Draft Quality Assurance Manual (QAM)

Sodo Junction (Dimtu) - Bilate Military Training Centre Road Project Table of Contents

T C
1 INTRODUCTION ..............................................................................................................................................5

1.1 GENERAL ..............................................................................................................................................................................................5

1.2 TEST CATEGORIES ...........................................................................................................................................................................6
1.3 TESTING PROCEDURES ..................................................................................................................................................................6
1.4 TERMS AND DEFINITIONS ............................................................................................................................................................7

2 PROJECT INFORMATION.............................................................................................................................9
2.1 DESCRIPTION OF THE PROJECT .................................................................................................................................................9
2.1.1 Historical Background ...........................................................................................................................9
2.1.2 The Project Road ...................................................................................................................................9
2.2 OBJECTIVES OF THIS QUALITY ASSURANCE MANUAL .............................................................................................10
2.3 BASIC CONTRACT DATA ............................................................................................................................................................11
2.3.1 Works Contract ....................................................................................................................................11
2.3.2 Consultancy Service Contract..............................................................................................................13

3 BASIC QUALITY RELATED CONCEPTS .................................................................................................14

3.1 GENERAL ............................................................................................................................................................................................14
3.2 THREE ELEMENTS OF A PROJECT ..........................................................................................................................................14
3.3 QUALITY AS ONE OF THE THREE ELEMENTS OF A PROJECT ..................................................................................14
3.4 FIVE ELEMENTS OF QUALITY ..................................................................................................................................................14
3.4.1QUALITY ASSURANCE AGAINST QUALITY CONTROL .................................................................15
3.4.2 QAM AS A LIVE DOCUMENT............................................................................................................15
3.4.3 QUALITY OF A PRODUCT AGAINST QUALITY OF THE MANAGEMENT PROCESS .................16
3.4.4 PROCESS CONTROL AGAINST PRODUCT CONTROL ..................................................................16
3.4.5 ATTITUDE TOWARDS QUALITY ......................................................................................................16
3.5 STATISTICAL PROCEDURES ......................................................................................................................................................17

4 QUALITY CONTROL PLAN ........................................................................................................................18

4.1 INTRODUCTION TO THE PROJECT QUALITY CONTROL SCHEME .........................................................................18
4.2 BREAKDOWN OF THE PROJECT INTO MAJOR WORK ITEMS ...................................................................................19
4.3 CONTROL AND CLAIBERATION OF MEASURING AND TESTING EQUIPMENT................................................20
4.4 GENERAL GUIDELINES FOR MATERIALS SOURCE APPROVAL ..............................................................................20
4.4.1 Approval of Natural Materials.............................................................................................................20
4.4.2 Approval of Processed Materials.........................................................................................................21
4.4.3 Approval of Manufactured Materials ..................................................................................................21
4.4.4 Approval of Designed Materials ..........................................................................................................21
4.4.5 Procedures for Source Approval .........................................................................................................22
4.4.6 Standard Forms of Submitting for Source Approval ...........................................................................22
4.5 GENERAL SAMPLING PROCEDURES ....................................................................................................................................27
4.6 PREPARATION AND STORAGE OF SAMPLES ....................................................................................................................27
4.7 FIELD TESTING LABORATORY ................................................................................................................................................27
4.8 ACCEPTANCE TESTING ...............................................................................................................................................................28
4.8.1 General ................................................................................................................................................28
4.8.2 Routine Acceptance Tests ....................................................................................................................28
4.8.3 Special Tests.........................................................................................................................................28
4.9 QUALITY CONTROL TEST STATEMENT (MONTHLY PROGRESS REPORT) ........................................................29
4.9.1 Interpretation of Test Results ...............................................................................................................29
4.9.2 Statistical Quality Control ...................................................................................................................29

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4.10 CONTRACTOR’S METHOD STATEMENTS ....................................................................................................................29

4.11 FIELD TRIALS ..............................................................................................................................................................................30
4.12 MONITORING OF THE CONSTRUCTION OF LAYER WORKS ...............................................................................31
4.13 PREAMBLES TO STANDARD QUALITY CONTROL FORMS AND Inspection and Test Plans (ITP) ..............31
4.13.1 Inspection and Test Plans (ITP) ..........................................................................................................31
4.13.2 Request for Inspection (RFI) and Inspection Record Books (IRB) ......................................................31
4.13.3 RFI Key Plan in the Form of Strip Chart ............................................................................................31
4.13.4 Work Inspection Record (WIR) ............................................................................................................31
4.13.5 Laboratory Test Request (LTR) ...........................................................................................................32
4.13.6 Non-Conformance Report (NCR) ........................................................................................................32
4.13.7 Conformance Report (CR) ...................................................................................................................32

5 STANDARD QUALITY CONTROL GUIDELINES ...................................................................................34

5.1 GENERAL ............................................................................................................................................................................................34

5.2 CLEARING AND GRUBBING ......................................................................................................................................................34
5.3 EARTHWORK IN EMBANKMENT AND SUB GRADE ......................................................................................................36
5.4 NATURAL AND CRUSHED SUBBASE MATERIAL ...........................................................................................................43
5.5 CRUSHED ROADBASE MATERIAL (GRADED CRUSHED STONE BASE (GB1)): .................................................49
5.6 PRIME, TACK COAT, SINGLE SURFACE TREATMENT AND SURFACEINGS .......................................................55
5.6.1 Prime (Mc - 30) & Tack Coat (RC - 70) ..............................................................................................55
5.6.2 Single Surface Treatments (Chipping and Mc - 3000) ........................................................................60
5.6.3 Bituminous Asphalt Surfacing..............................................................................................................65
5.7 DRAINAGE STRUCTURES ...........................................................................................................................................................74
5.8 STRUCTURES (RC BOX/SLAB CULVERT AND BRIDGES) ............................................................................................79

6 REPORTING AND RECORD KEEPING ....................................................................................................92

6.1 REPORTING ........................................................................................................................................................................................92
6.1.1 General Reporting Guidelines .............................................................................................................92
6.1.2 Contents of Project Reports .................................................................................................................92
6.2 SITE INSPECTIONS, DAILY REPORTS AND DIARIES ......................................................................................................93
6.2.1 Site Inspections ....................................................................................................................................93
6.2.2 Daily Inspection Reports......................................................................................................................93
6.2.3 Field Inspection Diaries ......................................................................................................................94
6.2.4 Record Keeping ....................................................................................................................................94
6.2.5 Breakdown of Records .........................................................................................................................95
6.2.6 Communication within the Consultant.................................................................................................95
6.2.7 File Numbering System ........................................................................................................................95

7 STAFF ORGANIZATION ..............................................................................................................................97

7.1 CONSULTANTS’ ORGANIZATION ...........................................................................................................................................97

7.1.1 The Main Supervisory Team ................................................................................................................97
7.1.2 Project Management ............................................................................................................................97
7.1.3 The Management Frame Works ...........................................................................................................97
7.1.4 Quality Cycle .....................................................................................................................................100
7.1.5 Staff and Responsibilities ...................................................................................................................100
7.1.6 Monitoring and Evaluation of The Performance of The Consultants’ Team ....................................100
7.2 GENERAL RESPONSIBILITIES OF THE SUPERVISOR ...................................................................................................101
7.3 FAMILIARITY WITH PROJECT AND CONTRACT DOCUMENTS AND REQUIREMENTS..............................102
7.4 AUTHORITY OF THE INSPECTOR/ SUPERVISOR ...........................................................................................................102
7.5 RELATIONSHIP WITH THE CONTRACTOR .......................................................................................................................103

8 COST CONTROL ..........................................................................................................................................105

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8.1 Interim Payment Statement ...............................................................................................................................................................105

8.2 Price Fluctuation .................................................................................................................................................................................105
8.3 Materials on site ..................................................................................................................................................................................106
8.4 Variation Orders..................................................................................................................................................................................106
8.5 Retention Money ................................................................................................................................................................................106
8.6 Repayment of Mobilization Advance .............................................................................................................................................106

9 CLAIMS ..........................................................................................................................................................107
9.1 General .................................................................................................................................................................................................107
9.2 Procedure for dealing with Claims ...................................................................................................................................................107
9.3 Extension of Time ..............................................................................................................................................................................108
9.4 Partial Taking-Over of the Works ....................................................................................................................................................108
9.5 Payment of retention Money ............................................................................................................................................................108
9.6 Statement at Completion (Final Account) ......................................................................................................................................109
9.7 Completion Report .............................................................................................................................................................................109
9.8 “As-Built” Drawings ..........................................................................................................................................................................109
9.9 Defects Liability Period .....................................................................................................................................................................110

10 CONCLUSION ...............................................................................................................................................112

11 ANNEX ............................................................................................................................................................113

11.1 DUITIES AND RESPONSIBILITIES ....................................................................................................................................113

11.2 STANDARD FORMS ...............................................................................................................................................................113
11.3 CODE OF PROFFESTIONAL CONDUCT………………………………………...............................113

LIST OF TABLES

Table 2-1 Basic Contract Data of The Works Contract ..........................................................................................................................11

Table 2-2 Basic Contract Data of The Consultancy Services Contract.............................................................................................13
T 4-1: A S F M S A C S C C ....................23
T 4-2: S F M S A S M E C
24
T 4-3: A S F M S A C R F .............................25
T 4-4: A S F M S A Q N G S .......................26
T 5-1 R L A S ........................................................................................................................36
T 5-2 M E / S ................................................................................37
T 5-3: T R I S /C M (T P D
)......................................................................................................................................................................................................38
T 5-4: M F E S - .................................42
T 5-5: T L E S -G L ......................................................................................42
T 5-6 G R N S M ..............................................................................................44
T 5-7 P R N S M ............................................................................................44
T 5-8: G R C S S M ...............................................................................45
T 5-9 P R C S M .............................................................................................45
T 5-10 C T S C .............................................................................................48
T 5-11 C S -D R ...................................................................................................49
T 5-12 G L C S B C M (GB1) ....................................................................50
T 5-13 P R C S B C M (GB1)....................................................51

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T 5-14: C T R B C ........................................................................................54
T 5-15 T F R B M ..........................................................................................................54
T 5-16 C R -D R ................................................................................................55
T 5-17 P R B (MC 30, RC 70 MC 3000)......................................................................56
T 5-18 S S T B ' U .......................................................57
T 5-19 G R S S T ..........................................................................................60
T 5-20 P R C S T ...........................................................................61
T 5-21 T F S T .................................................................................................................63
T 5-22 C T S T ...................................................................................................64
T 5-23: G R S ’ ..................................................................................................66
T 5-24 P R A S ’ ....................................................................................................66
T 5-25: S B B S ........................................................................67
T 5-26 T D R A S C ...........................................................................................67
T 5-27 D A T G M P S S (M )............................................72
T 5-28 T A S C ...............................................................................................72
T 5-29: M A D S ..........................................................................................................80
T 5-30: G F A .................................................................................................................................................81
T 5-31 N S G C A .......................................................................................................81
T 5-32: R P A ..................................................................................................................................81
T 5-33 C I I W U M C .............................................82
T 5-34 R ...................................................................................................................................82
T 5-35 C C ...............................................................................................................................................................83
T 5-36: C S T C ..............................................................................................................89
T 5-37 T F A ....................................................................................................................................90
T 5-38: M S S 150 S C ..........................................................90

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1 INTRODUCTION

1.1 GENERAL
This Quality Assurance Manual (QAM) provides guidelines to the Supervision Staffs for
inspecting and documenting the work during the implementation process of this contract in
subject. Although this note provides guidelines for inspecting the work items on this project;
it does not include all the details of the project works. For work items not covered in this
Manual, the Inspectors/Engineers must work with the Contractor and others as needed, to
determine:

 Items or processes to be inspected,

 Inspection processes, including timing of the inspections,
 Quality documentation,
 Processes to measure or calculate quantities of work performed,
 Other information that must be recorded in the appropriate report or format.

It is intended that this manual will complement instructions and directions included in:

 The Special Provisions of the ERA Standard Technical Specification, Standard

Technical Specification, specified in this contract and ERA Standard manuals for the
design and Construction,
 The Field Test Procedures, Design Drawings and
 Other Manuals relating to the Project such as AASHTO, ASTM, BS and other relevant
standards and specifications,

Ethiopian Government has been taking several challenging highway projects involving major
road works with a specific view to reduce the construction time and budget, increase the
quality of produce, systematized the process of works, to reduce traffic disturbances, etc…,
usually faced during construction (project implementation). While, speed is the criteria,
quality cannot be ignored under any circumstances. With this philosophy, and in view of the
same, it is decided to prepare a uniform Quality Assurance Manual (QAM) to be followed for
these projects.

This QAM has been prepared to compile the general procedures and guidelines to be followed
by the construction supervision personnel in carrying out all aspects of the construction
supervision tasks. This Manual mainly provides procedures for carrying out tasks related to
inspection, testing and reporting.

A concept of Levels of testing has been introduced in order to cover up elaborate planning of
testing of materials and products depending upon various factors related to each
material/product. Every effort has been made to design this Manual so that adherence to its
guidelines will result in efficient, safe and consistent supervision of the works in strict
conformance to the Specifications and other Contract requirements. This has led to the basic

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framework of this Manual being based on construction supervision procedures consistent with
standard international practices for construction of important road projects of this type, with
specific guidelines and forms, where appropriate, being generated based on standard
practices in the country’s standards and guidelines. In all cases, however, it is important that
all users of this Manual understand that the Contract Documents including the Specifications
are the controlling documents for the construction supervision process.

It is to be noted that although the intention of this Manual is to provide efficient, high quality
construction and safety, adherence to the adopted guidelines does not necessarily guarantee
that these attributes are achieved. This points to the need, therefore, for all users to
exercise judgment based on good engineering practice in all cases rather than blind
adherence to the adopted guidelines. This also points to the urgent need to periodically
review and update relevant guidelines and procedures, and hence the Manual is to be seen as
an evolving guide.

1.2 TEST CATEGORIES

Materials testing’s have four categories:

 Quality: The Site Materials Laboratory generally does quality tests. They are made to
determine if raw material from a particular source (such as subbase, crushed
aggregate, asphalt or gravel borrow pit, etc…) has an acceptable quality.
 Acceptance: Laboratory technicians or materials inspectors perform acceptance tests.
They document whether a specific lot of a pay item (such as asphalt concrete) meets
particular specifications for the item (such as gradation). Materials are accepted and
paid for by the Engineer based on acceptance tests.
 Assurance: The Central Laboratory usually performs assurance tests. These are used
as checks on your acceptance tests and assure that you are using the right procedures
and that your test equipment is working correctly.
 Information: Information sampling must be approved or at the request of the Material
Engineer. Be cautious with sampling for informational purposes. Information tests are
made on samples taken during the production of materials prior to the point of
acceptance. Tests taken to investigate apparent changes in the product are
informational and may serve to detect production problems before the scheduled
acceptance test, thus averting the rejection of a large quantity or the imposition of a
price reduction.
The gradation of aggregates, for example, is often checked as it is being crushed.
Either materials Inspector or the Laboratory Technician may make information tests.
Do not use information tests to replace Quality Control tests that are the
responsibility of the contractor.

