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UNIVERSITY OF AUCKLAND
INDUSTRIAL TRAINING
REPORT
CIVIL & ENVIRONMENTAL ENGINEERING
H.T. SHAMEERA WIJESOORIYA
08/08/14
MÄGA ENGINEERING (PVT) LTD
200 Nawala Road
Narahenpita
Colombo 05
Sri Lanka
Work Period
18.11.2013 – 15.02.2014
Executive Summary
This report details the skills and experience I gathered during my time working as an intern at MÄGA
Engineering. As an intern I was appointed as a training engineering assistant at the construction site of a
high rise building which would eventually be used as a hotel complex that included residential facilities
as well. During this internship I was able to apply my learnt academic knowledge in practical situations
as well as gather a vast array of methods and processes that was only possible to be learnt through
working on site. It was a gateway towards becoming a professional civil engineer.
Acknowledgments
I would like to express my deepest appreciation to Mr. M.G. Kularathna who is the Managing Director at
MÄGA Engineering for giving me the opportunity to work as a summer intern at the Hyatt Regency Hotel
Project – Kollupitiya.
Furthermore I would like to express my deepest gratitude to Mr. A. A. Thilakarathna who was the
Project Manager for the Hyatt Regency Hotel Project. His guidance throughout my training period was
invaluable.
I would also like to thank all other engineers, foremen, supervisors, co-workers and workmen for all of
their support and cooperation. I would especially like to appreciate the encouragement and assistance
given to me by Mr. Umayawan Gnaneswaran, Mr. Nuwan Wijayarathna, Mr. Rupasinghe and Mr.
Abeyrathna. Their counsel helped me vastly to attain a variety of skills and expertise which has guided
me to become a proficient engineer.
Finally I would like to thank all my lecturers and tutoring staff at the University of Auckland for providing
me with the knowledge and proficiency to conduct myself diligently at the workplace.
H.T. Shameera Wijesooriya
Faculty of Civil and Environmental Engineering,
University of Auckland,
Auckland.
Table of Contents
Introduction ..................................................................................................................................................1
History of the Company................................................................................................................................2
Project Briefing .............................................................................................................................................3
Organisation Structure................................................................................... Error! Bookmark not defined.
Site Layout.....................................................................................................................................................4
Scope of Works .............................................................................................................................................5
Summary of Construction Operations ..........................................................................................................7
Personal Responsibilities ..............................................................................................................................8
Direct Construction Works............................................................................................................................9
Technical Facilities ......................................................................................................................................19
Bibliography ................................................................................................................................................22
List of Tables and Figures
Figure 1 - Graphical rendering of building ....................................................................................................5
Figure 2 - Work on top level..........................................................................................................................8
Figure 3 - Propped aluminium formwork ...................................................................................................10
Figure 4 - Formwork of a column................................................................................................................11
Figure 5 - Formwork and concreting of the staircase.................................................................................12
Figure 6 - Reinforcement works and formwork..........................................................................................13
Figure 7 - Raising of a prefabricated structure ...........................................................................................15
Figure 8 - Ready mix concrete poured into concrete bucket .....................................................................17
Figure 9 - Concrete being poured into a wall..............................................................................................18
Figure 10 - View from tower crane.............................................................................................................19
Figure 11 - Construction Elevator ...............................................................................................................20
Table 1 - Concrete Mix Design ....................................................................................................................17
Page 1 of 22
Introduction
MÄGA Engineering (Pvt) Ltd is one of the leading construction firms in Sri Lanka. The company was
established in 1984 under the leadership of the present Managing Director, Capt. M.G. Kularathna. By
wisely managing its capital and resources, the company has evolved into one of the pioneering
construction companies in Sri Lanka, executing some of the most prestigious infrastructure and
development projects (1). The company collectively has the capability for the construction works of
buildings, bridges, roads, water supply, drainage facilities, irrigation, land drains, dredging, land
reclamation and electrical installations (2).
The Institute for Construction Training and Development (ICTAD) in Sri Lanka has awarded MÄGA
Engineering with the highest possible national grade C-1 for the majority of its civil operations. This
grade provided by the ICTAD evaluates the financial capability, technical ability of staff, plant and
machinery, and expertise gained in relevant fields.
Out of the numerous projects that MÄGA Engineering was working on at that time, I was assigned to its
flagship building construction project, which was the construction of the Hyatt Regency Hotel Colombo.
The site was located in the busy commercial capital of Sri Lanka hugging the coastline of the beautiful
Indian Ocean. During the period of my internship, the project had already progressed extensively. I was
fortunate enough to contribute to the construction of the structure from the 20th
floor to the 23rd
floor
during my assignment.
This project was initially commissioned to the private sector but later taken over by the government
when it was abandoned by the developer for over three years since 2008. This asset was taken into
government control under the revival of the Underperforming Enterprises and Underutilised Assets Act
of Sri Lanka. The Board of Investment (BOI) of Sri Lanka hereafter signed an agreement with Sino Lanka
Hotels and Spa (Pvt) Ltd. The BOI agreement awarded the approval for the Client to develop the
property and also to grant the necessary concessions for construction under the Strategic Development
Projects Act. The project was finally given the go ahead in March 2012 by the Cabinet of Ministers of Sri
Lanka. A consortium of investors including both private and state entities provided the capital to the
new project developer. The project was finalised to be a 45 storey 5 star luxury hotel and serviced
apartment complex upon completion to be managed by the Hyatt Regency brand.
Page 2 of 22
History of the Company
The company was incorporated under the companies Act No. 12 of 1982 on 2/12/1983 as a private
limited liability company and was registered under the name Chandranayake and Company (Private)
Limited. It was initially in the business of constructing of commercial or residential buildings, roadways,
bridges and other civil, electrical & mechanical engineering works. On 17/10/1989 the company name
was changed to MÄGA Engineering (Private) Limited.
In its early years the company was mostly engaged as a sub-contractor to several international
contractors operating in Sri Lanka. During this time, under the leadership of the present Managing
Director, Capt. M.G. Kularathna this company evolved into Sri Lanka’s pioneering construction firm. In
the modern age, MAGA is the market leader in both in volume and quality of work. Because of the
recognition earned by the company it would expand into foreign markets as far back as 1987 to go on to
complete over a dozen civil and coastal engineering projects.
During the company’s 18 year lifetime, it has completed well over 125 projects in multiple disciplines
which include numerous large scale prestigious projects. The company has been decorated with a
multitude of awards over the years, but the greatest award that MAGA achieved is the recognition of
the industry and its stakeholders for its capability to maintain an extremely high standard of quality
across the board.
