csdc · sector construc on sub-sector real estate and infrastructure construc on fabrica on occupa...

National Instructional Media Institutew w w . nimi. g ov. in

SectorConstruc�on

Sub-SectorReal Estate and Infrastructure Construc�on

Fabrica�onOccupa�on

Reference ID: CON/Q1206, Version 1.0, NSQF Level 4

Par�cipant Hand book Fabricator

Fabricator

CSDC

Price: 430/-

Address:

Email: Web: Phone: CIN No.:

CPB 103 & 104 (1st Floor) Block 4B, DLF Corporate Park, Phase III MG Road, Gurgaon- 122002,Near Guru Dhronacharya Metro Station

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the owners of the copyright material included in the book. The publishers would be grateful for

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©

May 2019

iii

Certificate

COMPLIANCE TOQUALIFICATION PACK - NATIONAL OCCUPATIONAL

STANDARDS

is hereby issued by the

CONSTRUCTION SKILL DEVELOPMENT COUNCIL OF INDIA

for the

SKILLING CONTENT: PARTICIPANT HANDBOOK

Complying to National Occupational Standards ofJob Role/Qualification Pack: ‘Fabricator’ QP No. ‘CON/Q1206 NSQF Level 4’

Date of Issuance: January 31st, 2017Valid up to: August 23rd, 2017

Valid up to the next review date of the Qualification Pack or the‘Valid up to’ date mentioned above (whichever is earlier)

Fabricator

Participant Handbook

iv

NationalSkillDevelopmentCorporation(NSDC)workingwiththeobjectofdevelopingunskilledandsemi-skilledlabourforceintoproductiveandskilledlabourthroughSectorSkillCouncils(SSCs)andAssessmentagencieshasentrusted the responsibilityofdevelopingparticipanthandbookswithNational InstructionalMedia Institute(NIMI).

NIMI,setupbytheGovernmentofIndiatodevelopinstructionalmaterialfortheoverallimprovementinthestandardoftraininginITIsandskilldevelopmentprogrammesishappytowidenthescopeofitsoutreachbydevelopingcontentforNSDC.

NIMI sincerly acknowledges the co-operation rendered by the media developers and their sponsoringorganisations to bring out the participant handbook under Construction Sector for Qualification Pack forFabrication.

ThisbookistheoutcomeofteamworkbyConstructionSkillDevelopmentCouncilandexpertsfromtheFabricationandConstructionIndustry.

NIMIthanksthemediadevelopmentcommitteemembers,dataentryoperators,CADDpersonnelandallothersfortheirdedicatedandcontinuedsupport.

Acknowledgements

Fabricator

v

ConstructionindustryisthesecondlargestemployerinIndia.Asoneoftheleadingavenuesforemploymentinthecountry,theroleplayedbythisindustryintheeconomicdevelopmentofIndiaispivotal.However,despiteitsvastpotential,theconstructionindustryfaceschallengeofshortageofskilledmanpower.Thishamperstheprogressoftheindustry,asthequalityoffabricatedandconstructedstructureispoorandmostprojectsfailtobecompletedinthestipulatedtime.

Thereisavastdifferencebetweentherequiredskillsetsandavailableskillsamongstworkersintheindustrytoday.Toreducetheskillgap,appropriateskillingoftheworkforceisofparamountimportance.Itwillnotonlyempowertheworker,butalsobenefittheconstructionframework.

This participant handbook is developed to impart skill training with appropriate and relevant knowledgerequiredtoworkasanFabricatorintheConstructionindustry.ItisdesignedbasedonFabricatorQualificationPackundertheNationalSkillQualificationsFramework.ItcomprisesthefollowingNOS/topics:

This book is designed considering the lower educational backgroundof the constructionworker. Therefore,special efforts havebeen taken to explain the concepts required for the jobwith ample visual support andillustrations.

Unitsandsymbolsusedinthebookhavebeenlistedbelow:

About this book

Symbols Used

......

