Ekeh Onyinyechi N. 1
Ekeh Onyinyechi N. 1
Ekeh Onyinyechi N. 1
BY
EKEH ONYINYECHI NENE
REGISTRATION NUMBER
FUNAI/BA/14/0902
OCTOBER, 2017
DEDICATION
To the almighty God and everyone who have in one way or the other cared for me
during my industrial training.
ACKNOWLEDGEMENT
I also wish to express my gratitude to Philip Chima for his faithful advice, my
gratitude also goes to the Head of department for his concern and effort about
our industrial training.
A special thanks goes to Mrs Emelogu Chinenye who have always called to know if
am doing fine and to Justin Okpala for his assistance financially and other wise.
Thanks to my Mum, Aunty and uncle for their prayers advice and financially. May
the almighty God reward everyone in abundance.
Amen!
PREFACE
They run test on clay to know the plasticity, strength and shrinkage ability. The
process of doing these have been reported, the works produced have also been
analyzed and discussed.
0.0 INTRODUCTION The students Industrial Work Experience Scheme (SIWES) is a
Skills Training Programme designed to expose and prepare students of
Universities, Polytechnics/Colleges of Technology/Colleges of Agriculture and
Colleges of Education for the Industrial Work situation they are likely to meet
after graduation. The scheme also affords students the opportunity of
familiarizing and exposing themselves to the needed experience in handling
equipment and machinery that are usually not available in their Institutions.
Before the establishment of the scheme, there was a growing concern among our
Industrialists that graduates of our Institutions of Higher learning lacked adequate
practical background studies preparatory for employment in Industries. Thus, the
employers were of the opinion that the theoretical education going on in higher
institutions was not responsive to the needs of the employers of labour. It is
against this background that the rationale for initiating and designing the scheme
by the Fund during its formative years – 1973/74 was introduced to acquaint
students with the skills of handling employers’ equipment and machinery. The ITF
solely funded the scheme during its formative years. But as the financial
involvement became unbearable to the Fund, it withdrew from the Scheme in
1978. The Federal Government handed over the scheme in 1979 to both the
National Universities Commission (NUC) and the National Board for Technical
Education (NBTE). Later the Federal Government in November 1984 reverted the
management and implementation of the SIWES Programme to ITF and it was
effectively taken over by the Industrial Training Fund in July 1985 with the funding
being solely borne by the Federal Government.
The Federal Government, the Industrial Training Fund (ITF), the Supervising
Agation
and Institutions have specific roles assigned to them in the management of the
SIWES
(a) To provide adequate funds to the Industrial Training Fund through the Federal
Ministry
(b) To make it mandatory for all Ministries, companies and Parastatals to offer
places for
The Decree under section 7A(2) stipulates penalties in default of section 7A(1)(b).
Section 7 (2)
“Any employer who is in breach of the provision of the sub-section (1) of this
section
(a) in the case of a body corporate, to a fine of N5,000.00 for the first breach and
to a fine of N1, 000.00 or two years imprisonment without option of fine for each
subsequent breach.”
i) Formulate policies and guidelines on SIWES for distribution to all the SIWES
iii) Receive and process Master and Placement Lists from the Institution and
vi) Organise biennial SIWES National Conference and Annual SIWES Review
Meeting;
viii) Provide logistics and materials necessary for effective administration of the
scheme, such documents as – ITF Form 8, ITF Form 8A the SPE 1and SIP A
ix) Ensure the visitation (tours) of ITF officers to the Supervising Agencies,
placement of students.
xi) Continuously review and carry out research into the operation of the SIWES.
their jurisdiction;
iii) Ensure adequate funding of the SIWES units in all the institutions.
iv) Vet and approve master and placement lists of students from participating
vii) Continuously monitor and review the job specifications of all the courses;
development;
ix) Regularly review courses qualified for SIWES in collaboration with other bodies;
x) Liaise with the ITF, to ensure the implementation of all Federal Government
PRODA
Brief History
PRODA was a creation of the defunct East Central State Government under Edict
No. II of 1971. It was charged with the broad function of generating and catalyzing
industrialization by carrying out industrial research from the laboratory stage to
the pilot plant stage, and by rendering consultancy services to Governments,
industry and individuals. It is, therefore, one of the oldest Research Institutes in
the Federal Ministry of Science and Technology (FMST).
