DECLARATION

I BENJAMIN, MOSES, declare that this practical work report titled CONSTRUCTION OF
WAREHOUSE BUILDING is my original work and has not been copied from someone or
somewhere else. Whatever compiled is from my technical and practical knowledge through
consulting various literatures, supervisor and other experts in the site during the period of this
semester’s Industrial Training.

…………………..

BENJAMIN, MOSES

10242/T.2017

i
 ACKNOWLEDGEMENT
Foremost, I would like to express my sincere gratitude to The Almighty God for His Divine
intervention throughout my First Year studies and through my site exposure period whilst
conducting my Industrial Training activities thereof.

I also appreciate Kanji Lalji Ltd., Growsun Investments Ltd. and Mbeya City Council for their
invitation and support at the site for learning.

I acknowledge the role of my Supervisor, Eng. Alexandre Mwashinga and his colleagues Eng.
Seif, Technicians Joseph and Thadeo for their advices, directions, guidance and constructive
comments that empowered me in writing this report paper. Along with them, are the site engineers,
contractors, craftsmen, senior technicians as well as other staffs whom unabated efforts built in me
this knowledge I now posses.

Finally, I express my deep gratitude of my multitude thanks to my fellow students, friends and
those who help me in one way or another.

ii
 DEDICATION
This work is dedicated solely to all the people who work tirelessly to aid the improvement and
growth of The Building Industry worldwide regarding the endless risks they put and encounter in
the process.

iii
 ABSTRACT
The report covers the practical studies undergone for the construction and renovation of A
Warehouse-cum-Garage built at Sinde, Ujenzi in Mbeya City. It is through guidance,
questionnaire, surveillance and consultations that practical knowledge was transmitted and
acquired in a quantity enough to write this report covering the construction activities assessed.

Along with the with the Literature assistance provided through books, this report embodies the
entire construction procedure as covered by the IT period. This includes an assessment of the
project’s false-work construction, structural components of the project, masonry work and other
details.

iv
 TABLE OF CONTENTS
CONTENTS PAGES

DECLARATION ............................................................................................................................. i

ACKNOWLEDGEMENT .............................................................................................................. ii

DEDICATION ............................................................................................................................... iii

ABSTRACT ................................................................................................................................... iv

LIST OF TABLES ........................................................................................................................ vii

LIST OF FIGURES ..................................................................................................................... viii

ACRONYMS ................................................................................................................................. ix

CHAPTER ONE ............................................................................................................................. 1

1.0: INDUSTRIAL TRAINING INTRODUCTION .................................................................. 1

1.1: Brief Description and Introduction ...................................................................................... 1
1.2: Methodology ........................................................................................................................ 1
1.3: Construction Approach ........................................................................................................ 2
CHAPTER TWO ............................................................................................................................ 3

2.0: FORMWORKS AND FALSE-WORKS ............................................................................ 3

2.0.1: COLUMNS ....................................................................................................................... 3
2.0.2: BEAMS ............................................................................................................................. 5
2.0.3: SLABS .............................................................................................................................. 7
2.0.4: RAMP AND WALKWAY ............................................................................................... 9
2.1: CONCRETE CASTING .................................................................................................... 10
2.1.1: Structures......................................................................................................................... 11
2.1.2: Removing Formworks and Curing .................................................................................. 15
2.2: WALLING ......................................................................................................................... 15
2.2.1: Masonry Block Walls...................................................................................................... 15
2.2.2: Concrete Monolithic Wall ............................................................................................... 16
2.2.3: Plastering and Skimming ................................................................................................ 19
2.3: STRUCTURAL STEELWORKS ...................................................................................... 21

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 2.3.1: Staircase .......................................................................................................................... 21
2.3.2: Slab and Beams ............................................................................................................... 22
2.4: ROOFING .......................................................................................................................... 23
2.5: BUILDING SERVICES..................................................................................................... 28
CHAPTER THREE ...................................................................................................................... 28

3.1 CONCLUSION ................................................................................................................... 31

3.2 RECOMMENDATION ...................................................................................................... 31

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 LIST OF TABLES
Table 2. 1 Column Reinforcement Types ....................................................................................... 4
Table 2. 2 Beam Reinforcement Types........................................................................................... 7
Table 2. 3 Column Dimensions. ................................................................................................... 12
Table 2. 4 Beam Dimensions ........................................................................................................ 13
Table 2. 5 Slab Dimensions .......................................................................................................... 13
Table 2. 6 Wall Dimensions.......................................................................................................... 16
Table 2. 7 Concrete Wall Reinforcements .................................................................................... 18
Table 2. 8 Staircase Parameters. ................................................................................................... 21
Table 2. 9 Truss Components ....................................................................................................... 24

