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UNIVERSITY
COLLEGE OF NATURAL SCIENCES DEPARTMENT OF CHEMISTRY BACHELOR OF SCIENCE IN INDUSTRIAL CHEMISTRY WORKSHOP PRACTICE REPORT IN CARPENTRY AND JOINERY
NAME: KYOMUKAMA DAVID COURSE CODE: ICH 1301 REGISTRATION NO.:11/U/239 STUDENT NO.:211001135 SUPERVISOR: MR SERWADDA JAMES COURSE COORDINATOR: MR MAIKI PETER PERIOD OF STUDY: JUNE-AUGUST 2012
THIS WORKSHOP REPORT IS ESSENTIAL FOR THE AWARD OF THE DEGREE OF BACHELOR OF SCIENCE IN INDUSTRIAL CHEMISTRY.
DECLARATION
I.do hereby declare that this report is original and it has not been submitted for the award of any academic certificate. Signature: .. Date: ..
DEDICATION
This report is solely dedicated to my friends and entire family who have strongly ensured that I reach this stage of my education. I also thank my instructor for the great skills and knowledge imparted in me. May the good Lord bless them all abundantly.
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ACKNOWLEDGEMENT
I acknowledge the help and support of the supervisor; MR SSERWADDA JAMES, coordinator, fellow students, Makerere University fraternity and most of all, the entire chemistry department facilitators for their help and contribution in setting up the workshop practice and ensuring the successful progress of the program.
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ABSTRACT
This workshop program report shows the basic requirements of a carpentry workshop and how the instruments are used to create desired products expected from the workshop. During the study period of the program, exposure to the workshop imparted skills like; knowing a number of hand tools and their purposes together with mechanical machines. The report has information on the naming, types and mode of action of a variety of tools and machines. To ensure the safety of the tools, machines and that of the equipment user, the general and machine safety precautions are explained. With the knowledge of all the workshop tools and the types of joints, a corner joint halving model is made with a step by step procedure on how to make it. Generally, the report out lists the basic skills and knowledge tips one is required to have in a carpentry workshop in order to develop necessary desired materials.
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Table of Contents
DECLARATION ................................................................................................................................................ i DEDICATION .................................................................................................................................................. ii ACKNOWLEDGEMENT .................................................................................................................................. iii ABSTRACT..................................................................................................................................................... iv
CHAPTER ONE
INTRODUCTION ................................................................................................................ 1
1.1 Carpentry and joinery ......................................................................................................................... 1 1.2 General safety precautions ................................................................................................................. 1 1.3 Machine safety precautions................................................................................................................ 2 CHAPTER TWO CHAPTER THREE CHAPTER FOUR HAND TOOLS ................................................................................................................ 3 JOINERS TABLE .......................................................................................................... 11 BASIC JOINTS .............................................................................................................. 12
4.1 Functions of joint .............................................................................................................................. 12 4.2 Requirements of joints...................................................................................................................... 12 4.3 Types of joints ................................................................................................................................... 13 4.3.1 Butt joint .................................................................................................................................... 13 4.3.2 Lap or halved joints .................................................................................................................... 13 4.3.3 Miter joints................................................................................................................................. 14 4.3.4 Rebate joints .............................................................................................................................. 14 4.3.5 Tongue and groove joints .......................................................................................................... 14 4.3.6 Tenon and mortise joints ........................................................................................................... 15 4.3.7 Dovetail joints ............................................................................................................................ 15 CHAPTER FIVE CARPENTRY DOCUMENTATION ..................................................................................... 16
5.1 Quotation .......................................................................................................................................... 16 5.2 Cutting list ......................................................................................................................................... 18 CHAPTER SIX CHAPTER SEVEN CHAPTER EIGHT CHAPTER NINE SEASONING OF TIMBER ................................................................................................. 19 MACHINES .................................................................................................................. 22 CARPENTRY MODEL ................................................................................................... 25 CONCLUSION, RECOMMENDATION AND REFRENCES ............................................... 26
CHAPTER TWO
HAND TOOLS
Hand tools are instruments used more so in a workshop or on site to accomplish the work of a joiner or carpenter of creating and setting up wooden structures. There are various hand tools required for a given workshop activity each serving a relatively different purpose. Some of these tools include; (a) SQUARES A square is basically made of a solid member called a stock which is held during use joined to a blade which has scales in inches and centimeters for measuring and also a blade hole where the tool is hanged during storage. Squares are of different types; Tool 90 degree square Function Used for measuring and testing right angles. It can also be used to draw line perpendicular to a plane surface.
