Industrial Training Report

APPROVAL

This is to certify that KIWANUKA AUGUSTINEa student of Makerere University pursuing a

BSc Degree in Construction Management has successfully completed his industrial training with
Kwik Build Contractors & Engineering limited and Archtech Consults (U) LTD.

ACADEMIC SUPERVISOR FIELD SUPERVISOR

.….………………………..... ………………………………

MR.MWANJE NASSIR ENG. TENYWA SAMUEL

DATE ……. / …… / ………. DATE ……. / …… / ……….

FIELD SUPERVISOR

………………………..

Architect Consults (U) LTD

DATE ……. / …… / ……….

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DECLARATION

I KIWANUKA AUGUSTINE declare that the content contained in this report is entirely the
outcome of my own research and findings and therefore has never been submitted to any
institution for any academic award

Signature…………………………… Date…………………………………….

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DEDICATION

With great happiness, i dedicate this report to my Mum Kizito Stellah who always gives me the
courage and any additional costs throughout my entire training period, my dad Mr. Kawooya
Gabriel and my brothers and sisters for all the support during my academic progress. May the
almighty GOD grant you peace and live for a long period of time

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ACKNOWLEDEGEMENT

Thanks to my God almighty who wishes me to do all and gives me the life I have.

Am also grateful to the following people and organizations that helped me during this period in
terms of assistance, technical guidance and facilitation;

 Field attachment supervisor Mr. Mwanje Nassir for their great contribution towards this
industrial training being a success.
 My lecturers for equipping me with the required knowledge
 Kwik Build Contractors for allowing me train under it.
 Eng. Tenywa Samuel and Ayo Alex, for being a very helpful and co-operating training
officer.
 My mum, Miss Kizito Stellah for her tireless efforts and encouragement throughout all
times during this period.
 I appreciate my friends and course mates with whom we shared ideas and
encouragements.
 Last but not least for the entire management and staff of Architect consults t for their kind
support during my stay for the training.

CHAPTER ONE:

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INTRODUCTION
BACKGROUND OF INDUSTRIAL TRAINING
This report concerns industrial training/internship which commenced from 4 th June to 5th August,
14, training with Kwik Build Contractors & Engineering limited and Archtech Consults (U) LTD
as the project managers.

The project is Refurbishment of the Cassava Regional Centre of Excellence Office Block located
at National Crops Resource Research Institute Namulonge ,Wakiso District

The contractor is Kwik Build Contractors & Engineering limited which is a private company and
some of its previous projects include construction of United Nations Regional Service Center
Office block in Entebbe

The Architect, project manager and consultant is Archtech Consults (U) LTD and some of
previous project they have worked on include the construction of Nutritional laboratories in
Namulonge

The client Ministry of Agriculture Animal Industry and Fisheries represented by National
Agricultural Research Organisation (NARO) and it was worth 6.5Bn (UG shillings).The site is
located National Crops Resource Research Institute in Namulonge Wakiso District on Gayaza-
Zirobwe road 8km from Gayaza town

Organizational structure of Kwik BuildContractors

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The organization structure of the Kwik Build Contractors is summarized in the chat below

Project Manager&

Contractor Representative

Site M&E Resident Engineer Site Safety

Surveyor Engineer Administration Officer

Supervisor

Craft Supervisor

Steel fixers& Electrician, HVAC concreting Brick Carpenters Plasters &

Bending Sanitation Operatives layers masons

The Site layout

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This is the organisation of the different facilities on the site. The different facilities include
toilets, site offices, gates, kitchen, shed for carpentry works. Below is the illustration;

Block molding machine Local materials sand aggregates Toilets

Meeting General
Concrete blocks
office store Concrete mixer
curing

Cement store

Resident Admin
Engineer Office

Proposed building Walkways

Materials driveway
Excavator

Tree Tree

Proposed Building

Kitchen Workers shade

First Aid

Visitors/Staff parking

Security house Sick bay Steel workshop

Gate Access road

Abstract

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The project involved the construction of the Cassava Regional Centre of Excellence Office
Block atNamulonge, Wakiso District.
The construction includes the ground floor level, first floor level etc. Accessibility to the
different floor levels is enhanced by stairs.
The building consists of offices, conference rooms, cafeteria, recreation rooms parking lot and
library.
To ensure safety at the site, putting on gum boots and helmets was emphasized and also for
security purposes, two security officers each at the different gates of the site existed.
Various activities took place at the site which includes carpentry, bar bending, bar cutting,

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Internship Training

Internship is a form of practical experience offered to students in order to enhance the theoretical
part of their particular lines of profession in different professional firms or organizations. The
student gets experience, practical work and can be able to learn, appreciate, and cope with the
differences and challenges that occur out there in the field other than the lecture room.

