Module 5: Practical Assessment & Quality Control 

1. Hands-On Steel Fixing Tasks

Assembling Reinforcement Cages

• Column Cages

• Vertical bars (main reinforcement) tied with spiral links/stirrups at specified spacing

• Use spacer blocks to maintain 40-50mm concrete cover on all sides

• Ensure laps are staggered and meet minimum lap length requirements

• Beam Reinforcement

• Bottom bars (tension reinforcement) bent up at supports

• Top bars (compression reinforcement) continuous over supports

• Stirrups spaced closer near supports (high shear zones)

• Slab Reinforcement

• Mesh or individually placed bars with chairs supporting top steel

• Maintain 25mm cover using plastic spacers

• Alternate bar spacing at slab edges for crack control

Practical Demonstration Requirements

1. Material Preparation

• Verify bar sizes match BBS

• Pre-cut and bend bars to required shapes

2. Assembly Process

• Position main bars first

• Fix links/stirrups at correct spacing

• Secure with ties at every intersection

2. Quality Checks

Alignment Verification

• Use string lines and spirit levels to check:

• Verticality of column bars

• Straightness of beam reinforcement

• Flatness of slab mesh

Cover Distance Inspection

• Measure from formwork to rebar using:

• Cover meters (non-destructive testing)

• Physical gauges (for spot checks)

• Spacer blocks (must remain in place during pour)

Tying Methods Assessment

• Check:

• All intersections secured (minimum 90% tied)

• Tie wire properly twisted and buried

• No excessive movement when shaken

3. Common Mistakes & Troubleshooting

Structural Errors

• Incorrect Lap Positions

• Problem: Laps concentrated in one section

• Solution: Stagger laps per design requirements

• Insufficient Cover

• Problem: Rebars too close to surface

• Solution: Add spacers before concrete pour

Workmanship Issues

• Loose Ties

• Problem: Bars shift during concreting

• Solution: Double-check all ties before pouring

• Improper Bending

• Problem: Sharp bends causing microcracks

• Solution: Use proper bending radius (4× bar diameter)

Documentation Problems

• Mismatched BBS

• Problem: Installed bars don't match schedule

• Solution: Cross-verify with engineer before proceeding

4. Assessment Criteria

Performance Metrics

• Accuracy (±5mm tolerance on positions)

• Completeness (All bars placed per drawings)

• Safety Compliance (PPE used, no hazardous conditions)

Evaluation Methods

1. Visual Inspection (Cover, alignment, tying)

2. Dimensional Checks (Bar spacing, lap lengths)

3. Load Test (For training mock-ups only)

5. Corrective Action Protocol

Non-Conformance Handling

1. Identify defect (e.g., missing stirrup)

2. Tag affected area

3. Correct before concrete placement

4. Re-inspect after correction

Preventive Measures

• Daily toolbox talks

• Peer checking system

• Sample checks for first-time elements

This module ensures trainees can execute quality steel fixing work while identifying and resolving common issues. The practical assessment verifies both technical skills and safety awareness, preparing workers for real-site conditions.

Next Steps:

• Mock-up construction and destructive testing

• Site supervision training