UGANDA TECHNICALCOLLEGE

P.O BOX 940, ELG

A REAL LIFE PROJECT FOR THE FABRICATION OF A METALLIC WINDOW FOR
A NEWLY CONSTRUCTED CLASS BLOCK BUILDING AT UTC ELGON.
COMPILED BY MUSUUBO SAMUEL
REGISTRATION NO: UBT002/2024/Ts/D/A/3213
DEPARTMENT: MECHANICAL
COURSE; MECHATRONICS ENGINEERING
YEAR ONE
SEMESTER ONE
TO BE SUBMITTED TO UGANDA BUSINESS AND TECHNICAL EXAMINATION'S
BOARD (UBTEB) AS A PARTIAL FULFILLMENT FOR THE AWARD OF
NATIONAL DIPLOMA IN MECHATRONICS ENGINEERING.
DECLARATION
I MUSUUBO SAMUEL declare that the information I have given in this report is from my
consent with crystal evidence and all the information is compiled by me for an award of
National diploma in mechatronics engineering and I assure you that this report has not been
presented at any initiative or ever submitted to any kind of academic institute before.

SIGN………………………………...

DATE………………………………...

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APPROVAL
This is to approve that Musuubo Samuel has carried out his real life skill traing under my
supervision and the information in the report given given is true and original and ready for
submittion

SUPERVISOR

Name: Mr. MUBOKI MOSSES

Signature……………….

Date……………………

Name: Mr. NAMOMO ERIA

Signature………………………………..

Date……………………………………..

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ACKNOWLEGEMENT
With pleasure, I would like to express my deepest appreciation to all those who provided me
the possibility to complete this project harmonically. A special gratitude I give to our final
year one semester one project manager, Mr. Mukwaya Edward whose contribution in
stimulating suggestions and encouragement helped me to coordinate my project. Special
thanks to also my supervisors that is Mr. Muboki Mosesand Mr. Namono Eria

Further appreciations go to Mr.EDENYU SAMUEL who gave me chance to have eyes on

and hands on there by providing me with tools and guidance towards my real life
project and also the college administration for providing training materials and equipment.
I acknowledge my sister Namutamba Monica who pays tuition for me my God bless her
abundantly.

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DEDICATION
Above all, I thank the mighty God who has granted me good - health, life, knowledge and
protection.

I also warmly dedicate this report to the next lot of year one semester one students.

I also devote the work of this real-life project to respectable and honorable instructors who
taught and supported me in developing my personality as a competent professional and the
lectures for giving us the knowledge and the opportunity granted to me to train and expand
my skills and knowledge in the field of Engineering.

Lastly, l also dedicate this report to my friends who asisted me in this project thank you may
God bless u

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ABSTRACT
This document contains the background of the project clearly stating the challenges it will
solve along with other objectives and its significance to the society. This project was
fabrication of a metallic window and the steps of how it was made considerately the working
mechanical drawing. Therefore, the following were undertaken for the completion of the
metallic window; plan interpretation, gathering necessary materials, tools and equipment.
Thereby also measuring, cutting, welding, Grinding and polishing, body filling and painting.

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Contents
DECLARATION..................................................................................................................................i
APPROVAL.........................................................................................................................................ii
ACKNOWLEGEMENT.....................................................................................................................iii
DEDICATION....................................................................................................................................iv
ABSTRACT.........................................................................................................................................v
LIST OF FIGURES...........................................................................................................................vii
ABBREVIATION...............................................................................................................................viii
CHAPTER ONE....................................................................................................................................1
1.0 Introduction..............................................................................................................................1
1.1BACKGROUND.......................................................................................................................1
1.2 PROBLEM STATEMENT.......................................................................................................1
1.3 Objectives.................................................................................................................................1
1.3.1 General objective................................................................................................................1
1.3.2 Specific objectives...............................................................................................................1
1.4 scope.........................................................................................................................................1
1.5 Significance of the study...........................................................................................................2
CHAPTER TWO.................................................................................................................................3
2.0LITERATURE REVIEW.................................................................................................................3
2.1Types of window designs used in modern building...................................................................3
2.1.1. Awning Windows...............................................................................................................3
2.1.2. Casement Windows............................................................................................................3
2.4 Double-Hung and Single-Hung Windows.............................................................................4
2. 5Picture Windows.....................................................................................................................5
2.6 Slider Windows.......................................................................................................................5
CHAPTER THREE.............................................................................................................................7
3.0 The fabrication of a metallic window....................................................................................7
3.1 Interpretation of the plan.....................................................................................................8
3.2 Procedure................................................................................................................................8
3.3 Methods used............................................................................................................................8
3.3.1 Procedure...............................................................................................................................8
3.4 EQUIPMENTS USED FOR WELDING.....................................................................................8
3.5 safety equipment’s..................................................................................................................9
 welding shield,.......................................................................................................................9