OBJECTIVES OF THE TRAINING

 To enable students to relate, supplement, enhance knowledge got from lecturers and
personal or individual research from textbooks with practical touch or experience from
the site. Students get to know methods of construction and consulting site engineers,
foremen and other members of construction team.
 To enable students gets hands on/real life experience they are expected to work in when
they are graduates.
 To provide an opportunity for students to apply the principles and techniques
theoretically learnt into real life problem solving situations.
 To provide an opportunity for students and academic staff to interact with the
stakeholders and potential employers and thus appreciated situations that will also
generate information for curriculum review and improvement
 To develop student understand of work ethics, employment demands, responsibilities and
opportunities

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CHAPTER TWO

Activities carried out:

PAD FOUNDATION EXCAVATION

The over burden (top soil) is first cleared mechanically about 100mm deep from ground level
manually by shovel.

This was then followed by ground leveling by which cut and fill was done in accordance with the
specified levels in the drawings from the datum. After a relatively horizontal surface of the site
was obtained then pad foundation excavation was done manually to a considerable depth from
which surface trimming and side shaping was also done manually.

The formation level compacted mechanically by a jumper, wooden concrete gauges (50mm)
prepared on the formation level, pesticide sprayed on the formation level, it is then ready for
weak concrete blinding (50mm).

Excavation of column bases

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STEEL WORK FOR PAD FOUNDATION BASE

Steel bars of specified diameter were cut to specified length in accordance with the designers
specifications in the bar bending schedule .The diameter and length of the steel bars varied with
varying dimensions of different pad foundation application and varying loads to be experienced
by particular foundations.

The steel bars were then brought near the trench and assembled together using binding wires.
Before the steel bars were put concrete spacers (50mm thickness) were placed on the already
blinded weak concrete. Then running bars were arranged on the weak concrete 200mm space
then the distributor bars were arranged on the top of the running bars with a uniform spacing of
200mm between each distributor bars, the concrete gauges joined with the running bars using
binding wires .The running bars and distributor bars also tied together at all joints using binding
wires .This was done by use of pincers which is used to pull and stretch the binding wire there by
tightly gripping the steel bars together.

.At this point the true verticality of the framework was ensured by use of a spirit level and
tightening it from all sides by tying it on various firm supports temporally driven into ground to
prevent it from deflecting from position. This was done until concrete was cast in to finally
provide a permanent support to the steel framework with constant inspection with the spirit level
to ensure that to has not deflected or displaced from position within the process of concrete
casting.

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CASTING OF CONCRETE FOR COLUMN BASES

Concrete for the column bases

Procedure

 A pit was dug according to the dimensions of the column bases.

 Spacer blocks of 50mm are provided on reinforcement used for the column bases to give
maximum protection for the reinforcement
 Gauge over which concrete was to be casted is provide was provided.
 Concrete of mix 1:1:3(1part of cement, 1part sand, 3 parts of concrete) was then casted.
 The concrete is then vibrated and also wood floated. It is left for some time and curing is
done by pouring water on it to keep the surface damp.
 Poker vibrator was used to compact the concrete to achieve maximum compaction of
concrete.
 Surfaces were then covered to prevent fast loss of water then curing was started the next day
basically to improve on the strength of concrete.