Notable Awards :
 2012 Sri Lanka’s Corporate Accountability Index – Platinum Rating, No. 3 Rank
 2011 National Business Excellence Award by National Chamber of Commerce of Sri
Lanka, Construction Sector – Winner
 2011 Central Environmental Authority, National Green Award for Private & Public Sector
 2010 National Business Excellence Awards by National Chamber of Commerce of Sri Lanka,
Construction Sector – Winner
 2010 National Construction Awards by National Construction Association of Sri Lanka (NCASL),
Buildings Sector – Winner
 2008 The Institution of Engineers Sri Lanka (IESL), Engineering Excellence Award (Infrastructure
Development)
 2008 Business Superbrands Certification
Page 3 of 22
Project Briefing
Project : Construction of Proposed Hyatt Regency Hotel – Colombo
Location : 116 Galle Road, Colombo-03, Sri Lanka
Client : Sino Lanka Hotels and Spa (Pvt) Ltd
Contractor : MÄGA Engineering (Pvt) Ltd
Consultant : Design Consortium Ltd
Project Initiation : 10/06/2012
Estimated Project Completion : 31/08/2014
Estimated Duration of Project : 2 years and 2 months
Contract Structure : Measure and Pay
Page 4 of 22
Site Layout
1. Proposed building
2. Material and equipment stores
3. Steel yard
4. Security office
5. Construction elevators
6. Tower crane 01
7. Tower crane 02
Page 5 of 22
Scope of Works
The structure was to be a 45 floor RCC framed structure with an approximate total of 565 rooms which
amounts to around 94,000 sqm of built up area. The luxurious hotel complex is to sustain 475
guestrooms with a variety of models which include different features. It would comprise of 54 suites,
265 King rooms, 150 twin rooms and 6 rooms with disability access. Furthermore the structure would
feature 84 serviced apartments. To accommodate parking needs of the guests the structure will include
of ample parking spaces involving 2 basement floors and exterior structures for car parks.
To establish the hotel as a glamorous modern architectural masterpiece in Sri Lanka, the designers have
endeavoured to incorporate some truly stunning features into their magnum opus. One of these
aspirations was the infinity pool and pool deck located at the 11th
floor of the structure. The deck sits
atop the western coastline of Sri Lanka looking into the vast Indian Ocean. The pool deck is expected to
have a seating capacity for 76 individuals.
Figure 1 - Graphical rendering of building
Page 6 of 22
Furthermore the complex is to consist of amenities such as a lobby lounge, dining areas, a multi-cuisine
restaurant, 3 more specialty restaurants, a bar, eight spa treatment rooms, a fitness centre, and a
Regency Club lounge. Moreover the complex will offer more than 17,000 sq ft of enclosed meeting
spaces the highlight of which will be the 7,500 sq ft, 27 ft high grand ballroom.
Upon completion the structure is to stand at 176 m which would make it the tallest structure in the
country surpassing the previous tallest building, the World Trade Centre Towers which stands at 152 m.
The WTO towers are visible across the undeveloped Galle Face promenade which will make it an
exquisite sight from the guests at the hotel. The hotel complex is expected to be inaugurated by the end
of October 2013 with the residential suites to be operational by August 2014.
Page 7 of 22
Summary of Construction Operations
Surveying
The continuous surveying and levelling operations during the construction works were quintessential
towards maintaining the accuracy of the dimensions construction works as proposed by the design
blueprints to an acceptable tolerance.
Formwork
Formwork is either a temporary or permanent structure used as a container or mould into which fresh
concrete can be poured to achieve the designed structure. It helps achieve the required shape and
dimensions of the concrete works. Additionally it acts as a platform to lay out the steel reinforcement
prior to concreting and also supports the fresh concrete until it has matured sufficiently to be self-
supporting. Numerous techniques and materials are available for formwork purposes but in this project
mostly plywood and specifically designed aluminium formwork systems were used.
Reinforcement Works
The concrete structure is reinforced with steel reinforcing to provide strength and resilience to the
structure. The reinforcement is usually required because of the lack of tensile and ductility capacities of
plain concrete which can be counteracted b using an appropriate composition of rebar.
Concreting Works
Concrete is a mixture of cement, water, and construction aggregates. Concrete is widely adopted in the
construction field because of its relative less cost, fire proofing capabilities and durability. Concrete has
excellent performance in compression making it excellent for high-rise structures.
Masonry Work
Masonry work is necessary in structures such as this to form partitions. Both clay bricks and concrete
blocks were used in the construction of this building.
Quality Control
The quality control and quality assurance sectors involved in the construction works help to monitor and
achieve the targeted quality standards approved for the project. Throughout which the continuous set
of records are maintained to prove that the quality standards are being met. Their scope not only
includes the construction works but also the construction materials and equipment as well.
Health and Safety
Even though everyone on site had to maintain their own health and safety obligations, there were also
specifically assigned safety officers who were in charge of implementing an adaptive health and safety
plan.
Page 8 of 22
Personal Responsibilities
The staff involved in the direct construction works was divided into sectors for reinforcement works,
concrete works, formwork and surveying. During my internship at the Hyatt Regency – Colombo project
working at MAGA, I was assigned to work with the reinforcement sector of the construction works. My
key task was to work with my peers and apply my engineering knowledge to manage and instruct the
workmen to perform the reinforcement works.
The company employed many subcontractors to perform the works. The subcontract groups were
assigned to carry out specific portions of reinforcement work or were used as labour supply to perform
more general work. They payment schedules of these two types of workers varied as well. The formerly
mentioned workers were paid using a rate based mechanism where they would be paid according to the
quantity of reinforcement works completed. The unit of measured quantity would usually be the
reinforcement used by weight. The later would be paid on a daily basis. Even though the workers in
general were cooperative, because of the characteristics of the payment schedule challenges did occur
when it came to motivating and regulating their work.
Figure 2 - Work on top level
Engineering drawings were extensively used on site as the primary for all construction works. A
comprehensive understanding of the drawings was required to quickly determine what was required to
be constructed. Drawings depicted the structure and layout of columns, beams, slabs and walls. The skill
Page 9 of 22
level of the workmen varied significantly with some being able to understand the drawings and some
finding it more difficult to grasp the information. Because of this my peers and I played a key role in
interpreting and conveying the contents of the drawings. Furthermore it was required by us to review
and scrutinize the works to check for defects before the final inspection for the item was conducted by
the consulting engineers.
Being part of the construction team on site meant that even though you were assigned to a specific
sector, the cooperation of other members was required in order to complete the tasks at hand. This
brought out a good teamwork ethic in the entire staff to collaborate with others from different sectors
to achieve the final goal of progressing through the construction works. Often times it was necessary to
communicate with the tower crane operators, signalman and bar bending staff to make sure the right
materials and prefabricated structures were delivered to the right location at the right time.
The concept of tight deadlines was heavily emphasised by the superiors. Even though different sectors
have their own specific tasks, they are all interlinked. Therefore a delay in one area would effectively
delay the entire process. For example if a delay occurs in laying the formwork it would delay the
reinforcement works and subsequently the final concreting. We were also made aware the ramifications
for the delays occurred on site. Every delay results in costs one way or the other. Furthermore it has
negative effect on the relationships between the members involved in the project. Although my primary
assignment was in the reinforcement section, to better understand the functions of the involved
construction works I extended my attention to other sectors as well.
