A TECHNICAL REPORT OF STUDENT INDUSTRIAL

WORK EXPERIENCE SCHEME (SIWES)

AT

NIGERITE LIMITED

41, OBA AKRAN AVENUE, IKEJA, LAGOS STATE,

NIGERIA.

BY

ADAMS, TAIWO DAVIDS

MATRIC. NO.: 110804003

SUBMITTED TO THE

DEPARTMENT OF CHEMISTRY

FACULTY OF SCIENCE, UNIVERSITY OF LAGOS, AKOKA.

IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE

AWARD OF BACHELOR OF SCIENCE (B.Sc.) DEGREE IN THE

DEPARTMENT OF CHEMISTRY

DECEMBER 2014 - FEBRUARY 2015

ACKNOWLEDGEMENT

I wish to express my sincere gratitude to my industry based supervisor, Mr. Adegoke

O. A., and the Quality Control Manager, Mr. Joseph for their genuine co-operation

and support through the course of my training.

I sincerely acknowledge the effort of my I.T departmental supervisor, and my SIWES

coordinator, may the good Lord continue to bless them. Amen.

Also, I thank the Department of Chemistry of the University of Lagos and the Centre

for Industrial Liaison and Placement Unit (CILPU), UNILAG for giving me the

opportunity to carry out my SIWES program.

My sincere regards to my dearly beloved parents, Mr. and Mrs. Adams and my

beloved Guidance Mr. and Mrs. Ogunsanya for their encouragements and full supports

through the period. To my colleagues that really made the memory great and lovely

may the Lord’s favour always remain with you. Amen.

Above all, I am grateful to the Almighty God for everything, for without Him, any of

these would not be possible.

TABLE OF CONTENTS

Title Page i

Acknowledgement ii

Table of Contents iii

Table of Figures iv

Abstract v

Chapter One:

1.0 Overview of the SIWES programme 1

1.1 Objectives of SIWES 1

1.2 Brief history of the Organization 1

1.3 Details of the firm’s organization structure 3

Chapter Two:

2.0 Equipment and Apparatus 4

Chapter Three:

3.0 Cement Analysis 6

3.1 Sand Analysis 10

3.2 Stone Analysis 12

Conclusion 14

Reference 15

TABLE OF FIGURES

Figure 1.1: Hierarchical representation of the firm’s organization structure

Figure 2.1: Jolting machine

Figure 2.2: Sieve shaker

Figure 2.3: Vicat apparatus

Figure 2.4: Compressive strength machine

Figure 2.5: Blaine apparatus

Figure 2.6: Buchner funnel set-up with vacuum pump

Figure 2.7: Thermobox

Figure 2.8: Mixer

ABSTRACT

This is a summary report of the training i underwent at Nigerite Limited, manufacturers of Fibre-

Cement Sheets, QSC/SHE department, Laboratory section. There we analyzed all the incoming raw

materials used for production, but only Cement, Sand and Stone (CaCO3) were routinely analyzed.

In the course of my training, some chemical/physical techniques were adopted, viz: sampling;

sieving; titration; filtration; weighing; sampling; heating using water-bath, sand-bath, oven, furnace;

etc. Some of the various analysis carried out, include:

Granulometry, which is carried out on cement, sand and stone. It is done to determine their

particle size distribution so as to know how much of them would adhere to the aggregate or

rather goes to waste.

Air permeability test is done using the blaine method. It is carried out both on cement and

stone. It is used to measure their fineness; this also has to do with how much of the raw

materials would adhere to the aggregates.

Thermography is done to determine the peak of heat evolution during the hydration of

cement. The rate at which heat is lost by the cement helps to know how long before the

products are dry enough to be depiled from the production line.

Loss on Ignition is carried out on cement and sand to determine their weight loss on heating.

On blasting the samples in a furnace, organic matter is lost for sand, while water and carbon-

dioxide is lost for cement.

Free-Lime test is done to determine the amount of uncombined lime in the cement sample.

High amount of the uncombined lime eventually causes cracks/leaks in the product overtime.

Setting time test is carried out to know how long it takes a cement product to cure. This also

helps to know how long

Strength test primarily determines the mechanical strength (flexural and compressive) of the

cement but can be related to the strength of the product: the stronger the cement used, the

stronger the product.

Silica test is carried out on sand to determine the amount of quartz in it.

Purity test is carried out on CaCO3 to determine how pure the sample is.

