Sri Lanka Institute of Information Technology

Report on In-plant
Training
At

Engineering Laboratory and Services (pvt) Ltd.

Name: Fernando B.A.V.W.
Registration No: EN 13523756
Course: BSc in Civil Engineering
Field of specialization: Civil Engineering
Period of training: 12 Weeks

Acknowledgement
It is a great pleasure for me to acknowledge the assistance and contributions of all the people
who helped me to make my industrial training a success. My training would not have been so
successful, without the dedicated assistance given by those individuals.
I would like to give my special thanks to Mr. Mahinda Rathnasiri (Gen. Manager-Engineering
Laboratory and services (Pvt) Ltd), Dr. Ganga Samarasekara (Department AdvisorDepartment of Civil Engineering- Industrial Training Division Sri Lanka Institute of
Information Technology) and all the officials of Industrial Training Division for placing me at
ELS.
I would also like to thank Mr. Kalyanapala Marakkalage (coordinator for training-SLIIT),
Prof. Ashoke Peris (Dean-SLIIT), Prof. Saman Thilakasiri (Department Head-Civil
Engineering-SLIIT) and all other Officials of Department of Civil Engineering for the
assistance and guidance they given towards this program.
In ELS, I would like to thank my managers, Mr. Tiran Jayasinghe (Laboratory Managers) and
Mr. Sudeep Perera (Piling Manager) for coordination and conducting of events. For their
extensive support I would also like to thank Mr. Gamini Wijethunge, Mr. Indika
Samaranayake, Mr. Nilantha Mallawaarachchi, Mr. Suneth Kalpage and Mr. Madushan
Egodahewa for providing necessary facilities, equipments and sharing their knowledge with
me.
Finally I would like to thank every individual (who I have not mentioned names above) who
gave me even the slightest support (even by words) to make my Industrial training a success.
Without their support, the completion of this training would not have been possible.
Sincerely yours,
Fernando B.A.V.W.
EN13523756
Department of Civil Engineering,
Sri Lanka Institute of Information Technology.

Table of contents
Acknowledgement

List of Figures

iii

List of Tables

iv

Abstract

Chapter 1

Introduction

01

1.1 Vision

01

1.2 Mission

02

1.3 Quality Policy

02

1.4 Organizing Structure

03

Chapter 2

Training Experience

04

2.1 Introduction

04

2.2 Work Plan

04

2.3 Exposure

05

2.3.1 Laboratory testing

05

2.3.1.1 Material Laboratory Testing

06

2.3.1.2 Aggregate Analysis

07

2.3.1.3 Concrete Analysis

08

2.3.2 On field Testing and Instrumentation

10

2.3.3 Piling site

16

2.3.3.1 Pile Preparation (cutting)

17

2.3.3.2 Welding Process

18

2.3.3.3 Pile Driving Process

19

2.3.3.4 Pile Cap Preparation

20

2.4 My Best Pickings

Chapter 3

22

Conclusion

23

References

24

Appendices

26
II

List of Figures
Figure 1: Organizing Chart

Figure 2: Satisfactory failure patterns of concrete cube

Figure 3: Un-satisfactory failure patterns of concrete cube

Figure 4: Schematic of rebound hammer operation

Figure 5: Field density apparatus

10

Figure 6: Bridge beam test

11

Figure 7: Bridge beam test

11

Figure 8: Bridge beam test

11

Figure 9: Bridge beam test

11

Figure 10:PIT machine

12

Figure 11:PIT machine

12

Figure 12: Inclinometer

13

Figure 13: Cement crack

14

Figure 14: Cement crack

14

Figure 15: Auto level with multimeter

15

Figure 16: Staff

15

Figure 17: Crack gauge

15

Figure 18: Crack gauge

15

Figure 19 Pipe cutting after driven

20

Figure 20: pile de-watering

21

Figure 21: pile de-watering

21

III

List of Tables
Table 1: Work Plan

Table 2: Material Laboratory Testing

Table 3: Aggregate Laboratory Testing

Table 4: Detectables and undetectables in Pile Integrity Test

12

IV

Abstract
I, Fernando B.A.V.W., Civil engineering undergraduate, Department of Civil Engineering, Sri
Lanka Institute of Information Technology have underwent an in-plant training as a
compulsory requirement for the engineering bachelors degree. The purpose of this In-Plant
training is to familiarizing ourselves with the professional engineering practices prior to
graduation and obtain the work experience in a real engineering-practicing environment. In
order to achieve both goals my choice was the Engineering Services and Laboratory (Pvt)
Ltd. There I functioned as engineering trainee for 12 weeks. In this report I have highlighted
the challenges that I encountered and actions taken or solutions to problems during my
training at Main construction laboratory, Boralesgamuwa and Piling site, Colombo Harbour
(East Container Terminal). I believe, I have gained enough knowledge that to prove myself
and the faculty with the training that I got from the ELS.