When in 1976, East Central State was split into Anambra and Imo States, The
Federal Government recognized the need not to balkanize PRODA by the
emerging states and hence took it over as a Federal Government Research
Institute under Decree No.5 of 1977; still retaining its acronym 'PRODA' and
motto; 'Industrialization Through Self-Reliance. In 1980 with the creation of the
Federal Ministry of Science and Technology, it became one of the Institutes.
Location
Mission Statement
Vision Statement
PRODA's MANDATE
PRODA function through a Governing Board which reports to the Federal Ministry
of Science and Technology, the supervising ministry. The board determines the
policy guidelines of the Institute and in its absence, its authority transfers to the
Supervising Ministry.
The Institute's Management Committee is made up of six Heads of Departments
and chaired by the Director General/Chief Executive Officer, who is responsible
for the day to day running of the Institute.
Processing of ceramic materials and other solid based minerals for industrial use,
including development of ceramic, glass and mineral technology;
Coal utilization;
Technical, analytical and consultancy service for existing and planned industries;
and
PRODA function through a Governing Board which reports to the Federal Ministry
of Science and Technology, the supervising ministry. The board determines the
policy guidelines of the Institute and in its absence, its authority transfers to the
Supervising Ministry.
Made of clay that has been heated to a very high temperature so that it becomes
hard
Clay is the decomposition of the feldspethic rock into minute particles or tiny
crystals which is made up of alumina, silica and chemically combined water. It can
be expressed in its purest form in the following molecular composition:
Al2O3:2SiO2:2H2O.
1. Plasticity
2. Power of suspension
3. Slaking properties
4. Shrinkage
5. Texture
6. Green strength
PLASTICITY
POWER OF SUSPENSION
This is the property of finely grained clay to remain in suspension in water for
hours with out settling at the bottom of the container. The power of suspension is
needed more in casting process where the clay in the mold are required to hold
themselves.
Texture
The plasticity, green strength , shrinkage e.t.c of a clay ware are affected by
the particle size and shape of the clay grains. This is called the texture of the clay.
A sieve test is used to determine the coarseness or fineness of a clay.
Shrinkage
This is a drying property, when clay is made wet and plastic, the particles are
all coated with films of water. During drying the water films are removed by
evaporation, and the clay perticles are drawn together until they touch each
other. This loss of water and drawing together of the particles results in shrinkage
of the ware.
Slaking properties
When a clay is soaked, water penetrates the clay, wetting it , it swells and breaks
into smaller pieces. The moro loosely the clay is bounded together, the quicker it
will disintegrate pr slake
1. Silica
2. Alumina
3. Iron oxide
4. Pyrite
5. Calcium oxide
6. Alkali oxide
7. Carbonaceous matters.
Silica
This occurs in clays as quartz SiO2 and when the quartz grains are large to be
seen with the naked eyes, they appear as sand, and the clay is described as sandy.
Excess quartz in clay lads to dunting or cracking during firing.
Alumina
Al2O3 it is usually present in clay, compounded with SiO2. Clays very in
alumina are often very refractory.
Iron oxide
Iron oxide in clay leads to discolouration both in the raw and fired state.
Hematite, fez03 imarts red colours to clays both in the raw and fired states.
Pyrite
feS2 iron sulphide this s common in fireclays and leads to specking or dark
spots in the clay after firing
Calcium oxides
Alkali oxide
K20, Na2O these act as fluxes and lowers the firing temperature of clays.
They occur in very small quantities and many a times are of little effect.
Carbonaceous matter
Types of clays
1. Primary clay: these are those clays which have been formed on the site of
their parent rocks and have not been transported, either by water wind or glacier.
Primary clay when they have been cleared of rock fragments tend to be relatively
pure and free from contamination with non-clay minerals. This is because most
primary clay originate from beds of more or less pure feldspar, a rock which is
relatively easil broken down by water alone.