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Casted column base

FORMWORK FOR STARTER COLUMNS

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Procedure

Making of the formwork

 Setting out of the formwork for the column
 Dimensions of the column are then marked on to the formwork.
 Three sides of the formwork are the joined together using 3 inches nails, the fourth side
was then marked with the dimension of the column
 The formwork is then cut according to the height of a column to a tri square so that the
column is cut at right angles.
 Putting of column formwork
 The binding wire that was used for attaching the supports to the reinforcement is the
untied

NB: the reinforcement is then support to the ground using reinforcement

 25mm spacer blocks are then tied on to the links to give maximum cover to the
reinforcement
 The formwork is then placed to enclose the reinforcement. The formwork is then placed
in such a way that it cannot slide or move.
 Making and putting support for the columns

Procedure

 Kickers are then provided to support the column formwork. The length of the kicker is
equivalent to the length and width of the column in order to keep the kickers in position.
 An offset distance of 500mm measured from Centre to Centre of each column. A string is
then stretched across the length and the width of the column.
 A distance of 350mm from the inner sides of the formwork is then measured to the
distance released using plumb bob released from the offset point on the string.
 The support on to the formwork is then attached supporting it on t the kickers using nails
of 3 inch and 4 inch. This is done for both sides of the column.

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Putting of column formwork lining of the columns

Casting of concrete for the columns

Thereafter removal of formwork followed after six days.

Reinforcement bars rose to a height of 1.5m, and plumbed using a spirit level. Concrete spacers
30 mm thickness were then placed on the reinforcement bars and wooden form work cleaned, for
easy removal of the form work after casting. The form work was then supported at all the sides
so that they were firm enough and ready for casting. Concrete in the ratio 1:2:4 of cement, lake
sand and coarse aggregate 25mm was the poured into the formwork using metallic pans and
vibrated at several stages using a concrete porker. The single columns were also cast to a height
of 1.2m

Thereafter removal of formwork followed after six days

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.
Single casted column DoubleCastedcolumn

EXCAVATION OF FOUNDATION STRIPS AND CONCRETE CASTING.

The strips were marked to a width of 690mm

Procedure for excavation of the foundation strips.

 Offset distance of 345mm Centre to center of every column to the sides was considered.

 Width of 690mm was then obtained for the foundation trench.

 Strings were then stretched along the whole length of the building maintaining a width of
690mm using sand and following the string strips were marked

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 Foundation trenches were excavated according to marked strips and the depth of 230mm
from the top surface of the column base

 The foundation trenches were then leveled both the sides and the bottom and a step was
provided in case of sloping length.

 Gauges of height of 230mm were put, a spirit level to ensure that the same level was
attained.

 Mix ratio of 1:2:4(1 part of cement, 2 parts of lake sand,4 parts of coarse aggregates
25mm in size respectively)

 This concrete transported from the mixers to the trenches using wheel barrows.

Concrete of grade 25 was casted to a thickness 230mm.

Ramming of concrete was done by the use of a ramper to ensure full compaction.

Curing was done on the following day by regular spraying of water until the concrete obtained
considerable strength and was free from surface cracking.

Excavation of strips

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Strips undergoing Excavation Casted strips

Slump test and making of concrete cubes.

Slump test was carried out to assess the consistency of fresh concrete. It is used, indirectly, as a
means of checking that the correct amount of water has been added to the mix.

Procedure for the slump test

 The steel slump cone is placed on a solid, impermeable level base and filled with the
fresh concrete in three equal layers.
 Each layer is rodded 35 times to ensure compaction. The third layer is finished off level
with the top of the cone.
 The cone is carefully lifted up, leaving a heap of concrete that settles or ‘slumps’ slightly.
The upturned slump cone is placed on the base to act as a reference, and the difference in

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level between its top and the top of the concrete was measured and recorded to give the
slump of the concrete.
 Concrete was then poured in to the concrete cubes at a third after applying some oil in to
the cubes

 For every third of the concrete placed, the concrete was compacted using a specified rod
of known weight with a free fall of 35 times was done to every third of the concrete that
was placed.
 The surface was then leveled and then marking of the concrete cubes was done. After a
period of a night the concrete cubes were then taken for curing after their removal from
the concrete mould.Testing was done for every 7 days, 14 days, and 28 days.