NOS code Major function/Task

CON/N1210:1. Inspectandcheckthefabricationmaterialsandtheirpreparation

CON/N1211:2. Overseefabricationactivites

CON/N07173. Erectstructuralsteelassembliesatconstructionsites

CON/N8001:4. Workeffectivelyinateamtodeliverdesiredresultsattheworkplace

CON/N9001:5. Work according to personal health, safety and environment protocol at constructionsite

StepsKeyLearningOutcomes

Notes Tips

!

Unites

PracticalExercise

vi

Table of Contents

Sl.No. ModulesandUnits PageNo.

1.Inspectandcheckthefabricationmaterialsandtheirpreparation

Unit1.1-Introduction 3

Unit1.2-IdentifyandShiftMaterials 12

Unit1.3-OverseesurfacePreparationofIdentifiedMaterials 33

2.Overseefabricationactivities

Unit2.1-OverseeJointPreparationActivities 69

Unit2.2-RepairFabricatedComponents 161

3. ErectStructuralSteelAssembliesatConstructionSites

Unit3.1-CheckandEnsurethatPreparatoryWorksareCompletedasperWork 195

RequirementPriortoErection

Unit3.2-ErectStructuralSteelAssembliesasperDrawing 244

4.WorkEffectivelyinateamtodeliverdesiredresultsattheworkplace

Unit4.1- InteractandCommunicateinanEffectiveandConclusiveManner 307

Unit4.2-Supportco-workerstoExecuteProjectRequirements 319

5.WorkaccordingtoPersonalHealth,SafetyandEnvironmentProtocolintheConstructionSite

Unit5.1- FollowSafetyNormsasDefinedbytheOrganization 325

Unit5.2-AdoptHealthyandSafeWorkPractices 379

Unit5.3- ImplementGoodHousekeepingPractices 403


1. Inspect and Check the Fabrication Materials and their Preparation

U n i t 1 .1 Introduction

U n i t 1 .2 IdentifyandShiftProperMaterials

U n i t 1 .3 OverseeSurfacePreparationofIdentifiedMaterials

C O N/ N1 2 1 0

AssistantSurveyor

1

The Destination for Books for ITIs & Short Term Skill Development Courses

National Instructional Media Institute

2

A t the end of this module, you w ill be able to:

1.

2. read and interpret drawings and work procedure

3. receive and segregate the materials

4. check the materials for any physical damage

5 . carry out cleaning of the surface of materials

6. carry out measuring and marking as per drawing

7 .

8 .

9.

K ey L earning O utcomes

Fabricator

3

Unit Objectives

U NI T 1. 1 Introduction

At the end of this unit, you will be able to:

1. identifythepurposeofthetraining

2. stateNationalOccupationStandardsandQualificationPack

3. explainthebenefitsofskilltraining.

At the end of this topic, you will be able to:

1. describethescopeofthetrainingprogramme

2. determinethebenefitofthetrainingprogramme

3. definetheroleandresponsibilitiesoffabricators.

1.1.1.1 Introduction

Thistrainingisdevelopedtoimpartspecificskillstoindividualswhowishtoworkasafabricator.Thistrainingprogrammeisbasedonthequalificationpackoffabricator.TheconstructionindustryinIndiahasgrownveryrapidlyinthelastfewdecades.Constructionofnewstructureslikeresidentialtowers.housingsocieties,schools,colleges,etc.,hasgivenrisetothedemandforgoodskilledworkers.ThereareveryfewskilledworkersavailablefortheconstructionworksinIndia.ThepurposeofthistrainingistoimpartskilltotheconstructionworkersasperthesetNationalStandards.Thiswillgivethemgoodcareeropportunitiesandgrowthintheconstructionsector.Thequalityofconstructionworkwillgreatlyimprovewiththeinductionofskilledworkforce.