Used to measure or create lines at 90 or 45 degrees. With the stock held firmly against a plane surface, straight lines can be drawn along the other plane using the blade.
Similar to the squares is a protractor bevel which consists of an adjustable stock with a protractor scale attached to a blade. This tool measures a variety of angles and the blade is fixed using a locknut on the stock for a required angle. The stock also has spirit level important in leveling off measurements. A protractor bevel
(b) SAWS Saws are tools used for cutting wood to required pieces. They majorly consist of a handle; which is usually wooden, and a blade with cutting teeth. The saws are of different types which include; Tool Rip saw Function The cutting members are made of diverting teeth which cut large wood pieces into smaller ones.
Tenon saw
Campus saw
Has an adjustable handle and is used for small and fine cutting wood work.
(C) HAMMERS Hammers are tools meant to deliver an impact to objects. The most common uses are for driving nails, fitting parts, hitting or pounding and breaking up objects. The usual features are a handle and a head, with most of the weight in the head. Hammers vary widely in their shape and structures some of which include; Type Claw hammer Features The head has one of its end flat and the other end of the head curves down and splits in the middle forming a "V" shape. 4 Function Primarily used for pounding nails into, or extracting nails from, some other objects.
Wooden mallet
Has a double faced head made of wood with a metallic or wooden handle
Used in woodwork to knock wooden pieces together for example joints, or to drive dowels or chisels.
Ball-peen hammer
The head has one of its ends rounded and the other flat supported by a metallic handle.
Used for light joinery work, hammering small nails to hold pieces like glass.
(d) CHISELS Chisels are tools with a characteristically shaped cutting edge of blade on its end, for carving or cutting a hard material such as wood. The cutting edge is at an angle of 45 at the end of a cutting stock. The stock is attached to a metallic or wooden handle. Chisels are of different sizes;8mm, 13mm,18mm, 25mm among others and types such as the butt, carving, corner and bevel chisel.
(e) GRINDING STONE A grinding stone is a rectangular block with one of its broad surfaces relatively rough used for sharpening woodworking tools such as chisels. Oil or water is applied at the rough surface before rubbing the chisel to ease movement and reduce friction.
(f) SCREW DRIVERS A screwdriver is a tool for driving screws or bolts with special slots. The screwdriver is made up of a head or tip, which engages with a screw and a relatively cylindrical handle in a shape to be held in ones hand. Screwdrivers are of different kinds some of which include; Star screw drivers; used for tightening or removing screws with star; phillips or frearson heads. The other is a minus screw driver that drives screws with minus heads. A mult-screw is another complex type of screwdriver whose head can be replaced to be used where necessary. A minus screw driver;
(g) PLIERS A plier is basically a hand tool used to hold objects firmly, for bending, or physical compression. Pliers generally consist of a pair of metal first-class levers joined at a fulcrum positioned closer to one end of the levers, creating short jaws on one side of the fulcrum, and longer handles on the other side. This arrangement creates a mechanical advantage, for it allows increased effect of ones effort. Pliers are of several types including; linemans or combination pliers, needle-nose pliers, pincers, locking pliers and many others. Diagram of a combination plier.
(h) MARKING GAUGE This is a tool used in joinery work to mark long pieces of wood. It consists of a relatively long rectangular wooden piece called a stock which is fixed through the mortise of a nobe to a desired measured length using a lock. Close to the end of the stock is a marking pin which leaves straight markings on a piece of wood on which its run. Diagram of a marking gauge.
(i) SAND PAPER Sand paper is necessary in woodworking workshops for its importance in smoothening surfaces of wood. Sand paper varies according to the roughness of the side used during smoothening from P30 to P180. The numbering indicates the roughness; the smaller the number thus P30, the rougher the surface of the sand paper and vice versa. When smoothening, the scrubbing surface of the paper is best applied along the grains of the wood. Sand paper;
(j) WOOD FILES These are other instruments also necessary in creating smooth surfaces of wood. There are various types of files each with different application but serving a similar purpose some of which include; File Round file application Used especially in filing round dowels
Flat file
Half-round files
(k) RIVETER MACHINE Riveter machines are some other joinery tools that are used to join metal onto wood. They are also of different types basing on how they are operated. A pressure press riveting machine works when a pushing force is applied on its handle onto the piece to join. A riveter machine;
(l) DRILLING MACHINES Drilling machines are tools used to create dowels in pieces of wood through drilling. The dowels can be used as points of attaching other wood pieces using nails or can be enlarged using chisels to create mortises. These machines are usually hand or energy powered hence the two types; Tool Power drilling machine operation Has a chuck that holds replaceable bits and also a switch the allows the control of power to put on or off the drill
The top handle is pressed on the wood to be drilled and the wheel rotated to move the bit into wood creating a dowel.
