 32

Figure 30: There is a hole at the Figure 31: There is a huge gap
bottom of the brick wall. It must be fill between the brick and the lintel. It
with brick. should be fill with mortar to cover the
gap.

3.2.3 Plastering and Skim Coat

Plastering
Contrary to popular belief, plastering is the term offered to the whole trade. This means
that skimming is really a method that a plasterer utilises, rather than plastering and
skimming being totally separate terms. Plasterers perform great deals of different types of
plastering and need to be very well-informed in their trade. For example, some materials
need more coats of plaster than others, and there are lots of different methods associated
with doing a good job. The aim of doing plastering is to get a level surface of a wall or
column or beam. There are different kinds of plasters that plasterers must understand how
to use:
 Cement plaster: Made from cement, sand and water and generally used on walls
where masonry work has been done
 Lime plaster: Made from lime and water
 Gypsum plaster: Made with water and calcium sulphate
 33

Plastering is the process where applying a thin cover of cement over the unprotected
surface in order to guard against saturation of rainwater, plastering is a process used to
produce an acceptable finish to walls and ceilings in buildings before the decoration
begins, this makes sure that there aren’t any bumps or lumps in the wall that would stand
out when the wall is decorated and finished.

Skimming
Skimming is the name provided to a plastering method where a wall is plastered with a
layer of thin coat. It is usually applied to an existing plaster to smooth the surface area.
The white layer of lime which is used to rough cement is called a skim coat. The plasterer
uses various methods to make the surface area smooth, and it might depend on the
tradesman’s proficiency. Then the skim coat can be painted to make it look far more
appealing. So overall, skimming is a subset of plastering. They are both used to decorate
structures and increase the durability of a wall, but skimming is done to update an old
building whereas plastering is done to a new one. Another difference between skim and
plaster is that plaster surface areas are constantly rough whereas a skimmed surface area
is smooth.
Skim coating is a technique that uses textures this is used to make a wall even. A
thin layer added to a plaster wall removes bumps and depressions in the texture of an old
plaster wall or hides the imperfections of a new plaster wall. The smooth, flat surface of
skim plaster easily accepts wallpaper or a new texture. The base layer that a plaster
installer applies to a wire-lapped wall consists of at least two layers of gypsum-based
plaster. Once the basecoat dries, the installer applies a basecoat to the drywall. Renovation
contractors usually do not remove the texture of an old plaster wall before applying the
skim coat.

Overall there are 3 coat for plastering and skim coat which is:
1st coat – render (plastering)
2nd coat – mortar (skim coat)
3rd coat – plaster finishing grey (3 coat)
 34

Based on QAQC work, the plaster thickness must not exceed 10mm for every layer. This
is to avoid the surface from hollowness and huge crack occurred.

There are 3 types of plastering these are:

Cement – made from sand and water and is generally used on walls where stonework has
been completed.
Lime plaster – made from lime and water.
Gypsum plaster – made from calcium sulphate and water.

How to skim walls

Mix a bucket of all-purpose sealant with an electric drill equipped with a caged drill until
the consistency of the joint compound matches that of hot butter. The premixed sealant
comes from the manufacturer in a bucket with all ingredients included.
Hold a 24-inch flat trowel at a 45-degree angle and use the edge of the trowel to smooth
the skim coat. Start at the top of the wall in a corner and work towards the ground. If the
skim coat begins to stick to the trowel blade, wet the blade with water. Allow the skim
coat to dry completely. The premixed all-purpose joint compound takes 24 hours to dry.
The quick setting joint compound indicates the drying time on its bag, usually between 5
and 30 minutes.

Figure 32: Electric drill equipped to mix the skim mixture.