1.1.1 Introduction to the Training Programme

Fig. 1.1.1 Classroom Session

1.1.1.2 Mode and Duration of the Training Programme

The trainingforthejobroleoffabricatoristoprovidethroughclassroomandpracticalsessions.Thetotaldurationofthetrainingprogrammeasrecommendedinthequalificationpackis12-16weeks.

Fig. 1.1.2 Practical Session


4

1. 1. 1. 3 Personal A ributes: Theindividualisexpectedtobephysicallyfitandmentallyalert.Thiswillhelpto

workacrossvariouslocationsandheights.Itwillalsohelptowithstandtheextremeweatherconditionswhile

working.Fabricatorsshouldhavegoodcommunicationskills,andbeabletoworkinateamandhandlevarious

tools,instrumentsandmaterials.

The training programme will enable an individual to:

usehandtools,powertoolsandequipmentusedinfabrication•

interpretdrawings,identifythecomponentsandfabricationsymbols•

recognisetheuseofdifferentstructuralelements•

carryoutfabricationactivities.Suchasmeasuring,marking,punching,cu ng,beveling,cleaning,drilling,•bolting,welding,torqueingandtensioning

carryoutrepairoffabricatedcomponents•

carryouterectionofthefabricatedstructureintheworksite•

workeffectivelyinateamtodeliverthedesiredresultsattheworksite.•

workaccordingtopersonalhealthandsafety,environmentprotocolinthesite.•

1.1.1.4 National skill qualification frame work - NSQF:

ThroughtheNationalpolicyonSkilldevelopment2009IndiarecognizedtheneedfordevelopmentofaNationalqualificationframework.ThenationalskillqualificationframeworkNSQFcameintobeingaspertheGazetteNotificationno8/06/2013dated27thDec.2013.NSQFisaqualityassuranceframework.

ItisanoutcomebasedapproachandeachlevelintheNSQFisdefinedanddescribedintermsofcompetencylevels thatwouldneedtobeachieved.TheNationalSkillQualificationFramework iscomposedof10 levels,eachrepresentsadifferentlevelofcompetencywithlevel1representingthelowestcompetencyandlevel10highestcompetency.Competencemeanstheprovenabilitytouseacquiredknowledge,skillsandpersonalandsocialabilitiesinthedischargeofresponsibilityofajobrole.ItisimportanttonotethattheNSQFlevelsarenotdirectlyrelatedtoyearsofstudy.

NSQForganizesqualificationsaccordingtoaseriesoflevelsofknowledge,skillsandaptitude.Theselevelsaredefinedintermsoflearningoutcomeswhichthelearnermustpossessregardlessofwhethertheywereacquiredthroughformal,non-formalorinformallearning.

EachlevelofNSQFisdescribedbyastatementoflearningoutcomesinfivedomainsknownasleveldescriptors.Thesefivedomainsare:

1.Process 4.CoreSkill

2.Professionalknowledge 5.Responsibility

3.Professionalskill

ThelevelmentionedbelowinthecareerprogressionchartcorrespondstoNSQFlevel-4.

TheFabricatorisassignedlevel-4basedontheabovefivecriterias.

1.1.1.5 Introduction to QP and NOS

Introduction to QP and NOS: ThisprogramisbasedonQualificationPackcalled“Fabricator”.TheQualificationPackisalsocalledaQP.ThecodeforFabricatorTradeisCON/1206.AQPconsistsofasetofNationalOccupationalStandards(NOS).NOSspecifiesthestandardcompetencyaworkermustachievewhencarryingoutafunctionintheworkplace.UnderthefabricatorQP,therearefiveNOS.whichprovideadetailedaccountofthefunctionstobeperformedintheworksite.

Fabricator

5

NOS Code Major Function/Track

1.CON/N1210 :InspectandChecktheFabricationMaterialsandtheirPreparation

2.CON/N1211 :OverseetheFabricationActivities

3.CON/N0717 :ErectStructuralSteelAssembliesatConstructionsSites

4.CON/N8001 :WorkEffectivelyinaTeamtoDelivertheDesiredResultattheWorkPlace

5.CON/N9001 :WorkAccordingtoPersonalHealth,SafetyandEnvironmentProtocolinthe ConstrutionSite

1.1.1.6 Benefits of the Training Programme

Aftercompletionofthetrainingprogramme,traineeswillbeassessedthroughatheoryandpracticaltest.