1.3 TESTING PROCEDURES

There are detailed procedures for each type of test that must be followed carefully. ERA uses
ERA Technical Specification 2013, AASHTO, ASTM, and BS standards for materials and test

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procedures: -

 The ERA Technical Specification 2013,

 AASHTO stands for the American Association of State Highway and Transportation
Officials.
A "T" designates AASHTO tests (Example: AASHTO T195).
An "M" designates AASHTO specifications (Example: AASHTO M156).
 ASTM stands for American Society for Testing and Materials.
 BS stands for British Standards

The objective of testing is to assure that materials meet the standards required by the
contract.

The objective is not to obtain the required number of passing test reports. Samples should
always represent the total quantity of material for which the test is intended, not fragments
of it. Never take a sample or make a test with the predetermined objective to pass or fail the
material or work.

1.4 TERMS AND DEFINITIONS

Assessment: - the evaluation process used to measure the performance or effectiveness of a

system and its elements. As used here, assessment is an all-inclusive term used to denote any
of the following: audit, performance evaluation, management systems review, peer review,
inspection, or surveillance.

Audit (Quality) - a systematic and independent examination to determine whether quality

activities and related results comply with planned arrangements and whether these
arrangements are implemented effectively and are suitable to achieve objectives.
Design: - specifications, drawings, design criteria, and performance requirements. Also the
result of deliberate planning, analysis, mathematical manipulations, and design processes.
Quality: - the totality of features and characteristics of a product or service that bear on its
ability to meet the stated or implied needs and expectations of the user.
Quality Assurance (QA) - an integrated system of management activities involving planning,
implementation, documentation, assessment, reporting, and quality improvement to ensure
that a process, item, or service is of the type and quality needed and expected by the client.
Quality Assurance Plan (QAP)- a document describing in comprehensive detail the necessary
QA, QC, and other technical activities that must be implemented to ensure that the results of
the work performed will satisfy the stated performance criteria.
Quality Control (QC): - the overall system of technical activities that measures the attributes
and performance of a process, item, or service against defined standards to verify that they
meet the stated requirements established by the customer; operational techniques and
activities that are used to fulfill requirements for quality.

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Quality Management (QM): - that aspect of the overall management system of the
organization that determines and implements the quality policy. Quality management
includes strategic planning, allocation of resources, and other systematic activities (e.g.,
planning, implementation, documentation, and assessment) pertaining to the quality system.
Quality System (QS): - a structured and documented management system describing the
policies, objectives, principles, organizational authority, responsibilities, accountability, and
implementation plan of an organization for ensuring quality in its work processes, products
(items), and services. The quality system provides the framework for planning,
implementing, documenting, and assessing work performed by the organization and for
carrying out required QA and QC activities.
Validation - confirmation by examination and provision of objective evidence that the
particular requirements for a specific intended use are fulfilled. In design and development,
validation concerns the process of examining a product or result to determine conformance
to user needs.
Verification - confirmation by examination and provision of objective evidence that specified
requirements have been fulfilled. In design and development, verification concerns the
process of examining a result of a given activity to determine conformance to the stated
requirements for that activity.

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2 PROJECT INFORMATION

2.1 DESCRIPTION OF THE PROJECT

2.1.1 Historical Background

The Federal Democratic Republic of Ethiopia, as part of its ingeniously planned; under the
Road Sector Development Program (RSDP), Phase IV to eradicate the persistent poverty and
lead the nation towards the development goals by exploiting the road networking and
improving advantages towards economic and social growth, has decided to upgrade and
construct the Sodo Junction (Dimtu) - Blate Military Training Center Road Project to an
Asphalt Concrete Road standard (DC5).

Also, as customary measure by the Government of the Federal Democratic Republic of

Ethiopia, for quite some time now to allocate sizable amount of money from the nation’s
budget, all for the above-mentioned goals. The Sodo Junction (Dimtu) - Blate Military Training
Center Road Project is about to be implemented, funded by the Government of Federal
Democratic Republic of Ethiopia’s budget.

The implementation of this program is decided to be made under the management of the
Ethiopian Roads Administration, as an Employer and Powecon Private Limited Company as a
Road builder/contractor party and the GONDWANA Engineering Plc, as an Employers
Representative, throughout the implementation period.

The last three were appointed through the nation’s stipulated competitive bidding process.
Under the legal contract agreement signed; for the physical implementation works, on 17th of
March, 2022 and notice to commence is given on 14th April 2022. For the road construction
supervision consultancy services, signed on 7st of July, 2022 and service commenced as of 21st
July 2022. Moreover, the detail Engineering design process was undertaken by Ethio-Infra
Engineering, PLC. The Engineer, Ethiopian Construction Design & Supervision Works
Corporation, Transport Design and Supervision Works Sector, was taking care of the
supervision works until the assignment of the new Engineer.

2.1.2 The Project Road

Sodo Junction (Dimtu) - Blate Military Training Center Road Project is located in the South
part of the country, and lies predominantly in the South Regional state in South Nations,
Nationalities and People’s Regional States (SNNPRS) of the Federal Democratic Republic of
Ethiopia, particular, in the Wolita Zone of the SNNPRS. The project road is classified as a link
road as per ERA designs manual 2013 due it is connectively and traffic level. The project road
starts at Dimtu- which is about 330 km from the Capital Addis Ababa.

The main access road shall be constructed to Asphalt Concrete (AC) Standard and it shall
have a 7.0 m carriageway width and 1.5 m shoulder width for flat and rolling terrains on both
sides in rural sections. Two types of typical cross sections are provided for town sections with
total carriageway and parking lane widths of 14m and 12m depending on their level of

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development. The town sections with 14m carriageway width will have reinforced-concrete
covered and concrete walls ditches on both sides of the road.

The military compound road shall be constructed to Asphalt Concrete (AC) Standard and it
shall have a 7.0m carriageway width. The other types of typical cross sections provided for
military compound road is with total carriageway and parking lane widths of 10m depending
on their classification. The military compound road sections with 10m carriageway width will
have reinforced-concrete covered and concrete walls ditches on both sides of the road with
walkway width of 2.5m. The military compound road with 7.0m carriageway width will have
un-covered concrete walls ditches on both sides of the road without walkway.

The runway shall be constructed to Asphalt Concrete (AC) Standard and it shall have 45.0
meter width including 7.5-meter shoulder at each side. Furthermore, 12.0-meter airstrip
width is proposed at each side and the total width of the airfield is 84.0 meter.

The Taxiway on the runway shall be constructed to Asphalt Concrete (AC) Standard and it
shall have 23.0 meter width including 7.5-meter shoulder at each side. Furthermore, 12.0-
meter airstrip width is proposed at each side and the total width of the taxi way is 62.0
meter.

The Apron on the runway shall be constructed to Asphalt Concrete (AC) Standard and it shall
have 180.0m*120.0m including 7.5-meter shoulder at each side. Furthermore, the apron will
have reinforced-concrete covered masonry U is proposed at each side.

2.2 OBJECTIVES OF THIS QUALITY ASSURANCE MANUAL

This Consultants’ quality Assurance Manual (hereafter called QAM) is prepared as a result of
the consultancy agreement.

The main objective of this QAM is to provide consistent supervisory methods to be followed
by each member of the Consultants’ team based on sound engineering norms. Such
standardized procedures are thus set for material sources control, inspection and testing for
process and product control, measurement, approval, record keeping, reporting, monitoring
and evaluation so that the Consultants’ personnel would render the required services in a
coordinated and systematic manner. The Resident Engineer will thus ensure that such works
achieve the objectives of the consultancy services.

As most Projects are apparently executed in a random manner without the prior adoption of
a proper QAM, it is assumed, in the preparation of this manual, that most of the supervisory
staffs do not have sufficient attitudes towards quality assurance. Hence, the manual also
covers some basic concepts regarding QA and QC so that all site staff will have the minimum
understanding of quality related review procedures.

2.3 BASIC CONTRACT DATA

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Data pertaining to the contractual matters of both the works contract and the supervision
contract are presented here after under sections 2.3.1 & 2.3.2 respectively.

2.3.1 Works Contract

Table 2-1 Basic Contract Data of The Works Contract

Sodo Junction (Dimtu) - Blate Military Training

Project Name
Center Road Project.

Government of the Federal Democratic Republic of

Funded by
Ethiopia (FDRE)

Ethiopian Roads Administration

Ras Abebe Aregay Street

P.O. Box 1770

Employer’s name and address Tel. +251-11-5156603

Fax. +251 11 5514866

e-mail: [email protected]

Addis Ababa, Ethiopia

Powercon Private limited Company.

Contractor’s name and address Tel. +251-944-100308/911-526656

Addis Ababa, Ethiopia

Gondwana Engineering, Plc. (GE)

P.O Box 23976/1000

Tele.: +251 11 4407468/70

Employer’s Representative
Fax : +251-011-440 74 69

Nifas Silk Lafto Sub-city, Kebele12/13, House

No.096, Addis Ababa, Ethiopia

Letter of Acceptance date March 4th, 2022

Date of Signing of Contract March 17th , 2022

Date of Commencement 14th of April, 2022

Type of Contract Admeasurement

Original Contract Price Ethiopian Birr 2,375,680,864.47

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Value of Variations Nil

Revised Total Contract Price To be determined after final account

Currencies/Proportion of Payment 100% ETB

Total Amount of Advance payment 20% of the contract amount less contingency, Provisional

Sum and Day Work.

Type of Advance payment Conditional

Guarantee

Start Repayment of Advance After certification of 30 % of the contract Price less

Payment Provisional Sum, Day Work, Contingency and VAT.

Repayment of Advance Payment 40% of monthly interim payment certificate.

5% of interim payment certificate, up to a

Retention maximum 5 % of the contract price, less the
provisional sums, VAT and Contingencies.

Amount of Liquidated Damages 0.1% of the remaining value of work per day.

Limit of Liquidated Damages 10 % of the remaining value of work.

25.23 km main road, 3.1km airfield and Approximately 22

Project Length
km military compound roads

Minimum Amount of Interim

ETB, 10,000,000,000.00
Payment

Minimum amount of third party ETB 2,000,000.00 Per occurrence with number of
insurance occurrences unlimited.

48 Months (including 6 months of mobilization period)

Time for Completion
plus 365 calendar days of defect liability period

Original Contract Completion Date 15rd of March, 2025

Extension of Time -

Defect Liability Period 730 Calendar Days

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2.3.2 Consultancy Service Contract

ERA has entrusted the Supervision Consultancy Contract to Gondwana Engineering, PLC.

Table 2-2 Basic Contract Data of The Consultancy Services Contract

Government of the Federal Democratic Republic of Ethiopia

Funded by
(FDRE)

Consultant/Employer’s
Gondwana Engineering, Plc.
Representative

Supervision Agreement Signed on 07th of July, 2022

Original Contract Price ETB 35,573,398.50 (including 15 % VAT)

Variations None

Revised Total Contract Amount same

Type of Contract Time Based Contract

Commencement Date 21st of July, 2022

Contract Expiration 36 Months from the Date of Commencement of Service plus

two month, within 24 months of the defect liability period.

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3 BASIC QUALITY RELATED CONCEPTS

3.1 GENERAL
In this section of the QAM, basic quality related concepts are defined and their interrelations are
briefed so that the supervisory staff has a minimum understanding of the need for consistently
defined quality management system and relevant terms. The section briefly covers terms and
interrelations of quality related terms such as Quality Assurance, Quality Control, Process
Control, Product Control, Attitudes, etc…

As quality is a broader issue to be satisfactorily covered by such a manual, the Resident Engineer
shall provide additional information to the supervisory staff during the mobilization of each staff.

3.2 THREE ELEMENTS OF A PROJECT

It is customarily understood that the three main elements of any project are time, cost and
quality. Such elements are thus to be fully optimized during the whole supervision project. These
elements are obviously interrelated. While better quality will generally take more time, and
consume more money.

3.3 QUALITY AS ONE OF THE THREE ELEMENTS OF A PROJECT

For the purpose of this project, the supervisory staff shall consider quality as the process as well
as the end product of the works to achieve the desired function. The desired function differs
from work item to work item and it includes but not limited to; strength, durability,
serviceability and maintainability.

So long as the specification is appropriate, the desired function is the project specification
supported by sound engineering practices. However, in cases of inaccuracies, omissions or
discrepancies in the specification of a certain work component, the desired function may not be
a function. Apart from the initial review of the project specifications, when any of the
supervisory staff feels that there are omissions, errors or discrepancies in the technical
specifications, he shall immediately bring the problem/s to the attention of the Senior Pavement
Materials Engineer (SPME) and /or the Resident Engineer (RE). The SPME (or the RE as
appropriate) shall subsequently study the problem, discuss with the relevant professional staff,
identify possible revisions, study the contractual implications and other pros and cons of the
proposed changes, and initiate such changes for the required approval of the Client/Employer.

3.4 FIVE ELEMENTS OF QUALITY

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The five elements of Quality for the Purpose of this QAM, are the following:

1. Quality Assurance
2. Quality Control
3. Quality of the Product
4. Quality of the Management Process
5. Attitudes

3.4.1 QUALITY ASSURANCE AGAINST QUALITY CONTROL

Quality assurance and Quality Control are sometimes misinterpreted both in their scope and use.
All the supervisory staff shall therefore differentiate and apply these key quality management
schemes.

Quality Assurance: is about developing a suitable quality management scheme at the start of
the project. This includes setting up, at the start, of standard systems for quality products
and quality management system.

Quality Control: is the controlling system that is applied during the implementation process
to ensure that every work item is delivered to the predetermined QA system. Hence, all the
project staffs are supposed to carry out the required quality Control at every stage of the
works based on the present QAM.

3.4.2 QAM AS A LIVE DOCUMENT

The whole idea just discussed (under section 3.5) implies putting higher emphasis on quality
Assurance to ensure that the process is correct at early stages, that in turn ensures early
components of the works are produced right and ensuring the right production at the start is to
mean the works in respect of quality are substantially achieved.

However, it is difficult to guarantee the best system as such frameworks are dependent on the
specific project, skills of the supervisory staff, the Contractor’s capacity and commitment to
quality. This manual shall neither substitute sound engineering norms nor shall be considered as a
live document which is subject to periodic improvement based on the day to day comments from
the concerned staff.

Hence, all of the Consultants’ staff are hereby strongly advised to thoroughly study the
document, just after their mobilization to the project, and shall bring any required revisions in
the QAM to the attention of the SPME at the earliest time possible. The SPME is responsible for
evaluating such proposed revisions and brings the proposal to the attention of the Chief Resident
Engineer. If the revision does not need the involvement of the Resident Engineer, the SPME shall
make a suitable revision and issue a copy to the Chief Resident Engineer and the Supervisory
team for the required incorporation into the next review of the QAM.

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3.4.3 QUALITY OF A PRODUCT AGAINST QUALITY OF THE MANAGEMENT PROCESS

Quality of the Product: is the quality of the works that provide the desired function that
solves the problem and is the ultimate arbiter of the project.