Direct Construction Works
Formwork
Formwork is a temporary or permanent mould required for the casting of concrete. A high quality
formwork system is cost efficient and quick & easy to assemble/disassemble. Specifically designed
aluminium panel system was used for beams, slabs, walls and columns while 12 mm thick plywood was
used for the staircases. An array of jack and pipes were used to prop up and support the panels. Chains,
chain blocks, turnbuckles and other accessories were used to brace and align the panels.
Page 10 of 22
Figure 3 - Propped aluminium formwork
Formwork for Columns and Walls
The columns had a rectangular cross section; therefore four aluminium panels were sufficiently enough
to cover the perimeter of the column. The panels used for walls are also designed to sufficiently cover it
but as the wall is connected to columns on its sides only the two larger faces are required to be
enclosed. Usually a 200 mm offset is marked using surveying equipment. The formwork would then be
erected using this offset as the basis to find the outline of the column or wall. Once the initial assembly
of the formwork is completed, the verticality of the formwork is checked using a plumb bob and
measuring tape. The plumb bob is left to hang from a known offset from the face of panel at the top of
the assembly. Then the offset distance of the plumb bob is measured from the bottom of the assembly.
If these two values are within the appropriate tolerance limits the formwork is acceptable, if not it has
to be adjusted using the accessories provided.
Page 11 of 22
Figure 4 - Formwork of a column
Formwork of Beam and Slab
The first step in the assembly of beam and slab formwork is to setup a uniform level by which the
heights to the formwork can be measured. This is achieved by making a 1000 mm mark on each of the
columns from the top of the slab on the floor beneath. The column heads are fixed subsequently and
then the formwork is then propped. A grid like structure is formed initially while the formwork for the
beams are installed first. After the sideboards are installed for the beams, the workmen then proceed to
finish off by completing the slab area between the beams. The level of the slabs and beams are fairly
accurate due to the use of the use of the same aluminium props. Hence if the concrete level of the lower
slab is done accurately the formwork should also be very consistent. If finer adjustments are required it
is done by placing a small square of plywood with a thickness that would account for the difference in
that area.
Formwork for Staircases
Initially the foundation for the flight of stairs is laid by constructing the beam at the bottom. After the
dimensions of the staircase have been set out the formwork for the landing is erected and supported
using adjustable steel props. The landing should be accurately levelled to ensure quality standards are
maintained. After this step the formwork to support the stringer and its sideboards are laid. When these
steps are completed the reinforcement of the staircase is installed. Following this step dimensional
Page 12 of 22
timber and plywood are used to form the risers of the staircase which can finally be followed by the
concreting works.
Figure 5 - Formwork and concreting of the staircase
Removal of Formwork
Because it is cost efficient to reuse the formwork equipment, they must be carefully removed at the
right time. Concrete gains strength over time and once the concrete is sufficiently strong enough the
disassembly of the formwork may begin. The concrete is allowed to reach its design strength before the
formwork is removed. This is usually attained after 28 days. To ease the removal of the aluminium
panels, form oil is applied prior to the concreting of the segment. The form oil used at the site was a
mixture of grease and diesel and is applied to prevent concrete from sticking onto the aluminium panels.
Reinforcement Work
Steel reinforcement is added to concrete mainly to increase its tensile, shear and ductile capacity. It also
helps to control the expansion and compression of the concrete which occurs due to numerous reasons
which include environmental factors and long term chemical reactions in the concrete. The steel
reinforcement comes in a myriad of sizes and grades. In this site Tor steel and mild steel was used
accordingly. The designers had specified the necessary size and grade of the steel reinforcement in the
drawings. They were chosen taking into consideration factors such as required tensile capacity,
bendability, availability and cost. Steel bars of all sizes arrived to the site in 11 m lengths, from which
they would be cut and bent appropriately.
Page 13 of 22
Figure 6 - Reinforcement works and formwork
Tor steel occupied a larger portion of the reinforcement works. It has a design tensile capacity of
460MPa and is used for a variety of purposes. Its surface is ribbed to provide extra friction with the
concrete which results in a better bond with the concrete. Mild steel has a design tensile capacity of
250MPa and is mainly used for some column stirrups and secondary reinforcement.
Bar Bending Schedule
A bar bending schedule is a document prepared in order to create a bending and cutting schedule for
the reinforcement bars. The steel reinforcing at times is required to be bent into shapes or cut
appropriately. The bar bending schedule specifies the quality and quantity of the required
reinforcement bars. It identifies information such as bar mark, location of the bar, quality of steel, size of
steel bar, dimensions, shape code, cut length etc.
Bar Notation
To recognize and relate bar details with the information provided in bar bending schedules, bar
notations are used in the engineering drawings. It is a simple and easy system to help people on site to
identify the reinforcing requirement of an element.
Eg: 5T10 – 06 – 150 B
5 - Number of bars required 06 - Bar mark
T - Tor steel (R = mild steel) 150 - Spacing of bars in millimetres
10 - Diameter of bar B - Bar location
Page 14 of 22
Crank Length
When reinforcement bars overlap they have to be cranked in order to maintain a linear force line. A
standard formula was introduced to identify this required length.
Crank Length = (d1 + d2 + 5) * 10 mm
d1 - Diameter of first bar
d2 - Diameter of second bar
Lap Length
When a reinforcement bar has to be connected to another bar to achieve its desired purpose it would
be overlapped. This overlapping enables complete transfer of the bars design tensile capacity. In order
achieve this complete tension transfer sufficient length of bar has to overlap the other in what is known
to be the lap length. Even though the calculation of the lap length requires the use of standards and
knowledge of the properties of the concrete and steel used, it has been simplified so that even an
unskilled worker can implement it.
Lap Length = (50 * d) mm
d - Diameter of smallest bar
Cover Blocks
When the reinforcement is being assembled over the formwork, the design specified cover must be
maintained between the outermost surface of the reinforcing and the formwork. This cover length is
required to deter corrosion and to increase fire resistance of the reinforcing amongst other reasons. To
achieve this blocks made out of mortar are placed in between the reinforcing and the formwork. These
are known as cover blocks and are usually made with a mortar mixture that would have a compressive
strength similar to that of the concrete poured into the element.
Cover block sizes :
Floor slabs - 25 mm
Beams - 30 mm
Staircase - 30 mm
Shear walls - 40 mm
Columns - 50 mm
Spacer Bars and Stools
When laying out the reinforcement for a slab there is usually a top and bottom layer. An effective gap
between the two layers must be maintained in order to obtain the design capacity of the slab. In order
to achieve this either spacer bars or reinforcement stools must be placed. Usually the absolute spacing
between the two layers is approximately 30 mm. In these areas 32 mm bars would be placed as a spacer
bar. The spacer bars are short lengths of steel bars which are usually obtained from cut-off material. In
other cases 10 mm bars are bent into shapes which can support the top layer of reinforcing.
Page 15 of 22
Prefabrication of Reinforcement Works
The traditional method of constructing the reinforcement is to build the assembly on the site itself
which is known as building in situ. There are times when the specific element is built offsite and
transported to the desired location using the tower cranes. There are many advantages to prefabricating
items. It is useful to have a proportion of the labour force working in the prefabrication areas as the
construction site can otherwise become congested with an excess of people and materials lying about.
