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 2.1

MATERIALS 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

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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 25C when tested in accordance with TMH 1 Method A-21T. 3.0 EQUIPMENT The following equipment shall be available for the work:i. ii. iii. iv. v. 2 1 1 6 4 1 vi. 2 4.0 4.1 No 140G Grader No. Bull dozer No. Front End Loader No 15 ton Tipper Trucks No Rollers (1No. grid roller, 2 No. Vibrating Steel Drum Rollers, No. Pneumatic Roller) No Water Bowser (each of capacity 21,000 litres)

CONSTRUCTION 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

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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 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
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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 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 Subclause 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 Working Force 1 1 1 2 3 4 Site Engineer Earthworks Foreman on site Soils Technician Laboratory Assistants General Workers for checking levels General Workers for picking rejected material
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8.1

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SELECTED layer Methodology

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 1 1 1 1 1 1 9.0 Bulldozer Operator Loader Operator Operator for each Grader Operator for each Roller Driver for each Water tanker Driver for each Tipper Truck driver Tractor (disk harrow)

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.

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