Concrete cubes ready for pouring

Cubes in concrete
being leveled after compaction

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DETERMINATION OF THE GROUND SLAB AND PLINTH WALL LEVELS USING

THE AUTOMATIC LEVEL

Procedure

 Setting up of the automatic level was done then followed by centering the bubble.
 In order to get the reference point, the level was used to focus the staff at the bench mark
 The automatic level is the placed at the reference point and the different levels were
determined.
 The levels were then marked on every column

NB; A water level was also used to determine the levels but the automatic level was used for
accuracy

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Taking of reading using an automatic level Marking of levels on the columns

PLINTH WALL CONSTRUCTION

Block work for plinth walls.

Blocks of dimensions 200mmx200mmx400mm were used. They were readily made at the site
using a block moulding machine.

Block moulding

Steps

Select a mixing platform

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Batching was by volume of, cement, stone-dust, and floor sand in the ratios of 1:4:6 respectively.
Then water was sprinkled to make it damp

Mixing. This is done for four times or three times depending on the weather. Four times during
the rainy season and three times during the sunny season.

The mixture was then scooped and put into moulds placed on pallet boards.

Initial compaction. This is majorly to compact the first sand that is placed onthe pallets.

Final compaction. This makes blocks strong enough.

Transportation. This is done using a wheel loader. Blocks are transported to the drying area
under a shade which must be levelled.

Curing. This is the process of keeping concrete blocks into damp conditions to enable
dehydration of cement and hence hardening. This was done by sprinkling waterusing a water
pipe connected to water source. This is done for 5-7 days.

Block moulding machine wooden pallets for placement of blocks

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Blocks on pallets curing blocks curing under a shade

Defects in the manufacture of blocks

 Old wooden pallets warp leading to production of irregular blocks in terms of sizes and
shapes.
 Unlevelled ground that makes the wheel to move poorly during transportation hence
altering the shape of the blocks.
 Power shortages some times to run the machine and machine break downs

Factors that may lead to poor ratios.

 Poor batching.
 Sand bulking. This refers to the increase in the volume of sand due to dampness.

Construction of the plinth wall

 Plinth Wall was constructed in five courses of block work of 25mm mortar joint.
 Mortar mix of 1:3(1part of cement and 3parts of sand)
 Every after two courses a hoop iron was placed on the blocks to increase the strength of
the wall
 Joints were properly filled with mortar to prevent termite attack and the joint surfaces
were smoothened

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 The levels of block work were determined using water levels.

 Line and pin was used to guide the block work.

Plastering of Wall

 Procedure
 Mortar that was used to plaster the walls was of mix 1:3(1parts of cement, 3 parts of
sand)
 A gauge of 30 mm of plaster was applied on to the 230mm wall.
 After applying the mortar on to the wall cutting of the excess mortar and filling the
spaces with mortar was done
 Floating of the walls was done using wooden float to smoothen the surface
 The plinth walls were built to a height of 1200mm

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ruction
Filling of mortar joints

BACK FILLING

After plastering was done on the plinth wall, soil back filling was done. The material used for
back filling borrowed away from the site. Trucks were used to transport soil from the soil deposit
to the site and then transported by wheel barrows to the plinth wall.

Back filling steps

First layer Soil roughly 75mm thickness spread and compacted using a jumper compactor

Second layer soil 75mm thickness again spread and compacted using same roller compactor.

After every layer water was sprinkled on the murram to achieve maximum compaction.

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Steel work for the ground beam:

The bars of H8 were used to make beam links. Bending was done in accordance to the
dimensions of the ground beam. Bars of H8 were bent using a pipe fixed in specific strong nails
to offer support when bending. These bars were in this case made into links. The horizontal bars
of H16 were fixed and tied on to the vertical ones with a binding wire one after the other. The
separation between the links was 200mm.

Steel work for ground beam

Procedure

The concrete spacers were tied on to the steel frame work at a spacing of about 1000mm from
one another. These spacers were 50mm thick and were made of cement: sand mortar in the mix

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ratios of 1:2 and their function is to provide a considerable concrete cover to steel bars in a way
of protecting them from rusting and subsequent corrosion.

Casting of the ground beam

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Hard core filling

Hardcore was placed and compacted using a roller to attain the required thickness followed by
blinding of the surfaces. This was after stretching over the compacted surface to mark the
thickness of 250 mm.

The hard core was compacted to prevent any unacceptable settlement beneath the solid floor.