2. Secondary clay: this is the type of clay that is found outside its original place of
formation which must have been transported to the place by the agent of erosion.
PREPARATION OF CLAY:
Clay can be found in the fields, along the bank of rivers and streams in the dry
river beds, lakes, creek, or steam beds. It is always advisable to dig from
deposited with thin overburden.
Clay are full of impurities as dug out of the ground and they require to be refined
or washed before use. It is essential to remove the unwanted roots, sticks, excess
sand, pebbles etc.
Until the right plastic consistency is obtained. It is advisable to allow the clay to
stay overnight after the water addition before final mixing. Any lump left in the
clay can be picked out during the mixing. For ease in moulding, and safety of the
ware in drying and firing, moulding clay should be homogeneous, free from lumps.
Wedge boards could be used in the slicing or cutting, or a piece of wire held taut
and drawn through the lump or mass of clay. After wedging, the clay is then
kneaded in the jelly roll or bull face fashion. Spirally turning and pressing and
rolling the clay mass until it it feels smooth and shows a more uniform
consistency.
a. Plaster mould
b. Large rubber bands
c. Paper or plastic coffee cup
d. Gallon porcelain slip ware
e. Clay sponge
Turn your gallon of slip ware horizontally and roll back the front for 5 minutes to
get the slip well mixed, you can also shake the gallon up and down but keep in
mind it will be heavy .
1. Take the empty plastic/paper coffee cup that you gathered from the
materials list and fill it up with slip from the gallon, once you have done this
place it aside for now.
2. Get your mould ready by making sure the inside is clean and dry. Match up
the two halves of the mould by making sure the pin holes are aligned. This
will ensure a sealed closure and no leakage when slip is poured into it.
3. When the two halves of your moulds are together, fasten them with the
large rubber band, make sure they are nice and strong. This will keep the
two halves together and further ensure no leakage.
4. Once you have placed the rubber band around your mould and secured it,
flip the mould hole up.
5. Take the coffee cup filled with slip and pinch the edge of the cup to make a
nice pouring spout. This ensure no spillage and that the slip will flow out of
the cup nice and smoothly. We are doing this because the pore holes in our
moulds are not so large and we want to decrease the amount of spillage.
6. Pour slip into the mould once and slowly, fill the mould until it is almost to
the brink.
7. Once you have finished pouring slip into the mould, you must wait for a
certain amount of time for a desired thickness to build along the walls of
the mould. While this is happening you will realize that the slip is getting
lower and lower. This is happening because your slip is building up on the
inside of the mould, it's literally soaking the liquid slip into the mould walls.
Thus, resulting in the lowering of the slip level;
10mins - 1/6 inch thick
15mins - 1/8 inch thick
30mins - 3/16 inch thick
40mins - 1/4 inch thick, you can wait for the settling amount of time you
desire.
9. You will begin to see layers of slip building up along the wall of the mould
as you keep refilling it.
10. Once you've waited to your desired thickness, begin to pour out your slip
from the mould slowly; make sure you are not completely flipping the entire
mould over but rather tilting it so that the slip pours out from one side of the
mould. This allows for cleanliness and ease of pouring. After you are sure that all
excess slip has been poured out of the mould, tilt it against the wall for a couple
of minutes to ensure that every drop of slip has leaked out
11. Place your mould hole down into a piece of paper towel and allow for further
drainage for about 10mins.
12. Tilt the mould to its side and allow for drying of the slip inside the mould. Wait
approximately two hours before releasing the mould.
13. Once you have waited for 2 hours you can release the mold to see if the
casting piece is ready to fall out. You can determine this by seeing if the casted
piece is slightly separating away from the walls of the mold.
14. Remove the casted piece from the mold by pulling slightly on it. A good cast
should allow the piece to just fall out. Do not pull too hard as this may tear the
piece. If it is giving you trouble wait a few minutes before trying again.
15. Trim away the bottom portion of your cast with the clay cutting knife. This
excess piece is always trimmed away as it is build up along the mold where the
reservoir was.
16. Wipe away the seam line and clean up the edge, bottom and any other
inconsistencies in the clay cast.