 35

Surface Preparation
First, get a new surface where it requires preparation such as removal of dust, dirt and
foreign matter. In case of cracks, voids & damages it should be repaired. Surface should
be in just wet condition, prior to putty application. If the surface was made by Cement
ghutai (smoothening) which normally is very smooth, bonding with putty may not become
sufficiently strong. Scraping the surface with emery stone/paper is recommended before
skim coat application. Surface should be in just-wet condition, prior to putty application

Work procedure
i. Product should be mixed in such quantities that it could be used within 2 hrs of its
preparation.
ii. Ensure that surface is totally clean.
iii. Fibre mesh should be install at every connection between brick and RC structure.
iv. Ensure that surface is moderately rough (neither too-rough nor too-smooth).
v. Ensure that surface is just-wet. Over-wetting resulting in accumulation of water on
surface should be avoided.
vi. Apply first coat which is render.
vii. Use spatula/ blade/ trowel on the wall with "bottom to top" configuration.
viii. Apply second coat (which is mortar) preferably after @ 12 hrs application of 1 st
coat.
ix. Re-mix putty paste again for @ 1 minute, if it is left undisturbed for @ 30 minutes.
x. Allow complete drying @ 2 days and then use fine emery paper to remove
application mark, if any or half an hour application of 2nd coat smoothening could
be done with trowel.
xi. After application of second coat, wet surface twice a day for at least one day, if
season demands Water shall be applied gently.
xii. Filler Coat should be applying after 3 or more days of Skim Coat of work for
bonding between skim coat and paint which is plaster finishing grey (last coat).
 36

Precaution
 Use rubber gloves while mixing.
 Precaution should be taken to avoid dust inhalation while handling putty powder or
during removal of application marks with fine emery paper say wearing nose mask.
 Once putty paste has hardened, it shall not be used by adding water.

Quality standard for plastering and skim coat (finishing)

 Plaster finishes: no visual cracks (assessment: method visual)
 Hollowness/Delamination: no hollow sound when tapped (assessment method:
tapping rod)

Figure 31: Fibre mesh and tapping rod equipment used.

Figure 32: Plastering work on column and beam.

 37

3.2.4 Lintel and Stiffener

Lintel:
A lintel is a structural horizontal support over an opening, in a wall or between two vertical
supports allowing loads to be transferred to the foundations without unnecessary stress
placed upon frames such as windows or doors. A lintel should have sufficient strength and
stiffness and be made of a material that is compatible with the masonry it supports.
Commonly, lintels are made from the following materials:
 Galvanised or stainless steel
 Reinforced or prestressed concrete
 Reinforced or prestressed masonry stone

Lintels are required for all openings over timber frames greater than 600mm in
width, & for all openings over steel frames greater than 900mm. Often the specifications
on the building plans will also state additional reinforcing measures such as steel rod
through bed joints in subsequent courses of masonry above openings. This is to ensure
that the masonry above becomes a solid mass, and adequately transfers load either side of
the opening.
Lintels must have adequate support at each end, and typically, the length of lintel
for a masonry wall is calculated by measuring the total width of the structural opening,
and adding 150 mm for end-bearings at each end. If lintels or end-bearings are inadequate
specified, they can cause cracking in decorations, or in the structure itself, and ultimately
can cause structural failure and collapse.
Lintels are lifted into position whilst constructing brickwork, which may be done
manually. A small gap is left above a window or door frame, to ensure that the lintel is
supporting the load, as well as allowing for minor movements such as settlement of
foundations or swelling of the frame itself. This is particularly applicable if timber frames
are installed, as timber tends to swell or contract depending upon environmental factors
such as moisture content or temperature.
 38

When installing a lintel, it is important to adhere to the following good practices:

 Be careful not to chip the lintels coating
Corrosion protection is an essential component in ensuring that the lintel installed
does not cause structural damage in the future. Moisture needs only the smallest of
exposed area to penetrate, creating areas of rust and causing the lintel to expand.
 The vertical leg of a steel lintel should always be the highest.
Careful calculations are made off-site to ensure that the lintel provided is adequate
to support the load above it. If the lintel is incorrectly installed, the lintel may no
longer be able to support the load and may visibly deflect over time, causing loads
to be place upon frames.
 Brickwork should not overhang steel lintels by more than the allowable distance.
Brickwork should not overhang lintels by more than 25mm, as a greater overhang
may cause horizontal cracking to the brickwork above.
 Brickwork should have mortar packing between brick & steel lintel.
A mortar packing between the brick and the lintel ensures that the lintel does not
twist whilst in service.
 Adequate bearing should be achieved at either side of the lintel.
A lintel will need a certain amount of cover or bearing either side of the opening
that it supports. This is to ensure that the lintel does not deflect under the load that
it is supporting.