Onsuccessfulpassingoftheassessments,acertificatewillbeawardedbytheConstructionSkillDevelopment1 . CouncilofIndia(CSDCI).

Thecertificatewillhelpthetraineestogetajobwithbetterwagesintheconstructionsector.2 .

The skills acquired alongwith the certificatewill also help the trainees to have career progression and3. growth.

Fig. 1.1.3 Theoritical Session

E x ercis eI. Answer the following questions.

WhatdoesQPconsistof?1 .

---------------------------------------------------------------------------------------------------------------------------------------------

WhatdoesNOSspecify?2 .

---------------------------------------------------------------------------------------------------------------------------------------------

NameanytwoNOSunderFabricator3.

---------------------------------------------------------------------------------------------------------------------------------------------

Mentionanytwobenefitsofthistrainingprogramme?4.

---------------------------------------------------------------------------------------------------------------------------------------------

II. State whether the following statements are True or False.

Thiscertificatewillhelpyoutogetajobandearnbetterwagesintheconstructionsector.1 .

True False

Theskillacquiredalongwiththecertificatewillalsohelpyoutogrowinyourcareer.2 .

True False

Theassessmentafterthetrainingwillhaveonlypracticalexamination.3.

True False

Notes---------------------------------------------------------------------------------------------------------------------------------------------------

---------------------------------------------------------------------------------------------------------------------------------------------------


6


1. identifyaspectsoftheconstructionsectorinIndia

2. identifyurbanandruralconstruction

3. definethefeaturesofmodernizationinconstructionsector

4. listoutmajoroccupationsintheconstructionsector.

1.1.2 An Overview of the Construction Sector

1.1.2.1 Introduction

Constructionreferstobuildingofdifferenttypesofstructures.Thesectorcomprisesofsmall,mediumandlargeindustriesorcompanies.Thecompaniesinvolveindifferenttypesofprojects.Theycreateadiverse,butthespecificrequirementofworkmen.

The construction sector can be broadly classified into two sub sectors: real estate and infrastructureconstruction,ruralconstruction.

1. Real estate and infrastructure construction: This sub sector comprises all theworks that are requiredfor construction of all types of infrastructure and real estate projects. Infrastructure projects are thosethatdirectly or indirectlyaffect thegrowthof theNation. Forexample, roads, airports, railwaybridges,dams, power plants, metros, industries, etc. Real estate projects are those which mainly focus onprovidingresidentialandcommercialworkplacestoallcategoriesofpeople.Forexample,residentialtowers,independenthouses,malls,sportscomplex,etc.

Fig. 1.1.4 Industrial Building Construction

Fig. 1.1.5 Rural Infrastructure roads and flyovers

2. Rural construction: This sub sector focuseson the constructional requirementsof rural India. It includesconstructionofruralhouseholds,warehouses,villageroads,etc.

Fabricator

7

1. 1. 2. 2 Modernization in Construction

Fromtheearlyagestothepresentday,theconstructionsectorhasgeneratedsubstantialemployment.Ithasalsoundergoneextensivemodernization,fromrawmaterialtotheuseofheavyequipment.Theuseofmodernequipmentandtechniquehasincreasedthespeedofconstructionwork.Ithasenhancedthequalityoffinishedstructures.Further,bymodernizationofconstruction,itisnowpossibletoconstructbuildingsinunderwateraswellasinveryhighaltitudes.Modernizationhashelpedtobuildhi-techbuildingsandatomicpowergenerationplants.