Prefabrication also increases the efficiency at which the elements such as beams columns and even
walls are constructed. The workers can construct the structure in a comfortable area which is likely to be
sheltered from the elements to a certain degree. Structures such as columns when being built in situ, is
relatively difficult to construct as the workers would have to mount themselves onto high scaffolding
and lower heavy bars from the top of the existing column. This is both strenuous and dangerous.
Prefabrication of these segments avoids these circumstances and often results in a much more quality
product. After prefabrication is complete diagonal bracing members are welded onto the segment,
hoisted to the appropriate floor and installed into the relative section.
Figure 7 - Raising of a prefabricated structure
Page 16 of 22
Concreting
Concrete is made from a mixture of cement, fine aggregates, coarse aggregates and water. At times
admixtures are added to the formula in order to adjust certain properties of the concrete such as setting
times and workability. The cement reacts with the water in an exothermic hydration reaction to produce
the concrete. The cement is made from a mixture of silicates and oxides which mainly have some lime,
aluminium and iron. Coarse aggregates increase the strength of the concrete and also reduce the
amount of cement required. Ideally they should be as angular as possible as this increases the surface
area the grout can adhere to. The fine aggregates help fill the voids in between the coarse aggregates.
They also help reduce shrinkage of cement on hardening. Sea sand should not be used for reinforcement
works as the high pH of saltwater could accelerate corrosion. Ideally the aggregates should be in a
saturated surface dry (SSD) state before being added to the mixture as this avoids surface adsorption of
the free water. Otherwise this loss of water would have to be taken into account during the batching
process.
After the concrete arrived at the site it would either have to be pumped or carried up using a bucket.
When concreting the slab and beam areas the concrete was pumped and distributed using a
combination of steel and rubber piping. When columns or walls were to be concrete the concrete would
be transported up using the tower crane in a large bucket and discharged either directly from the bucket
or with the use of a tremie.
Ready Mix Concrete
The concrete was not made in situ instead it was brought in from a concrete batching plant. Making
concrete for a large scale structure requires a lot of labour, plant equipment and materials. If all of this
were to be included in the site itself it would have been a tremendous inconvenience as it would occupy
a large area and would lead to congestion. This batching plant was owned by MAGA and it serviced
multiple construction sites at the same time which helped reduce costs. Additionally because of the
specialisation of the staff at the batching plant, a better quality of concrete can be obtained. After the
concrete is made at the batching plant it would then be transported to the site using agitating trucks.
Page 17 of 22
Figure 8 - Ready mix concrete poured into concrete bucket
Concrete Mix Designs
A concrete mix design is a schedule of the materials to add to the concrete mixture and the necessary
quantities. The concrete mix varies for different compressive strengths and the added admixtures may
also change depending on the element which is required to be concreted.
Table 1 - Concrete Mix Design
Grade 30 Grade 50
Cement 350 kg/m3 450 kg/m3
Fly ash 53kg/m3 70 kg/m3
Silica Fume 0 0
Chilled Water 165 l/m3 166 l/m3
Fine Aggregate 861 kg/m3 794 kg/m3
Course Aggregate 1011kg/m3 970 kg/m3
Retarders 0.70 l/m3 0.9 l/m3
Superplastic 2.84 l/3 4.68 l/m3
Page 18 of 22
Concrete Quality Control
The quality of the concrete used was continuously checked. The workability of the concrete was an
essential factor. As the site was using a concrete pump and steel pipes during large concrete pours, the
concrete had to have a sufficient workability. If this requirement wasn’t met there would be a possibility
that the distribution system would get clogged. To monitor the workability of the concrete a simple
slump test was conducted for every truckload of concrete.
Furthermore the compressive strength of the concrete must be monitored. The site maintained its own
set of testing procedures not relying solely on the suppliers guarantee. The cube crushing test was
conducted on site as a measure to maintain the required quality. A sample of the fresh concrete would
be poured into a steel cubic mould. After the concrete is set and cured for a specified time, its maximum
compressive strength is investigated by using a crushing apparatus.
Figure 9 - Concrete being poured into a wall
Page 19 of 22
Technical Facilities
Concrete Pump
The proposed construction site was to accommodate 45 floors. One of the greatest challenges was to
transport the material up there. Even though concrete could be transported to the top using the tower
cranes using various apparatuses, it would only be able to carry small commodities due to its maximum
lift capacity. Hence a much more practical approach is to merely pump the concrete upwards. In order
to generate the required pressure to transport the concrete to that height a concrete pump is used.
Truck Mixture
The truck mixture is used to transport the ready-mix concrete supplied from the concrete batching
plant. It continuously rotates its drum which is filled with concrete during transportation. This prevents
the concrete from setting during the transportation process. The concrete would be driven out of the
drum using a spiral blade and then poured into the necessary apparatus using a pull-out chute.
Tower Crane
This machine is used to lift and transport heavy loads. It is used extensively in transporting items such as
steel rebar, fresh concrete, prefabricated structures, cover blocks, water tanks etc. Tower crane no. 2
was a Luffing crane which had to undergo repairs. But due to the presence of the other tower crane
some of the adverse effects were mitigated.
Figure 10 - View from tower crane
Page 20 of 22
Poker Vibrator
Poker vibrators were extensively used on site as a means of compacting the freshly poured concrete.
They were very advantageous as they could be easily moved around, stored and quick to setup.
Construction Elevator
The construction elevator is a quick and efficient way to transport people and materials along the
building. Even though the site had a stairway which reached the top, in order to move masses of people
and materials it wasn’t a viable method to solely use the stairs. There was a site policy of always have at
least one elevator operational at all times. Designated operators were appointed to control the hoists.
The hoists were powered by an electrical generator situated on site. The hoist operators shared the
responsibility to monitor the fuel levels of the generator so as to avoid a sudden termination of power.
Figure 11 - Construction Elevator
Page 21 of 22
Conclusions
From this work experience I was able to attain a number of skills that a capable engineer should attain
and also the knowledge to go along side it. I have a gained a better understanding to work with my
peers and to work with 3rd
parties such as clients, consultants and subcontractors. I have been able to
successfully build relationships with them and use them instrumentally to perform the required works.
This experience has contributed towards improving my work ethic and also to take pride in my work as a
professional engineer.
Page 22 of 22
Bibliography
1. Maga Engineering (Pvt) Ltd. Home Page : Maga Engineering (Pvt) Ltd. Maga Engineering (Pvt) Ltd
Web site. [Online] Ultimax (Pvt) Ltd. [Cited: 03 March 2014.] http://www.maga.lk/.
2. Institution for Construction and Development. Home Page: Institution for Construction and
Development. Institution for Construction and Development. [Online] SLT Web Services, 31 January
2014. [Cited: 06 March 2014.] http://www.ictad.lk.
