SELECTED layer Methodology

UPGRADING OF APPROXIMATELY 104KM OF ROAD D104/D791 CHIPATA TO

MFUWE IN EASTERN PROVINCE

SELECTED FILL LAYER METHODOLOGY

1.0 SCOPE
This method statement covers the construction of selected fill layers from approved
natural gravel or partially crushed gravels. The summary includes notes on materials to
be used, equipment, and preparation of the area, construction operation and testing.

2.0 MATERIALS

2.1 General
Gravel material shall be obtained from approved sources in borrow areas or
cuts. Tests will have been made on potential borrow pits, cuts and on the
roadbed along the centre line of the existing road. The requirements to be
complied with by the material are set out on the Drawings and in the Project
Specifications for each of the 150mm layers. It shall be ensured that only
material which complies with the prescribed requirements is used in the
selected fill layers. Where natural gravel does not fully comply with the
requirements in respect of maximum size after having been broken down as
determined in Clause 3204 of SATCC specification, or after light crushing,
oversize material shall be removed as specified in Clause 3210.

2.2 Material Specification

In situ material falling within the selected sub-grade horizon shall, when not
conforming to the requirements for selected sub-grade material, shall be
excavated and replaced as ordered by the Engineer. Selected sub-grade shall
contain no material greater than two-thirds of the layer thickness. The
material will conform to the following requirements:
Minimum soaked CBR at 90% Mod. AASHTO . . . . 15 %
Maximum plasticity index . . . . 3 x grading modulus + 10

Upgrading of approximately 104Km of the chipata Mfuwe rd Page 1

SELECTED layer Methodology

2.5 COMPACTION REQUIREMENT

The minimum in situ compaction of gravel material shall be 93% of modified
AASHTO density.

2.4 Electrical conductivity

The maximum electrical conductivity of the dumped material on the road shall not
exceed 0.15 Sm-1 at 25°C when tested in accordance with TMH 1 Method A-21T.

3.0 EQUIPMENT

The following equipment shall be available for the work:-

i. 2 No 140G Grader
ii. 1 No. Bull dozer
iii.1 No. Front End Loader
iv. 6 No 15 ton Tipper Trucks
v. 4 No Rollers (1No. grid roller, 2 No. Vibrating Steel Drum Rollers, 1 No.
Pneumatic Roller)
vi. 2 No Water Bowser (each of capacity 21,000 litres)

4.0 CONSTRUCTION
4.1 Requirements applying prior to the construction of the layer
Fill layers shall be constructed only where the underlying layer meets all the
specified requirements and has been approved by the Engineer. Before the
construction of any fill layer, and also before any material for a fill layer is
dumped on the road, the underlying layer shall be checked to establish
whether there is any damage, wet spots or other defects, which shall be
rectified in accordance with the instructions of the Engineer before the next
layer is constructed.

4.2 Placing and compacting

The material for a selected fill layer shall be placed, spread, broken down,
watered if necessary and mixed, and oversize material shall be removed and
the layer compacted, all in accordance with the requirements of Section 3200
of the SATCC specifications. The following additional requirements in regard
to placement and compaction shall apply:
4.3 Crushing and screening

Upgrading of approximately 104Km of the chipata Mfuwe rd Page 2

SELECTED layer Methodology

Where fill material cannot be suitably broken down to the required size in
excavation and during processing on the road, the Engineer may prescribe
that the material be crushed and screened or crushed only, all as specified in
Section 3200.

5.0 PROTECTION AND MAINTENANCE

The completed layers shall be protected and maintained. Protection shall be
done against rain and flood water, and against any undue wear and tear of or
damage to the layers by construction or other traffic. Maintenance shall
include, inter alia, the immediate repair of any damage or defects that may
occur.

6.0 CONSTRUCTION TOLERANCES

The completed pavement layers shall comply with the construction tolerances
given below:

6.1 Level
The level tolerances referred to in Clause 7205 shall be as follows:
H90 .................................... 25 mm
Hmax ………………………………… 33 mm

6.2 Layer thicknesses

The thickness tolerances referred to in Clause 7205 shall be
as follows:
D90 ........................................ 30 mm
Dmax....................................... 40 mm
Daverage ………………………………… 10 mm

6.3 Width
The average width of the layer shall not be less than the specified width, and
nowhere shall the outer edge deviate by more than the following from the
edge lines shown on the Drawings: 3400-4
Upgrading of approximately 104Km of the chipata Mfuwe rd Page 3
SELECTED layer Methodology

Selected layer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 mm

6.4 Cross-section
When tested with a 3 m straight-edge laid at right angles to the road centre
line, the surface shall not deviate from the bottom of the straight-edge by
more than 6 mm. At any cross-section the difference in level between any
two points shall not vary from their difference in level computed from the
cross-sections shown on the Drawings by more than 15 mm.

6.5 Construction tolerances for rehabilitation work

The construction tolerances of Clause 3405 shall be applicable to
rehabilitation work, except where a gravel layer is placed on top of an existing
layer without it being required that the existing layer be trimmed first to
prescribed levels, the thickness tolerances of Sub-clause 3405(b) shall not
apply.

7.0 ROUTINE INSPECTION AND TESTS

The Engineer will do routine inspections and conduct routine tests to
determine whether the quality of material and workmanship provided comply
with the requirements of this Section. The test results and measurements
shall be assessed in accordance with the provisions of Section 7200.
8.0 PERSONNEL

8.1 Working Force

1 Site Engineer
1 Earthworks Foreman on site
1 Soils Technician
2 Laboratory Assistants
3 General Workers for checking levels
4 General Workers for picking rejected material
1 Machine Attendant for each item of plant and equipment
2 Mechanics for daily servicing and minor repairs

8.2 Plant Operators and Drivers

1 Bulldozer Operator
Upgrading of approximately 104Km of the chipata Mfuwe rd Page 4
SELECTED layer Methodology

1 Loader Operator
1 Operator for each Grader
1 Operator for each Roller
1 Driver for each Water tanker
1 Driver for each Tipper Truck
1 driver Tractor (disk harrow)

9.0 SAFETY, WORKERS AND PROTECTIVE CLOTHING

All works shall overally be supervised by a Site Engineer, who shall ensure
that a safe working environment is always maintained, and that on-site safety
procedures are followed at all times.

The Site Engineer shall see to it that adequate measures are taken to warn
and protect road users and construction workers. He shall instruct all
supervisors and foremen in safety measures including traffic control and use
of clean standard temporary road signs

The Safety Officer shall conduct regular on-site inspections of works,

equipment, tools and personnel. He shall also hold regular safety meetings
with all work groups to discuss and instruct in safety, and shall produce
weekly reports to Management.

Good working and handling practices shall be ensured on site

All workers shall be provided with such protective clothing such as hand
gloves, overall suits, boots, reflective jackets and dust masks.

Only suitable hand tools and devices, free from any defect, shall be used.

Only experience operators shall be used to operate plant and equipment on

site.

All detours shall be maintained in serviceable condition.

Upgrading of approximately 104Km of the chipata Mfuwe rd Page 5