Fig. 1.1.6 Old bridge Fig. 1.1.7 Modern bridge

Fig. 1.1.8 Old construction equipment Fig. 1.1.9 Modern construction equipment

1. 1. 2. 3 Job Roles in Construction

Construction is the second largest employment generating sector in India after agriculture. There aremanyjobrolesinconstruction.Dependingonthenatureofwork,somejobrolescatertotheemploymentneedsofmaximumnumberofworkmenandaremoreprominentthanothers.

Thefollowingjobsareverycommoninmostofthefabricationandconstructionprojects

Helperfabrication•

Assistantconstructionfitter•

Constructionfitter•

Fabricator•

1. Fabrication

Metal fabrication is the creation ofmetal structure bymarking, cu ng, bending, forming, grinding fi ng,assembling, welding and painting processes. Fabrication is one of the value added process involved in thecreationofmachineparts.Industrialbuildingstructuresbridgegirders,columnbeamstructurefromvariousrawmaterials.

Tackwelder•

Welders•

Grinderconstruction•

Gascutterconstruction•


8

Fig. 1.1.10 Fabrication Activities Fig. 1.1.11 Welding Activities

2. Welding

Weldingistheartoffabricationtechniqueusedforjoiningthemetalliccomponentpartsthroughtheapplicationofheattoasuitabletemperaturewithorwithouttheapplicationofpressureandwithorwithouttheuseofafillermaterial

3. Drilling

Drillingistheprocessofcu ngholesinsolidmaterialusingarotatingcu ngtool

4. Bolting

Bolted joints areoneof themost commonelements in steel structures, fabricationassembly anderection.Boltingconsistsoffastenersthatcaptureandjoinotherpartsandaresecuredwiththehelpofscrewthreads

5 . Steel structure erection and alignment

Theerectionofsteelstructureconsistsoftheassemblyofsteelcomponentsintoaframeatsite.Theprocessinvolvesliftingandplacingcomponentsinpositionthenconnectingthemtogetherthroughboltingandsometimeweldingisused

Alignmentworkconsistsoflining,levellingandplumbing.

Fig. 1.1.12 Drilling Fig. 1.1.13 Bolting

Fig. 1.1.14 Structural Steel Erection

Fabricator

9

6. Scaffolding

Scaffolding is a temporary support structure. Thematerials used arebamboo,timberor steel. This supportstructurehelpsduringconstructionactivities.Scaffoldingismadeforworkmentodotheirworksafelyandtokeeptheirtoolsandmaterials.

Fig. 1.2.15 Scaffolding

Few job roles under Scaffolding are as follows:

AssistantScaffolder1 . -System

AssistantScaffolder2 . -Conventional

Scaffolder3. -Conventional

Scaffolder4. -System.

7. Construction painting

Paintingisavitaloftheoverallfinishingworkofaconstructionproject.Applicationofpaintaddsaestheticvaluetoaconstructedstructure.Thismayalsoinvolvedecorativepaintingofbasicdesignsandpatterns.

Few job roles under Construction painting are as follows:

AssistantConstructionPainterandDecorator5.

ConstructionPainterandDecorator6 .

Chargehand7 . -PaintingandDecorating.

Fig. 1.2.16 Painting work by a painter

I. Answer the following questions.

Whatarethesubsectorsinconstruction?1 .

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Whatdoesruralconstructionfocuson?2 .

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Howhastheconstructionsectorbeenmodernised?3.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Mention4jobrolesthatarecommoninconstructionprojects.4.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -WhatarethemainobjectivesofFabricator?5.

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -WhatisFabrication?6 .

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - II State whether the following statements are True are False.

Realestateprojectsfocusontheconstructionofroads,airports,damsandpowerplants.1 .

True False

Modernequipmenthashelpedtoconstructunderwaterandinhighaltitudes.2 .

True False

E x ercis e


10

Scaffoldingisdoneusingbricksandconcrete.3.