Pots are usually dried slowly, to prevent warping and cracking. Ceramic wares
are also dried thoroughly to prevent explosion in the biscuit fire resulting to the
shattering of the pots. As a rule, the more plastic clays and the bigger pottery
forms are dried more slowly than the open or frigged bodies and small or thin
wares.
In drying, as the water on the surface of the pot is evaporated, the water in the
interior travels to the surface. In fast drying, the rate of flow of water to the
surface that a large mixture gradient is created. This differential in the moisture
content of the interior and surface tends to set up differential shrinkage quite
pronounced in thick wares which leads to cracking.
The bone dry green ware is fragile and must be loaded into the kiln with a
great deal of care. The kiln is closed and heating slowly begins. A slow
temperature rise is critical during the beginning of the bisque firing, the last of the
atmospheric water is more driven out of the clay. If it is heated too quickly, the
water turns into steam while inside clay body, causing the clay to burst.
When a kiln reaches about 160F, the chemically bonded water will begin to be
driven off. By the time the clay reaches 930F, the clay becomes completely
dehydrated. At this point the clay is changed forever; it is now a ceramic material.
The bisque firing continues until the kiln reaches about 1730F. At this
temperature, the pot has sintered making it less fragile while remaining porous
enough to accept the application of glazes.
After the desired temperature has been reached the kiln is now turned off, the
cooling is slow to avoid breaking the pots due to stress from the temperature
change.
1. Flatten piece of clay of about 1/4m thickness. Use rolling pin or a slab roller
to flatten the slab. Cut slab to desired dimensions, ahead of time prepare
clay coil by hand or with extruder. Make sure your pre made clay coils are
covered with plastic to keep them soft. Coils dry out very quickly.
2. Score the slip slab and lay the first layer of coil. Push the coil firmly into the
slab. Cut first layer of coil as illustrated below to insure perfect fit around
the parameters of the slab. Remove the unused coil piece and blend the
joint. Pinch/scrape the coil with one finger into the slab smoothly using
your finger, a rib or a wooden tool.
3. Place the next layer of coil pinch and smooth and in previous layer. When
merging tow layers, make sure that one hand is supporting the clay on one
side while the other pushing/smudging the other side.
4. Keep adding layers, you can add upto three at a time before blending and
smoothing, when cutting a slab or fit, make the cut in a different place to
insure that two joints are not directly one above the other.
5. To widen the pot, use longer coils. If taking a break cover your work and pre
made coils. So that the clay will remain most and soft.
6. Use the same method as to create the pot rim "un-smoothed" as if making
a large pot it might be too soft to hold it's full weight. Cover it and allow it
to set for a while before proceeding. When starting again, the next coil
added must be skipped and scored to the existing pot.
7. Use a paddle to bith the shape the pot and strengthen the coil wall. Dry
slowly by covering the pot loosely with plastic before bisquing.
METHOD ONE
1. Begin with good clay, duchess the designed for sculpting and that has small
and large - sized grog.
2. Check the temperature at which you will fire the clay.
3. Ensure that the clay u will use will mature at that temperature.
4. Work the clay when it is fairly dry.
5. Ensure that your clay tiles are at list 1/2inch (1.3cm) thick.
6. Roll a slab of clay into a hard working surface from which your clay can be
easily removed.
7. Use a slab roller to flatten the clay.
8. Calculate the diameter of ball of clay that is needed to reach your tile size,
including shrinkage.
9. Determine the clay ball that ended up to be the correct dimensions of your
tile and use that weight for the rest of the clay.
METHOD TWO
METHOD THREE
DRYING
FIRING
CHAPTER FOUR
CONCLUSION
exposure to some of the practical ceramics aspects. I’ve been opportune to know
casting and make molds, procedures on how to dry ceramic wares, how to fire
ceramic wares with both electric and local kiln, how to make tiles and how to make
coil pots. The program was highly beneficial, interesting, enlightening and
successful and I can say that all the set objectives were achieved.
RECOMMENDATION
Although SIWES has and is still achieving quite a lot of its stated objectives,
REFERENCES
Mr Mark Abu
Mr Phillip chima