However, implementation of a well-defined, previously proven ways of delivering the project

increases the chance of delivering a good product. Part of the QA of the product is following
standard procedures for its delivery. It is the organizational structure supported by the managing
capability of the individuals involved that implements this system. Hence, the Quality of the
management process is equally important. It is therefore the Resident Engineer’s primary task to
ensure that the contractor establishes a sound management process that implements the desired
quality Assurance.

3.4.4 PROCESS CONTROL AGAINST PRODUCT CONTROL

Product Control: is related to monitoring of the soundness of the finished work item or work
component with respect to the desired Function, the Technical Specification and the
Engineering Drawings.

The Process Control: is the follow-up of the soundness of each step of the continuous
production process with respect to the Desired Function.

A simple example in this regard is the construction of a certain activity, say a Sub-base. The
Quality of the Product in this regard may include the degree of compaction, the top width, CBR,
PI and the level of the layer. By employing width measurement, laboratory testing and in situ
density testing can be evaluated on such items. The quality of the Process, however, involves the
monitoring of the materials production, stock piling, hauling, windrowing, showering, mixing,
placing and compaction activities. Therefore, process control is more of Inspection whereas
product control is more of in-situ testing.

It is common for most contractors to use lower compaction, moisture content and employ higher
but detrimental compaction level. Here, the argument will be: As far as the contractor manages
to achieve the desired level of compaction, what is the problem with lower water content? This
is also related to attainment of the product without attaining the process. In case an inspector
may not be aware of the detrimental effects of over-compaction with lower moisture content, he
may simply entertain such requests.

The Resident Engineer shall therefore enforce proper process control. In this process control, the
Materials Engineer shall clarify the significance of each specification to each inspection staff as
appropriate.

3.4.5 ATTITUDE TOWARDS QUALITY

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Once the QA system is developed, it is the responsibility of the project staff to implement and
the Resident Engineer to ensure proper QC on the day-to-day activities of the project. However,
quality system requires proper attention of the consultants’ personnel, the contractor’s
management and the relevant contractor’s staff. Attitudes are defined as such beliefs and
commitments of firms and individuals towards quality. Having all the stakeholders believe in the
project, from the very start, is an important in-put to project success.

Contractors, however, usually consider quality control as the supervisor’s task. The Resident
Engineer and other team members shall make their utmost efforts to ensure that the contractor
is committed to quality and establishes sound quality assurance mechanism to satisfy himself
before bringing any matter to the senior supervision staff and ensure that each inspector shall
have the right attitude to quality.

3.5 STATISTICAL PROCEDURES

Inspection, measurement, and testing require definite and sound statistical practices that suit
the specific case. Setting of technical specifications without clearly indicating the type of
sampling, frequency of sampling and acceptance criteria is worthless and usually creates disputes
at site. Hence, by this QAM, it is attempted to supplement the project specifications (standard
and special specifications) with sound statistical practices and all project personnel are required
to use the practices.

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4 QUALITY CONTROL PLAN

4.1 INTRODUCTION TO THE PROJECT QUALITY CONTROL SCHEME

The quality control of the works shall generally be in accordance with the Works contract.

However, it is not uncommon that most contract documents are insufficient by themselves as
they contain discrepancies, deficiency and errors. It is also generally understood that contract
documents (especially technical specifications and drawings) are not complete by themselves. In
such cases, the Engineer shall employ proven yet suitable engineering standards and sound
engineering practices.

The consultant’s approach towards quality control shall generally carry out the following tasks:

 Upon the mobilization of each staff, a briefing shall be made about the main aspects of
this QAM and the RE shall ensure that the staff has properly studied this document.
 Proper design review shall be made, quite in advance of the contractor’s work schedule;
The following sequences shall be followed:

 The Resident Engineer shall program the stretches to be revised based on the
Contractor’s work schedule;
 The PME (and if necessary the Geotechnical Engineer) shall thoroughly revise all
factual data pertaining to sub grade soil, land slide and existing pavement. As
necessary, all laboratory tests shall be made to revise the existing test results.
Based on the test results and locally available construction materials, the PME may
propose a different type of pavement structure (different composition and/or
thickness);
 In the meantime, detailed topographic survey shall be made in any one section quite
in advance of the design reviews to be made for each 20 km road section. The Senior
surveyor shall present all changes in the centerline levels from the original design;
 The Highway Engineer and structural Engineer shall also make the necessary field
assessment (plan-in-hand field inspection type) and take all necessary inputs for the
revision of design and quantities;
 The PME, HE and SE shall forward to the RE office memos regarding their findings
and recommendations. The RE, DRE/ARE, PME, HE and SE shall arrange a meeting to
discuss and finalize design review issues;
 The PME, HE and SE shall make the agreed design changes and submit for the RE’s
approval. The changes in design shall be accompanied by the changes in quantities
and associated changes in contract amounts. Subsequent revisions may also be made
to optimize costs.

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 The Contractor shall be provided with the revised changes in design and he shall prepare
and submit the template drawings.
 Sources of all materials proposed by the contractor shall be evaluated as per the
procedures of “Materials Source Approval” which is dealt with in this document.
 Once the sources are approved, materials quality tests shall be made based on
predetermined frequencies. The Material Inspector shall also periodically inspect all
quarries and pits.
 Process and product control shall be made as per:

 Common Guidelines for Most Work items.

 Inspection and Test Plan (Annexed).
 Standard Checklists for Monitoring Major Work Items (Annexed).

 Reporting as per Section 6.2.2,

 Documentation and record keeping as per Section 6.2.4,

To achieve proper QC, the Engineer shall also ensure that the Contractor’s attitude towards
quality is generally positive. To this end, those contractor’s managerial staff and foremen are
given a brief clarification by the engineer upon their arrival. The necessary actions shall also be
taken on that staffs that deliberately violate general ethical and moral standards towards quality
control to an extent that removing such individuals from the project may be necessary.

4.2 BREAK DOWN OF THE PROJECT INTO MAJOR WORK ITEMS

For the sake of defining the desired guidelines and checklists towards monitoring, the works are
divided into the following major tasks:

For the purpose of this QAM, the following major activities shall be considered as work items:

1. Clearing and Grubbing

2. Earthworks
A. Road bed preparation
B. Cut to fill/embankment
C. Borrow to fill/embankment
D. Cut to spoil
E. Capping layer
3. Natural Sub-base Layer Construction
4. Crushed sub-base layer construction (If so required)
5. Road base layer construction
6. Asphaltic road surface layer construction
7. Single Surface Treatment
8. Double surface treatment
9. Minor drainage structures

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A. Concrete pipe culverts

B. Box/slab culverts
10. Major structures
A. Bridges
11. Ancillary works

4.3 CONTROL AND CLAIBERATION OF MEASURING AND TESTING EQUIPMENT

All measuring and testing equipment’s shall be properly maintained and stored; and when
appropriate, they shall be calibrated at regular intervals according to the requirements of the
standard specifications and manufacturer’s manual. To this end, the contractor shall supply all
manual and equipment catalogues and calibration certificates upon delivery of each measuring
testing facility. The surveyors and laboratory technicians shall properly review the manuals and
inform the PME in writing about the proposed calibration dates of each surveying/ laboratory
testing facilities. Calibration shall be made based on internationally recognized standards and in
compliance to manufacturer’s specifications and tolerances.

4.4 GENERAL GUIDELINES FOR MATERIALS SOURCE APPROVAL

All materials proposed by the contractor to be used in the project works are to be approved first.
In general, there are four types of materials to be approved.
(a) Natural Materials – materials with little or no processing except for perhaps screening for
oversize and removal of unsuitable particles, etc. An example of this is soil embankment
materials, etc...
(b) Processed Materials – materials that require significant processing, including removal of
unsuitable particles, crushing, screening and perhaps, blending of sizes. These materials are
homogeneous, but with specified gradations. An example of this is sand from river, etc...
(c) Manufactured Materials – especially homogeneous construction materials, like Portland
cement and bitumen that are used for blending with natural materials (generally soil or
aggregate) to obtain a pavement mix.
(d) Designed Materials- materials that involve the mixture, to specific proportions of two or
more different, natural, processed or manufactured materials to obtain a modified material
giving a set of desired specific properties.
Approval of each of the above material types is required, however the requirements for obtaining
approval of materials for each type differs slightly.
4.4.1 Approval of Natural Materials
Natural materials are mined (i.e., excavated) and hence the first step, following assurance that
the material(s) is acceptable for its intended purpose, is to obtain approval for the Borrow Area
or Quarry.

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Approval of the material for construction is then obtained by submittal of test results for all tests
required by the Specifications (i.e., to prove that the material meets all minimum properties
required), and, in some cases, by construction of trial sections to prove that this material can be
placed in the field so as to attain minimum required field properties (e.g. to meet minimum
density, etc.)
4.4.2 Approval of Processed Materials
Approval of processed materials follows that noted above for “natural” materials, except that
usually the specifications are tighter (e.g. the material may also have to meet stringent
gradation limits), and a greater variety of tests (and production/storage) conditions are required
to be met.
4.4.3 Approval of Manufactured Materials
Approval of manufactured materials, based on specific Specifications requirements, is generally
given in two stages.

(a) Initial Approval – given prior to receipt of the materials based on submittal of appropriate
testing results confirmed by the manufacturer (note that claims by manufactures, or tests etc. by
distributors, etc. are not to be accepted).
(b) Final Approval – given based on initial approval plus positive results being obtained for all
“acceptance” tests required by the Specifications, or as directed by the Engineer. The Quality
Assurance System and plan of the manufacturer shall also be examined before approval.

4.4.4 Approval of Designed Materials

Approval of “designed” materials for the project concerns those mix designs for Cement Concrete
(for concrete pavements, box culverts, bridges etc) and Asphaltic Concrete (flexible pavement
materials) including Asphaltic Road Base, Bituminous concrete, Single surfacing treatment, etc).
Due to the complexity of these “mixed” materials, and the plants for producing the range of
materials sizes, final approval is deferred until completion of the following steps:
(a) Approval of sources (generally quarries) for each of the processed material constituents to
be included in the final mix design.
(b) Approval of each of the individual processed materials and manufactured materials to be
included in the final mix design.
(c) Tentative approval of a laboratory based mix design, based on a mixture of approved
materials so that the mixture meets all Specifications requirements.
(d) Tentative approval of a plant mix design, based on proportioning of aggregate bins
materials and manufactured materials to closely approximate the proportioning of material
types/sizes finalized for the laboratory based mix design (i.e. and so that the mixture still
meets the minimum Specifications requirements).
(e) Conduct trial section of works (off the project site) using the tentatively approved plant mix
design and placing the mixture in accordance with a previously approved construction
methodology that conforms to Specifications requirements.

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(f) Based on successful laying of the mixture in accordance to the approved Methodology,
conformance of the placed mixture to required placing temperatures, levels and finish, etc.
and conformance to quality control requirements as verified by successful testing in accordance
with the Specifications, the Senior Pavement Material Engineer is to give final approval of the
mix design based on the plant mix proportions.
4.4.5 Procedures for Source Approval
The main purpose of tests for source approval is to ensure that all ingredient materials to be
used for permanent construction will satisfy contractual requirements. The site staff shall thus
give due attention for testing sources and number of samples as this is the main statistical
concern to approve same.

If an inferior source is approved with only one or two tests, the material taken from this source
will, on the whole of the works, manifests its impact. Hence, a desirable number of tests shall be
made for each source to ascertain that the works Contract is met and other generally acceptable
statistical requirements are achieved.

The number of tests will depend on:

 The quantity of the sources

 Visual uniformity/Variability of the sources
 Intended use (more tests will be made on marginal sources)
 Quality of the sources (more tests will be made on marginal sources)
 Type of tests (more number of tests will be appropriate for more important requirements)

The minimum number of tests, however, will not be generally lower than three.

4.4.6 Standard Forms of Submitting for Source Approval

The contractor shall thus submit his requests for source approval with a suitable format. The
engineer shall always discourage and reject submission of individual test results.

To this end, the following form is prepared so that the contractor’s request is standardized.

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Table 4-1: A Sample Form for Material Source Approval of Crushed Stone for Cement Concrete

Item Test Results Specification Comments

Test Type Remarks
No [Pass/Fail/Marginal]
Test 1 Test 2 Test 3 Average Desirable Absolute
1. A.C.V
2. L.A Loss
3. Flakiness Index
4. Soundness
(Sodium/Magnesium)
5. Clay Lumps
6. 63
ni[

50
seziS

37.5
eveiS

25
19
noitadarG

9.5
4.75
]mm

2.36
7 Absorption
8 Specific Gravity
Other Comments:

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Table 4-2: Sample Form for Material Source Approval of Suitable Material for Embankment Construction

Item Test Results Specification Comments

Test Type Remarks
No Test 1 Test 2 Test 3 Average Desirable Absolute [Pass/Fail/Marginal]
1. CBR on a set of 3
specimen
2. Liquid Limit
3. Plasticity Index
4. Swell
5. Thickness

Other Comments:

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Table 4-3: A Sample Form for Material Source Approval of Crushed Rock For different uses

Item Test Results Specification Comments

Test Type Remarks
No [Pass/Fail/Marginal]
Test 1 Test 2 Test 3 Average Desirable Absolute
1. A.C.V
2. L.A.A
3. 10 % Fine Value
4. Soundness
(Sodium/Magnesium)
5. CBR
7. Absorption
8. Specific Gravity

Other Comments:

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Table 4-4: A Sample Form for Material Source Approval Quarries for Natural Gravel Subbase

Item Test Results Specification Comments

Test Type Remarks
No Test 1 Test 2 Test 3 Average Desirable Absolute [Pass/Fail/Marginal]
1. CBR
2. Liquid Limit
3. Plasticity Index
4. 37.5
seziS

20
10
eveiS

5
2.36
noitadarG

]mm

0.425
0.075
ni[

5 Swell

Other Comments:

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4.5 GENERAL SAMPLING PROCEDURES

Sampling procedures for the following items shall comply with the relevant clauses of ERA
technical specification and AASHTO. The RE/DRE shall issue the direct photocopies of relevant
clauses to the inspectors and laboratory technicians.

All sampling (Sampling from Pits, quarry Sites, crushed stone stockpiles, Sand sources, Existing
Pavements, Existing sub grade soil etc..) is to be carried out in accordance with instructions to
be given by the Consultant. Sampling procedures are to follow recognized guidelines of good
engineering practice. These include:

(a) Obtaining samples from at least three areas.

(b) Ensuring that the sampled materials and locations are “typical” for the material to be
tested.
(c) Ensuring that all overburden etc. is removed within the stockpiles rather than from the
surface (top, side or base of the stockpile) in order to avoid the collection of segregated
materials.
(d) Ensure that sufficient quantities are sampled to enable all tests to the conducted, plus
additional material, to be stored for subsequent testing if required.
(e) Ensure that each sample bag is marked/labeled both inside and outside, giving the
sample number, material type, sample location, date and number of the bag, as well as
any additional information instructed by the SPME or his appointee.