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 LIST OF FIGURES
Plate 2. 1 Normal and Shear Column Reinforcements ................................................................... 4
Plate 2. 2 Normal and Shear Column formwork............................................................................. 5
Plate 2. 3 Beam formwork .............................................................................................................. 6
Plate 2. 4 Beam Reinforcement ...................................................................................................... 7
Plate 2. 5 Slab formwork ................................................................................................................ 8
Plate 2. 6 Walkway formwork ........................................................................................................ 9
Plate 2. 7 Floor beam and Ramp re-bars ....................................................................................... 10
Plate 2. 8 Concrete Mixer ............................................................................................................. 11
Plate 2. 9 Casted Normal and Shear column................................................................................. 12
Plate 2. 10 Casted beams .............................................................................................................. 13
Plate 2. 11 Casted slab .................................................................................................................. 14
Plate 2. 12 Casted slab .................................................................................................................. 14
Plate 2. 13 Bottom and Top Walls ................................................................................................ 16
Plate 2. 14 Concrete wall formwork ............................................................................................. 17
Plate 2. 15 Concrete wall reinforcements ..................................................................................... 18
Plate 2. 16 Concrete wall .............................................................................................................. 19
Plate 2. 17 Gypsum skim on Cement plaster ................................................................................ 20
Plate 2. 18 Staircase ...................................................................................................................... 22
Plate 2. 19 Slab for Office Workspace.......................................................................................... 23
Plate 2. 20 Roof truss .................................................................................................................... 24
Plate 2. 21 Hoisted Roof Truss. ................................................................................................... 25
Plate 2. 22 Eave Filling re-bars and casted concrete .................................................................... 26
Plate 2. 23 Gutter .......................................................................................................................... 27
Plate 2. 24 Roof cover with lighting panels .................................................................................. 28
Plate 2. 25 Electric Services Installed ........................................................................................... 29
Plate 2. 26 Drainage Pipes ............................................................................................................ 30

viii
 ACRONYMS
CCTV- Close Circuit Television

CEng- Consulting Engineer

KLL – Kanji Lalji Ltd.

GoT- Government of Tanzania

RB – Steel Reinforcement Bars

TPA- Tanzania Port Authority

IT – Industrial Training

OPC – Ordinary Portland Cement

ix
 CHAPTER ONE

1.0: INDUSTRIAL TRAINING INTRODUCTION

1.1: Brief Description and Introduction

The IT period covered a total of 9 effective weeks from 29th of July to the 27th of September 2019.
During this period an average of at least 8 hours of effort were put in daily so as to benefit as much
as possible from the experience within the site.

The site introduced to was located at Sinde, Ujenzi near the Metropolitan region of Mbeya. The
main contractor being Growsun Investments Ltd., with the nominated contractor Kanji Lalji Ltd.
and the structural engineer Chile Services Consulting Engineers and Mbeya City Council –
Department of Building Engineers, were already at work completing the early phases of major
demolitions, substructure and basement construction.

On arrival to the site the main activities after proper briefing from the officials, were to observe,
learn and participate to and from the ongoing construction works.

From these activities I was able to connect and put in practice various theoretical knowledge both
lectured at the University and collected from various literature reviews and works such as books,
pages, articles etc.

Briefly, the activities included construction of formworks, columns, beams, slabs, masonry block
and concrete monolithic walls, roofing, plaster finishing and finally fixing doors and carpentry.

1.2: Methodology
Upon admission to the site area, various methods were used as an approach towards getting the
best out of the IT period.

Experienced Site Engineers were a go to for providing background information on the previous
activities done, and also providing detailed information in situations where advance clarification
was required. Senior Administrative Personnel and Senior Engineers who have rich professional

1
experience were consulted in terms where questions about other activities arose. This included
giving clarification on materials used, architectural drawings interpretation and so forth.

Technicians, craftsmen, civil workers were a rich source of information where practical knowledge
were required. This provided the basis for understanding the tools used in construction, their
methods of working, how to operate them and handling. They were also useful in providing quick
access information and answers during working.

The Methodology approached towards writing this report involves basic procedures such as the
referring of notes taken from the site, recalling from diagrams, figures and plates all of which
originate from the site and the use of reference Building Construction books where required.

1.3: Construction Approach

Generally, the construction methods chosen by the Company were standard methods of
construction using appropriate plant/equipment all of which were used to construct the building
elements in situ.

For other specific elements however, assembly methods were used specifically in cases where the
materials and elements were imported from oversees through the TPA.

The construction entirely was divided into several phases were the covered phases in this report as
explained before include construction of the building formworks and minor demobilization.

2
 CHAPTER TWO

This chapter will focus on the activities carried out throughout the IT period.