3. Maga Engineering (Pvt) Ltd. Hyatt Regency Hotel: Maga Engineering (Pvt) Ltd. Maga Engineering (Pvt)
Ltd. [Online] Ultimax (Pvt) Ltd. [Cited: 06 March 2014.] http://www.maga.lk/?page_id=137.
4. ICRA Lanka & IMaCS Research & Analytics. Construction Industry in Sri Lanka. 2011.

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Shameera - Work Report - Maga Engineering

  • 1. Page 0 of 25 UNIVERSITY OF AUCKLAND INDUSTRIAL TRAINING REPORT CIVIL & ENVIRONMENTAL ENGINEERING H.T. SHAMEERA WIJESOORIYA 08/08/14 MÄGA ENGINEERING (PVT) LTD 200 Nawala Road Narahenpita Colombo 05 Sri Lanka Work Period 18.11.2013 – 15.02.2014
  • 2. Executive Summary This report details the skills and experience I gathered during my time working as an intern at MÄGA Engineering. As an intern I was appointed as a training engineering assistant at the construction site of a high rise building which would eventually be used as a hotel complex that included residential facilities as well. During this internship I was able to apply my learnt academic knowledge in practical situations as well as gather a vast array of methods and processes that was only possible to be learnt through working on site. It was a gateway towards becoming a professional civil engineer.
  • 3. Acknowledgments I would like to express my deepest appreciation to Mr. M.G. Kularathna who is the Managing Director at MÄGA Engineering for giving me the opportunity to work as a summer intern at the Hyatt Regency Hotel Project – Kollupitiya. Furthermore I would like to express my deepest gratitude to Mr. A. A. Thilakarathna who was the Project Manager for the Hyatt Regency Hotel Project. His guidance throughout my training period was invaluable. I would also like to thank all other engineers, foremen, supervisors, co-workers and workmen for all of their support and cooperation. I would especially like to appreciate the encouragement and assistance given to me by Mr. Umayawan Gnaneswaran, Mr. Nuwan Wijayarathna, Mr. Rupasinghe and Mr. Abeyrathna. Their counsel helped me vastly to attain a variety of skills and expertise which has guided me to become a proficient engineer. Finally I would like to thank all my lecturers and tutoring staff at the University of Auckland for providing me with the knowledge and proficiency to conduct myself diligently at the workplace. H.T. Shameera Wijesooriya Faculty of Civil and Environmental Engineering, University of Auckland, Auckland.
  • 4. Table of Contents Introduction ..................................................................................................................................................1 History of the Company................................................................................................................................2 Project Briefing .............................................................................................................................................3 Organisation Structure................................................................................... Error! Bookmark not defined. Site Layout.....................................................................................................................................................4 Scope of Works .............................................................................................................................................5 Summary of Construction Operations ..........................................................................................................7 Personal Responsibilities ..............................................................................................................................8 Direct Construction Works............................................................................................................................9 Technical Facilities ......................................................................................................................................19 Bibliography ................................................................................................................................................22 List of Tables and Figures Figure 1 - Graphical rendering of building ....................................................................................................5 Figure 2 - Work on top level..........................................................................................................................8 Figure 3 - Propped aluminium formwork ...................................................................................................10 Figure 4 - Formwork of a column................................................................................................................11 Figure 5 - Formwork and concreting of the staircase.................................................................................12 Figure 6 - Reinforcement works and formwork..........................................................................................13 Figure 7 - Raising of a prefabricated structure ...........................................................................................15 Figure 8 - Ready mix concrete poured into concrete bucket .....................................................................17 Figure 9 - Concrete being poured into a wall..............................................................................................18 Figure 10 - View from tower crane.............................................................................................................19 Figure 11 - Construction Elevator ...............................................................................................................20 Table 1 - Concrete Mix Design ....................................................................................................................17
  • 5. Page 1 of 22 Introduction MÄGA Engineering (Pvt) Ltd is one of the leading construction firms in Sri Lanka. The company was established in 1984 under the leadership of the present Managing Director, Capt. M.G. Kularathna. By wisely managing its capital and resources, the company has evolved into one of the pioneering construction companies in Sri Lanka, executing some of the most prestigious infrastructure and development projects (1). The company collectively has the capability for the construction works of buildings, bridges, roads, water supply, drainage facilities, irrigation, land drains, dredging, land reclamation and electrical installations (2). The Institute for Construction Training and Development (ICTAD) in Sri Lanka has awarded MÄGA Engineering with the highest possible national grade C-1 for the majority of its civil operations. This grade provided by the ICTAD evaluates the financial capability, technical ability of staff, plant and machinery, and expertise gained in relevant fields. Out of the numerous projects that MÄGA Engineering was working on at that time, I was assigned to its flagship building construction project, which was the construction of the Hyatt Regency Hotel Colombo. The site was located in the busy commercial capital of Sri Lanka hugging the coastline of the beautiful Indian Ocean. During the period of my internship, the project had already progressed extensively. I was fortunate enough to contribute to the construction of the structure from the 20th floor to the 23rd floor during my assignment. This project was initially commissioned to the private sector but later taken over by the government when it was abandoned by the developer for over three years since 2008. This asset was taken into government control under the revival of the Underperforming Enterprises and Underutilised Assets Act of Sri Lanka. The Board of Investment (BOI) of Sri Lanka hereafter signed an agreement with Sino Lanka Hotels and Spa (Pvt) Ltd. The BOI agreement awarded the approval for the Client to develop the property and also to grant the necessary concessions for construction under the Strategic Development Projects Act. The project was finally given the go ahead in March 2012 by the Cabinet of Ministers of Sri Lanka. A consortium of investors including both private and state entities provided the capital to the new project developer. The project was finalised to be a 45 storey 5 star luxury hotel and serviced apartment complex upon completion to be managed by the Hyatt Regency brand.