1.0

Introduction

Engineering Laboratory and Services (Pvt) Ltd or simply ELS is a very renown in the
industry for it's pioneering laboratory testing. ELS is among the companies in the industry
that has one of the humblest beginnings. Initially it was started with only few instruments
available and developed into one of the leading company in the laboratory testing arena. With
the initial success with the laboratory business, ELS ventured to construction and
manufacturing areas.
Today ELS head office and main laboratory are housed at 62/3, Neelamahara Road,
Katuwawala, Boralesgamuwa. This is where almost all the laboratory work is done. And also
the documentation work related to laboratory work, construction related documents(bidding
documents, tender documents...etc) and other clerical works. There are two concrete factories
located at Bemmulla, Gampaha and Suriyawewa, Hambanthota to provide all kinds of
concrete products(Hume pipes, pre-cast piles, bridge beams, light poles...etc). And a yard at
Boralesgamuwa to park/store and repair construction related vehicles and machinery.
ELS is graded by the ICTAD(Institute for Construction Training and Development, Sri
Lanka), P1 for Piling contractor(Highest grade) and C2 for bridge construction. And also geotechnical investigation division of ELS is well praised and highly demanded for their onshore
and offshore innovative competence in the field.
With the effective work done by the 8oo over workforce of ELS, to ensure that the work and
products quality are reflected by ISO 9001:2008 in addition to achieving SLS mark for few of
their products.
1.1 Vision
To be the leader and the most preferred engineering solution provider for specialized
foundation systems, bridges, pre-cast and pre-stressed concrete items, Geo-technical
Investigation and providing laboratory services to the construction industry.

1.2 Mission
We at ELS put together all our priorities in total customer satisfaction through delivering
quality goods and services in a timely and cost effective manner whilst ensuring the legal,
social and environmental obligations we are bound with.
1.3 Quality Policy
Fundamental quality policy is to maintain the position at the top grading in construction of
specialized foundation systems, bridges and other civil engineering structures, producing high
quality pre-cast products and providing reliable geo-technical investigation and laboratory
tests reports while ensuring legal, social and environmental requirements.
The long term commercial success and development of ELS depends on selecting quality
resources, selected suppliers, using modern and appropriate technologies, employing
dedicated, qualified and experienced staff to satisfy customer needs within affordable price.
It is also our policy to maintain procedures for early detection of actual and potential
deficiencies which would lead to dissatisfaction end product and enable the company to take
effective, preventive and corrective actions.
Provision is made to evaluate customer's satisfaction and the feedback from the customers
will be used for continual improvements.

1.4 Organizing Structure

Figure 1: Organizing Chart of ELS

3

2.0 Training Experience

In this chapter explains about my work plan, work sites and products/technologies that I
worked with. And also the type of work I did, problems encountered and solutions that came
up with to make the training a success.
2.1 Introduction
The reason of having an in-plant training or an industrial training is to have an exposure into
the into the real world industry. While being an undergraduate, this makes possible to identify
the qualities that should improve in life and also possible changes that can be made in the
educational path in order to compete with the real world. This experience is not only filled
with technical ones but also with the non-technical/social experiences too.
ELS provides engineering solutions in many areas such as tunnelling, bridge construction,
soil investigation, instrumentation, laboratory testing and piling.....etc. I was exposed to
mainly piling, geotechnical investigations laboratory testing and instrumentation. There I had
the opportunity to interact with directors, engineers, technicians, supervisors, contractors,
sub-contractors and labourers too, which gave me a deeper understanding about what actually
the real construction industry is.
2.2 Work plan
There wasn't any specific pre-planned training programme for a civil engineering student.
Then a plan was prepared by the General Manager, which was set to 12 weeks. Which were
- 2 weeks of laboratory testing at ELS Laboratory, Boralesgamuwa
-2 weeks of instrumentation, field testing
-2 weeks experience in a bridge construction site
-2 weeks experience in a piling site
-4 weeks experience in a tunnelling site at Kotagala
But the initial plan didn't go accordingly, due to various reasons. Finally I had the
- 2 weeks of laboratory testing at ELS laboratory, Boralesgamuwa
4