4.6 PREPARATION AND STORAGE OF SAMPLES

Samples collected are reduced and prepared as per standard methods, with an additional
sufficient quantity retained in appropriately sealed bag(s) or container(s) and separately kept
in the sample storage room of the laboratory for additional testing and/or future reference as
required. Concrete samples in particular are to be carefully cured and kept in the curing tank
of the laboratory. Access to stored samples is under the strict direct control of the PME.
Details of all samples stored are to be kept in a register to be administered by the PME.

4.7 FIELD TESTING LABORATORY

The Field-Testing Laboratory, including all furniture, testing equipment and apparatus as
required by the Specifications is to be provided and maintained by the Contractor together
with the provision of all necessary utilities (e.g. electricity, water, sewerage and drainage).
The design and layout of the laboratory is to be approved by the Chief Resident Engineer based
on recommendations by the PME. It is the responsibility of the Contractor to ensure that the
laboratory is proficiently guarded at all times of the day and night (i.e. to control access and
maintain security), is cleaned daily and is properly maintained.

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Testing equipment and apparatus are to be initially approved, and subsequently periodically
checked, by the Consultant to assure proper operation, accuracy, correct calibration and
complete conformance to all Specifications requirements. Likewise, all testing procedures
detailed in the Specifications and procedures instructed by the PME as part of his Quality
Control and Quality Assurance Plan are to be strictly adhered to by the Contractor. The
consultant is to supervise, monitor and check all aspects of the testing procedures, including
sample storage, preparation, testing and analysis and reporting of testing results.

4.8 ACCEPTANCE TESTING

4.8.1 General
All materials included in the construction works for which quality control tests are specified,
and for which approval by the Engineer has been previously given, are to be inspected and
checked for acceptability in accordance with the Specifications requirements.
Any of the completed construction works in which unapproved and/or untested and/or
unaccepted materials are incorporated without approval or written permission from the
consultant is deemed performed at the Contractor’s risk and is considered as unacceptable and
unauthorized.
4.8.2 Routine Acceptance Tests
All sampling and quality control testing, as well as checks test to verify quality of materials,
are to be conducted by the Contractor at his own expense under the direct supervision of the
Consultant.
The kind(s) of test(s) and frequency of testing should conform to the Minimum Quality Control
Testing Requirements of the ERA Specifications. Sampling and Testing should be in accordance
with the relevant AASHTO, ASTM, BS and other methods. Tests are to be reported on proper
forms, samples of which are shown in Annex B5.

4.8.3 Special Tests

It is noted that “The Engineer will seek prior approval of the Employer in issuing the order of
special tests”. The works contract generally notes that the Contractor will be responsible for
the cost of special tests if the tests show that the materials, plant or workmanship not be in
accordance with the provisions of the contract. Special tests are generally ordered by the
Engineer when there is some concern with some aspect of the routine acceptance tests (e.g.
sampling technique, sample contamination, testing equipment problem, operator error, etc).
Based on the above, the following procedure is to be adopted for special testing:
(a) Identify routine testing concern and request agreement from the PME and the CRE that
a special test is required.
(b) Identify what/how/where/when the special test is to be conducted.
(i) By the Contractor within the Field Laboratory
(ii) By the Internal Independent Testing (i.e. by the consultant within the field
Laboratory).
(iii) By external independent testing.

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(c) Obtain approval of the Employer for making the special test, if needed by contract
provision.
(d) Based on the results of the special test(s), identify who will be responsible for the
payment of the special test.
(e) Following implementation of any relevant actions indicated based on the results of the
special test, record the test results, and also include the results as part of the “Quality
Control Test Statement” to be submitted with, and as part of, the Supervision Consultant’s
Monthly and Quarterly Progress Reports.

4.9 QUALITY CONTROL TEST STATEMENT (MONTHLY PROGRESS REPORT)

The test results must be recorded systematically in a register, which must be signed by the
testing authority and the representative of the Engineer, if present during the tests.
In accordance with the Consultant’s contract agreement and standard construction supervision
practice, the list of laboratory test results completed during the month, and the statistical
interpretations, are to be included as an integral part of each of the supervision consultant’s
Monthly Progress Report to be submitted to the Employer. This summary of field and laboratory
test results is referred to as a Quality Control Test Statement and is to include the following:
(a) Item description and kind of test.
(b) Numbers of tests complete, passed and failed.
(c) Analysis of test results and establishment of trends.
(d) Any appropriate remarks or comments, based on trend detected and any corrective
action needed.
4.9.1 Interpretation of Test Results
The test results should be plotted on a graph sheet showing the dates/sample numbers on the x
-axis and the test values on the y-axis. The statistical “warning limits” and “action limits”
should be indicated on these graphs. When any test results fall outside the “warning limits”,
the cause should be investigated and suitable corrective action taken. When any test result
falls outside the “action limits”, the process should be stopped, and a thorough investigation
made into the entire process, and the cause for faulty performance determined. Suitable
remedial action should be immediately taken and the process brought under control.
4.9.2 Statistical Quality Control
Quality control based individual tests do not ensure well defined qualities of a product. One
has therefore, for many years in the industry, used statistical methods where works and
supplies are approved or rejected after an evaluation of the average and standard deviation of
a number of test results. Similar methods are gradually gaining way in the road construction
sector, and today it is not unusual to use statistical methods for the quality control. The use of
Control Charts for establishing the trend line, and the time when corrective steps are to be
taken is recommended.

4.10 CONTRACTOR’S METHOD STATEMENTS

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The Engineer shall ensure that the Contractor has submitted proper method statements before
carrying out field trials or subsequent site works.

Method Statement for each major work item shall be prepared based on the resources
required, technical specifications and standard engineering practices. The method statement
shall describe the steps to be followed and the sequence of activities to complete the works
and documentation as per the contract. They shall include the scope of work, reference
documents, pre-requisites like approval of borrow area, quarry, source of manufactured
materials, working drawings, setting out, process control, plant and manpower deployed,
acceptance criteria, test frequencies and tolerance limits for end products.

4.11 FIELD TRIALS

Field trials are of great importance to clearly define proven method of working and avoid
subsequent failure of bigger jobs like longer road sections. The importance will not only be for
the quality of the works but also for the Contractor’s further progress following consistent and
proven procedures. Hence, field trials shall be ordered based either on contractual
requirements or upon the request of the contractor and/ or the Engineer. Exhaustively done
field trials will certainly ascertain quality, consistency and progress.

For layer works, trial-paving sections of 50 to 200 meters long shall be ensured. The layer
works for this project include Roadbed Preparation, Embankment, Subbase, Road Base,
Asphaltic Surface and Single Surface Treatment.

Field trials will only be made after the primary approval of the sources of material and method
statements. Upon approval of the sources, field trials shall be made to obtain suitable working
methods and/or check the performance of the materials. Artificial showering on the trial paved
section with a suitable amount of water by using water truck can simulate heavy moisture.

Field trials may also be made for those materials, which are considered to be marginal. Paving
the material on a short section and exposing it to traffic or heavy moisture for longer period to
monitor its performance against loading, wearing and moisture may achieve the desired result.

Among the items to be checked for the field trials on such layer works include:

 Achievement of suitable compaction moisture content (as compared to OMC)

 Adequacy of thorough mixing to achieve uniform moisture content
 Adequacy of thorough mixing to avoid segregation
 Determination of the required equipment to achieve a certain output
 Number of passes and rolling patterns with different types of rollers to attain the
required but not excessive (sometimes detrimental) level of compaction
 To check the Contractor’s achievement of levels, lines and grades within the geometric
tolerances.

During exhaustive field trials of unbound layer works, the use of Sand Replacement Method is
recommended to verify the in-situ compaction and moisture content. The achievement of the

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amount and uniformity will be determined based on the average and standard deviation values
respectively.

The trial sections, which are made exhaustively, will be the basis for subsequent methods of
working. Additional field trials may also be made in the course of construction for the sake of
economy, safety or serviceability based on the request of the Engineer or the Contractor.

4.12 MONITORING OF THE CONSTRUCTION OF LAYER WORK S

The RE shall also issue standard Monitoring Procedures of the Construction of Layer Works to
the supervisory team based on the technical specification. These procedures include
procedures of stock piling, Showering and Compaction (Including desired lift thickness, etc…)

4.13 PREAMBLES TO STANDARD QUALITY CONTROL FORMS AND Inspection and Test Plans
(ITP)

4.13.1 Inspection and Test Plans (ITP)

An ITP is prepared for the various components of the work by itemizing each component that
requires checking by the supervisory staff of both the Contractor and the Consultants. These
items are to be jointly agreed upon before work commences. Each ITP has a unique number
for individual aspect of works. For this project detail of the items were elaborated at
Section 5.

4.13.2 Request for Inspection (RFI) and Inspection Record Books (IRB)
Each aspect of work will have its own bound volume of request for inspection forms. The
numbering system is unique for each item. The items that require inspection and checking
need to be entered for each lot of work. As there are large numbers of entries each day it
requires the separation of different kinds of work into separate IRB volumes to avoid
confusion.

The IR books provide the means for the Contractor to inform the consultants, the Laboratory
and the survey team that an activity requires checking testing or surveying. The form will
indicate the location, time and type of activity.

4.13.3 RFI Key Plan in the Form of Strip Chart

The Contractor shall prepare a summary sheet for layer works as well as structural works in
the form of Strip chart and individual cards/sheets respectively.

4.13.4 Work Inspection Record (WIR)

These forms are to be carried out by the supervision Consultants during their site visits,
make entries and sign. One sheet per item of work having the same unique number of IRB
will be maintained. These forms are also to be signed by the Contractor’s Supervisor.

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4.13.5 Laboratory Test Request (LTR)
The Laboratory will be informed via the IRB and LTR (having the same unique number) as to
the requirement of the test. The Lab Team will carry out the tests and return the results
attached to the LTR, for approval or otherwise. The Contractor will sign the IRB and submit
to the Consultants. The Consultants’ representative will sign the IRB after checking the test
results with the specifications. The results are filed with the LTR and can be easily retrieved
via the unique numbering system.

The frequency, type and location of the tests are to be decided by both the PME of the
Consultants and Contractor based on the specifications.

4.13.6 Non-Conformance Report (NCR)

NCR can be initiated by the Contractor and/or the Engineer. This report will show that a
section of work fails to meet the specification and no further work that could interfere with
the correction of the non-conforming item shall take place until the non-conformance has
been adequately addressed.

The Contractor shall propose the method of correcting non-conformance and approval shall
be obtained from the Engineer before any correction begins. The correction shall be any of
the following:

REWORK - The process by which a nonconforming item is changed to specified requirements

by further work.
REPAIR – The process of restoring nonconforming characteristics to a condition acceptable to
the Engineer, though that item may still not conform to the original requirement.
REJECT – The action taken to eliminate a nonconforming item from its specified use.
USE AS IT IS – The action taken to obtain the Engineer’s approval to accept an otherwise
unacceptable item.

Payment for work containing an uncorrected or unapproved non-conformance will not be

approved.

The NCR is not a weapon to be used against the contractor, but a statement of fact and an
effective method to ensure quality. Normally the contractor would like to see as few NCRs
as possible as any re-work is costly and time consuming. The Consultants can use the NCR as
a tool to identify the people who cause the most NCRs and can take action to have them
trained or replaced.

A log to control NCRs from issue to closeout shall be maintained. All NCRs corrected by
“REPAIR “or by “USE AS IT IS” shall be included in the “as –Built” document.

4.13.7 Conformance Report (CR)

The Contractor’s Quality Control Manager (QCM if any) has to submit the Conformance
Report for each lot of materials brought to site for use in permanent works. The reports

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contain LTR including all test results in tabular form, the acceptance criteria as per
specifications and comparison with the results.

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5 STANDARD QUALITY CONTROL GUIDELINES

5.1 GENERAL
Prior to the commencement of important item of work and activity (which may be listed by the
Engineer and given to the Contractor), the Contractor is required to submit for approval by the
Resident Engineer a “Methods Statement”, which describes the methodology as to how he (the
Contractor) plans to carry out that item of work/activity in accordance with the Specifications.
The Methods Statements shall be developed to a degree of detail depending upon:

(a) The intricacy of operations for carrying out the proposed construction activity; and

(b) The extent to which the methodology is detailed out in the Specifications.

The Methods Statement shall describe the equipment to the deployed (size/number/capacity),
the sequence of operations, field trials if any are involved, design of mixes, job-mix-formulae,
temporary works erection and launching, traffic management plan, safety precautions,
environmental protection measures etc.

The Methods to be furnished by the Contractor in respect of each major activity shall be step-
wise sequencing of tasks, and should be detailed and meaningful. The Engineer shall either
straightway give his consent or ask for modification before acceptance. The following lists out
some important activities, and details out what would be expected.

5.2 CLEARING AND GRUBBING

1. Scope

 The scope of work covers all the operations required to be executed as per
Division 2100 of the Technical Specification of the contract.

2. Reference Documents

2.1 Specifications

 Division 1204: Setting out of Works & Protection of Survey Monuments

 Division 2100: Clearing and Grubbing

2.2 Draw ings

 Bench Mark List Summary

 Horizontal and Vertical Curves List Summary
 Plan Profiles
 Approved Cross Sections

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2.2 Inspection and Test Plan

 As per RFI

3. Prerequisites:

3.1 Obtain & Check construction drawings.

3.2 The centerline of the proposed road shall be marked accurately using total station and
got checked.
3.3 The benchmarks shall be established after connection with the GPS benchmarks in the
region at least @ 4 nos. per km both sides of the road.
3.4 Trees and other utilities are enumerated and conceded authorities are approached and
the same shall be cleared as required.
3.5 Area where striping of soil is required shall be marked and area for stock piling of the
top soil identified.

4. Bench Marks

 Concrete Temporary Bench Marks to be fixed and toe line to be marked.

5. Equipment Details

5.1 Survey Equipment: Total Station, Auto Level, Staff, etc.

5.2 Stripping and loading: Dozer, Loader, Motor Grader and Trucks.

6. Safeties and Protection to Environment Etc.

6.1 All effective and requisite measured shall be implemented to ensure full safeties to all
the concerned work force machinery traffic and general public.

6.2 Effective and sufficient care shall be taken to minimize damage to the environment
and cleanliness in all works is given the utmost importance. AS far as possible, trees
and vegetation shall be retained unless it is essentially rewired to be removed

7. Personnel Employed for Supervision:

7.1 Inspector of works and Surveyor and the contractor's personnel,

8. Main Activity

8.1 RFI is initiated.

8.2 The vegetation is completely cleared and trees stumps are extricated along with roots
8.3 The pits formed due to stumps removal is made good with filling and compaction as
per specifications.
8.4 The useful materials shall be stockpiled and all other objectionable materials are
disposed.