Well compacted hare core

Importance of hardcore filling

 To fill in any small pockets that have form during over site excavation.
 To provide are firm base on which to place a concrete.
 To help spread any point loads over the greater area.
 It also acts against capillary action of moisture within the soil.

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Sand blinding

Lake sand was applied on the hard core (blinding), 50mm thickness.it was then compacted and
levelled.

Importance of blinding;

 Filling spaces in between the hard core,

 Blinding using sand also helps to minimize the cost of materials being used.
 In cases where the crushed hard core is too sharp to tear the dump proof course, blinding
protects the dump proof course from being damaged by the hard core.

Sand blinding

Laying of the Damp Proof Membrane (DPC) and the British Reinforcement Cage (BRC)

After sand blinding1000 Gauge polytheneDamp Proof Membrane sheeting laid on blinded
hardcore

Then a No.A142 Fabric Mesh reinforcement weighing 2.22 kg.Per square meter was laid on the
damp proof membrane

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Spacer blocks of 50mm thickness where placed below the BRC in order to support it from the
DPM

Placing of spacer blocks on the BRC

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Installation of electrical conducting and plumbing ducts

Electrical conduits and plumbing ducts were installed. These were also done before actually
casting the ground slab. Electrical personnel placed Conduits and Earthlings the BRC and tied it
to the BRC using binding wire. Sanitary pipes of diameter 150mm and 100mm were also placed
before casting.

Transferring levels for the ground slab and setting up gauges

The automatic level was set up and then followed by centering the bubble.

In order to get the reference point, the level was used to focus the staff at the bench mark

The automatic level is the placed at the reference point and the different levels were determined.

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The levels were then marked and gauges also set up.

Casting of the ground slab

After setting up the gauges the ground slab was casted

Procedure

Concrete of Class 25 with 20mm Aggregate was mixed in the in a concrete mixer.
Batching was by volume in the ratio of 1:2:4(1 part of cement, 2parts of fine aggregates and 4
parts of coarse aggregates)

It was then transported using wheel barrows up to the casting area and the poured gently.

Compaction the followed using a poker vibrator and then it was leveled using a straight edge.

The thickness of the slab was 150 mm ,then curing of the slab followed.

After a day a layer of pit sand was poured on the slab followed by water which was poured every
after one hour to reduce the heat of hydration and also prevent the slab from cracking.

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Curing concrete
Concrete is cured by sprinkling water on the columns. This is done daily for about seven days in
the evenings when the rate of evaporation is low.

Erection of Columns

Reinforcements for columns

Columns are structural members, which transfer the

load of the building to the base of the building.

Procedure

The reinforcements for the columns were made of high

tensile (T) 16mm diameter bars and R8 ribbed rings
connected using binder wire.

Reinforcement bar for the columns were first cut and

hooked at end so as to grip into the ring beam and then
given a slight bend in the middle to sit on the starter
bars. The bars were then connected from the ground
through R8 ring at a spacing of 200mm.

The reinforcements were then put in their respective

ound slab positionsCasted ground slab
and connected to the starter bars using rings and binder wire with an overlap of 1200-
1500mm between the reinforcement and the starter bars.

Spacer block were the connected to the sides of the reinforcement to ensure 30mm cover
concrete to prevent corrosion of reinforcement due to exposure to moisture.

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Column kickers aligning the columns

A plumb bob is suspended and a measuring tape is used to measure the distance from the plumb
line to the formwork board. Measuring is done both up and down. The distance from the
formwork board to the plumb line must be equal at the top and bottom. This ensures that the
form work is vertical so as to achieve a vertical column.

Column kickers

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Formwork for column kickers was made using 2 ' ' ×2 ' ' timber pieces for various dimensions of
the columns such as 300 ×350 mm , 300 ×230 mm∧230 ×230 mm depending on the load the
columns were anticipated to carry.

The formwork was then dressed on the reinforcement and the positions for the columns set out.
Transferring measurements from columns on the first floor using a plumb bob and a tape
measure first set out the positions for columns at corners of the building. Intermediate column
kickers were then a lined in position in relation to the column kickers at the corners using a
building line.

The formwork for the kickers was then nailed on the slab after ensuring uniform cover concrete.
The concrete for the kicker was placed, finished well using a wooden float and left to set.