True False

4. RepairingofFabricatorstructureisdonebyExperiencedFabricator.

True False

Notes

Notes

1.1.3 Fabricator Job Role and Responsibilities

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Fabricators should be able to:

readandinterpretorganizationprocedureforobtainingapprovalsandindentmaterials•

interpretdrawings•

performallthefabricationworkinsequence.Forexample,forming,cu ng,grinding,beveling,drilling,fi ng•andtackweldingofsmallpartsandfinishedproducts

useinstrumentsandequipment•

identifyanddistinguishmeasurementunits•

verifythefinaldimensionsoffabricatedcomponents•

installfabricatedcomponentsintheconstructionsite.•


1. listthejobrolesandresponsibilitiesoffabricator.

E x ercis eI. Answer the following questions.

1. Explainthefabricatorjobroleinconstructionsector.

----------------------------------------------------------------------------------------------------------------------------------------------

2. Drawasimplecarrerprogressionchartforthefabricationoccupation.

----------------------------------------------------------------------------------------------------------------------------------------------

II. State whether the following statements are True or False.

1. Thefabricatorcarriesoutgrindingandfilingworkindividually.

True False

2. Thereisahugerequirementforskilledworkforceintheconstructionsector.

True False

3. Afabricatorhandsoverthetoolandmaterialstothestoreafterthedayswork.

True False

Fabricator

11

Fabr

icat

or


12

UNIT 1.2 Identify and Shi Materials

Unit ObjectivesAt the end of this unit, you will be able to:

1.readandinterpretdrawings,andmaterialspecifications

2. identifythenamesofcomponentsandassembly

3.recognisetheconceptofstampingandheatnumber.


1. performunitconversions

2. refreshbasicknowledgeinmathematics–Arithmetic,algebraandgeometry

3. calculatearea,volume,anglesandlength.

1. 2. 1 Fabrication Mathematical Applications

Metric System & Inch System Units

1. Metric System Units

• Most countries use themetric system. Themetric system uses themeter and linear units based onthemeter,gramasitsstandardsofmeasureandprefixedbykilo,centiandmillietc.Allmultipliesandsubdivisionsofthemeteraredirectlyrelatedtothemeterbyafactoroften.Thismakesiteasytousethedecimalsystemforcalculationsinvolvingmetricunits.ThemoreoftenusedabbreviationsforlinearmeasurementareDecimeter“dm”,theCentimeter“cm”andMillimeter“mm”.

a. Kilometer(km),1km=1,000meter

b. Meter(m),1m=10dm=100cm=1,000mm

c. Decimeter(dm),1dm=10cm=100mm

d. Centimeter(cm),1cm=10mm

2. Inch System (Imperial System) Units

InchsystemismostlyusedinUSA,wherethingsaremeasuredinfeet,inchesandpounds.

• ThesmallestlinearmeasurementunitintheInchSystemistheinch“in”.1/1000ofinchiscalled‘Thou’.Otherunitsarethefeet“ft”andtheyard“yd”.

a. 1yd=3ft=36in

b. 1ft=12in

c. 1m=39.37inches

3. Units Conversion

• ExampleforInchtoInchFractionconversion:1/16”=1dividedby16=0.0625”

• ExampleforInchFractiontommconversion:0.0625”x25.4mm=1.58mm

• 1000litre=1m³.

• 1yd=0.9144m

• 1ft=0.30480m

• 1in=25.4mm

Fabricator

13

Arithmetic and its Applications

Arithmeticalcalculationknowledgeisneededinallareasoffabricationworks.Fabricatorshallbeabletoperformarithmetic calculations related to fabrication. Fabricator requires to calculate length, diameter, perimeter(circumference),bendingangles,elevation,coordinatesetc.Sometimes,pipesandconesmayberequiredtobefabricatedfromplates.HenceFabricatorshallbeabletomarktherequireddevelopmentsizesintheplatesoastocutandrollthepipeorconesetc.

Thefourbasicarithmeticoperationstobeperformedinfabricationworksareaddition,subtraction,multiplication,anddivision.