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8.5 Topsoil shall be stripped and useful, arterial is stockpiled,
8.6 Levels shall be taken before and after stripping/ clearing & grubbing/ bed compaction
8.7 The measurements are record and submitted for verification / documentation.
8.8 The RFI is closed

9. Tolerances

For topographic survey and fixing the TBMS, following tolerance limit will be followed as per
ERA Specification for survey works:

• Every benchmark is to be checked leveled by a forward run and a subsequent backward

run forming a closed '' loop''
• The following standard of accuracy will be maintained:

C= ±√ k

Where C = maximum permissible error of closure in centimeters,

K= distance between bench marks in kilometers

Table 5-1 Required Level of Accuracy for Surveys

K (km) 0.5 1.0 2.0 5.0 10.0

C (cm) ± 0.7 ± 1.0 ± 1.4 ± 2.2 ± 3.2
Cross-sections shall be taken to a minimum distance of 15 meters each side of the centerline
and at 20m interval in straight reach and 10m interval at curve portion along the center line of
the road. Profile leveling will be run between each pair of consecutive benchmarks previously
established and the leveling must close on each successive benchmark. For each succeeding
length of profile any error from the preceding length shall be discarded the elevation of the
intervening benchmark, previously established, being accepted and used for the succeeding
length of profile.

5.3 EARTHWORK IN EMBANK MENT AND SUB GRADE

1. Scope

This item covers all the operations required to form embankment, sub-grade and capping layer
to the required lines and levels as per the requirements of widening of existing road as well as
construction of new road.

2. Reference Documents

2.1 Specifications

 Division 2100: Clearing and Grubbing

 Division 4100: Preparation of Road Bed & Protection of Earthworks
 Division 4200: Roadway and Borrow Excavation

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 Division 4300: Borrow Materials
 Division 4400: Embankment Construction
 Division 10107: Testing

2.2 Draw ings

 Bench Mark List Summary

 Horizontal and Vertical Curves List Summary
 Plan Profiles
 Approved Cross Sections2.3 Inspections and Test Plan

2.3 Inspection and Test Plan

 As per RFI

3. Materials:

3.1 Source: The borrow areas shall be identified.

The material shall be conforming to General and Special Technical Specification Series
4400. It shall be free from logs, stumps, roots, rubbish or any other ingredient Likely
to deteriorate or affect the stability of the embankment/ sub-grade.

Table 5-2 Material requirements for Embankment/fill and Subgrade

Properties Specification Methods and Standards Testing Frequency

of the specified
Maximum Size,
2/3 thickness of compacted - do -
D Max
layer

For fill height >

600 mm: < 25%
- do -
Plasticity Index,
AASHTO T-89
% , Max For fill height <
600 mm: < 20%

For fill height >

600 mm: < 60%
- do -
Liquid Limit, % , AASHTO T-90
Max For fill height <
600 mm: < 45%

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Properties Specification Methods and Standards Testing Frequency

For fill height >

(CBR) @ 97% MDD
One test /3000m3
600 mm: > 6% (AASHTO T-180
CBR, % , Min
For fill height < method D)
600 mm:>10%

For fill height >

One test /3000m3
600 mm: <2.5% (with two surcharge
Sw ell, % , Max rings) in accordance
For fill height < with AASHTO T-193
600 mm:<1.5%

Moisture
+2 AASHTO T-180 - do -
Content

For rock fill max, loose

Layer thickness 200 to 100 mm, - do -
depth shall be 750mm

Table 5-3: Technical Requirements for Improved Subgrade / Capping Material (Tanzanian
Pavement Design manual)

Properties Specification

CBR [%] wet or moderate climatic zones 1) Min 15 after 4 days soaking

Min 15 at OMC
CBR [%] dry climatic zones 2) (both
requirements shall be met) Min 7 after 4 days soaking

CBR-swell [%] 2) Max 1.5

PI [%] Max 25

Max particle size, d MAX 2/3 of layer thickness

Compacted layer thickness [mm] Max 200

3.2 The materials obtained from roadway excavation will be tested for its suitability for
use as Fill material. Only when roadway excavation materials are unsuitable, fill
material shall be obtained from approved Borrow pits.

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3.3 Approved material from roadway excavation/borrow pits are excavated by excavators
and transported in dump trucks to the embankment site.

4. Road Bed Preparation:

4.1 The existing ground is cleared and grubbed as per specifications division 2100.
Unsuitable material as per Division 4100 to be taken out and replaced with good
material. The depth of excavation will be as directed by the Engineer.

 Unsuitable material Consists of:

 Peat materials from swamps, marshes and bogs that contain excessive number of
logs, tree stumps and other perishable material.
 Clay/Clayey material having a liquid limit exceeding 60%, or a Plasticity Index
(PI) exceeding 30%, or CBR value less than 3% at 95% of modified compaction
level after 4 day’s soaking or swell value of more than 2% (with two surcharge
rings) when determined in accordance with AASHTO T-193 at 95% of modified
compaction level
 or Clay/Clayey material having a PIw > 23 where PIw = Percent passing 425
micron X (PI/100),
 Any micaceous material or material consisting of deleteriousness or any adverse
engineering properties as determined by the engineer
 any material which is sufficiently wet and soft to prevent it from being
trafficked by normal bulk earth moving equipment.

 Replacement Material:
 CBR should be >7% at 95% of modified AASHTO compaction level,
 PI not greater than 20 and
 Swell should be less than 1.5% when tested in accordance with AASHTO T 180
and 2.5Kg surcharge.

4.2 Stripping and storing topsoil: The top soil shall be stripped to a depth not exceeding
200 mm and stored in stockpiles of height not exceeding 3m,

4.2.1 The original ground supporting the embankment shall be leveled to facilitate
placement of first layer of embankment, scarified, mixed with water and then
compacted by rolling as per Division 4100 of specification.

4.3 In case where the existing ground beneath embankment has a density below 95% of
MDD, the layer shall be scarified to a minimum depth of 150 mm, watered and re-
compacted in accordance with the requirements of division 4405.

4.4 The toe line of embankment/sub-grade shall be marked at regular intervals as guides,
the embankment shall be built sufficiently wider than the design dimension so that
surplus material may be trimmed to ensure that the remaining material is compacted
to the desired density and conforms to the specified side slopes.

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4.5 If the foundation of the embankment is in an area with stagnant water and is possible
to remove it the same shall be removed by bailing/ pumping out. Care shall be taken
to discharge the drained water so as not to cause damage to the works crops or any
other property.

4.6 The filing on unstable ground shall be carried out as per sub-clause 4103 (d), if so
required, after permission by the engineer.

4.7 Any new layer of less than 75mm in compacted thickness shall be bonded to the
pervious layer by scarifying to a depth of not less than 25mm or to such greater depth
that the total compacted thickness of the new layer plus the scarified portion of the
previous layer will not be less than 100mm.

4.8 All structures / pavements hindering the alignment shall be measured and dismantled.
Scarification and compaction of bed shall be carried out as per Division 4103 of
specification
5 Process

5.1 The approved soils from roadway excavation/ borrow areas shall be excavated and
transported to the site of embankment.

5.2 The material shall be spread in layers of uniform thickness not exceeding 200mm
compacted thickness over the entire width of embankment by mechanical means and
finished by motor grader.

5.3 The moisture content shall be checked and if found to be out of limits, the same shall
be made good.

5.3.1 If the moisture is high, it shall be dried, by aeration and exposure to the sun, till
the moisture content is brought down to the required level. Compaction shall be
suspended in inclement weather.

5.3.2 If the moisture content is less, water shall be sprinkled from a water tanker
having sprinkler attachment and mixed thoroughly in soil by blading, dishing or
borrowing until uniform moisture content is obtained.

5.3.3 The moisture content of each layer shall be checked. It shall be in between 2%
above OMC and below OMC

5.4 Compaction shall be done as per clause 4103. Vibratory or other rollers shall be used for
achieving the required results.

5.5 Around structures, compaction shall be done to achieve 95% of Modified AASHTO MDD in
layers by using small vibratory roller or plate vibratos as per Specifications.

5.6 The surface of the embankment shall be conducted to confirm the field dry density by sand
replacement method and rapid moisture meter shall be used to measure field moisture

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content.

5.7 Compaction tests shall be conducted to confirm the field dry density by nuclear density
gauge or by sand replacement method and rapid moisture meter shall be used to measure
field moisture content.

5.8 The next layer shall be placed only after achieving the required test result and due
approvals.

6.0 Personnel Employed for Supervision:

6.1 Works Inspector, Material Inspector, Laboratory Technicians and Surveyor from
consultant's side and contractor's technical personnel.

7.0 Tests and Sampling Procedures:

7.1 The sampling and testing of all materials as per specifications shall be conducted in the
laboratory established at site for this project.

8.0 Equipment Details

8.1 Excavations and Loading: Hydraulic Excavators

8.2 Transport: Dump Trucks
8.3 Spreading and grading: Graders and tractors
8.4 Watering: Water tankers fitted with sprinklers
8.5 Compaction: vibratory rollers
8.6 Testing equipment’s: AS per required standards

9.0 Safeties and Protection to Environment Etc.

9.1 All Effective and requisite measures shall be implemented to ensure full safety to all the
concerned work force, machinery, traffic and general public.

9.2 Effective and sufficient care shall be taken to minimize damage to the environment and
cleanliness in all works is given the utmost importance.

10. Activities

10.1 Perquisites

10.1.1 Obtain and check latest construction drawing.

10.1.2 The centerline and batter lines shall be marked and got checked by the Engineer's
representative.
10.1.3 The benchmarks shall be established after connecting with the GTS benchmarks in
the region.
10.1.4 The grid levels shall be recorded and got verified by Engineer's representative.

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10.1.5 The cross sections are plotted and the required profile of the proposed road section
is superimposed and the batter lines shall be identified and submitted for approval
of Engineer.
10.1.6 The layout is set out and beacons are established and protected.
10.1.7 Approvals of borrows material obtained.
10.1.8 Establish OMC & MDD and CBR value for all soils.

10.2 Main Activity:

10.2.1 Obtain and check latest construction drawings

10.2.2 RFI is initiated
10.2.3 Check for clearing and grubbing.
10.2.4 Check for stripping
10.2.5 Check for bed compaction
10.2.6 Check for approved borrow areas
10.2.7 Excavate transport and dump in approved areas for dumping.
10.2.8 Spread in uniform layer and grade to the required lines and levels
10.2.9 Check moisture content and rectify if needed.
10.2.10 Compaction using adequate mechanism/ rollers and verify field OMC for layers,
10.2.11 Check field density. If not achieved repeat from 10.2.8 until the required density
is achieved.
10.2.12 Record the test results and process the filing system.
10.2.13 Proceed from 10.2.5 for next layer until the level for next course is reached.
10.2.14 Close RFI

10.3 The stretch is ready for next process

11. Frequency of tests: Refer to table 5.2

11.1 Process Control shall be carried out as summarized below:

Table 5-4: Minimum acceptable Field density for Embankment and Sub-grade construction

Specified Density Number of % of modified AASHTO density

(% of modified Density Tests Per
Minimum Minimum density for any
AASHTO density) Lots
Mean Density single Test
3 and 4 93.7 90.4
95 % 5 93.9 90.2
6 94.1 90.0
12 Construction Tolerances

12.1 The works shall be constructed to the dimensional tolerances as given below:

Table 5-5: Tolerance Limits for Embankment and Sub-Grade Layer

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+ 25 mm and -
Levels The finished surface of the fill
50 mm
+250 mm and -
Common Fill
The transverse width at any level, 125 mm
horizontally from the centerline of + 500 mm and -
Rock fill
the road to the outside edge of the 250 mm
Width Selected Sub- fill, rock fill or selected subgrade + 150 mm and -
Grade Layers 100 mm
No specific tolerances are given, but the cut slopes
Cut slopes shall be finished to a standard generally attainable with
proper care

13. Routine Inspection and Testing

Routine inspection and testing will be carried out by Engineer to test the materials and
work man ship provided, for compliance with the requirements specified.

5.4 NATURAL AND CRUSHED SUBBASE MATERIAL

1. Scope

This Division covers the specification of materials for the construction of Crushed Sub-base
and Natural gravel Sub-base. The Sub-base shall be constructed to the dimensions and cross-
sectional profiles shown in the Contract drawings.

2.0 Reference Documents

2.1 Specification

 Division 5104: Material Requirements for Gravel Sub-Base

 Division 5105: Material Requirements for Crushed Stone Sub-Base
 Division 5107: Construction Requirements
 Division 5112: Testing
 Division 10107: Testing

2.2 Draw ings

 Bench Mark List Summary

 Horizontal and Vertical Curves List Summary
 Approved Cross Sections
 Plan Profiles

2.3 Inspection and Test Plan

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 As per RFI

3. Materials:

3.1 Source:

 The material shall be the consisting of natural gravel, scoria (cinder gravel)
weathered rock, crushed gravel, crushed rock or crushed boulders, or any other
material complying with the requirements of the sub clause 5400 of the project
specification and approved by the Engineer.
3.2 The following tests on material shall be done for Natural Subbase Material:

3.2.1 Grading Requirement for Natural Subbase Material: - The Natural Sub base material
shall be free from organic and other deleterious constituents and shall conform to
the grading requirements of type A or type B as per Table 5-6 given below:

Table 5-6 Grading Requirement for Natural Sub-base Material

Mass % passing
Sieve size, mm
A B
63.0 100 ---
50.0 90-100 100
37.5 --- ---
25.0 51-80 55-85
20.0 --- ---
9.5 --- 40-70
5.0 --- ---
4.75 35-70 30-60
2.0 --- 20-51
1.18 --- ---
0.425 --- 10-30
0.3 --- ---
0.075 5-15 5-15

3.2.2 Physical Requirement

Table 5-7 Physical Requirement for Natural Sub-base Material

Properties Spec. Methods and Standards Testing Frequency

Maximum Size, D of the specified thickness of

2/3 -do-
Max compacted layer

*Plasticity Index, One test Every

12 AASHTO T-90
PI % , Max 2510 m2

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Properties Spec. Methods and Standards Testing Frequency

Liquid Limit, % , One test

45 AASHTO T-89
Max Every 2510 m2

(CBR) shall be determined at

a density of 95% of the
CBR, % , Min 30 1 test/2km
MDD (AASHTO T-180 method
D)

(with two surcharge rings)

when determined in
Sw ell, % , Max 1 1 test/2km
accordance with AASHTO T-
193

Plasticity Product, (PP= PI x % age passing the

70 -do-
PP, % , Max 0.075 mm sieve)

(GM = [ 300 - (% passing

2mm) - (% passing
Grading Modulus 0.425mm) - (% passing
1.5 0.075mm)] / 100) -do-
(GM), Min
if approved by the
Employer’s Requirement
GM≥1.2

*Los Angeles
Abrasion, LAA, % , 51 AASHTO T-96 1 test/2km
Max

One test Every 2

Moisture content + 2 OMC AASHTO T-180 500 m2 or 1
test/km

200 to
Layer thickness after compaction -do-
100mm

3.3 The following tests on material shall be done for Crushed Stone Sub-base Material:

3.3.1 Grading Requirement for Crushed Stone Sub-base Material: - The aggregate used
for crushed stone sub-base shall be derived from a parent rock that is hard, sound,
durable, and unweather. It shall be obtained from sound rock from an approved
quarry or clean sound boulders. It shall contain no deleterious material such as
decomposed rock, clay, shale, or mica. The crushed aggregate shall comply with
the grading requirements as per Table 5-8 given below:

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Table 5-8: Grading Requirement for Crushed Stone Subbase Material

Mass % passing
Sieve size, mm
Type A, Nominal Size, 37.5mm
50.0 100
37.5 95-100
28.0 51-80
20.0 60-80
10 40-60
5.0 25-40
2.36 15-30
0.425 7-19
0.075 5-12

3.3.2 Physical Requirement

Table 5-9 Physical Requirement for Crushed Subbase Material

Properties Spec. Methods and Standards Testing Frequency

Plasticity Index, % , One test

6 AASHTO T-90
Max Every 2510 m2

Liquid Limit, % , Max 45 AASHTO T-89

(CBR) @ a density of
97% of the
CBR, % , Min 30 1 test/2km
MDD (AASHTO T-180
method D)

(with two surcharge

rings) when determined
Sw ell, % , 0 1 test/2km
in accordance with
AASHTO T-193

Crushed Aggregate At least two fractured

75 1 test/2km
Portion, % , Min faces

45 AASHTO T-96 1 test/2km

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Properties Spec. Methods and Standards Testing Frequency

Los Angeles
Abrasion, LAA, % ,
Max

One test Every 2 510

Moisture content + 2 OMC AASHTO T-180
m2 or 1 test/km

200 to
Layer thickness after compaction -do-
100mm

Grading Modulus,
1.5 but not less than 1.2, -do-
GM, Min

Field compaction, % ,
95 of MDD, AASHTO T 180 100m
Min

Flakiness Index, FI, BS812, Part 105 or ASTM

35 1 test/2km
% , Max, D3398

3.4 Approvals sought from Engineer

3.5 Approved material stockpiled at a selected location and care shall be taken to
prevent contamination of stockpiled material.
4 Process:
4.1 The sub-grade layer shall be checked for density before placing the sub base material
for any damage or deficiency which shall be made good as directed by the Engineer.