2.0: FORMWORKS AND FALSE-WORKS

Forms and false-works are temporary building works that are used to aid the construction of
permanent building elements by providing a base that improves workability, molding and casting
of concrete and provision of support throughout the construction process.

They are usually made of steel or as in this case timber and wood.

2.0.1: COLUMNS
Columns are vertical structural members of a building work such as a building, bridge that are
used to provide necessary support to the loads placed above them by transferring the loads to the
levels beneath them.

a) Reinforcements

All concrete columns were reinforced as required by structural drawing as a means of adding
tensional strength to concrete columns which are already strong in compression.

Steel columns however were not reinforced. In most cases, they were used as reinforcements
themselves in combination with concrete columns for much heavier load bearing.

The mode of construction followed vertical re-bars being fixed first from their extending roots in
the substructure to their apex height, and then fastening them with horizontal steel stirrups for grip
and reinforcement profile fitting.

As described above, whenever steel columns were included in concrete columns as reinforcements
and supports, they were placed at the center of the reinforcement, with their top heads fitted with
a steel base plate on which the above truss would come to rest on.

The types of different reinforcements used for columns are indicated below:

3
 COLUMN TYPE STEEL RE-BAR
Normal Columns Y-20-8
Shear Columns Y-20-10 and Y-12-8
Table 2. 1 Column Reinforcement Types

Plate 2. 1 Normal and Shear Column Reinforcements

b) Formwork

For columns, the formworks were made out of timber and plywood. These by carpentry techniques
were connected by the use of nails so as to form stable and strong shutters that would hold the
concrete being poured into them so as to make columns of variant sizes in shape.

Most concrete columns were constructed after walling and thus the formworking was made easier
as it only involved wrapping 4’x 6’and 4’ x 4’ timber with 12mm marine plywood boards around
the walls on both faces/sides, extending on both sides and fastened to the blockwork by means of
nails. If needed however, more timber supports and levers were used such as in standalone columns
to also ensure checks for straightness and alignment against buckling and slenderness.

4
 Plate 2. 2 Normal and Shear Column formwork

2.0.2: BEAMS
Beams can be defined as structural elements that are capable of withstanding loads by resisting
bending forces that are a result of external loads, own weight, span and external reactions all of
which result into bending moments.

a) Formwork

Beam formworks were also fashioned from 4’x 4’ and 4’x 6’ timber and 10 and/or 12mm marine
plywood boards.

The process was also mostly done after walling thus easing formwork construction as in this
matter, bottom panels and T-Beam supports were unnecessary. Hence, the construction included
fixing side panels to adjacent sides of the wall and firmly fastening them by nails to the blockwork.
The side panels were carefully checked to ensure parallel runs in order to avoid slanting and
irregular breadths. This was archived by timber braces and rope guides as references running from

5
one end of the beam to the other. Further, binding wires and ties were tied around the formworks
so as to restrict expansion and contraction of the formwork.

Plate 2. 3 Beam formwork

b) Reinforcements

Most beam reinforcements were prepared and fixed at GL and then hoisted into already prepared
formworks and correctly laid there into.

The first members of the reinforcements to be placed are the long bottom re-bars that run from one
end of the beam to the other while being intertwined in the middle so as to cover the entire run of
the beam’s lengths throughout the structure. Two long members are placed first with their bent
ends facing upwards. After this, two other similar members were added only these had their ends
facing downwards so as to form some sort of overlapping link when connected to the bottoms
ones.

Both members were then tied at the middle by a use of a binding wire and stirrup rings were
inserted into to the joint of the four steel re-bars. These stirrups were then distributed equally at
100mm intervals across the beam re-bars and then tired to the re-bars both on top at all four points
of contact by the use of binding wires. The procedure was repeated for all the available beams.

6
he following procedure was to add the extra longitudinal bars at the top and the bottom of the pre-
existing lapping re-bars containing stirrups. Finally, to conclude the reinforcements, spacers were
added to the re-bars.

Plate 2. 4 Beam Reinforcement

The steels once placed were then ready for being casted with concrete. Various types of steel re-
bars used in this procedure are as follows:

BEAM TYPE REINFORCEMENT TYPE

Beam 1 Y-16
Beam 2 Y-20
Table 2. 2 Beam Reinforcement Types

2.0.3: SLABS
These are horizontal structural elements with the top and bottom surfaces parallel or near so that
are used to provide a flat surface for particular purposes while either resting on the ground or as
on this case on more than one supports.

7
a) Formwork

Construction of slab formwork is relatively easy. The components are also made up from timber
and marine plywood mostly.

