INTRODUCTION

[CE 3.1]

This career episode relates to project titled “AL MACO factory Transformer’’. This project was carried out during my tenure at Systematic for Construction as Site Engineer.

BACKGROUND

[CE 3.2]

The ministry of Water and electricity in Egypt (the client) has realized that importing the transformers has become very expensive and budgeting a lot. They decided to reduce import costs and start assembling them locally.

[CE 3.3 ]

The aim of the project was to construct a momentous factory for manufacturing transformers closer to a small village with area of 300000 m2 nearly in order to create a large production line of transformers.

[CE 3.4]

The project Hierarchy is given below.

PERSONAL ENGINEERING ACTIVITY

[CE 3.5 ]

I was entirely responsible for the management of the project at each phase. In order to make this project easily executable and for being completed in stipulated time; I divided the project into multiple phases. In the first phase I studied all the basic scenarios of the project and drafted the phase completion sheet for proper project execution. In the final stage I employed professional strategies for effective completion of the project.

[CE 3.6]

My Roles & Responsibilities

• Constructing infrastructure works.
• Reading drawings and make changes when demanded or desired.
• Directing and supervising a technical team of labor’s, surveyors and supervisors.
• Calculating and measuring quantities.
• Constructing the internal roads of the factory (subgrade layers, subbase layers, asphalt coating)
• Doing designs for Construction elements when needed.
• Constructing two concrete buildings for management and staff.
• Constructing 1 workshop with over 12000m2 for the industrial machines used in the process of creating transformers.
• I was responsible for the street lighting pool (cut, concrete foundations and fixing the lighting columns)

[CE 3.7]

Problem Faced & their rectifications

Problem A

Problem Definition: While working on the sewage pipelines I faced a problem of applying the designed slopes along the pipeline network.

Effect of problem: Connecting the site pipeline network to the main network line outside the factory was impossible since the level of the exit point of the inner network is a 40 cm lower than the main manhole we are supposed to connect with.

Root Cause of Problem: When preparing the land for the installation of the foundations there was a mistake in some buildings base levels up to 20 cm

Final Solution: I decided to ignore the original slope design and redistributed the slope according to the data I obtained from the current situation. With a very small range of slope flexibility, I succeeded in connecting the networks proficiently.

Problem B:

During our work compacting the area for the industrial workshop, I noticed that there was a specific points experienced settlement compared to the rest of the area even after adding another two layers of soil they continued to level down by the next day. We tried adding soil for three times in 5 days and no change was observed.

Effect of problem: We are not able to continue with the plane concrete step in order to fix the steel and construct the reinforced concrete floor.

Root Cause of Problem: After finding no explanation to this; I suggested that we should dig these two points to understand the situation by finding out to what depth we can reach and get a sample of the soil to examine. My suggestion was approved and I led the process, we went down about 2 m to find out circular holes almost horizontally prolonged, one to the second hole and the second towards the mountain behind the site, the soil was expanding within the holes.

Final Solution: We cut all the surrounding area inside the workshop to a level which is beneath the level of the holes and refilled it with layers of soil of 25 cm each and compacted them one by one to reach our base level and we followed the cave to outside the site, uncovered it and destroyed it.

[CE 3.8]

I did make some checks on some reinforced concrete elements by analyzing them using SAP2000. I did also design columns and slabs only for checking and comparing results. I used AutoCAD and SAP2000 in my work using the WORKING method in designing. However, I often liked to design manually without any software using the ULTIMATE method.

I did sizing calculations as following -

The maximum % of reinforcement used for reinforcing a concrete column is 8% whilst the minimum is about 0.4%. If you are able to assume a steel % you can use an approximate method to size your column. Thus, for an axially loaded column, if you were to assume that the % steel reinforcement were of the order of 3% of the gross cross-sectional area of the column (ASC), you could use the following expression which relates the applied Axial load(N) with the concrete area and steel by transforming the area of steal into an equivalent area of concrete.

N = 0.4fckAc + 0.8fykAsc 1800*〖10〗^3=0.4*40*A_col-3/(100*A_col )+0.8*500*2*A_col/100 1800*〖10〗^3=16*0.97A_col +12*A_col=27.52*A_col A_col=(1800*〖10〗^3)/27.52=65407 mm^2 Assuming a square section: b=h=√65407=256 mm^2 Therefore, assume a 300-mm x 300 mm column made with grade 40 concrete Design of a column l=clear height=3500-550-200=2750 mm The effective height of column: l_0=β*l Where factor, from Concise EC2 Figure 5 (column design), each end = 0.7 l = clear height = 2750 mm l0 = 0.7 * 2750 = 1925 mm Slenderness λ=l_0/i=3.46*l_0/h-for rectangular sections s λ=3.46*1925/300=22.2 Limit slenderness - λ_lim=20*ABC/n^0.5 A = 0.7 B = 1.1 C = 1.7 –rm = 1.7 n=N_Ed/(A_C*F_cd )=〖940*10〗^3/(〖300〗^2*0.85*40/1.5)=0.46 λ_lim=20*ABC/n^0.5 =20*(0.7*1.1*1.7)/〖0.46〗^0.5 =38.6 〖λ=22.2<λ〗_lim=38.6 Column is short, so the second order effects can be ignored, then M_Ed=M_02 M_02=Max{〖|M〗_top│,|M_bottom | }+e_i*N_Ed e_i= max⁡{l_0/400,h/30,20} =max⁡{2750/400,300/30,20 }=20 M_02=( 20*940*〖10〗^3)/〖10〗^6=18.8kN.m Design column reinforcement using chart Cover to link – 25 mm Diameter of main bars – 32 mm Diameter of links - 10 mm d_2=25+10+32/2=51 mm d_2/h=51/300=0.17 Use chart for rectangular columns d_2/h=0.15 and d_2/h=0.20 N_Ed/(bhf_ck )=(940*〖10〗^3)/(300*300*40)=0.26 M_ED/(bh^2 f_ck )=(18.8*〖10〗^6)/(300*〖300〗^2*40)=0.017 (A_s f_yk)/(bhf_ck )=0 – from chart Provide 4 H32 bars (3220 mm2) Maximum area of reinforcement Outside the laps 4% of Ac 0.04* 300 * 300 = 3600mm2 At lap location 8% is the maximum 0.08*300*300 = 7200mm2 Minimum area of reinforcement A_(s,min)=0.10*N_ed/f_yd =0.10*(1800.*〖10〗^3)/435=414 mm^2

[CE 3.9]

As a lead Civil-Engineer starting with no outside help I arranged records and reports for unfurling the entire procedure. I was similarly responsible to display reports and advance points of interest to the officials. I oversaw all the venture related errands since venture management is additionally a key piece of architect's fundamental parts and obligations.

[CE 3.10 ]

Summary

The project frolicked significant role in my professional career. The project also raised my project preparation, development, leading & administration skills. I also acquired know how of using external capitals when the team was not able to outbreak the complex issues. I also cultured a lot about team supervision ability. Overall this project played a part of edifice block in my professional practice.