4.2 The approved crushed or natural sub-base material from stockpile shall be
transported to the site.

4.3 The material shall be spread in layers of uniform thickness not exceeding 200 mm
compact thickness over the entire width by mechanical means and finished by motor
grader.

4.4 The moisture content shall be checked and if found to be out of limits, the same
shall be made good.

4.4.1 If the moisture is high, it shall be dried, by aeration and exposure to the sun,
till the moisture content is brought down to the required level. Compaction
shall be suspended in inclement weather.

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4.4.2 If the moisture content is less, water shall be sprinkled from a water tanker
having sprinkler attachment and mixed thoroughly by balding, dishing or
borrowing until uniform moisture content is obtained.

4.4.3 The moisture content of each layer shall be checked. It shall be in between
2% above and below OMC.

4.5 The compaction shall be completed as soon as possible after the material has been
spread. Vibratory rollers shall be used for achieving the required results.

4.6 The surface of the sub base shall be maintained to the required cross fall.

4.7 The tests shall be conducted to confirm the field dry density by Sand Replacement
Method.

4.8 Before commencement of the actual construction of sub-base layer, a trial section
of area not established (a trial area of not less than 1000 square meters)

4.9 Only when such a trial section has been satisfactorily laid and finished, and complies
with the specified requirements, the actual sub-base layer work shall commence.

5.0 Personnel employed for execution and supervision:

5.1 Inspector of Works, Laboratory Technicians, Material Inspector and Surveyor besides
Contractor's personnel, shall be supervising the activity.

6.0 Tests and Sampling Procedures:

6.1 The samples of all materials as per specifications shall be collected and tested in the
laboratory established at site for this project.

7.0 Equipment details

7.1 Excavation and Loading: hydraulic Excavators/ loaders

7.2 Transport: Dump Trucks
7.3 Spreading: Motor graders
7.4 Grading and Mixing: Motor Grader
7.5 Watering; Water tankers fitted with sprinklers.
7.6 Compaction: Vibratory rollers
7.7 Testing equipment’s: As per required standards.

8.0 Safety and Protection to Environment Etc.

8.1 All effective and requisite measures shall be implemented to ensure full safety to all
the concerned work force, machinery, traffic and general public.

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8.2 Effective and sufficient care shall be taken to minimize damage to the environment
and cleanliness in all works is given the utmost importance.

9.0 Activities

9.1 Prerequisites

 Obtain and check latest construction drawing.

 The centerline and batter lines shall be marked and got checked by the
Engineer's representative.
 The benchmarks shall be established after connecting with the GTS
benchmarks in the region.
 The Sub grade compaction and levels shall be recorded and got verified by
Engineer’s representative.
 The layout is set out and beacons are established and protected.
 Approvals of Lot of subbase material at Stockpile obtained.
 Establish OMC and MDD for Stockpile material and 4-days soaked CBR value as
per the test frequency.
 Trial section has been satisfactorily laid and approved by the Engineer.

9.2 Main Activity

 RFI is initiated
 Check for sub grade top layer immediately before laying
 Load, transport and dump the approved stockpiled material in approved areas.
 Spread in uniform layer and grade to the required lines and levels
 Check moisture content and ratify if needed.
 Compaction using adequate mechanism/ rollers
 Check field density and repeat the activities from 9.2.4 until the required
value is achieved.
 Record the test results and process the filling system.
 The reach is ready for next process.

10. Construction Tolerances

10.1 The works shall be constructed to the dimensional tolerances as given below:

Table 5-10 Construction Tolerances in Sub-base Construction

Construction Tolerance Minimum number of tests

One test
Tolerances per lot
(3 points per cross
+25mm 10-20 m
Surface levels section)
+25mm - Isolated spots

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(3 points per cross

Thickness -25mm 10-20 m
section)
Width -50mm 10-20 m -
Cross section ±25mm 10-20 m -

11. Frequency of tests: Stated in table 5.7 and 5.9

11.1 Process Control

The minimum in- situ dry density of natural sub-base material shall be of a 97% of
modified AASHTO density.

Table 5-11 Construction of Sub base- Density Requirements

Specified density (% % of AASHTO T 180 MDD

Number of
of Modified AASHTO Minimum density for
Tests per lot Minimum mean Density
MDD) any Single test

3&4 97.5 95.5

97% 5 97.6 95.5

6 97.7 95.5

11.2 Routine inspection and Testing

Routine inspection and testing will be carried out by Engineer to test the materials and
workmanship provided, for compliance with the requirements specified.

5.5 CRUSHED ROADBASE MATERIAL (GRADED CRUSHED STONE BASE (GB1)):

1. Scope

This Division covers the specifications of materials for, and the construction of road base
pavement layers from approved base materials. It includes the use of crushed, stones or
gravels base materials. The road base shall be constructed to the dimensions and cross-
sectional profiles shown in the Contract drawings.

2.0 Reference Documents

2.1 Specification

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Section 7: Staff Organization
 Division 5204: Materials Requirements
 Division 5208: Construction Requirements for Crushed Rock and Crushed
Boulder Road Bases
 Division 10107: Testing

2.2 Draw ings

 Bench Mark List Summary

 Horizontal and vertical curves List Summary
 Approved Cross Sections
 Plan Profiles

2.3 Inspection and Test Plan

 As per RFI

3. Materials:

3.1 Source: The quarry for GB1 material shall be identified.

 This material is produced by crushing fresh, quarried rock (GB1) and may be
recombined to produce a desired particle size distribution, as per the
specifications. The material shall be clean and free from organic matter, lumps
of clay or other deleterious substances. The material shall be of such a nature
that it can be readily transported, spread and compacted without segregation.

3.2 The following tests on material shall be done:

3.2.1 Grading Requirement: The combined grading of the material shall be a smooth
continuous curve falling within the grading limits shown in Table as shown
below:

Table 5-12 Grading Limits for Crushed Stone Base Course Materials (GB1)

Mass % passing
Sieve size, mm Nominal Maximum Particle Size
37.5mm
50 100
37.5 95 -100
28 ---
20 60-80
10 40-60
5 25-40
2.36 15-30

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Mass % passing
Sieve size, mm Nominal Maximum Particle Size
37.5mm
0.425 7-19
0.075 5-12

3.2.2 Physical Requirement

Table 5-13 Physical Requirement for Crushed Stone Base Course Materials (GB1)

Testing
Properties Specification Methods and Standards
Frequency

Plasticity Index, PI,

NP AASHTO T-90 -do-
% , Max

of MDD achieved in the ASTM

CBR, % , Min 103 Test Method D 1557 (Heavy 1 test/2km
Compaction)

(with two surcharge rings)

when determined in
Sw ell, % , 0 1 test/2km
accordance with AASHTO T-
193

Aggregate crushing British Standard 812, Part

25 1 test/2km
value, ACV, % , Max 110

British Standard 812,

Wet TFVT, K N, Min 110 1 test/2km
Part 111,

Los Angeles
Abrasion, LAA, % , 40 AASHTO T-96 1 test/2km
Max

Moisture content + 2 OMC AASHTO T-180 1 test/100m

200 to
Layer thickness after compaction -do-
100mm

AASHTO T 104/ASTM C 88/

Soundness, Max 12 1 test/2km
BS 812 Part 12

Flakiness Index, FI,

30 BS 812 Part 105-1990 1 test/2km
% , Max,

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3.3 Approvals sought from Engineer

3.4 Approved material stockpiled at a selected location and care shall be taken to
prevent contamination of stockpiled material.
4. Process:
4.1 The sub base layer shall be checked for density before placing for any damage or
deficiency which shall be made good as directed by the Engineer.

4.2 The approved road base material from stockpile shall be transported to the site.

4.3 The material shall be spread in layers of uniform thickness not exceeding 200 mm
compact thickness over the entire width of capping layer by mechanical means and
finished by motor grader.

4.4 The moisture content shall be checked and if found to be out of limits, the same
shall be made good.

4.4.1 If the moisture is high, it shall be dried, by aeration and exposure to the
sun, till the moisture content is brought down to the required level.
Compaction shall be suspended in inclement weather.

4.4.2 If the moisture content is less, water shall be sprinkled from a water tanker
having sprinkler attachment and mixed thoroughly by balding, dishing or
borrowing until uniform moisture content is obtained.

4.4.3 The moisture content of each layer shall be checked. It shall be in between
2% above and below OMC.

4.5 The compaction shall be completed as soon as possible after the material has been
spread. Vibratory rollers shall be used for achieving the required results.

4.6 The surface of the sub base shall be maintained to the required cross fall.

4.7 The tests shall be conducted to confirm the field dry density by Sand Replacement
Method.

4.8 Before commencement of the actual construction of base course, a trial section of
area shall be established (not less than 1000 square meters)

4.9 Only when such a trial section has been satisfactorily laid and finished, and complies
with the specified requirements, the actual base course layer work shall commence.

5.0 Personnel Employed for Execution and Supervision:

5.1 Inspector of Works, Laboratory technician, Material Inspector and Surveyor besides
contractor's personnel, shall be supervising the activity.

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6.0 Tests and Sampling Procedures:

6.1 The samples of all materials as per specifications shall be collected and tested in the
laboratory established at site for this project.

7.0 Equipment details

7.1 Loading: Loaders

7.2 Transport: Dump Trucks
7.3 Spreading: Motor graders
7.4 Grading and Mixing: Motor Grader
7.5 Watering: Water tankers fitted with sprinklers.
7.6 Compaction: Vibratory rollers
7.7 Testing equipment’s: As per required standards.

8.0 Safety and Protection of Environment Etc.

8.1 All effective and requisite measures shall be implemented to ensure full safety to all
the concerned work force, machinery, traffic and general public.

8.2 Effective and sufficient care shall be taken to minimize damage to the environment
and cleanliness in all works is given the utmost importance.

9.0 Activities

9.1 Prerequisites

 Obtain and check latest construction drawing.

 The centerline and batter lines shall be marked and got checked by the
Engineer’s representative.
 The benchmarks shall be established after connecting with the GTS
benchmarks in the region.
 The Sub-base compaction and levels shall be recorded and got verified by
Engineer’s representative.
 The layout is set out and beacons are established and protected.
 Approvals of Lot of Granular material at Stockpile obtained.
 Establish OMC and MDD for Stockpile material and 4-days soaked CBR value as
per the test frequency.
 Trial section has been satisfactorily laid and approved by the Engineer.

9.2 Main Activity

 RFI is initiated
 Check for sub base layer immediately before laying,
 Load, transport and dump the approved stockpiled material in approved areas.
 Spread in uniform layer and grade to the required lines and levels

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 Check moisture content and ratify if needed.
 Compaction using adequate mechanism/ rollers
 Check field density and repeat the activities from 9.2.4 until the required
value is achieved.
 Record the test results and process the filling system.
 The reach is ready for next process.

10. Construction Tolerances

10.1 The works shall be constructed to the dimensional tolerances as given below:

Table 5-14: Construction Tolerances in Road Base Construction

at least 90 % of the level

w ithin + 20 mm of the specified levels
Level and measurements
Grade
Isolated spots within the + 20 mm

Length of Grade Measured in Maximum Variation from Specified

meter Grade (% )
Length of 2 0.34
Grade 5 0.27
10 0.21
20 0.13
30 0.08

nowhere shall be more than 50 mm

Width outer edge of the base
inside the edge lines

At least 90 % of all the

≥the specified thickness minus 27
thickness measurements taken
mm
before any thickness repairs are
Thickness
The mean layer thickness of the ≥the specified thickness minus 5
lot mm

3 m straight-edge laid at right

not deviate from the bottom of the
angles to the road center line
straight-edge by more than 10 mm
the surface
Cross
Section not vary from their difference in
any transverse section the
level computed from the cross
difference in level between any
sections shown on the Drawings by
two points shall
more than 20 mm

11. Frequency of tests: Stated in table 5-13 and,

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Table 5-15 Testing Frequencies for Road Base Materials

Test after Processing and Minimum test per

One Test Every
Compaction lot

Field Density and OMC 1000m2 4

Atterberg Limits and

2000m2 4
Grading
Materials
MDD and OMC 2000m2 4

CBR and ACV 2000m2 4

3 pts per cross
Surface Levels 20m
section
Construction Base layer Thickness 20m 30
Tolerance Base layer Width 200m 20 m
Smoothness (Cross Section) 20 m2 As directed

Source control shall consist of the sampling and testing of material sources or stockpiles at
least once per week while the said sources and/or stockpiles are in use. this testing shall
consist of grading, Atterberg limits, proctor testing, swell and CBR, relative density. This
testing shall consist of Aggregate grading and bituminous penetration test. Should any
problem with consistency in material properties or appropriate occur, the frequency of
testing may be increased as directed by the engineer.

11.1 Process Control

The minimum testing frequency that will be followed for the purpose of process control
shall be as per Table 5-10.