6’ x 4’ timbers were first used to form a nested overlapping structure that spreads out on the area
to be covered by the slab the origin of the timbers being a column or a support on a pre-existing
member. Bottom timbers run parallel to the beam formworks and perpendicular to other timbers
that were nailed above them to form an overlapping formwork. The timbers were then help up by
supports that were placed at the bottom of the timbers with their endings fixed with levers that are
nailed to the floor.

Once an adequate amount of timber was reached and safety and strength through the supports was
ensured then, 12mm marine plywood boards were laid across the timber formworks and then nailed
firmly so as to avoid slipping and loose contacts.

Plate 2. 5 Slab formwork

b) Reinforcements

Slab reinforcements were laid across the slab formwork from one end to the other by linking them
through their bent U loops to the top longitudinal reinforcements in the beams available at both
ends of the structure. In between the middle, the reinforcements were passed under the existing
beam re-bars and tied by the use of binding wires.

8
The same procedure was then repeated in the perpendicular direction of the first laid re-bars so as
to form a netted overlapping re-bar appearance. By the use of a plincer, the overlapping joints were
joined together by the use of binding wires tied tightly in the points of contact.

This same procedure in its wholesome was repeated so as to form bottom and top layers of slab
re-bars. At this instant also, reinforcements were added to beams by joining top beam re-bars to
the top slab reinforcement bars using short U shaped steel reinforcements. In this case also, binding
wires were used to fasten the two components together.

2.0.4: RAMP AND WALKWAY

Ramps are termed after any sloped member in a construction work such as buildings, that is used
to provide safe access between two levels of considerable vertical difference.

Walkways are simply constructed spaces that are used to give comfort on the users of a particular
building or place when going on about from one area to another.

a) Formwork

Formworks for both ramps and walkway are very similar to those of slabs. The only particular
difference is that for ramps and walkways, there are no bottom formworks and thus the number of
supports are relatively kept at minimum – that is, only the battering side panels made of 10mm
thick marine boards and 4’ x 4’ timber panels for bracing and supports by the sides.

Plate 2. 6 Walkway formwork

9
b) Reinforcements

Re-bars for both ramp and walkway, together with one for a floor beam were all fixed at site.
The walkway reinforcement was made from a light steel precast mesh of 12mm thickness. The
mesh was simply cut to profile and then spread over as a bay on the ground on top of several
concrete covers. The ramp re-bar was laid horizontally flat to the SL, and other re-bars were laid
perpendicular on top of it so as to create 200mm sq. overlapping boxes and firmly fixed with
binding wires. The ends to these re-bars were fixed onto the floor beam.

The floor beam itself was fixed as any normal beam and interconnecting it with both the
walkway and ramp reinforcements.

Plate 2. 7 Floor beam and Ramp re-bars

2.1: CONCRETE CASTING

The concrete that was used in the casting of various building members in the construction of this
particular building was a Tembo Supaset Portland Pozzolana Cement, fine and coarse aggregate
mixture at a 1:1,5:3 ratio forming a Grade 30 mixture of concrete which its quality and strength is

10
sufficient for most construction works. When required chippings were also mixed into the
concrete.

Plate 2. 8 Concrete Mixer

2.1.1: Structures
a) Columns

Casting of concrete into the column formwork was done by using a pump or traditional pans in
fair areas. First, the shutters were oiled in the inner surface to avoid adhesion between the concrete
and the marine plywood boards. A light putty mixture was also poured into the formwork prior
casting for the same purposes. Next, a concrete cover was immersed into the formwork to hide the
appearance of protruding re-bars.

Simultaneous to casting, a poker vibrator was immersed into the formwork so as to work the
concrete by avoid the separation of water from the concrete mixture and assuring the firm
mechanical packing of concrete to the re-bars and throughout the allocated column space.

11
 Plate 2. 9 Casted Normal and Shear column

Once the column formwork was filled with concrete to the desired level, then the pump and poker
were removed and the concrete left to dry. During this period, the column shutter formwork was
left to keep the concrete in place.

The same procedure was repeated for various columns whose sizes varied as follows:

COLUMN TYPE COLUMN DIMENSIONS [MM]

Normal Column 300 X 300
Shear Columns 1150 X 300
Table 2. 3 Column Dimensions.

b) Beams and Slab

Casting of concrete into the Beam and Slab formworks were done simultaneously. But as protocol,
the surfaces to be casted upon were well cleaned and oiled so as to be free of dirt and impurities
and to also reduce the sticking effect of concrete to the formwork. Then after, concrete cover blocks
were placed at various points throughout the surface to be casted with concrete including the beams
also.

The pump was used again in this case. For this scenario, the beams were casted first. Once the
pump was loaded with concrete, the hose was directed towards the beam formwork where concrete
was poured until its level reached the brim of the formwork i.e. the level of the adjacent slab. At
this instant, a poker vibrator was used to distribute the concrete into the beams and also to improve
12
the workability of the concrete by restricting the separation of water from the mixture so as to keep
the concrete at a state of original strength.

