Work Bench Procedures

Formwork
Step 1: Obtain a sheet of plywood measuring ½” x 4” x 8”. With the aid of a measuring
tape and a pencil, mark the Plywood at 24” x 56”. Then cut using a circular saw.

Step2: Obtain a baulk of pine timber measuring 2”x 4”x 12”. Measure Four pieces each,
measuring 2” x 4” x 24” and cut using a circular saw.
Step 3: Obtain another baulk of pine timber measuring 2” x 4”x 12”. Measure three
pieces each, measuring 2” x 4” x 48” and cut with a circular saw. Given that four
pieces are needed. The remaining piece in step two can be used.
 Assembling the form work for the seat

Step 4: Gather the four pieces of timber measuring 2” x 4”x 24” obtained in
Step 2. Using two pieces only, join them together with wood glue and
screw them together. With 3” screws using a hand drill so as to make a
single piece measuring 4”x4”x 24”.
Do this as well for the remaining two pieces of timber.
Place wood glue along the ends of the plywood measuring 24” then
screw one piece of the 4”x4”x 24” timber along each end of plywood with
the aid of a hand drill making sure that it stays flush with the plywood.
Step 5: Gather the four pieces of timber measuring 2”x4”x 48” obtained in step 3
using two pieces only join them together with wood glue and then screw
together with 3” screws, using a hand drill so as to make a single piece
measuring 4”x4”x 48”.
Do this as well for the remaining 2 pieces of timber.
Place wood glue along the ends of plywood measuring 48” then screw
one piece of the 4”x4”x 48” timber along each end of plywood using a
hand drill making sure that it stays flush with the plywood.
Step 6: Obtain a baulk of pine timber with measurements of 1”x 8”x 8”. Measure
the baulk at 1”x 8”x 8”. Measure the baulk at 1”x 8”x 5” using a
measuring tape and a pencil then cut with a circular saw.

Step 7: Using a table saw fix the fence at 1” away from the blade. Make sure that
the blade is tilted 135o to the left and that it is raised 1 1/8” high.

Take the board to the table saw and make three rips using a push
stick to avoid injuries.
Step 8: Tilt the saw blade at 90o. Take two angle fillet and crosscut 4” off of each
using a mitre gauge. Make sure that the blade is raised 1 1/8” high and
that the mitre gauge is set at 0 o.

Step 9: Take the remaining angle fillet to the table saw and crosscut off 18” using
a mitre gauge. A remaining piece of 32” will be left.
Step 10: Take the angle fillet obtained in Step 9 and rip 16” off of it. (that is rip in
half) using a mitre gauge.

Step 11: Take one of the 16” angle fillet and add wood glue to one of the sides
(not the bevelled side) and add glue to the 24” side of plywood where the
Angle fillet is to be placed on. Make sure that the bevelled side stays
turned inwards for the bevelled edge to be created on the concrete
bench.
The angle fillet flush along the side of the 4”x 4” x 24” board. Do this as
well for the other 16” angle fillet on the opposite side.
Now take one of the 46” angle fillet and add wood glue to one of the
sides. (not the bevelled side) and add glue to the 48” side of the plywood
where the angle fillet is to be placed on. Make sure that the bevelled
side stays turned inward for the bevelled edge to be created on the
concrete bench.
Place the angle fillet flush along the side of the 4”x 4” x 48” board
between the two 16” angle fillet. Do this as well for the other 48” angle
fillet placing it on the opposite side between the two 16” angle fillets.
Step 12: Obtain the remaining sheet of plywood in step 1. Measure and mark four
pieces of the plywood at ½” x 14” x 16” with the aid of a measuring tape
and a pencil then cut using a circular saw.

Step 13: Obtain a baulk of pine timber measuring 2”x 4”x 12”. Measure four
pieces of 2”x 4”x 14” each and cut with the aid of a circular saw
Step 14: Gather two pieces of 2”x 4”x 24” and two pieces of ½”x 14”x 16”
plywood.
Place one piece of plywood flat on the ground and add wood glue
on both sides where the 2”x 4”x 14” boards will be placed on.
Screw the plywood onto the board with 2” screws using a hand
drill such as the side measuring 4” of the board stays vertical and
flush along the end of the plywood.
Do the same for the other piece of board on the opposite side of
the plywood.
After having done this, place glue along the 2”x 14” sides of the
boards and place the other piece of plywood on top making sure
that it stays flush with the boards beneath it then screws the
plywood onto the board with 2” screw using a hand drill.
Follow the same procedures for making the other leg.
Step 15: Attach an angle bracket onto each 5” side of the leg with 1”
screws using a hand drill. Make sure that the bottom of angle
bracket stays flush with the bottom of each leg. Also make sure to
place the angle brackets at the centre of the 5” side of the leg.

Step 16: Obtained a 3/8” wood bit and drill two holes where the leg
brackets will be placed to secure the legs onto the seat.
Obtained four bolts to fit in the hole made for the legs. Fit one in
each hole with the head of the bottom and place the legs onto the
seat. Using a 3/8” spanner, tighten the bolt by placing a
Nut on top of the hole where the bolt will push out.
Steel Work

Step 1: Obtain a 20’ 3/8” reinforcing steel.

Measure three pieces of 46” and cut using a chop saw and wear a
face shield for safety.

Step 2: Measure five pieces of 14”and cut using a chop saw

and wear a face shield for safety purposes.

Step 3: Gather all pieces of steel.

Place a piece of the 46” 14” parallel 46” piece of steel.
Place a piece of 14” steel on both ends of the 46” steel forming a square
and place the three pieces spaced between the 40” length to form the
 steel reinforcement and tie the steel where they intersect each other.
Using tying wire and a nipper to tighten them.

Step 4: Measure four pieces of steel at a length of 16” for the piece that will
attain the legs onto the seat and cut them using a chop saw.

Step 5: Measure six pieces of steel at a length of 12” to form the

reinforcing steel for the legs and cut using a chop saw.
Step 6: Gather the pieces that will form the reinforcement for the legs.
Place the three horizontally flat with spacing of 4” between them.
Place the 2 pieces of 18” steel, one on each end of the 12” parallel
steel and tie with tying wire with steel intersecting each other.
Concrete Mix
Materials:
Standard household bucket
4 ½ buckets of Aggregate
½ bucket of water
1 sack of cement
Step 1:
Mix the cement and the aggregate together on a flat open area using a shovel

Step 2: Spread the mix creating a barrier and leaving a hole in the middle using a
spade or shovel.
Step 3: Add the half bucket of water into the middle of the mix.

Step 4: Shovel the exterior part of the cement surrounding the barrier
into the middle of the mix without breaking the barrier which
holds the water.
Step 5: When the inside of the mix is filled, break the barrier and
mix the concrete completely and add enough water, if necessary,
just until the mix reaches at a point between softness and
hardness.