Table 5-16 Construction of Road base- Density Requirements

% of AASHTO T 180 MDD

Specified density (% of Number of
Modified AASHTO MDD) Tests per lot Minimum mean Minimum density for
density any Single test
3&4 103.4 102
103% (% of Modified AASHTO)
or 88% apparent relative 5 103.6 100
density whichever is greater
6 103.7 100

11.2 Routine inspection and Testing

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Routine inspection and testing will be carried out by Engineer to test the materials and
workmanship provided, for compliance with the requirements specified.

5.6 PRIME, TACK COAT, SINGLE SURFACE TREATMENT AND SURFACEINGS

5.6.1 Prime (Mc - 30) & Tack Coat (RC - 70)

1. Scope

This Division covers the application of a bituminous prime coat to a prepared pavement layer.

2.0 Reference Documents

2.1 Specification

 Division 6102: Prime Materials

 Division 6103: Safety
 Division 6112: Testing
 Division 6202: Tack Coat Materials
 Division 6203: Safety
 Division 6211: Testing
 Division 10109: Testing

2.2 Draw ings

 Horizontal and vertical curves List Summary

2.3 Inspection and Test Plan

 As per RFI

3. Materials:

3.1 Source:

 The priming material shall be MC -30 and the tack coat material shall be
RC-70 cutback bitumen complying with AASHTO M 81 or M 82, as
applicable or as directed by the Engineer.

3.2 The following tests on material shall be done on delivery of the material:

3.2.1 Physical Requirement

Table 5-17 Physical Requirement for Bitumen (MC 30, RC 70 and MC 3000)

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MC 30 RC 70 MC 3000
Properties Min Max Min Max Min Max
Kinematic viscosity at 60°C (140°F) (See
30 60 70 140 3000 6000
Note 1.) mm2/s
Flash point (Tag, open-cup), degrees C
38 (300) --- -- -- 66 --
(F)
Water, percent -- 0.2 -- 0.2 -- 0.2
Distillation test:
Distillation, percentage by volume of
total distillate to 360°C (680°F)—
to 190°C (374°F) -- -- 10 -- -- --
to 225°C (437°F) -- 25 50 -- -- --
to 260°C (500°F) 40 70 70 -- 0 15
to 315°C (600°F) 75 93 85 -- 15 75
Residue from distillation to 360°C
(680°F), volume percentage of sample 50 -- 55 -- 80 --
by difference
Tests on residue from distillation:
Absolute viscosity at 60°C (140°F) 120 240 30
30 (300) 60 (60) 120 (1200)
(See Note 2.) Pa.s (Poises) (1200) (2400) (300)
Ductility, 5 cm/min, cm (See
100 -- 100 -- 100 --
Note 3.)
Solubility in Trichloroethylene,
99 ---- 99 -- 99 --
percent
Spot test (See Note 4.) with:
Negative for all Negative for all
-- --
Standard naphtha grades grades
Naphtha-xylene solvent, percent Negative for all Negative for all
-- --
xylene grades grades
Heptane-xylene solvent, percent Negative for all Negative for all
-- --
xylene grades grades

3.2.2 Application Rates

The rate of application of prime shall be in the range of 0.6 to 1.1l/m2 of cutback
bitumen.

The rate of application of tack coat shall be in the range of 0.30 to 0.8 l/m2 of cutback
bitumen.

3.3. Approvals sought from Engineer

3.4 All prime and tack coat materials stored in a heated condition and shall be stored in a
container with a properly functioning circulation system and a securely fitting lid.

Table 5-18 Storage and Spraying Temperature for Bitumen's Used in the project

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Maximum storage temperature 0C

Type of prime Spraying temperature 0C
Up to 24 hours Over 24 hours
MC-30 50 30 45 – 60
RC-70 70 50 27 - 65
MC-3000 155 100 135-155
AC 50/70 135 175 135-160

4. Process:
4.1. The road base/Crushed Sub-base layer shall be checked for density for any damage
or deficiency which shall be made good as directed by the Engineer.
4.2. Traffic control is implemented and maintained, according to the Traffic Control
Plan,

4.3 The approved of MC 30/RC 70 from the stock, or approved of MC 30/RC 70 from the
distributor tank (which the mix was done at the site) shall be transported to the
site,

4.4 Limits for the work are properly identified and marked and both the Contractor and
Inspector understand the markings,

4.5 The equipment shall be capable of applying uniform, proper applications of the
specified materials, and the spreading equipment shall properly be calibrated to
apply the specified quantity of material,

4.6 The distributor’s spray bar shall be set at the correct height to provide a triple lap
coverage of liquid asphalt,

4.7 Weather conditions shall be suitable to perform the work and to allow the asphalt to
cure or set,

4.8 The Contractor shall acceptably clean up and disposes of unwanted material.

4.9 Before commencement of the actual applications of the prime, a trial section of
area shall be established.

4.10 Only when such a trial section has been satisfactorily spray and finished, and
complies with the specified requirements, which the actual spraying shall
commence.

5.0 Personnel Employed for Execution and Supervision:

5.1 Inspector of Works, Laboratory Technician, Material Inspector and Surveyor besides
contractor's personnel, shall be supervising the activity.

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6.0 Tests and Sampling Procedures:

6.1 The samples of all materials as per specifications shall be collected and tested in the
laboratory established at site for this project.

7.0 Equipment details

7.1: Mechanical Sweeper

7.2: Bitumen Distributor
7.3: Air blowers
7.4: Spraying: Bitumen Distributor
7.5: Testing equipment’s: As per required standards.

8.0 Safety and protection to Environment Etc.

8.1 All effective and requisite measures shall be implemented to ensure full safety to all
the concerned work force, machinery, traffic and general public.

8.2 Effective and sufficient care shall be taken to minimize damage to the environment
and cleanliness in all works is given the utmost importance.

9.0 Activities

9.3 Prerequisites

 Obtain and check latest construction drawing.

 The centerline lines shall be marked and got checked by the Engineer's
representative.
 The benchmarks shall be established after connecting with the GTS
benchmarks in the region.
 The crushed Sub-base and the road base compaction and levels shall be
recorded and got verified by Engineer’s representative.
 The layout is set out and beacons are established and protected.
 Approvals of Prime material obtained.
 Establish the correct application rate of the prime as per the test frequency.
 Trial section has been satisfactorily done and approved by the Engineer.

9.4 Main Activity

 RFI is initiated
 Check for crushed subbase and road base layer immediately before spraying,
 Load and transport the approved prime material,
 Check moisture content and ratify if needed, and Compaction using adequate
mechanism/ rollers,
 Spray in uniform manner to the required lines,
 Record the test results and process the filling system,

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 The reach is ready for next process,

10. Construction Tolerances

10.1 The actual spray rates shall not deviate from the required spray rate as specified or
ordered by the Engineer by more than 0.05 liters/m2.

10.2. The actual spray rates of the tack coat shall not deviate from the required spray
rate as specified or ordered by the Engineer by more than 0.05 liter/m2.

11. Frequency of tests: as delivered to the site.

11.1 Process Control

Process control is desirable if the prime coat and tack coat is produced at the site.

11.2 Routine inspection and Testing

Routine inspection and testing will be carried out by Engineer to test the materials and
workmanship provided, for compliance with the requirements specified.

5.6.2 Single Surface Treatments (Chipping and Mc - 3000)

1. Scope

This Division covers the materials, constructional equipment, and construction methods and
requirements common to the construction of single surface treatments.

2.0 Reference Documents

2.1 Specification

 Division 62A02 & 62B02: Materials

 Division 63A03: Plant and equipment’s
 Division 63A05: Cutback of bitumen
 Division 63A11 & 63B03: Construction of Surface Treatment
 Division 63A19: Testing
 Division 10105 & 10107: Testing

2.2 Draw ings

 Bench Mark List Summary

 Horizontal and vertical curves List Summary
 Approved Cross Sections
 Plan Profiles

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2.3 Inspection and Test Plan

 As per RFI

3. Materials:

3.1 Source:

 Bitumen: Bituminous binder for surface treatment shall be of MC - 3000,

complying the table 5-17,
 Chippings: The material for chippings shall consist of approved crushed stone.
The following tests on material shall be done:

3.2.1 Grading Requirement

Table 5-19 Grading Requirements for Single Surface Treatment

Mass % passing
Sieve Size, mm Nominal Size,
13.2mm
19 100
13.2 85-100
9.5 0-30
6.7 0-5
0.425 0-0.5

3.2.2 Physical Requirement

Table 5-20 Physical Requirement for Chippings for Surface Treatment

Testing
Properties Spec. Methods and Standards
Frequency

Aggregate crushing British Standard 812, Part

25 1 test/2km
value, ACV, % , Max 110

Mechanical British Standard 812,

Strength
110 Part 111, (minimum 1 test/2km
Requirements
w et/dry ratio shall be 75% )
(TFVT), K N, Min

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Testing
Properties Spec. Methods and Standards
Frequency

Los Angeles
Abrasion, LAA, % , 30 AASHTO T-96 1 test/2km
Max

The polished stone

50 -do-
value, PSV, Min

Soundness, % Max 12 AASHTO T 104 1 test/2km

Flakiness Index, FI,

25 BS 812 Part 105-1990 1 test/2km
% , Max,

3.2 Approvals sought from Engineer

3.3 Approved material stockpiled at a selected location and care shall be taken to
prevent contamination of stockpiled material.
4. Process:

 The primed road base layer shall be checked for any damage or deficiency which
shall be made good as directed by the Engineer.
 Aggregates are properly manufactured to comply with contract requirements and
are acceptably stockpiled,
 The approved chipping and bituminous material shall be transported to the site.
 Adequate traffic control is implemented and maintained, according to the Traffic
Control Plan,
 Limits for the work are properly identified and marked and both the Contractor
and Inspector understand the markings,
 The spreading equipment shall properly have calibrated to apply the specified
quantity of material, the distributor’s spray bar is set at the correct height to
provide a triple lap coverage of liquid asphalt,
 The surfaces, upon which the application is to be made, are in proper condition for
the treatment,
 Building paper shall be placed at the location of each intermediate construction
joint to assure a smooth, uniform joint,
 Spread rates for the asphalt cement and aggregates are appropriate,
 The moisture content of the aggregate is maintained so that the aggregate is
surface damp at the time of placement on the asphalt cement,
 Aggregate is spread on the asphalt cement immediately after its application and
before the asphalt cement starts to set or cure (break),

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 Compaction is performed immediately behind the aggregate application,
 The Contractor acceptably cleans up and disposes of unwanted material,
 Before commencement of the actual construction of single surface treatment, a
trial section of area shall be established (a trial area of not less than 1000 square
meters).
 Only when such a trial section has been satisfactorily laid and finished, and
complies with the specified requirements, the actual single surface treatment work
shall commence.

5.0 Personnel Employed for Execution and Supervision:

5.1 Inspector of Works, Laboratory Technician, Material Inspector and Surveyor besides
contractor's personnel, shall be supervising the activity.

6.0 Tests and Sampling Procedures:

6.1 The samples of all materials as per specifications shall be collected and tested in the
laboratory established at site for this project.

7.0 Equipment details

7.1 Transport and Spraying: Bitumen distributor

7.2 Transport: Dump Trucks
7.3 Spreading: Chip spreaders
7.4 Watering; Water tankers fitted with sprinklers.
7.5 Compaction: Rollers (Pneumatic-tired Roller, Rubber-soled Flat Rollers and Steel-
tired Flat Rollers)
7.6 Cleaning: Brooms
7.7 Testing equipment’s: As per required standards.

8.0 Safety and protection to Environment Etc.

8.1 All effective and requisite measures shall be implemented to ensure full safety to all
the concerned work force, machinery, traffic and general public.

8.2 Effective and sufficient care shall be taken to minimize damage to the environment
and cleanliness in all works is given the utmost importance.

9.0 Activities

9.5 Prerequisites

 Obtain and check latest construction drawing.

 The centerline lines shall be marked and got checked by the Engineer's
representative.

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 The benchmarks shall be established after connecting with the GTS
benchmarks in the region.
 The road base compaction and levels shall be recorded and got verified by
Engineer’s representative.
 The layout is set out and beacons are established and protected.
 Approvals of Lot of chipping material at Stockpile and bitumen MC 3000 shall
be obtained.
 Trial section has been satisfactorily laid and approved by the Engineer.

9.6 Main Activity

 RFI is initiated
 Check for road base top layer immediately before laying
 Load, transport and dump the approved stockpiled material in approved areas.
 Spread in uniform layer and grade to the required lines and levels
 Check moisture content and ratify if needed.
 Spraying of the bitumen at the application rate,
 Spraying of the chippings at application rates,
 Compaction using adequate mechanism/ rollers
 Record the test results and process the filling system.

10. Construction Tolerances

10.1 The actual spray rates shall not deviate from the required spray rate as specified or
ordered by the Engineer by more than 0.05 liter/m2.

11. Frequency of tests: Stated in table 5-20

11.1 Process Control

Table 5-21 Testing Frequency for Surface Treatment

Test Interval

Flakiness Index and Grading 250m3

ACV, Soundness, and Dry 10%

Materials 1000m3
Fineness Value

Dry and Wet 10% Fineness Ratio 2000m3

Bituminous
Compliance On delivery to the site
Binder

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Test Interval

All Materials Application Rates 100m

Source control shall consist of the sampling and testing of material sources or stockpiles at
least once per week while the said sources and/or stockpiles are in use. This testing shall
consist of Aggregate grading and bituminous penetration test. Should any problem with
consistency in material properties or appropriate occur, the frequency of testing may be
increased as directed by the engineer.

11.2 Construction Tolerances

Table 5-22 Construction Tolerance for Surface Treatment

Test after
Processing and One Test Every
Compaction

Surface Levels
The requirements relating to the road base
Cross Section on which the surfacing is constructed shall
Construction apply
Tolerance Surface Regularity
One test every 100 m, after every spray
Width
run

Bitumen Application rate + 0.06 litres/m2 net bitumen cold (20°C)

Chippings Application rate + 5%

11.2 Routine inspection and Testing

Routine inspection and testing will be carried out by Engineer to test the materials and
workmanship provided, for compliance with the requirements specified.

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5.6.3 Bituminous Asphalt Surfacing

1. Scope

This section covers all work in connection with the construction of asphaltic bases and
surfacing. It includes the procuring and furnishing of aggregate and bituminous binder, mixing
at a central mixing plant, spreading and compaction of the mixture.

2.0 Reference Documents

2.1 Specification

 Division 6402: Materials

 Division 6403: Composition of Asphaltic Road Bases and Surfacing Mixtures
 Division 6404: Plant and Equipment
 Division 6406/7/8: Producing, Mixing and Compaction
 Division 6414: Quality of Materials and Workmanship
 Division 10105 and 10109: Testing

2.2 Draw ings

 Bench Mark List Summary

 Horizontal and vertical curves List Summary
 Approved Cross Sections
 Plan Profiles

2.3 Inspection and Test Plan

 As per RFI

3. Materials:

3.1. Source:

 Bitumen: Bituminous binder for both asphaltic road base and wearing course
shall be of AC 50/70, complying the table below
 Aggregates: The material for aggregate shall consist of approved crushed stone.