-2 weeks of instrumentation, field testing

-8 weeks experience in a piling site at Colombo port, ECT
Table 1: Work Plan

Work Plan
Duration

12 Weeks

No

Target

From 29th September to 21st December

Place

laboratory testing

2
3

No of

From

Boralesgamuwa

Weeks
4

To
29th Sept to

instrumentation, field testing

, laboratory
Boralesgamuwa

28th Oct
29th Sept to

piling site

, laboratory
Colombo port

28th Oct
29th Oct to
21st Dec

It's important to note that during first 8 weeks (laboratory testing and on field testing/
instrumentation) work have been done; not strictly sticking to the schedule with doing only
laboratory testing or only doing instrumentation during the regarded time period. It is said
that it October- December time period is a light work period, when considering other times of
the year.
2.3 Exposure
I was not assigned to any specific work during my training. But there I was free to observe,
engage, participate, question and learn.
2.3.1 Laboratory testing
It was in the laboratory that I came to know the role of a construction laboratory in the civil
engineering industry. And how significant a construction laboratory is. All the testing are
done according to an accepted standard. Basically in a construction laboratory, testing are
done according to the requirement of the client(consultants) and their choice of the standard,
if they didnt prefer a specific standard, it's ELS then suggest a standard that the test has to be
done. ELS do almost every-kind of more popular testing in the Sri Lankan construction
industry and also testing that are rarely done (which kind of testing that other laboratories
5

don't). So here are some laboratory testing that I had observed during my time period in the
laboratory. Since every sample and testing are essential, and the results to be accurate, I had
to observe the process and learn while experienced technician themselves did the test. I was
encouraged to to the same testing all by myself and compare the results with their ones, if any
sample is left enough. And those results didn't count, only gave an experience.
2.3.1.1 Material Laboratory testing
Here are some main testing that done to check material properties and their respective
commonly used test methods.
Table 2: Material Laboratory Testing

Test Description
Moisture Content of soil
Specific Gravity
Sieve Analysis
Index Properties Test (Liquid Limit &
Plastic limit)
Hydrometer analysis
Lab CBR test (including moisture
density relationship)
Proctor Compaction Test (Standard)
Proctor Compaction Test (Modified)
Consolidation Test

Test method
ASTM D2216 10
ASTM D854 14
ASTM C136 06
ASTM D4318 10e

ASTM D422 63(2007) e2

ASTM D1883 07e2
ASTM D698 - 12e1
ASTM D1557 12
ASTM D2435 / D2435M 11

2.3.1.2 Aggregate Analysis

Here are some testing that done to obtain required aggregate properties and their respective
commonly used test methods.
Table 3: Aggregate Laboratory Testing
Test Description

Test method

Particle Size Distribution (Sieve Analysis)

ASTM C136 06

Water Absorption

ASTM C127 - 12

Specific Gravity

ASTM C128 12:

Flakiness Index

BS 812-105.1:1989

Aggregate Crushing value

BS 812-110:1990

Aggregate Impact value

BS 812-112:1990

Los Angeles Abrasion Value(LAAV)

ASTM C131 / C131M 14:

Bulk Density

ASTM C29 / C29M 09

2.3.1.3 Concrete Analysis

2.3.1.3.1 Compression Strength Test for test cube 150mm x 150mm
BS 1881-116:1983: Testing concrete. Method for determination of compressive strength of
concrete cubes
This test is one of the most used concrete test, which is to determine the compressive strength
of the concrete. After obtaining 3 or more cubes of the size 150mm x 150mm, The sample
cubes are set in a curing process. The test is done in 3,7,28 days respectively, based upon the
compressive value and the failing pattern, it is decided satisfactory or unsatisfactory failure.
In a Satisfactory failure generally all four faces are cracked approximately equally, with little
damage to faces in contact with the platens. Other wise tensile cracks formed in an
unsatisfactory failure.

Figure 2: Satisfactory failure patterns of concrete cube

Figure 3: Un-satisfactory failure patterns of concrete cube

* A copy of a test report on 'Compressive strength of concrete cubes' is attached .