Steel Lintels Installation Guide

1. Steel Lintels should be installed with a minimum end bearing of 150mm, bedded on
mortar and levelled along its length and across its width.
2. Raise the inner and outer leaves simultaneously to avoid excessive eccentricity of
loading, with a maximum height difference of 225mm (Masonry should be laid on
a mortar bed and all perpendicular joints should be filled.)
3. Allow the mortar to cure before applying floor or roof loads (Temporary propping
beneath a steel lintel is practised to facilitate speed of construction).
 39

4. When installing concrete floor units or other heavy components above a lintel, care
should be taken to avoid shock loading and floor units should not be dragged into
position. Masonry immediately above the lintel should be allowed to cure.
5. Point loads should not be applied directly onto lintel flanges. Steel Lintels should
have a minimum of masonry 150mm high between the flange and the application
level of any form of loading.
6. The external lintel flange must project beyond the window/door frame and it is
recommended that a flexible sealing compound is used between the underside of the
lintel flange and the frame.
7. When the underside of a lintel is exposed, its appearance can be enhanced by the
addition of lintel soffit cladding. Do not cut lintels to length or modify them in any
way.

Figure 33: Ensure lintel is level along its length.

 40

Figure 34: Lintel must bed on the bricklaying mortar have a nominal 150 mm at end
bearing.

Stiffener:
Stiffener columns will be cast after completing each part of brick walls (~1.5m height)
If the Reinforcement starters would will be provided at the location of stiffener beams &
columns from the structural elements. If the Reinforcement starters would not be provided
at the location of lintels from the structural elements, chemical anchor HIT - RE 500 will
be used for anchoring reinforcement to the structural elements. These Reinforcement
anchors would be provided while concreting the structural elements and construction
detailing for anchors will be carried out as per the attached sketches.
Although it is reinforced concrete structure too but being non load bearing, therefore they
are used abundantly in masonry to stiffen the brick/block wall. Spacing of stiffeners
depend on type of brick or block, for instance:
 Half brick wall (4”) requires spacing up to 3.0 m between 2 stiffeners
 Full brick wall (8”) requires a spacing up to 6.0m between 2 stiffeners

Quality Assurance and Quality Control System

 Following checks & inspections will be carried out.
 Locations of brick walls & openings in brick walls will be marked on floor by
referring the off lines of main grids.
 41

 Verticality & the alignment of brick walls will be checked by using spirit level
plumb.
 Cement/ sand mortar will be mixed manually or mechanical mixer & volume of
cement & sand will be measured using gauge boxes. Mix ratio of cement & sand is
1:5 (by volume)
 Inspection with the engineer’s representative will be carried out while work is in
progress.

Figure 35: Lintel being install at every 3m of the brick wall.

3.2.5 Post-concrete Inspections

Post concrete inspection of concrete is essential to check for any damage or defects that
may require repair. Immediately after stripping the form work all concrete members casted
are carefully inspected and any defective work or small defects either removed or made
good before the concrete has thoroughly hardened. In case of doubt regarding the grade
of concrete used either due to poor workmanship or based on results of cube strength tests
the compressive strength test of concrete on the basis of core test, ultrasonic test and/ or
load test is carried out. In case of results of cube strength are observed to be lower than
the required designed strength at 28 days as per specifications, ultrasonic test is carried
out by the digital ultrasonic concrete tester.
 42

Post-concrete inspection is for the purpose to check the defects in formwork,

concrete casted honeycomb, shrinkage, steel reinforcement weathers its exposed or not
and the accuracy of the dimensions. In my scope of work, I need to check the verticality,
evenness and dimensions at every column for post-concrete inspections. The equipment
used is spirit level, steel wedge and measuring tape. Every checking criterion have their
own tolerance.

Checking tolerance:
i. Verticality: between 0 to 6 mm
ii. Evenness: between 0 to 8 mm
iii. Dimension: between 5 to 10 mm

The verticality and evenness will be check at the middle, left and right of the column
surface and wall (after plastering).