This same procedure was repeated for the slab. Here more importantly, the concrete was poured
from one end towards the other. Areas where concrete was already poured were then roughly level
by the use of long wooden rods of timber. As the activity continued, more even levels were
archived by using trowels and a Bump Cutter that removes air bubbles forming up in the concrete.

Once all the re-bars were covered with concrete and the whole structure was casted, the concrete
was left to harden over time as it awaited curing.

The dimensions of the casted beams and slabs were as follows:

BEAM TYPE DIMENSIONS [MM]

Beam 1 260 X 300 X 16000
Beam 2 260 X 300 X 32000
Beam 3 150 X 300 X 3000
Beam 4 150 X 300 X 2800
Table 2. 4 Beam Dimensions

SLAB TYPE DIMENSIONS [M]

Slab 1 7.50 X 3.00
Table 2. 5 Slab Dimensions

The casted beams and slab ares hown in the illustration below:

Plate 2. 10 Casted beams

13
 Plate 2. 11 Casted slab

c) Ramp and Walkway

The casting of both ramp and walkway match exactly the same as that of slabs.

The most significant factor here is the slept kept when casting the ramp. According to standards,
for effective comfortable ramps, the slope is desired to be at 1/10 (h/l) so as avoid harshness, slips
and elongated spans. Thus, the concrete on ramps was casted first at level zones and then from the
highest level towards the lowest that is at the SL

Plate 2. 12 Casted slab

14
2.1.2: Removing Formworks and Curing
Once the casting of concrete was done, and the members had remained undisturbed for some time,
then the formworks could be removed. This procedure started with various columns during the
construction of beams and slab formworks and now it was extended to beams and slabs. Ramp and
walkway formworks were remove much earlier.

An estimated time of 2 weeks passed until all the formworks were removed by the use of tools
such as crowbars, hammers, chisels etc.

For the curing procedure, an adequate amount of water was poured to the concrete works that were
covered in sisal cloths and wraps to avoid quick loss of water. The curing period was at a minimum
of three weeks at a rate of three times per day and once in winter and moist days. This was done
to ensure maximum concrete strength was archived.

2.2: WALLING
Walling is simply the action of construction of a structure that defines an exact area providing
shelter and safety and acting as a support for loads above it or as an element that defines partition
in a building, this structure being known as a wall.

In this case of practical study, the type of walls focused upon were partition and external walls, all
of which are made from masonry concrete blocks.

2.2.1: Masonry Block Walls

These types of walls were used for internal partitioning walls and external walls. They involved
basic steps which were setting out and laying of courses.

a) Setting Out

This compulsory step involved the use of a tape to make out distances from pre-existing known
control points so as to map out the wall to be built.

Once the parameters were set out for the perimeter of the wall, the base to which the wall was to
be built was made wet by moistening it with water – so as to avoid adhesion of water by the mortar,
15
and then a thick paste of cement-sand mortar at a 1:3 ratio was applied to the floor. This followed
with laying of the base course of blocks following the same set out parameters.

More mortar was added on top of this course and then another course was placed in a simple
Stretcher bond. This course was checked for alignment using a plumb bob and a spirit level and
once satisfied, another mortar paste of 10mm thickness was placed above it. This procedure was
repeated for each course until the whole wall was completed.

The dimensions of the wall elements were such that:

WALL ELEMENT DIMENSIONS[mm]

a) Bottom/First Story Walls 260 X 150 X 450
b)Top Story Wall 150 X 260 X 450
Mortar 10
Table 2. 6 Wall Dimensions.

Plate 2. 13 Bottom and Top Walls

2.2.2: Concrete Monolithic Wall

This type of wall was made entirely out of concrete for more additional strength in the structure.

a) Formwork

4’ X 6’ and 4’ X 4’ timber parts, 12mm thick marine plywood boards and wooden levers and
supports were used as formworks for a concrete monolithic wall.

16
Marine boards were the first surface face of the formwork with timber bracings nailed to the back
of it at regular intervals to ensure strength in both axes. To these were hoisted diagonally wooden
levers that were responsible for keeping the formwork upright and intact both structurally i.e. for
checks such as straightness by spirit levels, and formwork strength i.e. for terms of casting in the
near future. They were nailed to the horizontal timbers up top and fastened to the ground below
with bracings in the middle.

Plate 2. 14 Concrete wall formwork

b) Reinforcements

Heavy rei-bars were used on this wall as it served two main purposes; to support a steels floor
above it and to act as a return wall capable of providing soundproof between a noisy and quite
zones.