IfPipeoutsidediameter(OD)andinsidediameter(ID)aregiven,thenpipethicknesswillbe

½(OD-ID).IfpipeODandThickness(t)aregiven,thenpipeIDwillbeOD-2t.

Example 3.1-IfPipeODis508mmandpipeIDis480mm,thenpipethicknessis½(OD-ID)=½(508-480)=14mm

Example 3.2-IfpipeODis610mmandwallthicknessis20mm,thenpipeIDwillbeOD-2t=610-40=570mm.

Algebra and its Applications

Basic Algebraic formulas applicable for fabrication include

• (a-b) 2 =a 2 -2ab+b 2

b)b)(c(c -

Fig 1.2.1 Right Angle Triangle - side dimension calculation

hypotenuse

c

9 0°

b

a

Theaboveformulaswillbeapplicablewhilecalculatingcoordinatesandelevationsandthirdsideofrightangletriangle.

Inarightangletriangle,ifoneside‘b’andhypotenuse‘c’dimensionsaregiven,theothersidecanbecalculatedasbelow.

a. a 2 +b 2 =c²

b. a 2 =c²-b 2

c. a 2 =(c+b)(c-b)

d. a=

Example 3.3:Intheabovetrianglehypotenusedimensionis13cmandonesideis5cm,calculatetheothersidedimension.

Byapplyingtheaboveformulaa=

a= =

Theothersidedimensionis12cm.

Geometry and its Applications

Geometricalknowledgeisessentialforfabricatortoperformstructurefabricationandinstallation.

Acircleisageometricformofwhicheverypointontheoutsideofthecircleisthesamedistanceawayfromthecenter.Thedistancearoundtheedgeofthecircleiscalledthecircumference.Thedistancefromonesideofthecircletotheother,goingthroughthecenterofthecircle,isthediameter.Twotimestheradiusisthediameterofthecircle.

b),b)(c(c -

1 8 x 8 ) 1 21 44


14

Shape FormulasforArea(A)andCircleCircumference(C)

Triangle A=½bh=½xbasexheight

A=axa=a²Where‘a’issidedimensionoftheSquare

A=lw=lengthxwidth

A=½(b 1 +b 2 )h=½xsumofbasesxheight

A=bh=basexheight

(‘π’valueis3.1416or3.142)

(A=πr 2 =πd 2

Square

Rectangle

Trapezoid

Parallelogram

Circle

1. Formulas for Area of Circle, Circumference Calculation

Importantformulasforareaandcirclecircumferencecalculationsareastabulatedbelow:

Example 3.4: Calculatetheareaoftrapeziumshapesupportfoundationwhenbottomwidthoffoundationis600mm,topwidthtrenchis400mmandfoundationdepthis350mm.

• FormulafortrapeziumareaisA=½(b 1 +b 2 )h=½xsumofbasesxheight

• Applyingthegivenvalues,foundationareais½(400+600)x350=175000mm 2 =0.175m2

Table 3.1 - Formula for calculating area and circumference

2. Perimeter / Circumference Calculation

a. Perimeterofasquare:s+s+s+s,where‘s’islength/sizeofoneside d.areaofcircle=πr 2 (R-Radious)

b. Perimeterofarectangle:l+w+l+w,where‘l’islength&‘w’iswidth e.circumference =2πR

c. Perimeterofatriangle:a+b+c,a,b,andcaresize/lengthsofthe3sides

3. Volume Calculation:

a. Volumeofacube:s×s×swhere‘s’islength/sizeofoneside(Allsidesareequalincube)

b. Volumeofarectangularbox:l×w×h,where‘l’islength&‘w’iswidthand‘h’isdimensionofheight

c . Volumeofasphere:(4/3)×π×r3,where‘r’isradiusofsphereandπvalueis3.1416

d . Volumeof a cylinder: π × r 2 × h,where ‘r’ is radius of the circle of the base and ‘h’ is height of thecylinder.

Fig 1.2.2 Cube Fig 1.2.3 Sphere Fig 1.2.4 Cylinder

4

Point r

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