2.3.1.3.2 Non-Destructive Hammer Test

ASTM C805 / C805M 13a: Standard Test Method for Rebound Number of Hardened
Concrete
Rebound hammer or Schmidt hammer is widely used non-destructive test for a rapid
assessment of the condition of the concrete structure. The mission to take cores from existing
structures is severely restricted or even forbidden. In such situations the rebound hammer is
more viable alternative to estimate the compression strength of concrete. There are many
other application areas where access restrictions or need for speed mean there is no practical
alternative for rebound hammer.This test method covers the determination of a rebound
number of hardened concrete using a spring-driven steel hammer. For a given concrete
mixture, the rebound number is affected by factors such as moisture content of the test
surface, the type of form material or type of finishing used in construction of the surface to be
tested, vertical distance from the bottom of a concrete placement, and the depth of
carbonation. Before the testing, the rebound hammer (Schmidt hammer or Swiss hammer)
must be calibrated using the calibration test anvil provided by the manufacturer for specific
product. Usually 12 reading should be taken, and dropping the lowest value and highest
value, an average is determined using the remaining ten values. Since using this test method
only give an indirect measurement of the strength of the material, this is used for making
comparison between samples or estimating the compressive strength.

Figure 4: Schematic of rebound hammer operation

2.3.2 On-field / in-situ testing and instrumentation

Just like the laboratory testing, these in-situ testing and instrumentation also done according
to an accepted standard. These on field testing also done on a request of a client. Unlike in the
laboratory testing in the on-field testing I was encouraged to engage in the testing. Mostly
because in the field, samples are abundant and can do several times if something goes wrong.
In instrumentation also I had the better chance with engaging with the instrumentation
process. This allowed me to visit lots of construction sites, and understand which kind of
testing are done frequently and in what kind of situations.
2.3.2.1 Mackintosh probe test
The Mackintosh Probe is a lightweight and portable penetrometer. It is a considerably faster
and cheaper tool than boring equipment especially when the depth of exploration is moderate
and the soils under investigation are soft or loose.
2.3.2.2 Field density (soil/ ABC): sand cone method

Figure 5: Field density apparatus

ASTM D1556 07: Standard Test Method for Density and Unit Weight of Soil in Place by
the Sand-Cone Method
This test method may be used to determine the in-place density and unit weight of soils using
a sand cone apparatus. This test method is applicable for soils without appreciable amounts of
rock or coarse materials in excess of 1 1/2 in. (38 mm) in diameter. This test method may also
be used for the determination of the in-place density and unit weight of intact or in-situ soils,
provided the natural void or pore openings in the soil are small enough to prevent the sand
10

used in the test from entering the voids. The soil or other material being tested should have
sufficient cohesion or particle attraction to maintain stable sides on a small hole or excavation, and be firm enough to withstand the minor pressures exerted in digging the hole and placing the apparatus over it, without deforming or sloughing.
2.3.2.3 Bridge beam test

at Bemmulla,ELS Factory
Figure 7: Bridge beam test

At Bemmulla,ELS Factory
Figure 6: Bridge beam test
Figure 8: Bridge beam test

Figure 9: Bridge beam test

This bridge beam test was held at ELS factory at Bemmula. RDA acted as the client and had
the presence when doing the test. Its simply measuring the deflection at a given load and
analysed the results according to the beam bending theory.

11

2.3.2.4 Pile integrity test

at Nagananda,Biyagama
Figure 10: PIT machine

ASTM D5882-00: Standard Test Method for Low Strain

Figure 11: PIT hammer

Integrity Testing of Piles

This test method covers the procedure for determining the integrity of individual vertical or
inclined piles by measuring and analysing the velocity (required) and force (optional)
response of the pile induced by an (hand held hammer or other similar type) impact device
applied axially to the pile normally at the pile head.
Here are some detectable and undetectable facts from the pile integrity test.
Table 4: Dectectables and undetectables in Pile Integrity Test
Detectable

Undetectable

reflections from the toe

reflections from significant inclusions. (510% or more of the pile diameter)

gradual increases or decreases in

cross section

curved forms

reflections from horizontal cracks

reflections from joints (as pre-cast

concrete piles).

small inclusion of foreign

materials

local loss of cover

debris at the toe of the pile

reflections from increase and decrease in

cross section.

reflections from changes in the soil layer

12

2.3.2.5 Pile dynamic analysis

ASTM D4945-00: Standard Test Method for High-Strain Dynamic Testing of Piles
This test method covers the procedure for testing vertical or batter piles individually to
determine the force and velocity response of the pile to an impact force applied axially by a
pile driving hammer to the top of the pile.
2.3.2.6 Inclinometer monitoring

at Narahenpita
Figure 12: Inclinometer

ASTM D6230 13: Standard Test Method for Monitoring Ground Movement Using ProbeType Inclinometers
An inclinometer is a device for measuring deformation normal to the axis of a pipe by passing
a probe along the pipe and measuring the inclination of the probe with respect to the line of
gravity. Measurements are converted to distances using trigonometric functions. Distances are
summed to find the position of the pipe. Successive measurements give differences in
position of the pipe and indicate deformation normal to the axis of the pipe. In most cases the
pipe is installed in a near-vertical hole. Measurements indicate subsurface horizontal
deformation. In some cases the pipe is installed horizontally and the measurements indicate
vertical deformation.