(m) MEASURING UNITS These are instruments used to take measurements of wood pieces. The measurements are preferably long or short because the units can be adjusted. The units include a measuring rod and a tape measure. The tape measure has different scales in meters, centimeters, feet, inches and millimeters. A tape measure;
(n) HAND PLANES A hand plane is a tool for shaping wood. Planes are used to flatten, reduce the thickness of, and impart a smooth surface to a rough piece of lumber or timber. Planning practice is used to produce horizontal, vertical, or inclined flat surfaces on work pieces usually too large for shaping. Planes have similar features but vary in sizes. The smallest plane is the smoothening plane also known as plane number four; this is used to carry out the final smoothening. The jack plane is slightly larger than the smoothening plane used for general smoothing of the edges, sizing of wood and jointing edges; its also known as plane number five. The longest is the tri-plane; plane number six. This is initially used and helps to maintain the level of timber. Parts of a plane;
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CHAPTER THREE
Joiners Table
JOINERS TABLE
This is also known as a Jointer. A typical joiners workshop consists of a large table like structure usually made out of wood were most of the hand work is carried out, this is known as a joiners table. The table provides a supportive ground for activities like holding wood pieces for cutting, sanding, planning among others. The joiners table consists of a dowel in between two raised extensions of wood of equal length known as the slates. At the end of slate is a stopper; another wooden structure usually replaced according to the required length of the joiner. Close to the stoppers, either side of the table is a V-cramp. The whole system of the dowel, slates, V-cramp and stoppers is supported by four wooden or a time metallic stands to form a complete joiners table. The dowel holds the working to therefore eliminates the placing of tools anywhere in the workshop, slates provide working area for the joiner. The stoppers are diagonally fixed on different slates; this reduces the resultant force for the joiners using the table and also offers enough working space. Illustration of a Jointer
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CHAPTER FOUR
BASIC JOINTS
A woodwork joint is the area or part of wood pieces where a pair of individual items of timber is connected to form other wooden structures for example in moldings such as window and door casing, baseboards, crown molding and cabinets.
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4.3.2 Lap or halved joints For this joint, one piece of wood overlaps another. This requires the removal of stock to exactly half of the overall thickness of the piece, in order for a similar piece to join with it. They are mostly used to assemble light frames which are going to be covered with hardboard or plywood. They are also used to join long lengths of timber as for fencing. They also include cross-halving joints inform of a cross. Cross-halving joint;
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4.3.3 Miter joints This is similar to a butt joint, but both pieces have been beveled usually at an angle of 45. Constructing it usually relies on glue but nails are also applicable. Normally they are used for picture frames where they are nailed with panel pins. A horse tail mitered joint is another kind of miter joint of roughly a greater strength and design. Miter joint Horse tail mitered joint
4.3.4 Rebate joints A rabbet is a recess cut into the edge of a piece of wood. When viewed in cross-section, a rebate is two sided and open to the end of the surface. The rabbet allows the back to fit flush with the sides. Another example is the insertion of a glass pane by using a rebate around the edge of the frame.
4.3.5 Tongue and groove joints Each wooden piece has a groove cut all along one edge, and a thin, deep ridge; the tongue, on the opposite edge. The other case may be a thin long wooden strip; the tongue, joined to two wooden pieces with grooves, the loose tongued joints. They can be used to make wide tabletops out of solid wood or other large boards.
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4.3.6 Tenon and mortise joints Tenon and mortise joints are one of the strongest woodworking joints. One end of a piece; tenon, is inserted into a hole in the other piece; the mortise. A mortise is a cavity cut into a piece of wood to receive a tenon while a tenon is a projection on the end of a piece of wood to insert into a mortise. They are used normally to join two pieces of wood at 90-degrees.
4.3.7 Dovetail joints Dovetail joints are very strong, neat joints and good for tensile strength. They are usually used to make drawers and boxes.