Figure 36: Equipment used in post-casting inspection: steel wedge and spirit level.

Figure 37: The checking reading will be recorded at every column.

 43

Figure 38: Spirit level was used to check the verticality of the column and wall.

3.3 Civil and Structure Work (C&S)

In civil and structural work, I need to manage and supervise site structural work aspects
to ensure that everything is in compliance with the required or approved drawings in line
with construction standards and safety. The duties and responsibilities of civil and
structural engineer are listed below:
 Managed the structural supervision and implementation of the site from the start of
mobilization to project turn over.
 Review and approval of the subcontractor or contractor’s materials, documents and
shop drawings submittals. This can include method statements, calculations, pre-
qualification documents, etc.
 A review of the proposed structural engineering changes received from the
contractors and advises the Resident Engineer of any potential issues.
 Addressing RFI’s or request for information related to structural engineering raised
by the contractor about the project.
 44

 Responsible for the submission of Progress reports or Periodical Inspection Reports

for the projects involved. You may also require conducting or support periodic
inspections if the structural inspector is not around to determine if structural works
have been done in accordance with contract specifications.
 May be required to witness tests, such as soil compaction, moisture content,
aggregation, graduation, concrete slumps, air entrainment, concrete compression,
lines, and grades survey, bolt torques, and concrete coring and can call for additional
testing if necessary.
 Responsible for making instruction, project follow-up on the contractor’s tasks and
perform other structural site engineering role as may be deemed necessary.

3.3.1 Pre-concrete Inspections

Inspection of concreting works is an important step to achieve greater strength and

durability of the structure. Although it is easy to remember number of checks during
inspection of concrete member, a checklist is always required for record of the placement
of concrete and quality control measures taken at site. Pre-pouring concrete inspection
means before and during concrete pouring we have to check weather all related discipline
already ok and approved from the consultant or client as example earthwork, form-work,
electrical, mechanical, steel reinforcement etc.

i. Checking formwork verticality.

Formwork is a mold including all supporting structures. It used to shape and support the
concrete until it attains sufficient strength to carry its own weight. It should be capable of
carrying all imposed dead and live loads apart from its own weight. Formwork is
commonly made of steel and timber.
 45

Figure 39: Timber and steel formwork.

The quality of the formwork is as follows:

 It should be water tight.
 It should be strong.
 It can be reusable.
 Its contact surface should be uniform.
 It should be according to size of member

In this site they more used steel formwork rather than timber. This is because of the
advantages of steel formwork which is:
 It can be used for a number of times.
 It is non-absorbent.
 Smooth finish surface obtained.
 No shrinkage of formwork occurs.
 Easy to use.
 Its volume is less.
 Its strength is more.
 46

There are three stages of formwork:

i. Assembly and erection
ii. Concrete placement
iii. Stripping and dismantling

Different structure of formwork got different scopes of work:

i. Formwork for wall
After completing one side of the formwork reinforcement is provided at the place
then the second side formwork is provided.
ii. Formwork for column
After completing one side of two end and two side planks are joined by the yokes
and bolts.
iii. Formwork for slab and beam
Beam formwork rests on head of the scaffold. Slab formwork rests on battens and
joists. If the prop scaffolding height are more than 8’, need to provide horizontal
braces for the slab.
iv. Formwork for stairs.

Figure 40: typical wooden formwork for stairs

 47

Quality assurance of formwork (Pre-casting inspection)

Figure 41: Inspect column formwork verticality.

 48

The formwork can be remove as follows:

iv. Checking the installation of reinforcement bar.

Reinforcement bar or rebar, also known as reinforcing steel, is a steel bar or mesh of steel
wires used as a tension device in reinforced concrete and reinforced masonry structures to
strengthen and hold the concrete in tension. The type and grades of the reinforcement bar
are different depends on the strength grades.

Figure 42: Types and grade of reinforcement bar.

