General Sir John Kotelawala Defence University, Sri Lanka

Faculty of Engineering

Department of Civil Engineering

Field visit report to new auditorium

project in KDU

Student Name : D.M.T. Dissanayake

Service/Index Number : D/ENG/20/0014/CE
Instructed by : Dr. Thanuja Kulathunga
Stream/Intake : CE/Intake 37
Module Code/ Name : CE 2011 Industrial Visits and Report Writing
Date of submission : 20/08/2021
Table of Contents

Table of Contents
Table of Contents .......................................................................................................................ii
List of Figures .......................................................................................................................... iii
Acknowledgement .................................................................................................................... iv
1 Introduction ........................................................................................................................ 1
2 Industrial Process ............................................................................................................... 2
2.1 Bar schedule, bar bending and bar cutting .................................................................. 2
2.2 Reinforcement and formwork ..................................................................................... 3
2.2.1 Column Reinforcement ........................................................................................ 3
2.2.2 Beam Reinforcement ........................................................................................... 3
2.2.3 Slab Reinforcement .............................................................................................. 4
2.3 Chemical Anchoring ................................................................................................... 5
2.4 Store Management....................................................................................................... 5
2.5 Curing .......................................................................................................................... 6
3 Observation ........................................................................................................................ 7
4 New Knowledge Gained .................................................................................................... 8
5 Conclusion ......................................................................................................................... 9
6 References ........................................................................................................................... 10

ii
List of Figures
Figure 1-1-New KDU Auditorium……………………………………………………………..1

Figure 2-1-Bar Bending Machine……………………………………………………………...2

Figure 2-2-Bar Cutting Machine……………………………………………………………….3

Figure 2-3-Lapping and Cracking Detail………………………………………………………4

Figure 2-4-Slab Formwork…………………………………………………………………….4

Figure 2-5-Chemical Anchoring……………………………………………………………….5

Figure 2-6-Curing Tank………………………………………………………………………..6

iii
Acknowledgement
I would like to acknowledge with much appreciation to Dr. Thanuja Kulathunga, head of the
Civil Engineering department who made our visit a success. Also, I would like to thank our
instructors who were supporting us during the industrial visit.

When conducting the industrial visit to the KDU auditorium site we received tremendous help
from the tri-forces project coordinators. It is with great pleasure that we, Civil Engineering
batch of intake 37 would like to convey our most sincere and greatest gratitude to all personnel
that helped us during this COVID-19 pandemic.

In addition to that I would like to thank each and every person who helped us in every single
way.

D.M.T. Dissanayake

20.08.2021

iv
1 Introduction
On 4th of August 2021, we participated for an industrial visit in KDU auditorium. The field
visit was arranged by Dr. Thanuja Kulathunga, the head of the civil engineering
department, and with the accompanied by Eng. C.K. Ganewatte. The main aim of this
industrial visit is to give us knowledge on practical aspects as well as theoretical aspects
behind an actual ongoing project. We were divided into two groups. Instructors were
appointed to every group to show us the necessary areas inside the construction site. First,
we were given a brief introduction about the ongoing project by the army officer who was
in charge of the whole project. We had observed different construction works within the
site and instructions were given by the engineer in charge.

The new KDU Auditorium construction site is located in front of the parade ground of
General Sir John Kotelawala Defence University, Ratmalana. The project was commenced
in September 2010 and the constructions had been continued until 2017. After 2017 the
ongoing constructions were stopped for three years. Then the construction activities were
recommenced on 11th March 2020.

Main consultant of the ongoing project is Central Engineering Consultancy Bureau

(CECB). Sri Lanka Army is the contractor of the project. The construction of the new
auditorium will be completed by 2022. The new auditorium has State of the art facilities
and has a seating capacity of 1410 seats.

Figure 1:1 New KDU Auditorium

1
2 Industrial Process
In the construction site several industrial processes were observed and some of the industrial
processes were ongoing activities. Those industrial processes are listed below.

▪ Bar schedule, bar bending and bar cutting

▪ Reinforcement and formwork
▪ Chemical Anchoring
▪ Store Management
▪ Curing

2.1 Bar schedule, bar bending and bar cutting

First, we had visited to the place where bar bending and bar cutting happen. It was a steel yard
within the site for storing, cutting, and bending of bars. Reinforcement bars are taken required
lengths and bent into required shapes either manually or by means of machinery.

There were various bars differ from the diameter 25mm,30mm and 40mm were some of them.
Raw bars have to be cut and bend according to the required sizes in the bar bending yard.
There’s a document called shape code which describes the shapes, lengths, and other required
measurements.

In manual operations, labourers used the bar bending bench on which strong nails are fixed and
GI pipes with suitable lengths to bend the bars. That is used for smaller diameter bars. For
bending of larger diameter bars, bar bending machine is used. After bending all reinforcement
bars were bundled and clearly numbered consistent with the bar mark in order that steel fixers
won't face any difficulty when fixing them.