Boards for column form work were nailed on braces and made for various column dimensions.
However, for columns at the expansion joint 25mm board was incorporated in the middle to
create space for fixing tile foam after casting and striping off formwork. The column boxes was
later dressed on to the column kickers, plumbed vertical using a spirit level and then carefully
strutted in position.

Site inspection and meeting

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Site meeting and inspection was held after month in order to assess the progress of the project

It comprised of members from the client’s side represented by Architect consults, the funder’s
side which was World bank represented by National Crops Resource Research
Institute(NaCRRI) ,the contractor represented by the site engineer and trainees

Site inspection was first held first then followed by the meeting. The inspection involved
measuring the progress of the project, occupational health and safety and the quality of materials
used by the contractor.

In the meeting the contractor was advised to create more time to compensate the lost time during
the rains .so they advised him to work day and night to compensate the time

Site inspection

Site inspection
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Chapter 3

Problems and challenges faced during the training period

 The training was successful though during the course of the training, we faced a few
obstacles which included;
 Weather; rapid variations in the weather pattern from being very sunny and hot to sudden
rainfall made the field work very hard as it had to come to a standstill and hence led to
more expenses on the side of the company. Most especially rainy weather had affected
different actives at the site, for example foundation excavations, concrete work, hard core
filling and soil back filling was the most affected.
 Power and water shortages sometimes bought work at a standstill .for the case of power
the block molding machine was the most affected
 Delays in the supply of materials especially cement also brought work to come at
standstill
 Spending a busy day at the site from reporting 8:00 am up to 6pm was also one of the
challenges which taught me that as an engineering student, I have to prepare for such in
my career.

Other problems
 Lack of supervision of the workers. Most of the workers pretended to be working yet they
would actually be doing nothing.
 Ignorance and stubbornness of the laborers. It was emphasized on site that everyone had
to be in a helmet but some workers stubbornly did not put them on.
 Demolition of works. Some of the works did not come out as required hence such works
had to be demolished and rebuilt and this results into wastage of both time and resources.

CONCLUSIONS AND RECOMMENDATIONS

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Perception of the Profession in the Field

The profession is not widely understood. It’s most times mistaken for civil engineering by the lay
man. Construction managers are rarely employed for small Projects and are thus mostly
employed by large projects since many clients consider it an extra cost that could be saved.

Perception of the Firm in which training was done

Kwik Build Contractors is a great company to train with as one gains experience in both
technical and social experiences. It owns different sorts of engineering equipment used in the
construction process giving one a chance to learn what they are and their use.

Recommendations

I strongly recommend the use of safety gadgets at the site. Although workers were not
responsible for the proper use of safety gadgets that discouraged the company from providing
them enough safety gadgets to the workers. when workers given safety gadgets they misuse them
or even some lose them very easily, and when the company introduces control measures that
whoever doesn’t have safety gadgets will not be allowed to work at the site and will be deducted
the cost of the safety gadget he/she loses from his/her pay. Some even decided to quite their
duty.

The workers should also be motivated since many of them work without any enthusiasm

During my stay for the training in the site there were few accident cases that are very miner, but
if there were proper use of safety gadgets at the site these accidents could haven’t been
happened.

For example minor cuts on the hand, mostly carpenters and steel fixers who do not wear gloves.

Minor knocks on head, mainly people working on hardcore filling who did not use helmet.

These and other minor accident cases can be reduced and also the company will make savings on
medical bills because some cases of accidents needs to be taken to external medical centers for
further treatments that cannot be done at the sites safety and health department.

Generally the issue of safety might not be a serious concern at this level since the site is on
ground floor slab, but in future really needs maximum attention for safety issues at the site.

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Conclusion
Industrial training was successfully completed and a lot of skills were acquired. Knowledge and
skills acquired during training were divided into technical and non-technical skills

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APPENDIX

Artistic impression of the project after Completion

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 Industrial Training Report

The project sign post

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 Industrial Training Report

REFERENCES

Concrete technology, A.R Santhakumar

Design of concrete mixes, Alexanderson, J.A

The master builder, NegMicon India

Handbook of concrete engineering, McGraw-Hill

Understanding structures, Esward Derek

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