The reinforcement bar should not be left in direct contact with ground. It should be
stacked on elevated ground and on top of timber sleepers, concrete sleepers or others to
avoid the reinforcement bar contact with the ground. The bar bender should prepare a bar
bending schedule of reinforcement bar prepared in advance before cutting and bending of
rebar. The schedule contains all details of size, shape, number and dimension of rebar that
the bar bender need to be cut as per the drawing requirement. The bars shall be bent in
accordance with the dimensions shown in the schedule. The bar must be bend slowly to
avoid capillary crack. The samples may be check by the engineer to avoid wastages.
General reinforcement need:
 49

i. Over lapping: It is done when length of the reinforcement bar is small but we need
a longer reinforcement.
ii. Ties: Columns have closed lateral ties spaced approximately uniformly across the
column. Also used to ties the link with the main bar.

Figure 43: the equipment used to tie the link with the reinforcement bar.

iii. Hook: Used to resist expansion and shall be bent 135 degrees.
iv. Stirrups: Used to resist shear and diagonal tension stresses in a beam.

Figure 43: Arrange and ties the reinforcement bar for column as in the drawing.
 50

Figure 44: Reinforcement bar for beam and slab.

At the ground floor, after backfill and compact until the ground level, they will pour
the lean concrete first before erecting the reinforcement bar. This is to avoid the
reinforcement bar contact with ground and at the same time is to avoid the reinforcement
bar from directly contact with the water. This is because, it will cause erosion to the
reinforcement bar and drop its strength to carry the load.

Figure 45: Fixing of chairs and spacing of the links.

Figure 46: Fixing of concrete cover block for nominal cover of the reinforcement bar.
 51

3.3.2 Concrete casting.

Concrete is one of the most commonly used building materials. It is a composite material
made from several readily available constituents which is aggregates, sand, cement and
water. The mixing of concrete is done using the following methods:
i. Volumetric batching: Boxes of certain size are made and with the help of these the
mixing is done. The bulking of sand needs to be taken into consideration while using
this method.
ii. Weight batching: The concrete proportioning is done according to the weight of the
material. The mix is properly designed in this case. The bulking of sand does not
have a marked effect on concrete while using this method.

The concrete can be mixed manually on site or can also ready mix from the concrete
plan. The concrete will be check for slump test first before go for casting. This is to make
sure that the concrete is still good to be used for casting the structure. Before placing the
concrete, there are few things to be prepared, which is:
i. Pour the cement slurry or bonding agent at the construction joint.
ii. Keep all the equipment ready such as labor, concrete pump and vibrator.
iii. Never pour too low slump concrete as the concrete will harden quickly. Cannot
adding much water to avoid the concrete from harden because this can low the
strength of the concrete.
iv. Restrict height of free fall through reinforcement as much as possible.
v. Place the concrete within stipulated time.
vi. Avoid use of vibrator to spread the concrete.

This is the precaution need to be taken during compaction of concrete:

i. Vertical penetration a few inches into previous lift (which should not yet be rigid)
of systematic regular intervals will give adequate consolidation.
ii. Check the direction of rotation of the vibrator.
iii. Never touch the needle to the reinforcement as it can make the reinforcement move
from its original place.
 52

iv. Insert quickly once the concrete has been pour and take out slowly after finish.
v. Insert the vibrator till previous level.

For finishing of concrete, power float is better to be used on a large slab area as it is
more easy and fast. Hand floating can be used on a small area to get a smooth layer after
finishing. Concrete hardener is pour on the concrete surface during finishing of concrete.
Finishing of concrete need to be done properly to avoid bleed water appears on the surface
after the concrete harden. Curing of concrete start as soon as the concrete is set. Minimum
time to cure the concrete is 7 days.

Figure 47: Concrete pump is used for casting at large slab area.
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Figure 48: Tower crane is used to carry the ready mix concrete from lorry to
casting the column.

Figure 49: Power floating and hand floating used for finishing of concrete.