  • 6. Page 2 of 22 History of the Company The company was incorporated under the companies Act No. 12 of 1982 on 2/12/1983 as a private limited liability company and was registered under the name Chandranayake and Company (Private) Limited. It was initially in the business of constructing of commercial or residential buildings, roadways, bridges and other civil, electrical & mechanical engineering works. On 17/10/1989 the company name was changed to MÄGA Engineering (Private) Limited. In its early years the company was mostly engaged as a sub-contractor to several international contractors operating in Sri Lanka. During this time, under the leadership of the present Managing Director, Capt. M.G. Kularathna this company evolved into Sri Lanka’s pioneering construction firm. In the modern age, MAGA is the market leader in both in volume and quality of work. Because of the recognition earned by the company it would expand into foreign markets as far back as 1987 to go on to complete over a dozen civil and coastal engineering projects. During the company’s 18 year lifetime, it has completed well over 125 projects in multiple disciplines which include numerous large scale prestigious projects. The company has been decorated with a multitude of awards over the years, but the greatest award that MAGA achieved is the recognition of the industry and its stakeholders for its capability to maintain an extremely high standard of quality across the board. Notable Awards :  2012 Sri Lanka’s Corporate Accountability Index – Platinum Rating, No. 3 Rank  2011 National Business Excellence Award by National Chamber of Commerce of Sri Lanka, Construction Sector – Winner  2011 Central Environmental Authority, National Green Award for Private & Public Sector  2010 National Business Excellence Awards by National Chamber of Commerce of Sri Lanka, Construction Sector – Winner  2010 National Construction Awards by National Construction Association of Sri Lanka (NCASL), Buildings Sector – Winner  2008 The Institution of Engineers Sri Lanka (IESL), Engineering Excellence Award (Infrastructure Development)  2008 Business Superbrands Certification
  • 7. Page 3 of 22 Project Briefing Project : Construction of Proposed Hyatt Regency Hotel – Colombo Location : 116 Galle Road, Colombo-03, Sri Lanka Client : Sino Lanka Hotels and Spa (Pvt) Ltd Contractor : MÄGA Engineering (Pvt) Ltd Consultant : Design Consortium Ltd Project Initiation : 10/06/2012 Estimated Project Completion : 31/08/2014 Estimated Duration of Project : 2 years and 2 months Contract Structure : Measure and Pay
  • 8. Page 4 of 22 Site Layout 1. Proposed building 2. Material and equipment stores 3. Steel yard 4. Security office 5. Construction elevators 6. Tower crane 01 7. Tower crane 02
  • 9. Page 5 of 22 Scope of Works The structure was to be a 45 floor RCC framed structure with an approximate total of 565 rooms which amounts to around 94,000 sqm of built up area. The luxurious hotel complex is to sustain 475 guestrooms with a variety of models which include different features. It would comprise of 54 suites, 265 King rooms, 150 twin rooms and 6 rooms with disability access. Furthermore the structure would feature 84 serviced apartments. To accommodate parking needs of the guests the structure will include of ample parking spaces involving 2 basement floors and exterior structures for car parks. To establish the hotel as a glamorous modern architectural masterpiece in Sri Lanka, the designers have endeavoured to incorporate some truly stunning features into their magnum opus. One of these aspirations was the infinity pool and pool deck located at the 11th floor of the structure. The deck sits atop the western coastline of Sri Lanka looking into the vast Indian Ocean. The pool deck is expected to have a seating capacity for 76 individuals. Figure 1 - Graphical rendering of building
  • 10. Page 6 of 22 Furthermore the complex is to consist of amenities such as a lobby lounge, dining areas, a multi-cuisine restaurant, 3 more specialty restaurants, a bar, eight spa treatment rooms, a fitness centre, and a Regency Club lounge. Moreover the complex will offer more than 17,000 sq ft of enclosed meeting spaces the highlight of which will be the 7,500 sq ft, 27 ft high grand ballroom. Upon completion the structure is to stand at 176 m which would make it the tallest structure in the country surpassing the previous tallest building, the World Trade Centre Towers which stands at 152 m. The WTO towers are visible across the undeveloped Galle Face promenade which will make it an exquisite sight from the guests at the hotel. The hotel complex is expected to be inaugurated by the end of October 2013 with the residential suites to be operational by August 2014.
  • 11. Page 7 of 22 Summary of Construction Operations Surveying The continuous surveying and levelling operations during the construction works were quintessential towards maintaining the accuracy of the dimensions construction works as proposed by the design blueprints to an acceptable tolerance. Formwork Formwork is either a temporary or permanent structure used as a container or mould into which fresh concrete can be poured to achieve the designed structure. It helps achieve the required shape and dimensions of the concrete works. Additionally it acts as a platform to lay out the steel reinforcement prior to concreting and also supports the fresh concrete until it has matured sufficiently to be self- supporting. Numerous techniques and materials are available for formwork purposes but in this project mostly plywood and specifically designed aluminium formwork systems were used. Reinforcement Works The concrete structure is reinforced with steel reinforcing to provide strength and resilience to the structure. The reinforcement is usually required because of the lack of tensile and ductility capacities of plain concrete which can be counteracted b using an appropriate composition of rebar. Concreting Works Concrete is a mixture of cement, water, and construction aggregates. Concrete is widely adopted in the construction field because of its relative less cost, fire proofing capabilities and durability. Concrete has excellent performance in compression making it excellent for high-rise structures. Masonry Work Masonry work is necessary in structures such as this to form partitions. Both clay bricks and concrete blocks were used in the construction of this building. Quality Control The quality control and quality assurance sectors involved in the construction works help to monitor and achieve the targeted quality standards approved for the project. Throughout which the continuous set of records are maintained to prove that the quality standards are being met. Their scope not only includes the construction works but also the construction materials and equipment as well. Health and Safety Even though everyone on site had to maintain their own health and safety obligations, there were also specifically assigned safety officers who were in charge of implementing an adaptive health and safety plan.
  • 12. Page 8 of 22 Personal Responsibilities The staff involved in the direct construction works was divided into sectors for reinforcement works, concrete works, formwork and surveying. During my internship at the Hyatt Regency – Colombo project working at MAGA, I was assigned to work with the reinforcement sector of the construction works. My key task was to work with my peers and apply my engineering knowledge to manage and instruct the workmen to perform the reinforcement works. The company employed many subcontractors to perform the works. The subcontract groups were assigned to carry out specific portions of reinforcement work or were used as labour supply to perform more general work. They payment schedules of these two types of workers varied as well. The formerly mentioned workers were paid using a rate based mechanism where they would be paid according to the quantity of reinforcement works completed. The unit of measured quantity would usually be the reinforcement used by weight. The later would be paid on a daily basis. Even though the workers in general were cooperative, because of the characteristics of the payment schedule challenges did occur when it came to motivating and regulating their work. Figure 2 - Work on top level Engineering drawings were extensively used on site as the primary for all construction works. A comprehensive understanding of the drawings was required to quickly determine what was required to be constructed. Drawings depicted the structure and layout of columns, beams, slabs and walls. The skill
  • 13. Page 9 of 22 level of the workmen varied significantly with some being able to understand the drawings and some finding it more difficult to grasp the information. Because of this my peers and I played a key role in interpreting and conveying the contents of the drawings. Furthermore it was required by us to review and scrutinize the works to check for defects before the final inspection for the item was conducted by the consulting engineers. Being part of the construction team on site meant that even though you were assigned to a specific sector, the cooperation of other members was required in order to complete the tasks at hand. This brought out a good teamwork ethic in the entire staff to collaborate with others from different sectors to achieve the final goal of progressing through the construction works. Often times it was necessary to communicate with the tower crane operators, signalman and bar bending staff to make sure the right materials and prefabricated structures were delivered to the right location at the right time. The concept of tight deadlines was heavily emphasised by the superiors. Even though different sectors have their own specific tasks, they are all interlinked. Therefore a delay in one area would effectively delay the entire process. For example if a delay occurs in laying the formwork it would delay the reinforcement works and subsequently the final concreting. We were also made aware the ramifications for the delays occurred on site. Every delay results in costs one way or the other. Furthermore it has negative effect on the relationships between the members involved in the project. Although my primary assignment was in the reinforcement section, to better understand the functions of the involved construction works I extended my attention to other sectors as well. Direct Construction Works Formwork Formwork is a temporary or permanent mould required for the casting of concrete. A high quality formwork system is cost efficient and quick & easy to assemble/disassemble. Specifically designed aluminium panel system was used for beams, slabs, walls and columns while 12 mm thick plywood was used for the staircases. An array of jack and pipes were used to prop up and support the panels. Chains, chain blocks, turnbuckles and other accessories were used to brace and align the panels.