The results gotten from the various analyses are compared with the industry’s standard. If met they

are passed otherwise they are rejected.

CHAPTER ONE

INTRODUCTION

1.0 OVERVIEW OF THE SIWES PROGRAMME

The students industrial working experience scheme (SIWES) is a programme initiated in 1973 by the

industrial training fund to bridge the gap between theory and practice for students of tertiary

institution. The need to build human resources in order to have a pool for industrial, technological

and economic development cannot be undermined as being pursued with the vision of the

programme (SIWES). The programme exposes students of tertiary institution to industrial

environments and is also designed to correlate the essentials of classroom knowledge to their on-field

application, such that the participating student is afforded the opportunity of entrenching his/her

theoretical knowledge in a solid base of practical application.

1.1 OBJECTIVES OF SIWES

The industrial attachment programme is purposely organized to:

1. Expose the students to the practical aspect of their respective courses.

2. To expose students to various methods and techniques of handling equipment’s and

machinery that may not be available in their institution.

3. To prepare students for the industrial work situation they will encounter after graduation

To re-engineer the Nigerian educational system towards practical knowledge acquisition needed for

technological development.

1.2 BRIEF HISTORY OF ORGANIZATION

Nigerite Limited was incorporated in Nigeria on the 29 th of April 1959 as a joint venture between

Etex Group of Belgium and O’dua Investment Corporation Limited of Nigeria. Nigerite is one of the

largest organization in West Africa engaged in the manufacturing, marketing and installation of New

Technology fibre cement roofing and ceiling sheets, compressed sandcrete roofing tiles (Crete Tile

French and Crete Tile Mission) and vinyl floor tiles (Luxe). Nigerite Limited is a building

component solution company, providing gainful employment for over 700 Nigerians.

It also markets and installs Gemstone, TwinTile EcoTile roofing tiles and light guage steel roof truss

system among others. The company’s roofing and flooring brands are exported to ECOWAS

countries such as Ghana, Republic of Benin, Togo and Liberia.

Nigerite’s New Technology fibre cement products are made from Portland cement, cellulose and

polyvinyl alcohol (a derivative of crude oil) only. The compressed sandcrete roofing tiles are made

from coarse and soft aggregates mixed with Portland cement and iron-oxide pigments only. It is

pertinent to state that over 90% of these raw materials are sourced locally in Nigeria.

Nigerite now offers Alurr shingles, Gemstone, Kalsi and Siniat plaster boards for Dry Construction

Solution. We have also taken the challenge of addressing the housing deficit in Nigeria and indeed

Africa by introducing Integrated Building System, a method of dry construction with significant

LEED credits. It delivers faster project lead time and reduces on site waste.

1.3 DETAILS OF THE FIRM’S ORGANIZATION SRUCTURE

Fig. 1.1: Hierarchical representation of the firm’s organization structure

Managing Director

Internal Auditor

Auditor 1

Auditor 2

Auditor 3

Vacant

Dbase Analyst

Legal Affairs Mgr. QSC/SHE Mgr.Environ

ment Services

Mgr.

Safety Officer 1

Safety Techn.

Safety Officer 2

Q.C. Manage

rQ.C.

Superv.

Lab. Techns.

Lab.

Technologist

Lab. Techns.

HR/CA Mgr.

Conf. Secretary

HR Services Mgr.

HR Clerk

Training Officer

Snr. Corp. Affairs Officer

Receptn./Switch Board

Health Centre

Security

Canteen

CHAPTER TWO

EQUIPMENT AND APPARATUS

Fig. 2.3: Vicat apparatus

Fig. 2.1: Jolting machine

Fig. 2.2: Sieve shaker

Fig. 2.4: Compressive strength

machine

Fig. 2.5: Blaine apparatus

Fig. 2.6: Buchner funnel set-up with

vacuum pump

Fig. 2.7: Thermobox

Fig. 2.8: Mixer

CHAPTER THREE

ANALYSIS

3.0 CEMENT ANALYSIS: Cement makes up 70% of the product’s composition. For the

product to meet the required standard, it is necessary to ensure that the cement used for

production meets the required standard too. The various test include:

3.0.1 THERMOGRAPHY

AIM: To determine the peak of heat evolution during the hydration of cement.

PROCEDURE:

Mix 400g of cement sample with 150mL of water at 30oC in a mixing bowl.