Foremost, there were 100mm diameter hollow steel columns, aligned and fixed at intervals
throughout the spread of the wall. To these columns were welded 16mm and 12mm vertical and
horizontal re-bars respectively, to form squares of 300 x 120 sq. mm after joining them.

A floor beam reinforcement was provided at the bottom of these combined re-bars to aid the wall
against shear and support it on the floor beneath.

17
 REINFORCEMENT DIMENSIONS[MM]
Circular Hollow Steel Columns 100 int. diameter
Floor Beam Y-20-10
Vertical Bars Y-16
Horizontal Bars Y-12
Table 2. 7 Concrete Wall Reinforcements

Plate 2. 15 Concrete wall reinforcements

c) Casting

The formwork was casted with concrete by the used of local equipment such as wheelbarrows,
pans and buckets. For strength and quality requirements, a 1:1:3 concrete of chippings as coarse
aggregates was used in this procedure so as to ensure the construction of a wall of high quality.
Simultaneously, a poker vibrator was used so as keep the concrete at a good rate of mixture during
casting.

After two days, the formwork was removed leaving the wall well completed and ready of further
processing. This period after, the wall was cured daily for several days by the use of a water hose
so as to attain suitable maximum strength.
18
 Plate 2. 16 Concrete wall

2.2.3: Plastering and Skimming

Plastering is the use of tools to apply a lean mortar composed of binding materials such as lime or
cement with fillers such as sand and crashed stones to surfaces such as walls for protection and
decoration.

Skimming is similar to plastering, only that it is applied as a final coat of the plaster and can
function as the undercoat to the finishing coat of materials such as paints.

a) Setting Out

On plastering, setting out is done first by fixing/applying patches of plaster mortar as levels on key
points of the wall surface. These help to determine the amount and level of plaster to be applied
throughout the wall. The first level was applied at the very far left top corner of the wall by using
a trowel and a putty knife and then a plumb bob was hung from the center of the mold towards the
bottom. Another was put at the far right corner. The two were then joined by a straight rope to test
if they were on the same levels.

The procedure then moved on to the bottom of the walls where two similar levels were applied
and at each instance they were tested for alignment with the top ones using a long timber rod to
19
connect them to the top ones. In instances where the span of the wall was too long and extended,
then a third level was fixed at the middle in between the two levels at the far ends of the walls and
then set out by the same procedures as the previous.

b) Coating

After setting out, the plaster was applied in three homogeneous coats. The first and second coats
were a 1:3 cement mortar that was thick to about 12mm. This second coat was applied roughly by
the use of a putty knife then the surface was left uneven. In some instances, dry sand particles were
blown on the coated surface to increase integration and adhesion between the plaster mortar. A
timber rod was then run roughly across the surface of the plaster.

The final coat was of 3mm. A putty knife and a trowel were used to smoothen the texture and
surface of the plaster so as to get an appealing finish and an even surface throughout. The plaster
was then left to dry far from disturbance and dirt.

Once dried and archived significant strength, skimming followed. An A-100 Finishing Coat
Gypsum Plaster (for internal), and an Eco CIMSA White Portland Limestone Cement (for
external) were the material used where by as powders, they were mixed into clean water and
worked until the desired form of viscosity was reached. The paste was then applied as a very thin
layer to the plaster by the use of squeegee and taping knives.

Plate 2. 17 Gypsum skim on Cement plaster

20
2.3: STRUCTURAL STEELWORKS
These confine all works in construction whose primary members are fashioned out of graded steel
that is used in various aspects i.e. as components, standalone members, structures and elements,
provided that the steel is adequate and determinant for structural use.

2.3.1: Staircase
A staircase was employed into the design so as to connect two vertical floor levels 3 meters apart
in terms of providing access and passage for the users whom were in this case the
overseers/administrative officers of the building.

Structural steel was used to forge all the components of staircase as detailed below:

ELEMENT DIMENSIONS (MM)

Stringers and Kerb H-Beam (100 x 200 x 5000)
Riser 200
Going 300
Flight Width 1200
Flight Span 5000
Railing 50mm internal diameter
Table 2. 8 Staircase Parameters.

The mode of construction involved fixing the H-Beam stringers to the adjacent wall first, then to
it welding flat steel plates which were cut to profile as treads firmly in only one primary weld.
Another stinger was added to the far end and the ready weld treads were weld to it. Secondary
weld and sharpening was done thereafter. Risers were later added in a similar fashion.

The stringers were fixed by firm steel rivers at the bottom to the concrete bed to avoid collateral
slipping, and by fixing at the top by connecting it to steel beams by hardworking with hammers
and welding.

The railing, which was of 50mm internal diameter steel was welded on the staircase so as it rested
on the top of the stringers. The vertical members were welded first then followed by the connecting
horizontal members all which shared the same dimensions.