13

2.3.2.7 Piezometer monitoring:

A piezometer is either a device used to measure liquid pressure in a system by measuring the
height to which a column of the liquid rises against gravity, or a device which measures the
pressure (more precisely, the piezo metric head) of groundwater at a specific point. A
piezometer is designed to measure static pressures, and thus differs from a pitot tube by not
being pointed into the fluid flow

2.3.2.8 Vibration monitoring

at Thunder and Neon,

Boralesgamuwa
Figure 14: Cement crack

at Thunder and Neon,

Boralesgamuwa
Figure 13: Cement crack

Above figure shows a concrete crack due to vibration. It's simply monitoring the vibration
using specified vibration measurement instrument. This was done at 'Thunder and
Neon',Boralesgamuwa

14

2.3.2.9 Settlement monitoring

Figure 15: Auto level

with micrometer

Figure 16: Staff

This is settlement monitoring of a concrete floor, simply measuring the reading and
comparing it with previous data. at Labour department building, Narahenpita.
2.3.2.10 crack gauges monitoring

Figure 18: Crack gauge

Figure 17: Crack gauge

This is concrete crack gauge used for measure the crack level and compared with previous
results. At Labour department building, Narahenpita.

15

2.3.3 Piling site

unlike the two experiences before, this gave me a real life experience of working in a site. In
the in-situ testing only 1-3 days were spent at the site, but in the site almost 2 month spent on
the site. It allowed me to see the bigger picture. In this Colombo port site(East Container
Terminal), ELS act as a subcontractor, while Hyundai Engineering Co-operation (HEC) and
as the main contractor and Sri Lanka Port Authority (SLPA) as the Client and also the
consultant. When comparing the whole scope of the project, ELS do only of a fraction of it.
But it's a much important task of the whole project. ELS do the piling for the proposed crane
rail. Crane rail is built with capping beam on the top of the completed pile.
Apart from observing/supervising in piling site area, I had the privilege of visiting the
breakwater of the Colombo port, visit the mixing plant by HEC, visit the material laboratory
by HEC, observing other sites around the project, observing testing and monitoring
procedures, observing surveying and co-operating with other SLPA and HEC officers and
engineering trainees which allowed to share our knowledge with ourselves.
I also participated in a workshop on Occupational Health and Safety Management system
-OHSAS 18001 organized by University of Kelaniya since I was interested about it.
*in this section 'we' and 'us' refers to a team built with other engineering trainees from
University of Moratuwa and SLIIT. The tasks which we assigned done in a circular shift way,
where everyone gets the general understanding of each task.

16

2.3.3.1 Pile preparation (cutting)

Simply the pipe is cut using a cutting machine, during the process. But there were some
requirements to consider such as pipe length, bevel angle. And also smoothness of the cut,
pipe diameter, and thickness of the pipe and straightness of pipe like facts had to be checked
and recorded during the process. Before the cutting happens any kind of coating or rust has to
be removed. A semi-automatic plasma cutter have been used during the process. But upon the
unexpected breakdown of the plasma cutter the gas cutter had to be used to complete the task.
This process is supervised by ELS while inspected by both HEC and SLPA at every time that
a pipe is cut. The supervisors should record the above mentioned data in a check-list (a
certifying document), signed and should submit to the HEC and SLPA for their approval.
It was our responsibility to maintain a check-list database and prepare daily, overall pipe
cutting summary from time to time. We were advised to act as the supervisors and implement
the process when their presence not in the site. As a supervisor 1 plasma cutter, 1 gas cutter, 1
operator (plasma cutter), 3 labourers, 1 cutting trolley, 1 mobile crane will be provided with
the operator. So to act as the supervisor it is essential to observe the process and functions of
the supervisor. This whole process should be executed according to the method statement.
*Copies of a cutting check-list and a page in a cutting summary are available in the
appendices.