Empty the mixture into a nylon (transparent in black), then insert into a thermo-can.

Place a thermocouple probe into the thermo-can and seal with paper tape.

Place the thermo-can in the thermo-box and insulate with wool.

Take the first temperature reading using the digital thermometer after an hour, then

subsequent temperature readings at 15minutes intervals until it reaches its peak and

begin to drop.

CONCLUSION: If the peak of evolution falls within the range of 6hours, then it is passed.

The implication of this test to know how long before the products are depiled, in readying the

moulders for the next batch.

3.0.2 FREE LIME TEST

AIM: To determine the percentage of uncombined lime contained in the cement.

PROCEDURE:

Heat 10g of cement sample in the oven for an hour then allow cooling in a dessicator

for about 15minutes.

Weigh 1g of the sample into a conical flask.

Add 40mL of ethanediol to the sample in the conical flask.

Cork conical flask and mix thoroughly.

Place the conical flask in an hot water bath at 65oC-70oC for 30minutes, shaking it at

intervals of 10minutes.

Using a Buchner funnel – vacuum pump setup, filter the mixture with an ethanediol

moisted filter paper.

Rinse residue with 30mL of ethanediol.

Add 4 drops of bromothymol blue indicator to the filtrate.

Titrate filtrate with 0.1M HCl until colour changes to yellowish green.

Record volume of titrant used and check against standard chart.

CONCLUSION: If the range falls within 0.5-1.55, it is passed. The implication of this test is

to tell whether the amount of free lime would cause cracks in the product overtime. Free lime

combines with atmospheric air and water to form CaCO3, which causes leaks in the product.

3.0.3 GRANULOMETRY TEST

AIM: To determine the particle size distribution of the cement.

PROCEDURE:

Weigh 10g of dry cement sample it into the mesh.

Record the residual weights in each mesh.

Tabulate the percentage retention.

W1+W2+W3+W4 * 100 where W1>W2.W3>W4>W5

W5

CONCLUSION: The implication of this test is to know how much of the cement would be

retained in the product as to how much of it would go to waste.

3.0.4 SETTING TIME

AIM: To determine the cure time of the cement.

PROCEDURE:

Mix 300g of cement sample with 90mL of water in a mixing bowl.

Transfer the mixture into the vicat moulders.

Take the first reading after an hour, then subsequent readings at 5minutes intervals.

CONCLUSION: The implication of this test to know how long it would take the product to

dry.

3.0.5 STRENGHT TEST

AIM: To determine the flexural strength and the compressive strength.

PROCEDURE:

Mix 400g of cement sample with 225mL of water.

Add 1350g of sand to the mixture.

Transfer the mixture into the moulder.

Set up the moulders on the jolting machine and time to slam for 60seconds.

Repeat timer to slam for another 60seconds to ensure proper filling.

Demould after 24hours, weigh then place it in the warm water bath.

Determine the flexural strength and compressive strength after 2days, 7days and

28days for the moulds using the compressive/flexural strength machine.

CONCLUSION: The strength of the products is reliant on the strength of the cement. The

implication of this test is to know how strong the product would eventually be in relation to

the strength of the cement used.

3.0.6 AIR PERMEABILITY TEST (BLAINE METHOD)

AIM: To determine the fineness or surface area per gram of the cement.

PROCEDURE:

Put a filter paper into the cell then weigh 2.84g of cement sample into it.

Put another filter paper on it and compress with the plunger.

Attach the cell on top of the U-tube manometer.

Evacuate the air in the manometer through the side tube using the aspirator bulb until

the oil reaches level 1.

Close the side valve and monitor the oil as it starts to fall.

Using a stopwatch, measure the time taken for the oil to fall from level 2 to level 3

Blaine = k√t where k is 524

CONCLUSION: The implication of this test is to know if the fineness of the cement is

suitable for production as very high blaine could lead to waste, and low blaine would require

blending if it must be taken by the roller belt with other components during production.

3.0.7 LOSS ON IGNITION

AIM: To determine the weight loss of the cement on blasting.

PROCEDURE:

Weigh about 1000mg of cement sample into a crucible.

Place crucible into the furnace at 950oC for an hour

Allow to cool in dessicator for 20minutes

Determine weigh of sample.

(Wi - Wf) / Ws * 100 Wf is weight after heating

Wi is weight before heating

Ws is sample weight

CONCLUSION: On blasting in the furnace, water and carbon-dioxide are given off.