  • 14. Page 10 of 22 Figure 3 - Propped aluminium formwork Formwork for Columns and Walls The columns had a rectangular cross section; therefore four aluminium panels were sufficiently enough to cover the perimeter of the column. The panels used for walls are also designed to sufficiently cover it but as the wall is connected to columns on its sides only the two larger faces are required to be enclosed. Usually a 200 mm offset is marked using surveying equipment. The formwork would then be erected using this offset as the basis to find the outline of the column or wall. Once the initial assembly of the formwork is completed, the verticality of the formwork is checked using a plumb bob and measuring tape. The plumb bob is left to hang from a known offset from the face of panel at the top of the assembly. Then the offset distance of the plumb bob is measured from the bottom of the assembly. If these two values are within the appropriate tolerance limits the formwork is acceptable, if not it has to be adjusted using the accessories provided.
  • 15. Page 11 of 22 Figure 4 - Formwork of a column Formwork of Beam and Slab The first step in the assembly of beam and slab formwork is to setup a uniform level by which the heights to the formwork can be measured. This is achieved by making a 1000 mm mark on each of the columns from the top of the slab on the floor beneath. The column heads are fixed subsequently and then the formwork is then propped. A grid like structure is formed initially while the formwork for the beams are installed first. After the sideboards are installed for the beams, the workmen then proceed to finish off by completing the slab area between the beams. The level of the slabs and beams are fairly accurate due to the use of the use of the same aluminium props. Hence if the concrete level of the lower slab is done accurately the formwork should also be very consistent. If finer adjustments are required it is done by placing a small square of plywood with a thickness that would account for the difference in that area. Formwork for Staircases Initially the foundation for the flight of stairs is laid by constructing the beam at the bottom. After the dimensions of the staircase have been set out the formwork for the landing is erected and supported using adjustable steel props. The landing should be accurately levelled to ensure quality standards are maintained. After this step the formwork to support the stringer and its sideboards are laid. When these steps are completed the reinforcement of the staircase is installed. Following this step dimensional
  • 16. Page 12 of 22 timber and plywood are used to form the risers of the staircase which can finally be followed by the concreting works. Figure 5 - Formwork and concreting of the staircase Removal of Formwork Because it is cost efficient to reuse the formwork equipment, they must be carefully removed at the right time. Concrete gains strength over time and once the concrete is sufficiently strong enough the disassembly of the formwork may begin. The concrete is allowed to reach its design strength before the formwork is removed. This is usually attained after 28 days. To ease the removal of the aluminium panels, form oil is applied prior to the concreting of the segment. The form oil used at the site was a mixture of grease and diesel and is applied to prevent concrete from sticking onto the aluminium panels. Reinforcement Work Steel reinforcement is added to concrete mainly to increase its tensile, shear and ductile capacity. It also helps to control the expansion and compression of the concrete which occurs due to numerous reasons which include environmental factors and long term chemical reactions in the concrete. The steel reinforcement comes in a myriad of sizes and grades. In this site Tor steel and mild steel was used accordingly. The designers had specified the necessary size and grade of the steel reinforcement in the drawings. They were chosen taking into consideration factors such as required tensile capacity, bendability, availability and cost. Steel bars of all sizes arrived to the site in 11 m lengths, from which they would be cut and bent appropriately.
  • 17. Page 13 of 22 Figure 6 - Reinforcement works and formwork Tor steel occupied a larger portion of the reinforcement works. It has a design tensile capacity of 460MPa and is used for a variety of purposes. Its surface is ribbed to provide extra friction with the concrete which results in a better bond with the concrete. Mild steel has a design tensile capacity of 250MPa and is mainly used for some column stirrups and secondary reinforcement. Bar Bending Schedule A bar bending schedule is a document prepared in order to create a bending and cutting schedule for the reinforcement bars. The steel reinforcing at times is required to be bent into shapes or cut appropriately. The bar bending schedule specifies the quality and quantity of the required reinforcement bars. It identifies information such as bar mark, location of the bar, quality of steel, size of steel bar, dimensions, shape code, cut length etc. Bar Notation To recognize and relate bar details with the information provided in bar bending schedules, bar notations are used in the engineering drawings. It is a simple and easy system to help people on site to identify the reinforcing requirement of an element. Eg: 5T10 – 06 – 150 B 5 - Number of bars required 06 - Bar mark T - Tor steel (R = mild steel) 150 - Spacing of bars in millimetres 10 - Diameter of bar B - Bar location
  • 18. Page 14 of 22 Crank Length When reinforcement bars overlap they have to be cranked in order to maintain a linear force line. A standard formula was introduced to identify this required length. Crank Length = (d1 + d2 + 5) * 10 mm d1 - Diameter of first bar d2 - Diameter of second bar Lap Length When a reinforcement bar has to be connected to another bar to achieve its desired purpose it would be overlapped. This overlapping enables complete transfer of the bars design tensile capacity. In order achieve this complete tension transfer sufficient length of bar has to overlap the other in what is known to be the lap length. Even though the calculation of the lap length requires the use of standards and knowledge of the properties of the concrete and steel used, it has been simplified so that even an unskilled worker can implement it. Lap Length = (50 * d) mm d - Diameter of smallest bar Cover Blocks When the reinforcement is being assembled over the formwork, the design specified cover must be maintained between the outermost surface of the reinforcing and the formwork. This cover length is required to deter corrosion and to increase fire resistance of the reinforcing amongst other reasons. To achieve this blocks made out of mortar are placed in between the reinforcing and the formwork. These are known as cover blocks and are usually made with a mortar mixture that would have a compressive strength similar to that of the concrete poured into the element. Cover block sizes : Floor slabs - 25 mm Beams - 30 mm Staircase - 30 mm Shear walls - 40 mm Columns - 50 mm Spacer Bars and Stools When laying out the reinforcement for a slab there is usually a top and bottom layer. An effective gap between the two layers must be maintained in order to obtain the design capacity of the slab. In order to achieve this either spacer bars or reinforcement stools must be placed. Usually the absolute spacing between the two layers is approximately 30 mm. In these areas 32 mm bars would be placed as a spacer bar. The spacer bars are short lengths of steel bars which are usually obtained from cut-off material. In other cases 10 mm bars are bent into shapes which can support the top layer of reinforcing.