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 gloves.....................................................................................................................................9
 safety boots............................................................................................................................9
 overall....................................................................................................................................9
3.6 COMPRESSOR MACHINE..................................................................................................9
3.7 Tools.......................................................................................................................................10
TOOL..........................................................................................................................................10
IMAGE........................................................................................................................................10
Cutting disc.................................................................................................................................10
For cutting the metal sheet using a grinder..............................................................................10
Marker and scriber....................................................................................................................11
For marking different positions, scribing lines for cutting......................................................11
Centre punch...............................................................................................................................11
For marking centres where holes were drilled.........................................................................11
Table 1..........................................................................................................................................11
3.7Personal protective equipment.................................................................................................11
3.8New skills acquired........................................................................................................................11
3.9.0 Working place......................................................................................................................12
3.9.1Procedure..............................................................................................................................12
3.9.2 Methods used.......................................................................................................................12
3.9.3 New knowledge and skills acquired.....................................................................................12
3.9.4 DESIGN PROCEDURE....................................................................................................12
I. MEASURING.........................................................................................................................12
II.CUTTING...............................................................................................................................13
3.3.4 GRINDING AND POLISHING.........................................................................................14
3.3.5 PAINTING.........................................................................................................................15
CHAPTER FOUR.............................................................................................................................17
4.1 Challenges..............................................................................................................................17
NEW SKILLS ACQUIRED........................................................................................................17
4.3 Conclusion..............................................................................................................................18

LIST OF FIGURES

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Figure 1: Awning Windows....................................................................................................................3
Figure 2: Casement Windows................................................................................................................4
Figure 3: Double-Hung and Single-Hung Windows................................................................................4
Figure 4: Picture windows.....................................................................................................................5
Figure 5: Slider Windows.......................................................................................................................6

ABBREVIATION
UTC Uganda Technical college – Elgon

NDMT National Diploma in Mechatronics Engineering

MM Millimetre

IC Isolation centre.

PPE Personal Protective Equipment

viii
ix
CHAPTER ONE

1.0 Introduction
The real- life project on the fabrication of a metallic window.

Real life project is a project that requires one with practical skills in fabrication; machining
and fitting of various engineering components there by fully exercise hand on.

Fabrication is the joining of similar and dissimilar metals by fusion. It can also be termed as
welding.

1.1BACKGROUND
The project was carried out to integrate with majorly the durability of windows and cop up
with the ease and comfortable use, given the fact that the prevailing windows are of weak
material with poor design. So, by doing this project hopefully an award willbe granted,
therefore the responsible households around the college will witness the new ventured design
(metallic window).

1.2PROBLEM STATEMENT
The newly constructed class block building lacks windows and therefore necessitated
fabrication of a window

1.3 Objectives
1.3.1 General objective
To fabricate a metallic window

1.3.2 Specific objectives

 To study materials and tools needed for fabricating a window
 To identify, select and obtain the size of materials required for the window design
 To develop the layout of the window and determine the cost.
 To acquire knowledge and skills for welding
 To learn how to use and operate different machines involved in fabrication

1.4 scope
The fabrication of the metallic window wass limited to a width of 1500mm and height
of 1500mm

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1.5 Significance of the study
The project was aimed at providing windows for a newly constructed class block
building and impart practical skills and knowledge to the learner

The project

The project study has enabled me acquire skills of plan interpretation, cutting, making
various measurements.

This has also made me gain field work confidence and innovative skills.

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CHAPTER TWO

2.0LITERATURE REVIEW

2.1Types of window designs used in modern building

2.1.2. Casement Windows

Casement windows also open out (like awning windows) and usually pivot from side hinges.
Many casements have fairly large glass panes to provide ample light that is uninterrupted by
minting bars or other framing. Casements also typically offer more open ventilation area than
other window types. When closed and locked, casement windows can make a very effective
seal for improved energy performance. Like awning windows, casements should not open out
into traffic lanes.

Figure 1: Casement Windows

2.4 Double-Hung and Single-Hung Windows

Ddouble-hung and single-hung windows are the most common and familiar window types.
The only difference between them is that single-hung has a movable lower sash and a fixed
upper sash, while double-hung has two movable sashes; the upper sash slides down.