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CHAPTER FIVE
CARPENTRY DOCUMENTATION
5.1 Quotation
A quotation is a document that contains the items, quantity and price required to fabricate or make a given desired structure. This document is a customer and joiner interaction therefore the use of more joinery technical terms is minimized to ease communication. A quotation is written by one who is to carry out the structure formation; the joiner to the customer. Preparation of a quotation A quotation contains a header and the body. The header contains company or workshop name and address which are document centered. The body which is indented contains: to whom the quotation is to be received, the person writing it, date of market survey, subject, table of items with corresponding amount and the salutation. It is recommended not to write the customers name in the document if one is not certain of it. At the end of the table is a short summary containing the subtotal of material cost, transport fee, labor cost and grand total. At the end of the quotation, indicate the date of the survived prices. An example of a quotation for the fabrication of ten tables;
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SMART CAMPUS JOINERS Email: campusjoiners@cns.mak.ac.ug P.O BOX 7062 Kampala UGANDA TO: FROM: DATE: SUBJECT: RE: QUOTATION FOR TEN TABLES Dear sir/Madam; Below shows the materials needed to carryout fabrication works for ten tables ITEMS Timber QUANTITY 2 pcs SIZE 2"6"14 1"12"7 (for top) UNITCOST (Ushs) 35,000 AMOUNT (Ushs) 70,000
Nails Varnish Sand paper Wood glue Subtotal of material cost Transport cost Labor cost 30% of subtotal Grand total
200,000
30,000 60,000
290,000
Prices as per..
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SMART CAMPUS JOINERS Email: campusjoiners@cns.mak.ac.ug P.O BOX 7062 Kampala UGANDA TO: FROM: DATE: SUBJECT: RE: FIVE DOOR FRAMES OF DIMENSIONS 37 EACH Dear Sir/Madam, Below are the given sizes for the frames needed to be made. ITEMS Jambs Transoms Heads QUANTITY 10 pcs 5 pcs 5 pcs SIZES EACH 2"8"7
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CHAPTER SIX
Timber seasoning;
SEASONING OF TIMBER
Timber seasoning is a controlled process of drying up timber or eliminating moisture from timber to required moisture content. The water content of a newly harvested piece of wood or timber is disadvantageous for the wood and the woodworker. Reducing of the moisture content is necessary because of the following reasons; Consequently the timber shows fewer tendencies to warp, split or shake. Seasoned timber although lighter is stronger and more reliable. The sap in timber is a food for fungi and wood parasites. Removal of the sap from the wood through seasoning makes timber less attractive to these dangers. Dry well seasoned timber is easier to work with and consequently safer especially in machine working. Timber with higher moisture content is difficult to finish thus; paint, varnish among others. The most important goal of timber seasoning is to reduce the moisture content of the wood to about 15 percent or less, according to timber. Seasoning of timber is in two ways; the natural and artificial methods. Both methods require the timber to be stacked and separated to allow the full circulation flow of air around the stack. Natural or air seasoning Air seasoning is the method used with the timber stacked in the open air; The timber is stacked on foundations to keep it off the ground. Strips of wood (about 38 x 19 mm) are placed between the layers of boards to allow air to circulate. Ends of boards may be painted to retard drying and prevent splitting. A waterproof covering is placed over the stack to protect the timber from the sun and the weather. The whole process of air seasoning is long and requires plenty of time to produce timber ready for use. Natural stack house
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Advantages of natural seasoning It is a less expensive method of seasoning of timber therefore favorable in case one has low income. The method does not require a lot of skilled labor thereby can be handled by many people in need of prepared wood. The method allows free drying of timber reducing the risks of breaking or cracking of wood. Less monitoring of timber during drying is required therefore gives one room for other activities. Natural seasoning though has some disadvantages such as; Very time consuming. The process requires plenty of time to produce quality timber required on the market. Air seasoning is also very unreliable because of the risks the timber is expose to such as rain, strong wind, dust and many others. When poorly leveled, timber gradually tangentially curves and is difficult to straighten. The period for receiving quality timber is not predetermined leaving each one in suspense.
Artificial or kiln seasoning Kiln seasoning is done in a large oven-like structure in which air circulation, humidity and temperatures are controlled. The kiln uses funs and heat which is circulated in a confined stack component. The timber is stacked on the trucks in the same way as for air drying. The trucks are on rails so that they can be moved into the kiln. The process of drying should be frequently monitored to ensure that removal of water is not rapid. There are two main methods used in artificial seasoning, compartmental, and progressive. Both methods rely on the controlled environment to dry out the timber and require the similar factors such as; Forced air circulation by using large fans, blowers among others. Humidity control provided by steam jets. Heat of some form provided by piped steam.