17

2.3.3.2 Welding Process

In a nutshell, two pipes are weld together during the welding process. To weld the two pipes a
fabrication process should be done which prepares the pipes for the welding according to the
method statement and make other requirements to execute the welding.
This process is almost done with a changed design of welding, apart from the method
statement. That new 'welding Procedure Specification' (WPS) was designed according to the
code API 1104; welding of pipelines and related facilities.
Accordingly to the new WPS, 2 weldings had to be done to a single pile location. Its 3 pipes
had to be used; which ultimately created the three steps in the driving process. The 2G pipe
welding method was new used for the welding process.
Prior to the welding, the fabrication process was done. Which was to smooth the surfaces
from grinding, achieving the verticality of the pipe and tick welding the two pipes with the
support of welding dogs. While fabrication process takes place, the pipe is held vertically by a
mobile crane.
This fabrication process requires 2 fabricators (welders), 2 labourers, 1 mobile crane, 1 arc
welding plants, sufficient welding rods, 2 grinders and sufficient grinding wheels.
After the fabrication is over, the welding process will take place. While the crane still holding
the pipe,, the three stages of welding; root run, hot pass, filling will be done. Both welding
and fabrication is done by two welders, operating at the same time. Maintaining the symmetry
of the fabrication and welding.
In the welding test process, it also wasn't done according to the method statement, where
every 25% of all joints had to be tested with a NDT (non-destructive testing; such as x-ray,
cathode-ray) method. But the agreement was to use 6G qualified welders, who are able to
pass the NDT test for a test piece. For the 2G welding.
This welding process requires 1 welding engineer, 2 6G qualified welders, 1 MIG welding
plant, 1 arc welding plant, sufficient amount of welding rods and flux coated wires.
This process should be recorded and certified by the welding engineer from the ELS. HEC
supposed to inspect while work continues, and SLPA certifies after the inspection or test.
18

It was our responsibility to collect and maintain the welding records database. Daily welding
summaries were made daily and overall welding summaries were made from time to time
(twice a week).
*Copies of a welding record and a page of a welding summary are available at the
appendices.
2.3.3.3 Pile driving process
Simply the pipe which used as the pile is driven in to the ground using a hammer at the
required location. This whole pile driving process is compiled to conduct according to the
standard: ICE- specification for piling and embedded retaining walls (1996)
In this operation K35 diesel, MB40 diesel and BSP CX110 had been used as the piling
hammers.
The driving process is executed in three steps initial driving, secondary driving, final driving
this steps are designed such that according to the pipes used for a pile location.
During the initial driving, placing the pile at centring the right pile location, making the pile
vertical using both the plump bod and spirit level methods. It is ordered to check the pile shoe
prior to ever initial driving. In the secondary driving the verticality of the pile maintained
using both methods in the same manner.
In the final driving it should be driven until the 'final set' is achieved. The term final set is
defined such as the driven length per hammer blow of 1mm.
It is important to note that initial and secondary driving is carried by the MB40 hammer,
while final driving is done by the BSP CX110 hammer. It is compiled to achieve the final set
using the BSP CX110 with its 6MT rammer weight.
It is also complied to do a high strain dynamic load test (PDA) for 25% of total pile driving
points and static load test per 1% of total pile driving points.
For a single pile driving, it requires 1 supervisor, 1 piling hammer (with stationed crane) with
its operator, 1 set of plumb bob method equipment, 1 set of spirit level method equipment, 5
labourers.

19

It is the supervisors responsibility to implement pile driving procedures according to the

method statement and record the pile driving records, which is to be certified by the ELS,
HEC and SLPA. The certification for the pile will be given by the HEC upon inspection when
work continues and witness inspection of the final set is required for SLPA.
It was our responsibility to maintain the driving records database, preparing daily driving
summaries and preparing overall pile driving summaries from time to time (twice a week).
And also to observe the pile driving process and report if something going on not according
to the method statement to the piling manager.
*Copies of a pile driving record sheet and a page of a driving summary are available in the
appendices.
2.3.3.4 Pile cap preparation
After the pile driving is done (when the final set is achieved) and after having the certification
from the consultants, the pipe will be cut at +1m level (considering mean sea level as the base
level). Required points have to be marked on the pipe, with the help of auto-level or water
level methods. Then the pipe is will be cut by the plasma cutter or the gas cutter, while a
mobile crane is holding the pipe from the top, to hang the off-cut piece upon cutting. The
same pipe cutting team will be implemented to do this task too. And the length of the offcuts
are measured and recorded.
Since the pile is a tubular pipe, and due to hammering,
the sand between in the cross section area of the pipe
will automatically compacted. If the sand level is lower
than the mean sea level automatically water will rise
up, and also from rain water could also gather inside
the pile. Because of that de-watering will be done with
the usage of water pump or manual methods. This
process is advised to do at the low tide time period.

Figure 19: Pipe cutting after driven

After the de-watering is done, sand will be filled and compacted up until the sand level 1.5m
downwards from the pile cap or -.5m level. A measuring tape will be used for measure the
correct sand level from the pile cap.