The main advantage of double-hung windows is somewhat better ventilation. With both
sashes opened about halfway, air naturally flows in through the lower opening and out
through the upper opening. Double-hung windows also can be cleaned inside and out without
the need to clean from outside.

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Single- and double-hung windows work in most locations and have a classic decorative look.
They typically offer less open area than casement and slider windows and can be more prone
to air leakage than casements.

Figure 2: Double-Hung and Single-Hung Windows

2. 5Picture Windows

Picture windows are best in areas where airflow is not important because they do not open.
They are often large glass expanses occupying the center portion of a wall to provide broad
views and ample sunlight. Picture windows also work well for high windows in two-story
foyers. Because they do not open, picture windows are less prone to air leakage than operable
windows, but their large glass panes can lose or gain a lot of heat (compared to an insulated
wall), even with energy-efficient double-pane construction.

Figure 3: Picture windows

2.6 Slider Windows

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Slider windows slide open sideways. Like casements, they can offer clear views and ample
ventilation, but they cannot be sealed as tightly as casements. Sliders are commonly used for
egress windows in basement or below-grade bedrooms, due to their large openings and easy
operation. Utility windows at the tops of basement walls also tend to be sliders.

Sliders are quite simple, having no mechanical parts (other than a lock), and usually very
basic seals and no tension mechanism. This simplicity often makes them the least expensive
type of window.

Figure 4: Slider Windows

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CHAPTER THREE

DATA PRESENTATION:

3.1. site visiting.

3.2. Planning
Identify the project by inspecting the site

Taking the measurements or dimension of possible size frame

Designing
Coming up with the diagrammatic views for the designs required for that particular chosen
project.

Identifying the materials, tools and equipment to use during the process of making the
project.

Cutting the materials to the required sizes or measurements for easy fittings.

Figure 5

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3.0The fabrication of ametallic window.
Real life project about fabrication of a standard metallic window followed are the procedural
steps taken;

3.1 Interpretation of the plan

This is the transformation ofthe measurements and dimensions from a working drawing to the
work pieces:

3.2Procedure
We came out with the working drawing/plan and we analyzed the plan as a group of which
we came out with the measurements that we transferred to the work piece. Whenever we got
stuck, we consulted the supervisors.

3.3Methods used
These are the methods we used to interpret the plan;

 Following the supervisor’s instructions

 Discussion
 Sharing experience
 Observation
 Interpretation

3.3.1Procedure
We went to the work shop with the instructor; we listed materials basing on the work plan.
The materials include
 Window frame
 Flats 20*2mm
 louvres
 Hollow sections 30*20*5mm
 Hollow sections 20*20*1.5mm
 Body Filler
 Paint
 Welding rods,
 Thinners
 Sand paper
 Window hinges
 Window locking system

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 Stays
 Red-oxide

3.4 EQUIPMENTS USED FOR WELDING

Grinding machine

for polishing and grinding.

4) weldingtorch

>for welding or joining metals

3.5 safety equipment’s

 welding shield,
 gloves
 safety boots
 overall

3.6 COMPRESSOR MACHINE

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 >used for design and painting

3.7 Tools.
Table 1

TOOL USE IMAGE

Tape measure. For setting out
dimensions and
checking for various
lengths of the chair.

Hacksaw. For cutting the hollow

sections to be used.

Cutting disc. For cutting the metal

sheet using a grinder.

Chipping hammer. For removing slag after

welding process.

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Marker and scriber For marking different
positions, scribing lines
for cutting.

Tri square. For checking squareness

of the chair as well as
scribing perpendicular
lines.

Grinding disc. For grinding/polishing

welded beads using a
grinder.

Centre punch. For marking centres

where holes were
drilled.

3.7Personal protective equipment.

Table 2

PP IMAGE
E
Ov
era
ll.

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 Saf
ety
bo
ots.

Hel
me
t.

3.8New skills acquired

 Taking measurement
 Selection of materials and tools

3.9.0 Working place

This is a room/place equipped with necessary equipment where we carry out our real life.

3.9.1Procedure
I had to look for a working place with working equipment, well ventilated, equipped with
power source and having enough space.

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3.9.2 Methods used
I visited different work places with an aim of looking for the best equipped one.

3.9.3 New knowledge and skills acquired

I acquired the skill of looking for a good working place

3.9.4 DESIGN PROCEDURE.

I.MEASURING.
Measuring is the process of setting out dimensions on a workpiece.

After interpreting the plan, the total length of the chairs was calculated and measured off
from the hollow section using a tape measure and marker.

Methods used.