  • 19. Page 15 of 22 Prefabrication of Reinforcement Works The traditional method of constructing the reinforcement is to build the assembly on the site itself which is known as building in situ. There are times when the specific element is built offsite and transported to the desired location using the tower cranes. There are many advantages to prefabricating items. It is useful to have a proportion of the labour force working in the prefabrication areas as the construction site can otherwise become congested with an excess of people and materials lying about. Prefabrication also increases the efficiency at which the elements such as beams columns and even walls are constructed. The workers can construct the structure in a comfortable area which is likely to be sheltered from the elements to a certain degree. Structures such as columns when being built in situ, is relatively difficult to construct as the workers would have to mount themselves onto high scaffolding and lower heavy bars from the top of the existing column. This is both strenuous and dangerous. Prefabrication of these segments avoids these circumstances and often results in a much more quality product. After prefabrication is complete diagonal bracing members are welded onto the segment, hoisted to the appropriate floor and installed into the relative section. Figure 7 - Raising of a prefabricated structure
  • 20. Page 16 of 22 Concreting Concrete is made from a mixture of cement, fine aggregates, coarse aggregates and water. At times admixtures are added to the formula in order to adjust certain properties of the concrete such as setting times and workability. The cement reacts with the water in an exothermic hydration reaction to produce the concrete. The cement is made from a mixture of silicates and oxides which mainly have some lime, aluminium and iron. Coarse aggregates increase the strength of the concrete and also reduce the amount of cement required. Ideally they should be as angular as possible as this increases the surface area the grout can adhere to. The fine aggregates help fill the voids in between the coarse aggregates. They also help reduce shrinkage of cement on hardening. Sea sand should not be used for reinforcement works as the high pH of saltwater could accelerate corrosion. Ideally the aggregates should be in a saturated surface dry (SSD) state before being added to the mixture as this avoids surface adsorption of the free water. Otherwise this loss of water would have to be taken into account during the batching process. After the concrete arrived at the site it would either have to be pumped or carried up using a bucket. When concreting the slab and beam areas the concrete was pumped and distributed using a combination of steel and rubber piping. When columns or walls were to be concrete the concrete would be transported up using the tower crane in a large bucket and discharged either directly from the bucket or with the use of a tremie. Ready Mix Concrete The concrete was not made in situ instead it was brought in from a concrete batching plant. Making concrete for a large scale structure requires a lot of labour, plant equipment and materials. If all of this were to be included in the site itself it would have been a tremendous inconvenience as it would occupy a large area and would lead to congestion. This batching plant was owned by MAGA and it serviced multiple construction sites at the same time which helped reduce costs. Additionally because of the specialisation of the staff at the batching plant, a better quality of concrete can be obtained. After the concrete is made at the batching plant it would then be transported to the site using agitating trucks.
  • 21. Page 17 of 22 Figure 8 - Ready mix concrete poured into concrete bucket Concrete Mix Designs A concrete mix design is a schedule of the materials to add to the concrete mixture and the necessary quantities. The concrete mix varies for different compressive strengths and the added admixtures may also change depending on the element which is required to be concreted. Table 1 - Concrete Mix Design Grade 30 Grade 50 Cement 350 kg/m3 450 kg/m3 Fly ash 53kg/m3 70 kg/m3 Silica Fume 0 0 Chilled Water 165 l/m3 166 l/m3 Fine Aggregate 861 kg/m3 794 kg/m3 Course Aggregate 1011kg/m3 970 kg/m3 Retarders 0.70 l/m3 0.9 l/m3 Superplastic 2.84 l/3 4.68 l/m3
  • 22. Page 18 of 22 Concrete Quality Control The quality of the concrete used was continuously checked. The workability of the concrete was an essential factor. As the site was using a concrete pump and steel pipes during large concrete pours, the concrete had to have a sufficient workability. If this requirement wasn’t met there would be a possibility that the distribution system would get clogged. To monitor the workability of the concrete a simple slump test was conducted for every truckload of concrete. Furthermore the compressive strength of the concrete must be monitored. The site maintained its own set of testing procedures not relying solely on the suppliers guarantee. The cube crushing test was conducted on site as a measure to maintain the required quality. A sample of the fresh concrete would be poured into a steel cubic mould. After the concrete is set and cured for a specified time, its maximum compressive strength is investigated by using a crushing apparatus. Figure 9 - Concrete being poured into a wall
  • 23. Page 19 of 22 Technical Facilities Concrete Pump The proposed construction site was to accommodate 45 floors. One of the greatest challenges was to transport the material up there. Even though concrete could be transported to the top using the tower cranes using various apparatuses, it would only be able to carry small commodities due to its maximum lift capacity. Hence a much more practical approach is to merely pump the concrete upwards. In order to generate the required pressure to transport the concrete to that height a concrete pump is used. Truck Mixture The truck mixture is used to transport the ready-mix concrete supplied from the concrete batching plant. It continuously rotates its drum which is filled with concrete during transportation. This prevents the concrete from setting during the transportation process. The concrete would be driven out of the drum using a spiral blade and then poured into the necessary apparatus using a pull-out chute. Tower Crane This machine is used to lift and transport heavy loads. It is used extensively in transporting items such as steel rebar, fresh concrete, prefabricated structures, cover blocks, water tanks etc. Tower crane no. 2 was a Luffing crane which had to undergo repairs. But due to the presence of the other tower crane some of the adverse effects were mitigated. Figure 10 - View from tower crane
  • 24. Page 20 of 22 Poker Vibrator Poker vibrators were extensively used on site as a means of compacting the freshly poured concrete. They were very advantageous as they could be easily moved around, stored and quick to setup. Construction Elevator The construction elevator is a quick and efficient way to transport people and materials along the building. Even though the site had a stairway which reached the top, in order to move masses of people and materials it wasn’t a viable method to solely use the stairs. There was a site policy of always have at least one elevator operational at all times. Designated operators were appointed to control the hoists. The hoists were powered by an electrical generator situated on site. The hoist operators shared the responsibility to monitor the fuel levels of the generator so as to avoid a sudden termination of power. Figure 11 - Construction Elevator
  • 25. Page 21 of 22 Conclusions From this work experience I was able to attain a number of skills that a capable engineer should attain and also the knowledge to go along side it. I have a gained a better understanding to work with my peers and to work with 3rd parties such as clients, consultants and subcontractors. I have been able to successfully build relationships with them and use them instrumentally to perform the required works. This experience has contributed towards improving my work ethic and also to take pride in my work as a professional engineer.
  • 26. Page 22 of 22 Bibliography 1. Maga Engineering (Pvt) Ltd. Home Page : Maga Engineering (Pvt) Ltd. Maga Engineering (Pvt) Ltd Web site. [Online] Ultimax (Pvt) Ltd. [Cited: 03 March 2014.] http://www.maga.lk/. 2. Institution for Construction and Development. Home Page: Institution for Construction and Development. Institution for Construction and Development. [Online] SLT Web Services, 31 January 2014. [Cited: 06 March 2014.] http://www.ictad.lk. 3. Maga Engineering (Pvt) Ltd. Hyatt Regency Hotel: Maga Engineering (Pvt) Ltd. Maga Engineering (Pvt) Ltd. [Online] Ultimax (Pvt) Ltd. [Cited: 06 March 2014.] http://www.maga.lk/?page_id=137. 4. ICRA Lanka & IMaCS Research & Analytics. Construction Industry in Sri Lanka. 2011.