3.4 Mechanical and Electrical Work (M&E)

'M&E' in construction refers to mechanical and electrical systems. Mechanical systems

can include elements of infrastructure, plant and machinery, tool and components, heating
and ventilation and so on. Electrical systems might include, power supply and distribution,
telecommunications, computing instrumentation, control systems and so on.
Clearly there is a great deal of overlap, with many systems including both
mechanical and electrical components, hence the term M&E. Combined mechanical and
electrical engineering courses are available, with joint accreditation between the
Engineering Council, Institution of Engineering and Technology(IET) and Institution of
Mechanical Engineers.
The terms M&E or M&E engineer are often taken to be interchangeable with
building services or building services engineer and M&E engineers will often hold a
degree in mechanical, electrical or M&E engineering. Building services are the systems
installed in buildings to make them comfortable, functional, efficient and safe and might
include:
 Building control systems.
 Energy distribution.
 Energy supply (gas, electricity and renewable sources such as solar, wind,
geothermal and biomass).
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 Escalators and lifts.

 Façade engineering (such as building shading requirements).
 Fire safety, detection and protection.
 Heating, ventilation and air conditioning (HVAC).
 Information and communications technology (ICT) networks.
 Lighting (natural and artificial).
 Lightning protection.
 Refrigeration.
 Security and alarm systems.
 Water, drainage and plumbing (including sustainable urban drainage systems
(SUDS)).
 Carbon emissions calculations and reduction.

However, mechanical and electrical engineering can be a wider field than this,
including areas beyond building design and construction, such as; large-scale power
generation and transmission, transportation systems, infrastructure controls, industrial
installations and so on.

3.4.1 Mechanical and electrical works for a building project

Major works are to be handled by Mechanical people because of HVAC or air
conditioning system and that has piping work for cold and hot water, fabrication works
for ducts, dampers and controllers, thermal / cold insulation works, and erection of
machines like chiller unit, air handling units, grills, diffusers etc. Another important
Mechanical works are Drinking water, Drainage and Sewerage systems. Other Mechanical
works are firefighting works that included piping, sprinklers and Pumps.
Electric works mainly included Electrical Power and Lighting but others like
Transformer substations, Emergency power, UPS / Central battery, Voice / Data
communication, TV, Security systems like CCTV surveillance system, Access control
System, Public address system, building management system (BMS), Fire alarm system,
aircraft warning lights, Traffic Barrier, Surge Protection system, and Lightning protection
system.
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3.4.2 Construction method of external, exterior and outdoor lighting system

External, Exterior and Outdoor Lighting System includes lighting units with luminaires,
lamps, ballasts, poles / support structures, and accessories and related power distribution
and control, protective earthlings and related builder's work including column
foundations, cable pits, cable trenches and ductwork.
Related Sections include the following: Section "Basic Electrical Materials and
Methods", Section "Interior Lighting" for interior fixtures, lamps, ballasts, emergency
lighting units, and accessories; and for exterior luminaires normally mounted on
buildings or outside buildings.

Definitions in external, exterior and outdoor lighting system:

1. Lighting Unit: A luminaire or an assembly of luminaires complete with a common
support, including pole, post, or other structure, and mounting and support
accessories.
2. Luminaire (Light Fixture): A complete lighting device consisting of lamp(s) and
ballast(s), when applicable, together with parts designed to distribute light, to
position and protect lamps, and to connect lamps to power supply.

Extra materials in external, exterior and outdoor lighting system:

Spare Parts: Provide items necessary for maintenance, and up to 5 percent (or nearest
whole unit) of installed quantities of each type of lamp, control gear, fuses, luminaire
covers, special bolts or nuts, lamp-holders and the like which are subject to burning,
breakage or failure.
Furnish extra materials described below that match product installed and that are packaged
with protective covering for storage and identified with labels clearly describing contents
and contract number.
1. Lamps: 10 for every 100 of each type and rating installed. Furnish at least 5 of
each type.
2. Glass and Lenses, Covers, and Other Optical Parts: 1 for every 50 of each type and
rating installed. Furnish at least 2 of each type.
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3. Ballasts: 1 for every 50 of each type and rating installed. Furnish at least 2 of each
type.
4. Globes and Guards: 1 for every 20 of each type and rating installed. Furnish at
least 1 of each type.

Connections in external, exterior and outdoor lighting system:

1. Ground equipment. Tighten electrical connectors and terminals according to
manufacturer's published torque-tightening values.
2. Ground metal poles/support structures according to Division 16 Section
"Grounding and Bonding."
3. Non-metallic Poles: Ground metallic components of lighting units and
foundations.
4. Connect luminaires to grounding system with conductor as shown on plans or in
accordance with Regulations.