Figure 2:1: Bar Bending Machine

2
 Figure 2:2 Bar Cutting Machine

2.2 Reinforcement and formwork

2.2.1 Column Reinforcement

Next we had observed the column reinforcement. Army officer who was in charge of the area,
given clear description about the column reinforcement. The column reinforcement bars should
be stared from the Footing. The upper column reinforcement bars are cranked at the laps and
connected. Special care should be taken during this to make sure the lap lengths. After erection
of main reinforcements, cover blocks were attached to column reinforcements to take care
of the desired protect column reinforcement. Most of Columns centers were located at
intersections of grid lines.

2.2.2 Beam Reinforcement

Then we had observed beam reinforcement. Beam is a horizontal structural member resting on
two or more supports. It is used to transfer the load to the columns. Beam reinforcements are
arranged after the construction of beam and slab formwork. The procedure for the arrangement
of beam reinforcement as follows. First top most reinforcement bars are hung over the beam
formwork then the stirrups are placed and bound at correct positions. Thereafter the bottom
reinforcement bars are placed and bound to the stirrups. Then the remainder of the
reinforcement bars and tension bars are inserted into the cage in step with structural drawings.
Then cover blocks are fixed to bottom and side reinforcements before placing the concrete.

Top reinforcement of the beam shall be lapped at the middle of the span of between two
supports. Bottom reinforcement of the beam shall be lapped at the end of the span of the two
supports. Considering the region where the maximum bending movement is existing.

3
Lapping is did the place which the tension is didn’t act. Normally 2/3 of the length is choosing
for lapping. When lapping top & bottom re-bar, it is better to follow the following method.
Otherwise, it might cause to reduce the concrete covering thickness of the topmost & bottom
most slab reinforcement.

Figure 2:3 Lapping and Cracking Detail

2.2.3 Slab Reinforcement

At the 4th floor of the auditorium, there were slab reinforcement. Reinforcement detailing of a
slab is done based on its support conditions. Slab may be supported on walls or beams or
columns. Slabs could be simply supported, continuous or cantilever. We had observed that
there was a cantilever slab reinforcement. Cantilever slabs are common features in auditoriums
due to need larger spaces.

Figure 2:4 Slab Formwork

4
2.3 Chemical Anchoring

Then we had observed the chemical anchoring process. Our incharge engineer explained the
how process is going on. Chemical anchoring is a technique for fastening to concrete and
similar substrates that provides more flexibility than mechanical anchoring. In here, a resin is
injected into the hole prior to insertion of the stud. With this, the chemical naturally fills in all
irregularities and therefore makes the hole airtight and water proof, with 100% adhesion.

Figure 2:5 Chemical Anchoring

2.4 Store Management

Store Management is a vital aspect during a construction site. Material requirement should be
calculated and therefore the orders should be placed before so material is quickly available
when work begins. the positioning stores during this site mainly manage receiving, issuing and
storing of material and the maintenance of plant & equipments.

Characteristics of well-managed store;

• Availability of materials whenever required

• A properly maintained recording system facilitating the preparation of usage

reports, regular stock counts, monitoring the inward and outward movements.

• Material should be stored in such a manner that they are easily accessible.

The documents maintained in the store ;

• Goods Received Note (GRN)

• Gate Pass

• Material Requisition Note (MRN)

• Purchase Order / Request Order

5
2.5 Curing

Curing is finished by 3,7,28 and 56 days. Concrete cube and cylinder specimens being
cured within the curing tanks. This device provides for maintaining a continuing temperature
and limiting moisture loss from the specimen. Different sorts of steel, like galvanized
and stainless-steel, swell as different dimensions, are available.

Figure 2:6 Curing Tank

6
3 Observation
▪ Bar bending
▪ Bar cutting
▪ Reinforcements
▪ Formwork
▪ Chemical anchoring
▪ Curing
▪ Store management
▪ Fire precautions
▪ Stage.
▪ Balcony.
▪ Lowered area for the instrumental band under the stage.
▪ Angular roof structure.
▪ Curing tank.
▪ Scaffolding structure.
▪ Clamps.

7
4 New Knowledge Gained
● We learnt how the bars are cut and bended into required size with the bar schedule
and the shape code.

● We learnt how the reinforcement done and the method of binding the bars using bar
tying tool.

● We gained new knowledge about how a cement production plant works and its
mechanism.

• Gained knowledge about chemicals used for chemical anchoring process.

• We learnt how to test concrete cube compressive strength and the importance of a
curing tank.

• We learnt about safety precautions to be taken at construction site.

8
5 Conclusion
The field visit to the KDU auditorium site is a great opportunity to understanding the processes
happen on construction sites. The experience that we have gained from the constrction site
helps us to improve our civil engineering career. We had identified the severe problems that
could face in the future and learnt how to solve those problems. We got information about new
techniques and latest materials used in construction. Finally, I would like to tell this feld visit
was very effective and gained practical knowledge not limited to theory about the construction
works.

9
6 References
▪ KDU. (n.d.). Re Launching Construction of KDU Auditorium. [online] Available at:
https://www.kdu.ac.lk/re-launching-construction-of-kdu-auditorium/ [Accessed 14 Aug.
2021]

▪ Structural Systems Repair Group. (n.d.). Building Reinforcement & Strengthening.

[online] Available at: https://ssrg.com/what-we-do/reinforcing-strengthening.

10