20

This process will be executed under the supervision of a supervisor and other required
resources are 2 labourers, 1 water pump, shovels and pans, 1 measuring tape. Most of the
time we had to supervise the de-watering and sand filling process; since supervisors are busy

Figure 20: pile de-watering

Figure 21: pile de-watering
with other tasks happening around the site.
Accordingly to the design of the pile cap, a reinforcement will be done. Since reinforcement
preparation cannot be done inside the pile, its prepared on the workshop and then put into the
pile. It was our responsibility to check whether, the reinforcement is prepared accordingly to
the design. And to record the amount that prepared in a day, which helped us to prepare daily
and overall summery of the reinforcement preparation.
After all above procedures have been done, re-dewatering will be done to remove the water as
possible up until the sand level (-.5m) to the pile. Then he prepared reinforcement will be put
in to the pile with the help of a crane. Finally concrete will poured into the pile, while poking
from the vibrating poker, up to the pile cap level (+1m). This concrete pouring process will
inspected by both HEC and SLPA, under the supervision of ELS. It was our responsibility to
observe the process and keeping a record of finalized pile caps and maintaining its data base.
And also wrapping the barricade tapes around the concrete poured areas was also done.

21

2.4 My best pickings

*In this, I like to discuss the things that interested me most during the training and also the
experience and understanding I got.
It was in the laboratory that I came to know about the 'standards'. In a laboratory all you have
to do is follow the procedures and standards. what is a standard? It is agreement which made
up by some party on the basis of experience, results, and many other things. Just like a law.
There are several standards in construction industry mostly accepted are the British
standards(BS), American society for testing methods(ASTM), International Standards(ISO),
and locally we have Sri Lanka Standards(SLS) which I believe that has to improve a lot.
There are many standards not only for testing but also every activity of construction industry.
Most importantly its always not important to know each and every test on earth, the way
standards interpret testing and its procedure make even an amateur to conduct a test
accurately. With the experience and familiarity of the user with the standards you can easily
reached to the expert level.
The other thing learnt form the site is everything on the site done according to the clients
proposal. All most every activity should be done according to a system, which were
developed through years of research. There are some construction firms worldwide, act as
consultants or the advisor for particular type of construction. As an example in site at East
Container terminal the whole piling process was designed according to the Scott Wilson
Group, piling practice.
When working in a project, its not the construction process matter the most, when comparing
the project management process. Since construction industry greatly deals with time, cost
and quality, giving great concern about project management is very crucial. This will
definitely reduce and cut-off the unnecessary and avoidable cost in great margins. It's also
important to provide basic necessities such as water, sanitary facilities, transportation, safety
wear. Not only in providing but also in checking whether all the facilities supplied in time ,
also important, since construction industry always depend on the people.

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3.0 Conclusion
The primary objective of this industrial training programme is to allow undergraduates to gain
real world experience of the construction industry. And look for the occasions where to use
the right theory at right time which learnt back in the university. I firmly believe I got the
right experience and understanding , and when and where to apply the right theory in an
appropriate manner. And also to make some industrially based connections such as
companies, influential people,
During the time at ELS as a trainee, I was expected to observe, engage, question, practice and
learn. Unlike some big named companies where a some work given and expected to stick to it
and repeating the same process. In ELS I wasnt given any specific task and always free to
learn what ever the situation were. It was my duty to fulfil that expectation of ELS, which is
also 'win win' situation for both the parties. In some in-situ testing I had to act as the engineer
and answer the clients and other parties question with technical solutions. In the piling site,
supervising and project management tasks had to be done as an engineering trainee.
The training I received from the ELS is not only oriented towards technical stuff. It is also
about project management, interpersonal communication, conflict resolving and most
importantly adopting to the new environment. We should observe such topics carefully and
should be able to overcome them.
I am really happy about the exposure I had to industry as an undergraduate and I would
recommend ELS to anyone who is keen on areas like laboratory testing, concrete technology
and piling (specially pre-cast, steel tubular and micro).