Cleaning and adjusting in external, exterior and outdoor lighting system:

1. Clean units. after installation. Use methods and materials recommended by
manufacturer.
2. Adjust amiable luminaires and luminaires with adjustable lamp position to provide
required light distributions and intensities.

3.4.3 Install a concealed electrical wiring system.

Concealed conduit electrical wiring systems are a popular choice in domestic premises as
they are aesthetically appealing. They are the most commonly used house electrical wiring
system as it protects the wires from external damage and increases their longevity.
The wires are installed in 4 steps:
Step 1: Laying the electrical conduits in the slab.
Step 2: Laying the electrical conduits in the wall.
Step 3: Installation of switch boards back boxes.
Step 4: Installation of distribution boards.
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Step-1: Laying of Electrical Conduits in Slab.

 The slab conduits for house wiring should be 2 mm thick and 25 mm in size for PVC
conduits. Lay the slab conduits between the top and bottom reinforcement.
 Use only deep junction boxes in slabs. Properly bind the PVC conduits using the
binding wire.
 It would be ideal to follow the colour coding for conduits for electrical wires and
data such as LAN and telephone wire. Use grey PVC pipes for data, black PVC
pipes for electrical wires and PVC solvent for joining the accessories.
 Check the wall drops carefully and determine the concrete thickness.
 Check the conducting as per the service drawings and see where the switchboards
are located and how many points need to be installed at each location.
 Take special precautions while concreting the slab.
 Replace all the broken pipes.
 Ensure that all the joints are watertight.
 Once the slab and beam are de-shuttered, pass the GI wiring immediately. Document
any choke up or alternate route for future references.
 Provide all the necessary sleeve in beams, columns prior to slab casting as per
electrical & air-conditioning.
 Provide the pull boxes at suitable locations.
 Do not cluster the pull and junction boxes at one place. Arrange them so that they
cannot be seen easily from heavy movement areas as per the electrical drawings

Step-2: Laying of Electrical Conduits in Wall

 Carry out the concealed conduit work after the construction of masonry walls but
before the plastering work starts.
 Once the curing of brickwork is completed, carry out the chasing work. Ideally,
maintain a gap of 7 days between the two activities.
 Do the wall chasing with wall cutters only, as this would avoid damage to the wall.
 Fix the electrical conduits with the approved clips to ensure proper routing and
wiring.
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 Once the conduits, boxes and accessories are fixed, fill the chiselled surface with
cement mortar and chick mesh wrapped around the conduits.
 Start the wall conducting activity with level marking on the wall, keeping the height
above FFL (Finished floor level) in mind.
 Limit the width of chasing as per the number of conduits.
 The depth of chasing should be at least 10 mm from the masonry wall to have the
conduit recess.
 Make sure that all the horizontal conduit runs are straight at the box level. The light
point conduit should run straight vertically to the switch box. Make sure no wall
conduit is taken haphazardly.
 Do not use any elbows or bends. Use a spring to bend if you want to change the
direction of the pipe.
 Do not run power conduits near any communication line.
 Run the conduits above the false ceiling with proper support. Do not rest them on
the false ceiling in any case. Seal the vertical runs with open ends at the top if you
have false ceiling work.

Step-3: Installation of Switch Boards Back Boxes

 Fix the concealed switchboard properly in level based on the architect’s design, for
example, distance and height from the finished floor level (FFL).
 Ensure that the gap between the concealed switchboards is uniform. Maintain the
same uniformity across all the installations.
 The switchboards must be readymade modular type metal boxes of the approved
make. Fix the concealed box 3 mm below the plastered surface.
 Finish the box fixing before the plastering work while doing the wall conduiting.
Fill the boxes with thermocol while the plastering work is being done.

Step-4: Installation of Distribution Boards

 Conceal the distribution board before the plasterwork.
 Fix the DB box in a proper line and level the recess provided in the brickwork.
 59

 Ready the box as per the design such as fixing the number of conduits entering the
distribution box.
 Place the PVC pipes from the given entry holes only.

Figure 50: Architectural drawing including electrical point.