21
 Plate 2. 18 Staircase

All members were Zinc coated prior fixing during preparatory works.

2.3.2: Slab and Beams

These served the purpose of providing the building with an office onto which the administrative
personnel on the building could oversee all activities carried out within the warehouse and still
have a real estate to accommodate himself and perform other duties.

Both being prefabricated elements, they were simply brought into the site and fixed in their
respective positions.

Here, the I-Beams were laid first to span 3600 meters across the office space from one end to the
other. At one end, they were fixed in between a masonry wall that pre-existed and at the other, a
RC Beam was casted connecting all the beams and 100mm diameter steel columns which as
previously stated were used as supports for this particular floor and as concrete wall reinforcement
also.

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On top of these, were laid slab bays of 1.2 x 2.4 m and then welded at the bottom to the beams in
3-inch weld joints for firm grip and circumvention of hollow spaces beneath the slab which would
cause massive comfortability and structural issues to the users i.e. bouncing, slipping etc. laid in
two numbers so as to cover the whole span, these bays were fixed center to center on top of the I-
Beams throughout as indicated in the pictures below:

Plate 2. 19 Slab for Office Workspace

2.4: ROOFING
A roof is a structure forming the upper covering of a building that has the primary function of
protecting elements and also acts as a shelter for security, protection, privacy and insulation. In
conditions, roofs have been found a suitable method of ventilation for the said structure.

Roofing involves the complete setup in ensuring and securing a roof onto a building for their
particular purposes. The procedure is carried out in two component categories as detailed below.

a) Truss

The truss is the component that makes up and hold up the roof together in unison as a whole unit.
Hence, its construction was done first under very cautious environment to avoid truss failure which
has hazardous effects in the near future.
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The material used for the truss was structural steel whose dimensions can be detailed below:

TRUSS COMPONENT STEEL SECTION DIMENSIONS [INCHES]

Purlins Z 5 and 6
Rafter Circular Hollow 2
Tie and Strutting Beam Circular Hollow 4 and 3
Underpurlin Supports Circular Hollow 1
Struts and Web Bracings Circular Hollow 2
Table 2. 9 Truss Components

Truss construction was by assembling the truss members at GL on site and then hoisted onto the
building. The tie beams were first laid, then followed by the rafters which were welded at the
apex according to the truss layout profile. In between these two were the struts and bracings
which were also welded so as to connect both the rafters at the top to the tie beams at the bottom
in that specific order. This was the primary welding.

The secondary welding was done further later on to ensure firm grip and a more rigid truss by
associating the weld with other operations such as sharpening of joints and working with steel
manipulating hammers.

Plate 2. 20 Roof truss

Them trusses were then painted in two coats: 1st coat of Red Oxide for rust protection and 2nd coat
of High Gloss Enamel pain in Ascot Gray color.

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Once done, the trusses were then hoisted top of the building by using a Crane Mechanical Plant.
The truss was meant to rest on top of the steel column head caps that were integrated into the
reinforcement of the RC columns. Further, the presence of a RC beam, ensured that the loads on
the truss were evenly carried and distributed to the substructure. Welding methods were used to
fasten the truss into its place.

Various checks and adjustments were done to ensure the truss was well fixed. These included
alignment test which checked for equal truss spacing – when needed, plants were used to push or
pull to favored positions. In these positions, 30mm bottom supports were welded thought the truss
to restrict further movement.

Purlins were then welded on top of the truss rafters by first using ropes as guideline references
from the far end of the building over all trusses to the other end. For strong positions, L-Angle
cleats were also welded to connect the purlins and rafters.

Supports for purlins were also used as alignments to ensure equivalent purlin spacing by
perpendicularly connecting all the purlins in one reach at certain intervals.

Plate 2. 21 Hoisted Roof Truss.

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b) Eave Filling

Filling the voids and spaces formed in between the purlins and filling on the ridge cap were
unusually done by the use of reinforced concrete as per client request.

The method of construction therefore, from reinforcements, formworks and casting were done as
exactly as beams as explained earlier.

Plate 2. 22 Eave Filling re-bars and casted concrete

c) Gutter Construction

The gutter, made of steel was welded at one end of building’s rear elevation alongside the
endpoints of the end purlin. Securing the gutter was done by fixing it with cleats to the bottom
flange of the Z-Section purlin in regular intervals which maximized rigidity and also set the gutter
in a position where it would collect water easily.

The 200 mm average width of the gutters profile ensured maximum collection of rain water which
was then collected to drainage pipes and rainwater shoes at the GL.