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Advantages of kiln seasoning The carefully controlled conditions can minimize degrade seasoning defects which occur while drying. Kiln drying permits drying to the exact moisture content required, which may be much less than that of air dried timber. The heating of the timber while in the kiln kills eggs, larvae and adult borers which may be present in the wood. The process takes a shorter time compared to natural seasoning. The period of receiving ready timber is predetermined. Greater turnover is possible by reductions in drying time, and less timber yard storage space required. Some of the disadvantages of kiln seasoning include; Accessing or acquiring the kiln is expensive with the services inclusive. Warping of wood is likely to occur in case heating is not controlled. The process of monitoring the timber and regulating heat requires a lot of skilled labor. Heavy losses are likely to occur in case regulations are miss-handled
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CHAPTER SEVEN
Wood working machines
MACHINES
Besides the hand tools, woodwork; more so in joinery requires the use of machines to simplify work and also achieve the desired wood structures in the shortest time possible. The major woodworking machines used include; (a) Mortising machine This is also known as a mortiser. A mortise is a specialized woodworking machine used to cut square or rectangular holes in a piece of lumber, such as a mortise in a mortise and tenon joint. Mortisers are of different types which include a square chisel mortise, horizontal or slot mortise and a chain mortise. All these have a similar mode of action; a chuck that hold the bits and drill. The square chisel mortise combines the cutting of a four-sided chisel with the action of a drill bit in the center. The bit clears out most of the material to be removed, and the chisel ensures the edges are straight and clean. Drawing of a hollow mortising chisel and bit
(b) Sanding machine The sanding machine is an electrically powered tool used to smooth wood by rapidly rotating sandpaper of the wood piece. It is usually used to sand large wood pieces. The sanding machine consists of an adjustable knob used to adjust the sand to the required position, two rollers, a round disc used for sanding round corners to create circular surfaces and a guard to keep the piece being worked on in position.
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(c) Circular saw cutting machine The circular saw machine uses a toothed metal cutting disc or blade to cut wood and also make narrow slots called dados. The machine cuts are straight and relatively accurate and the cutting is by teeth on the edge of a thin blade. The material to be cut is securely clamped and the saw is advanced slowly across it or in other saws; the saw is fixed and the material to be cut is slowly moved into the saw blade.
(d) Planning and thickness machine This machine is a woodworking machine which is usually used to create boards that are of an even thickness throughout their length and flat on both surfaces. The machine consists of majorly three components: a cutter head which contains the cutting knives; a set of rollers which draw the board through the machine; and a table which is adjustable relative to the cutter head to control the resultant thickness of the board.
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(e) Combined wood working machine This is a woodworking machine that combines the functions of two or more separate machines into a single unit for example the jointer-thicknesser or a circular power saw and a mortising machine. The design of the machine depends on the work required. Some combination machines run all of their functions from a single motor; others may use more than one.
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CHAPTER EIGHT
Corner half-lap joint Model
CARPENTRY MODEL
The model is to be designed from a long piece of wood using the tools as mentioned; a rip saw, claw hammer, sand paper of different sizes, tape measure, and a 90 square. Model procedure; From the long piece of wood, measure 12 inches using a tape measure, mark round using a pencil with the aid of a square and cut using a rip saw. From the cut out piece, divide it into half; to obtain two 6 inch pieces. Measure from the end of one piece the length equivalent to the width of the other and mark out using a pencil. Using a pencil, half the thickness of each piece of wood to be joined is cut away with a rip saw. The next stage to sand the pieces along the grains starting with a more rough sandpaper for example P40. Then further sand to make the pieces smoother and join the two pieces with half the nails diagonal to each other. Illustration;
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Carpentry is generally a skilled hands-on technique that requires concentration and determination for the activity. The safety of tools and machines used, the personnel involved, and use of the carpentry workshop is greatly considered. This can be seen in the emphasis on how to use hand tools of different sizes and common machines for their rightful purposes.
9.2 Recommendation
The field of carpentry being more technical and requires basic knowledge of tools and machines, the following recommendations are necessary to improve on the better understanding of the basics and acquiring of other skills; Provision of more carpentry materials such as cutting tools and fittings to have enough hands on experience. Setting up more fixed carpentry workshops with a number of equipment to ensure working experience. Implementing the acquired carpentry skills with in the workshops as a means of practice.
9.3 References
Carpentry and Joinery: Job Knowledge, Book 1 2nd Ed. Modern Carpentry and Joinery, Fred T. Hodgson www.wikipedia.com/ www.googlescholar.com Lecture notes
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