23

References
1. ASTM D2216-10, Standard Test Methods for Laboratory Determination of Water
(Moisture) Content of Soil and Rock by Mass, ASTM International, West
Conshohocken, PA, 2010, www.astm.org
2. ASTM D854 14: Standard Test Methods for Specific Gravity of Soil Solids by
Water Pycnometer. ASTM International, West Conshohocken, PA, 2010,
www.astm.org
3. ASTM C136 06: Standard Test Method for Sieve Analysis of Fine and Coarse
Aggregates. ASTM International, West Conshohocken, PA, 2010, www.astm.org
4. ASTM D4318 10e: Standard Test Methods for Liquid Limit, Plastic Limit, and
Plasticity Index of Soils. ASTM International, West Conshohocken, PA, 2010,
www.astm.org
5. ASTM D422 63(2007) e2:Standard Test Method for Particle-Size Analysis of Soils,
ASTM International, West Conshohocken, PA, 2010, www.astm.org
6. ASTM D1883 07e2: Standard Test Method for CBR (California Bearing Ratio) of
Laboratory-Compacted Soils, ASTM International, West Conshohocken, PA, 2010,
www.astm.org
7. ASTM D698 12e1: Standard Test Methods for Laboratory Compaction

Characteristics of Soil Using Standard Effort (12 400 ft-lbf/ft3 (600 kNm/m3)),ASTM International, West Conshohocken, PA, 2010, www.astm.org
8. ASTM D1557 12: Standard Test Methods for Laboratory Compaction

Characteristics of Soil Using Modified Effort (56,000 ft-lbf/ft3 (2,700 kNm/m3)),ASTM International, West Conshohocken, PA, 2010, www.astm.org
9. ASTM D2435 / D2435M 11: Standard Test Methods for One-Dimensional
Consolidation Properties of Soils Using Incremental Loading, ASTM International,
West Conshohocken, PA, 2010, www.astm.org
10. ASTM C136 06: Standard Test Method for Sieve Analysis of Fine and Coarse
Aggregates, ASTM International, West Conshohocken, PA, 2010, www.astm.org
11. ASTM C128 12: Standard Test Method for Density, Relative Density (Specific
Gravity), and Absorption of Fine Aggregate, ASTM International, West
Conshohocken, PA, 2010, www.astm.org
12. British Standards Institution (2010) Methods for determination of particle shape.
Flakiness index. Testing aggregates. BS 812-105.1:1989. British Standards
Online(online). Available at: http://bsol.bsigroup.com(Accessed: 11 Jan 2014)
13. Methods for determination of aggregate crushing value (ACV).Testing aggregates
812-110:1990.British Standards Online(online). Available at:
http://bsol.bsigroup.com(Accessed: 11 Jan 2014)
24

14. British Standards Institution (2010). Method for determination of aggregate impact
value (AIV).Testing aggregates BS 812-112:1990.British Standards Online(online).
Available at: http://bsol.bsigroup.com(Accessed: 11 Jan 2014)
15. ASTM C131 / C131M 14: Standard Test Method for Resistance to Degradation of
Small-Size Coarse Aggregate by Abrasion and Impact in the Los Angeles Machine
ASTM International, West Conshohocken, PA, 2010, www.astm.org
16. ASTM C29 / C29M 09: Standard Test Method for Bulk Density ("Unit Weight") and
Voids in Aggregate. ASTM International, West Conshohocken, PA, 2010,
www.astm.org
17. British Standards Institution (2010).Method for determination of compressive strength
of concrete cubes. Testing concrete..BS 1881-116:1983..British Standards
Online(online). Available at: http://bsol.bsigroup.com(Accessed: 11 Jan 2014)

25

Appendices
1. A copy of a test report on 'Determination of field density'
2. A copy of a test report on 'Particle size distribution of soil'
3. A copy of a test report on 'Specific gravity of soil'
4. A copy of a test report on 'Compressive strength of concrete cubes'
5. A copy of an inspection check-list for preparation of pile(pipe cutting)
6. A copy of a page in a cutting summary
7. A copy of an inspection check-list for steel tubular pile driving
8. A copy of a page in a pile driving summary
9. A copy of an inspection check-list for welding of pile (pipe welding)
10. A copy of a page in a welding summary
11. A copy of a construction plan on 'Crane rail foundation pile arrangement'
12. A copy of a construction plan on 'Crane rail pile cap details'

26

Appendix 1: 'Determination of field density' test report

27

Appendix 2: 'Particle size distribution of soil' test report

28

Appendix 3: 'Specific gravity of soil' test report

29

Appendix 4: 'Compressive strength of concrete cube' test report

30

Appendix 5: An inspection check-list for steel tubular pile driving

31

Appendix 6: A page in a cutting summary

32

Appendix 7: An inspection check-list for steel tubular pile driving

33

Appendix 8: A page in a pile driving summary

34

Appendix 9: An inspection check-list for welding of pile (pipe welding)

35

Appendix 10: A page in a welding summary

36

Appendix 11: A construction plan on 'Crane rail foundation pile arrangement'

37

Appendix 12: A construction plan on 'Crane rail pile cap details'

38