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 Plate 2. 23 Gutter

d) Roof Cover

To finish off roof construction, an Industrial Trough 28 Graded covering material was used for
this purpose due to its strength advantages. Painted on both sides, the roof sheets measuring 13000
x 850 mm were brought to site from the industry and fixed onto the long span of the roof truss
extending towards the rear of the building. To cover the whole span, two of these were stacked up
vertically. The same was done to the front of the building with roof sheets of 2500 x 850 and 1500
x 850 mm laid also back to back.

Electrical drilling machines were used to fasten these sheets to the top flanges of the purlins
beneath them with 3½ or 4 inch bolts for 5 inch and 6 inch purlins respectively. In back to back
situations, an overlap of 150mm was done so as to fasten the sheets together.

2ft. ridge caps were also fixed at the apex of the roof. In general, the overhang of the roof cover
was 150mm on the fronts and back measured from the truss eave, and in the roofs long span above
the warehouse space were allowances for roof sheets with light transmitting panels.

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 Plate 2. 24 Roof cover with lighting panels

2.5: BUILDING SERVICES

To the building were added various services whose purpose is to aid the comfortable use of
warehouse to the users and provide them assist whilst they perform various functions in their
respective areas.

The two particular services that were employed during construction were:

2.5.1: Electrical Services

These involved the installation of conduits, switches, sockets and the likes to various areas so as
to be used in electrical dependent equipment within the building.

Preparation of such service installation included chipping off block walls for conduits paths which
was done by the use of hammers, chisels and grinders. The depth cut was up to 2 inches for UPVC
conduits, 700 mm above GL and 3 inches for normal sockets and switches, while the electric mains
required more space allowance. The lengths of the conduits and such were all determined by
electrical drawings supplied by the sub-contracting engineer.

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 Plate 2. 25 Electric Services Installed

Finally, the electric services were covered up with respective materials for both safety and
aesthetics.

2.5.2: Drainage Services

All drainage systems were performed with class B drainage pipes of varying sizes. Their functions
were to collect and transport drainage waste from the latrines to a soak away pit located off site.

Thus, the channels for the installation of these pipes were prepared by drilling off the concrete bed
and the block wall first to 160 x 180 mm and 80 mm depths respectively for the high mass waste
and water waste from urinals and basins. The pipes used in these fittings were 4’ pipes and 1¼’
pipes with all respective accessories such as elbow joints, reducing pipe condenser joints etc.

In connection of several pipes, UPVC Cement glue was found useful. The first pipes to be installed
were the high mass pipes from the Asian toilet sinks, which were laid on top of crash dust for
protection and then pipes from urinals and basins were brought to discharge into these pipes
through reducing joints as illustrated below.

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 Plate 2. 26 Drainage Pipes

The mild slope created between the main pipe and its resting bed was just enough to ensuring safe
deposition of all wastes away from the building with ease.

The excavations were then covered with concrete made up of crash dust, chippings and cement.

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 CHAPTER THREE
This final chapter will shed light on the experience as a whole exposed from the IT period.

3.1 CONCLUSION
As the function stands, the IT period was a massive source of education and knowledge that cannot
be directly imposed from theory lecturers and seminars. This is from the exposure on the conditions
on the site itself, the use of tools, equipment, the close assistance from experienced consultants
and workmen and other factors that feed the brain with enriched construction knowledge.

Despite the challenges and problems faced such as the presence of language barrier where most
works, tools and instructions are admitted in the local language, the prior lack of practical
knowledge on handling of tools and even junior experience in running plants and understanding
their mechanism, the lack of safety guidelines which surprisingly is not taught in lectures, but yet
all these can be countered for the better in order to archive the acquired goals as no path is ever
easy.

3.2 RECOMMENDATION
The necessity of IT cannot be stressed enough. As a practical field of study, the lack of practice
beyond doubt raises an alert on the extent to which the theoretical knowledge can be applied in the
field despite the working criteria. In this essence, it is of very high importance that the IT period
be one that shouldn’t be taken lightly since it gives aid on understanding the field of expertise.
With this in mind, it would be a good recommendation that the producers of theoretical knowledge
say, The University, provide guide and close assistance in these times of high importance.

The use of tools can be difficult to archive per each person per se, but at least the preliminary
exposure to construction sites and the visual acknowledgement of various procedures, equipment
and plants can be in order to favor both the receiver of the knowledge and the provider in order to
help build the whole society as expert construction workers in general.

Further assistance - not that what is done is less but, can be provided to students when selecting
the companies to conduct their IT periods in. These should be ones that are qualified and trusted
to have experienced Consulting Engineers (CEng.) who can provide reliable information to the
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scholars and assessments that build their knowledge and characters. Companies with poor utilities
and mediocre approaches in handling their matters should be avoided as much as possible since
they source the corruption of knowledge.

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