Figure 51: Need to check and make sure all the wiring conduits being install accordingly
before casting and all switch point being install accordingly to the drawing.
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Figure 52: Make sure the PVC pipe is install between top and bottom BRC. Repair the
broken pipe before concrete casting the slab.

3.5 Site Machinery

Heavy construction equipment is used for various purposes in large projects. Selection of
different types of heavy equipment depends on the size of the work and economy of the
project. These make construction process easier and faster.

3.5.1 Types of Heavy Construction Equipment

Different types of heavy equipment commonly used in the construction are as follows:
1. Excavators
Excavators are important and widely used equipment in construction industry. Their
general purpose is to excavation but other than that they are also used for many
purposes like heavy lifting, demolition, river dredging, cutting of trees etc.
Excavators contains a long arm and a cabinet. At the end of long arm digging bucket
is provided and cabinet is the place provided for machine operator. This whole cabin
arrangement can be rotatable up to 360º which eases the operation. Excavators are
available in both wheeled and tracked forms of vehicles.
 61

Figure 53: Excavators.

2. Backhoe
Backhoe is another widely used equipment which is suitable for multiple purposes.
The name itself telling that the hoe arrangement is provided on the back side of
vehicle while loading bucket is provided in the front. This is well useful for
excavating trenches below the machine level and using front bucket loading,
unloading and lifting of materials can be done.
3. Tower Cranes
Tower cranes are fixed cranes which are used for hoisting purposes in construction
of tall structures. Heavy materials like pre-stressed concrete blocks, steel trusses,
frames etc. can be easily lifted to required height using this type of equipment. They
consist mast which is the vertical supporting tower, Jib which is operating arm of
crane, counter jib which is the other arm carries counter weight on rear side of crane
and an operator cabin from which the crane can be operated.

Figure 54: Tower crane.

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4. Mobile crane
A mobile crane is a cable-controlled crane mounted on crawlers or rubber-tired
carriers or a hydraulic-powered crane with a telescoping boom mounted on truck-
type carriers or as self-propelled models. They are designed to easily transport to a
site and use with different types of load and cargo with little or no setup or assembly.

Figure 55: Mobile crane.

Figure 56: People in site should always aware with the moving machinery.
 CHAPTER 4

SUGGESTIONS AND RECOMMENDATIONS

4.1 Introduction

This chapter is the final chapter in this report. Summary of student reports and activities in
the industry will be discussed in conclusion. Suggestion and recommendations for industry
and university throughout industrial training will also be discussed in this chapter.

4.2 Suggestion and recommendation

Company:
 The company should hire extra workers in order to handle office work.There are
only two person incharged currently for the project documentation task where they
find though to handle so many projects at a time.
 The company should increaase the salary of the employees since most of them
expect more amount of increment in salary.
 The company should always have ‘Family Day’ (e.g) as it would enhance the
relationship between the working staffs.
 The company should also give the internship students the certificate of working in
that company as the token of appreciation and it would be useful for their

University:
 64

 The period of the industrial training ahould be increase so that the students can
learn more things during training session.
 It is better if the indusrial training can be done after finish the last semester so that
the students can take the opputunity if they get the work offer from the company.
 The university should give the internship students a chance for them to finish up
their industrial training earlier so that it would be easier for them to organise
themseleves before entering the university as some students stay further from the
campus.
 65

CONCLUSION

In conclusion, from this internship program I got very useful experience and
knowledge. The task given in the internship program is to introduce students to the
working environment and the requirements in the industry. The tools and knowledge
needed to complete the project is quite advanced and students need to explore more
and not only expecting to learn from the supervisor and the company.

Besides that, in the duration of this training, I have obtained skills and knowledge
that is crucial and useful in the industry such as:
i. Practice and implement the theories and knowledge acquired from classes during
the process of finishing the tasks given in the training
ii. Adapting to working environment, by working in projects and communicating
with team member
iii. Learn new knowledge and skills that cannot be taught in classes
iv. Increase soft skills such as communication skill and time management skill

From this training, students can learn as much as they can to prepare themselves for
the industry. This training is also a platform to improve and polish themselves with
new skills and experience that can be used as added value when searching for jobs in
the future.