3.1.0 SAND ANALYSIS: Sand is a major aggregate in the production of Crete-tiles. This also is

required to meet a standard before being used. The various tests carried out on sand include

granulometry, loss on ignition and silica content.

3.1.1 GRANULOMETRY

AIM: To determine the particle size distribution of the sand.

PROCEDURE:

Dry 150g of the sand sample in the oven to constant weight, then allow it to cool in a

dessicator for 20minutes.

Stir the sample then weigh 10g of it into the mesh.

Record the residual weights in each mesh.

CONCLUSION: The implication of this test is to know how well the sand would adhere into

the product, as larger particle size could lead to irregular/poor adhesion with other

aggregates.

3.1.2 LOSS ON IGNITION

AIM: To determine the organic content of the sand.

PROCEDURE:

Weigh about 1000mg – 1500mg of dry sand sample into a crucible.

Place crucible into the furnace at 1000oC for an hour

Allow to cool in dessicator for 20minutes

Determine weigh of sample.

(Wi - Wf) / Ws * 100 Wf is weight after heating

Wi is weight before heating

Ws is sample weight

CONCLUSION: On blasting in the furnace, organic content (silt) is burned off.

3.1.3 SILICA CONTENT

AIM: To determine the quartz content of the sand.

PROCEDURE:

Weigh 400mg of dry sand sample into a platinum crucible.

Add some drops of distilled water till slurry is formed.

Add 2.5mL of dil. HNO3, 10mL of dil. HF at 48% and 5mL of HClO4 to the slurry.

Place the crucble in the sand bath and heat for 2hours.

Allow to cool in a dessicator for 20minutes

Determine weight of sample.

(Wi - Wf) / Ws * 100 Wf is weight after heating

Wi is weight before heating

Ws is sample weight

CONCLUSION: Through the reaction workup from digestion to heating, all other metals are

removed from the sand leaving just the silica content.

3.2.0 STONE ANALYSIS: CaCO3 is another major aggregate in the production of Fibre-Cement

Sheets,and it must meet the standard before being used. The various tests carried out on

CaCO3 include granulometry, purity test and air permeability test.

3.2.1 GRANULOMETRY

AIM: To determine the particle size distribution of the calcium carbonate.

PROCEDURE:

Weigh 150g of the CaCO3 sample into the mesh.

Record the residual weights in each mesh.

CONCLUSION: The implication of this test is to know how much of the CaCO3 would be

retained in the product as to how much of it would go to waste.

3.2.2 PURITY

AIM: To determine the percentage purity of the calcium carbonate.

PROCEDURE:

Weigh 5g of CaCO3 from the final mesh (the smallest microns) into a beaker.

Add conc. HCl in excess.

Filter using the Buchner funnel-vacuum pump set-up.

Dry the residue in the oven.

Weigh the dry residue.

Calculate percentage impurity.

(Wi - Wf) / Ws * 100 Wf is dry residue weight

Wi is wet residue weight

Ws is sample weight

CONCLUSION: This test tells us how pure the sample is, whether it is has been mixed with

some other products or not.

3.2.3 AIR PERMEABILITY TEST (BLAINE METHOD)

AIM: To determine the fineness or surface area per gram of the CaCO3.

PROCEDURE:

Put a filter paper into the cell then weigh 2.8g of cement sample into it.

Put another filter paper on it and compress with the plunger.

Attach the cell on top of the U-tube manometer.

Evacuate the air in the manometer through the side tube using the aspirator bulb until

the oil reaches level 1.

Close the side valve and monitor the oil as it starts to fall.

Using a stopwatch, measure the time taken for the oil to fall from level 2 to level 3

Blaine = k√t where k is 503.5

CONCLUSION: The implication of this test is to know if the fineness of the CaCO3 is

suitable for production as very high blaine could lead to waste, and low blaine would require

blending if it must adhere with other components during production.

CONCLUSION

My Industrial training went a long way in exposing me to the relevance of my course of study to the

industry. I discovered that the knowledge of chemistry becomes necessary from the very inception of

the product through its life-span. Going from the design of the product and the processes necessary

for its production; through the quality control and assurance of the product; the preservation of the

product; to the recycling of the product.

REFERENCE

Olusegun A.T. Mafe, Excerpts from “Guide to successful participation in

SIWES”.