The window was divided into two portions, one for the top part for the louvres and other part
for the shatter.

Therefore, the mild steel would then be measured and cut in to different pieces dimensioned
according to the drawing plan.

Steps taken.

For the top part, different distances were then marked off on the mild steel starting with half
the length of the adding height from it to top and width of the top and the height again and
then the length leftto give allowance when fixing in the finished house.

For the bottom part, different distances were marked off and used a tri square and angle line
to test for proper squareness plus angles of the window.

From each of the marked points on the mild steel, 10mm were then marked on its either sides
to give allowance when fixing.

Metal pieces were marked off basing on the dimension given accurately.

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II.CUTTING.
Cutting is the process of obtaining a desired length or shape by removing off the unwanted
part.

Methods.

Cutting was done using a hacksaw for hollow sections and grinder with cutting disc for
cutting the square bars.

Steps taken.

The mild steel of 1500x1500MM and 1.5 thickness is cut into square bars basing on
dimensions of 1200mm by 1000mm using a grinder with cutting disc.

III. JOINING /WELDING

welding is the process of joining two similar or dissimilar metals by fusion.

Method.

The top part and bottom part were then joined considering proper squareness using spot
welding together the formerly marked half lengths.

The square hollow sections were also joined using spot welding to form shatters.

Then after finding accurate squareness and angles, full welds were made.

Steps taken.

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The top and bottom part, welded them considering the proper squareness and angles being
equal using spot welding. The square hollow sections were also spoted welding considering .

the side to side shatters. Then full welds after ensuring that there are propersquareness and
angles.

IV. FILING.

Filing is the operation carried out after chipping to obtain a proper surface finish.

Method.

Cross and draw filing.

3.3.4 GRINDING AND POLISHING.

Grinding is the process of removing extra layer of material (metal) using a grinder attached
with a grinding disc.

Method.

Grinding was done using a grinding machine to create a smooth surface.

Steps.

The chair was made to stand in different positions such the grinder could access all the
welded joints.

Welded joints were made smooth by grinding away the excess layer of beads and spatter.

After grinding, a highly polished and smooth surface was obtained.

Sharp and rough edges of the metal sheets were also grinded away to create a smooth surface.

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3.3.5 PAINTING.
Painting is the action of adding an extra layer of adhesive on the material (metal) to prevent
corrosion, rusting etc.

Method

Paint was applied to the grinded chair using a compressor.

Steps.

The metallic window was cleaned properly and raised above the ground using clean pieces of
wood to prevent dust from contaminating the paint.

Paint was then prepared and the compressor switched on for the process.

Paint was then sprayed on every part of the chair and left to dry thereafter.

3.3.6 COST OF PRODUCT

BILL OF QUANTITIES

Table 3 Bill of Q quantities

S/N1 Item Specificatio Quantity Rate Amount

ns

1 Door frame 1.25 pcs 30000 37500

2 Hollow section 20x20x1.5 2.5 pcs 20000 50000

mm
3 Hollow section 30x20x1.5 2.o3 pcs 30000 60900
mm
4 Stay 2 pcs 4000 8000

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 5 louvre 4 pcs 10000 40000

6 Flat 20x2mm 3.1 pcs 12000 37200

7 hinges 2 pairs 5000 10,000
8 locks 2 pcs 4000 8000
9 Red oxide 1 ltr 10500 10500
10 thinner 0.5 ltr 7000 3500
11 0.15 g 20000 3000
Body filler
12 Sand paper 0.5 m 2000 1000

TOTAL 269600s

Labour=15%x production cost

15/100*269600=40440

CHAPTER FOUR

4.1 Challenges
 Work place was small leading to congestion.
 Shortage of enough equipment for grinding and welding torches.
 Insufficient protective equipment such as shield masks and gloves
 Power blackouts

NEW SKILLS ACQUIRED.

 I learnt how to set out dimensions on the workpiece before bending.
 I also learnt how to spot weld different joints without spoiling the workpieces.
 I learnt how to polish the surfaces using a grinder and files.
 I also learnt how to spray using a compressor.

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4.2Recommendations

As I was carrying out my real-life project, I came up with some suggested resolutions as
follows;

 The college should provide enough tools and equipment to facilitate the real- life project
 The college should provide a powerful standby generator to overcome the problem of
power blackouts.
 There should be provision of straitening machines to correct deformations in the material.

4.3 Conclusion
I thank the almighty God who has enabled me to come to a successful conclusion of my real-
life project. During my real life, I have acquired new skills and knowledge. I have also got
new ideas.

4.4 References

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APENDICE

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