3.1.1 Grading Requirement

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Table 5-23: Grading Requirements for asphaltic Surfacing’s

% Pass (Surfacing)
Size, mm
Min Max
13.2 100 100
9.5 82 100
4.75 54 75
2.36 35 50
1.18 27 42
0.600 18 32
0.300 11 23
0.150 7 16
0.075 4 10

3.1.2 Physical Requirement

Table 5-24 Physical Requirement for Asphaltic Surfacing’s

Methods and Spec. for Testing

Properties Frequency
Standards Surfacing

Aggregate Crushing
BS 812, Part 110 25 1 test/1000 m3
Value, Max %
AASHTO T 84/ 3 tests from each
1.5
ASTM C 128 representative
Absorption, Max % source
AASHTO T 85/
1
ASTM C 127
160 1 test/1000 m3
10% Fine Value, Min KN BS 812 Part 111
75 % 1 test/1000 m3
Los Angeles Abrasion, Max AASHTO T96 /
30 1 test/1000 m3
% ASTM C 131
3 tests from each
Adhesion, Min, % TMH1 Method C5 75 representative
source
Polished Stone Value,
BS 812, Part 114 50 1 test/1000m3
Min, %
1 test per source
or as warranted
AASHTO T 176/
Sand Equivalent, Min % 50 by change in
ASTM D2419
quality of
material

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Methods and Spec. for Testing

Properties Frequency
Standards Surfacing

AASHTO T
Soundness, Max, % 104/ASTM C 88/ BS 12 1 test/1000m3
812 Part 12
Flakiness Index, Max % B.S 8 12 part 105.0 25 1 test/250m3
3 tests from each
Coating and stripping AASHTO T-182 > 95 representative
source

Table 5-25: Specification for Bituminous Binder for asphaltic Surfacing

Specification
Test Test method (ASTM)
50/70
Based on original bitumen
Penetration at 25°C D5 50-70
Softening point (°C) D 36 46-56
Flash point (°C) Min D 92 232
Solubility in trichloroethylene (%) Min D 2042 99
TFOT heating for 5h at 163°C D 1754
a. Loss by mass (%) Max – 0.5
b. Penetration (% of original) Min D5 54
c. Ductility at 25°C Min D 113 50

3.1 Approvals sought from Engineer

3.2 Approved aggregate stockpiled and at a selected location and care shall be taken to
prevent contamination of stockpiled material.

Table 5-26 Table Design Requirement Asphaltic Surface Course

Parameters Surface Course
Stability (kN at 600C) 9
Flow (mm) 2-4
Void in the mix (%) 5-7
Void in Mineral Aggregates, min (%) 16-18
Void Filled with Bitumen (%) 60-70
Marshall Quotient, Stability/Flow
2-4.5
(KN/mm)
Filler /Binder, Ratio 1.3-1.5
Water Sensitivity, Loss of stability on
Minimum 75% retained
immersion in water at 600C (ASTM D
strength
1075)

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Parameters Surface Course
Compaction level (Number of blows) 75 blows

for Asphaltic Surface Course, the normal Marshall design procedure using 75 blows on each
face should be completed first to provide an indication that the Marshall design parameters
are met. Thereafter, these mixes shall be designed to refusal density following the extended
Marshall compaction method [in accordance with the requirements of BS - 598 Part 104
(1989)] and also the procedure described in APPENDIX-D of ERA Pavement Design Manual
2002: Volume I – Flexible Pavements and Gravel Roads.” The resulting air voids in the mix
shall not be less than 3%.

3 Process:

 Confirm Survey Control Procedures are appropriate and effective for the
intended purposes.
 Inspect and confirm pavers, trucks and compactors are clean, smooth and free of
holes.
 Confirm the presence of truck and record the truck No., discharge time or
batching time, arrival time at site and temperature of asphalt.
 Inspect and record the temperature of the discharged asphalt into the paver
hoppers or the paved mat immediately behind paver.
 Inspect, survey, measure and confirm mat thickness using depth gauges, tapes,
straight edges, survey control stakes and strings. Also, check the uniformity and
finished levels of mat.
 Ensure placed loose lifts and finished compacted thickness are within the
Tolerable specified limits.
 Confirm the correct temperatures and the recommended compactors are used
for the different stages of compaction or as per material and compaction
specifications.
 Confirm the rolling pattern of compactor is suitable and is as per the
recommended practice or specification.
 Institute and conduct process control of rolling and compaction operations by
non-destructive testing,
 Confirm the finished surface is surveyed at the required intervals for finished
levels, uniformity and smoothness,
 Confirm that the necessary testing is conducted on the retrieved asphalt samples
as per specifications.
 Confirm coring of material to determine thickness of the layer as per the
specifications.
 Confirm location of tests and the test results have been mapped and
documented. Locations should be noted on the set of construction plans, and
kept as a permanent record.

5.0 Personnel employed for execution and supervision:

5.1 Inspector of Works, Laboratory Technician, Material Inspector and Surveyor besides
contractor's personnel, shall be supervising the activity.

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6.0 Tests and Sampling Procedures:

6.1 The samples of all materials as per specifications shall be collected and tested in the
laboratory established at site for this project.

7.0 Plants and Equipment details

7.1 Plant: Asphalt Mixing Plant

7.2 Transport: Dump Trucks
7.3 Spreading: Paver
7.4 Compaction: Vibratory and Pneumatic Rollers
7.5 Testing equipment’s: As per required standards.

8.0 Safety and Protection to Environment Etc.

8.1 All effective and requisite measures shall be implemented to ensure full safety to all
the concerned work force, machinery, traffic and general public.

8.2 Effective and sufficient care shall be taken to minimize damage to the environment
and cleanliness in all works is given the utmost importance.

9.0 Activities

9.7 Prerequisites

 Obtain and check latest construction drawing.

 The centerline lines shall be marked and got checked by the Engineer's
representative,
 Check the records for previously written approval for crushed subbase and base
courses,
 Check and confirm that sufficient amount of equipment operator and skilled
labor are available for the paving operation,
 Check the plant operation, Plant capacity, Plant production schedules, number
of haul trucks, number of pavers, number of compactors and type of compactors
for suitability and adequacy for the planned activity.
 Check that sufficient quantity of approved materials is in stock.
 Check with the materials for details for Job Mix Design
 Keep copy of parameters for reference handy during inspection.
 Inspect and confirm that the pavers are in compliance with the specification and
in suitable working condition.
 Inspect and confirm location of stakes on site.
 Trial section has been satisfactorily laid and approved by the Engineer.

9.8 Main Activity

 RFI is initiated

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 Check for crushed subbase and/or asphaltic road base layer immediately
before laying
 Load, transport and dump the approved stockpiled material in approved areas.
 Spread in uniform layer and grade to the required lines and levels
 Compaction using adequate mechanism/ rollers
 Check field density and void analysis and repeat the activities until the
required value is achieved.
 Record the test results and process the filling system.
 The reach is ready for next process.

10. Construction Tolerances

a. Level and grade

H90 + / - 15 mm

H max + / - 20 mm

Deviation from the specified longitudinal grade due to deviations from the specified levels
shall not exceed the values given below:

Length of variation in grade Maximum variation from

(m) specified grade (% )

2 0.354

5 0.224

10 0.158

20 0.112

30 0.091

b. Width

be at least equal to that show n on

average w idth
the draw ings

the outer edge of the layer be inside the lines shown on the
drawings by more than 15 mm

c. Thickness

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The total thickness of bituminous premix courses determined here in the specification shall
not be less than the design thickness, and shall not be more than 6mm resulting in uneven
surface. when the total thickness is less than the minimum specified, the deficient area shall
be corrected at the Contractor's expense ether by an overlay course, or by removal and
replacement of the unsatisfactory thickness. the corrective measure will be subject to the
approval of the Engineer.
d. Cross section
When tested with a 3m straightedge laid at right angles to the road center line the surface
shall not deviate from the bottom of the straight-edge by more than 6 mm for freeways and
by more than 10 mm for other roads.
At any transverse section, the difference in level between any two points shall not vary from
their difference in level computed from the cross section shown on the drawings by more
than 15 mm for freeways and 20 mm for other roads.

e. Surface regularity
When tested with a rolling straight-edge as described in clause 10111 the number of surface
irregularities shall not exceed those given below (applied to base and surfacing)
(1) Average number of irregularities per 100 m equal to or exceeding the specified value
when taken over 300 m - 600 m lengths:
Freew ays (3 mm irregularities)
Asphaltic mixes with rolled-in chippings .......5
Stone-mastic asphaltic mixes ..........................4
Other asphaltic layers ......................................3
Other roads (5 mm irregularities)
Asphaltic mixes with rolled-in chippings .......4
Other asphaltic layers ......................................2
(2) Number of irregularities equal to or exceeding the specified value when taken over 100 m
sections:

Freew ays (3 mm irregularities)

Asphaltic mixes with rolled-in chippings .......8
Stone-mastic asphaltic mixes ..........................6
Other asphaltic layers ......................................5
Other roads (5 mm irregularities)
Asphaltic mixes with rolled-in chippings .......6
Other asphaltic layers ......................................3
(3) The maximum value of any individual irregularity when measured with the rolling straight-
edge or a 3 m straight-edge laid parallel to the road centre line:

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Freew ays
Asphaltic mixes with rolled-in chippings ...... 5 mm
Stone-mastic asphaltic mixes......................... 6 mm
Other asphaltic layers .................................... 4 mm
Other roads
Other roads..................................................... 8 mm
f. Multiple-layer base
Where the base is constructed from more than one layer, the requirements specified shall
apply to the combined layers in respect of width and thickness. The requirements for cross-
section, smoothness and grade shall apply to the final layer only but the lower layers shall be
constructed so as to ensure that these requirements in the final layer can be met.
g. Surfacing of bridge decks
The completed surfacing shall comply with the requirements for base in section 5211 in
respect of surface tolerances for grade, smoothness, cross section and width.

h. Grading Tolerance
The combined aggregate and filler grading shall not deviate from the approved target grading
for the working mix by more than that given in table 6400/15. The mean grading of each lot
of the working mix (minimum of 6 tests per lot) shall be determined from samples obtained
in a stratified random sampling procedure.

Table 5-27 Deviation from Approved Target Grading Material Passing Sieve Size (Mm)
Permissible deviation from approved target
Sieve size in, mm
grading (% )
26.5 ±5.0
19 ±5.0
13.2 ±5.0
9.5 ±5.0
6.7 ±5.0
4.75 ±4.0
2.36 ±4.0
1.18 ±4.0
0.6 ±4.0
0.3 ±3.0
0.15 ±2.0
0.075 ±1.0*
* When statistical methods are applied the permissible deviation for the 0.075 mm fraction is
+ / -2.0%.
i. Other tolerance

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Binder Content ± 0.3%

Void in mix 0%

be ≥ (97- void in mix of approved

Density
mixture), %

11. Frequency of tests: Stated in table 5.24.

11.1 Process Control

Table 5-28 Testing frequencies for Asphaltic Surface Course

Description Type of test Testing Frequency

Marshall Density, Stability & Flow
Min,6 sample per lot
Value, Air Void, VMA, & VFB
3 tests from each representative
Retained Strength
source
Core density & Thickness of compacted
Min, 6 Cores per lot
layer
Asphaltic Temperature during preparation of mix At regular close interval
Surface Course Temperature during mixing, laying &
At regular close interval
compaction
1 set of test/ on individual
constituents and mixed
Mix grading after binder extraction aggregate from the dryer for
each 400 ton of mix per plant
per day

11.2 Routine inspection

Routine inspection will be carried out by Engineer to test the materials and workmanship
provided, for compliance with the requirements specified.

11.3 Sampling and Testing

 All samples shall be taken in a stratified random pattern.

 Sample size indicates the minimum number of tests to be conducted.
 Test results shall be assessed with statistical judgment plan B
 Test results shall be scanned for possible outliers as below: -
 Co= (Xo-X mean), where Xo=the value of the test result differing most from the
mean, if absolute value of Co is > C (critical value), then Xo is an outlier and shall
be excluded from the sample.

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 Acceptance Limit for sample mean shall be calculated excluding outliers as under
table 10200/11 of the ERA Technical specification.

 Where the lot is rejected under statistical judgment plan B but the results are such
that the lot complies with the requirements for conditional acceptance (sample mean
lie within the rejection limit) hereafter, the engineer may accept the lot at reduced
payment in lieu of complete rejection provided that:

i. Conditional acceptance shall be in the sole discretion of the Engineer and

not an option which may be exercised by the Contractor or a right the
Contractor may claim;
ii. The lot is approved in respect of all other requirements not judged by
statistical judgment plan;
iii. The contractor shall have the option to remove and reinstate at his own
cost conditionally accepted work with work, which complies with the
requirements for acceptance for full payment.
iv. Conditional acceptance may be applied a) Relative compaction, b) Binder
content and, c) Void in mix

5.7 DRAINAGE STRUCTURES

(PERFABRICATED PIPE CULVERT, RETAINING /GABION STRUCTURE AND OTHER

PROTECTION WORK S)

1.0 Scope

1.1 The Scope covers the work in connection with the construction of prefabricated units of
culverts together with Inlet and outlet structures, side drains and Protection structures
as per the line and levels of the approved drawings and specifications.

2.0 Reference Documents

2.1 Specification

 Division 3200: Culverts and Appurtenant structures

 Division 3300: Concrete Lining of Open Drains
 Division 3400: Pitching, stone work and Erosion Protection
 Division 7100: Pre-cast Concrete Construction-Pipes & Beam
 Division 8200: Formwork
 Division 8400: Concrete for Structures
 Division 8900: Stone Masonry Structures
 Division 8000: Construction Tolerances for Structures
 Division 9100: Gabion

2.2 Draw ings

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 Bench Mark List summary
 Approved working Drawings for structures

1.2 Inspection and Test Plan

• As per RFI

2.0 Materials

2.1 The general requirements of material (cement, Aggregate, Steel etc.) shall conform
to the provisions in Division 8000 of Specifications.

2.2 Aggregates

The coarse aggregates shall comply with the requirements of AASHTO M 80 and fine
aggregate shall comply with the requirements of AASHTO M 6 Class B. Aggregates shall not
contain deleterious or organic materials such as grass, timber or similar Materials.

3.3 Stone

(i) Stone for pitching shall be sound, tough and durable, with no stone less than 200 mm in
minimum. Rocks or stone shall be of such a shape as to form a stable protection structure of
the required Section. Rounded boulders or cobbles shall not be used on slopes steeper than
2:1 unless grouted.

(ii) All stone intended for use on any particular pitching job shall receive the prior approval
of the Engineer,

(ii) For masonry work, stones shall have a thickness of not less than 120 mm, widths of not
less than 1.5 times their respective thickness, with minimum width of 300mm and lengths of
not less than 1.5 times their respective widths. Where headers are required their lengths
shall be not less than the width of bed of the widest adjacent stretcher plus 300mm.

(iv)The stone for gabion shall conform to specification clause 9100.

3.4 Water

Water shall be clean and free from detrimental concentration of acids, alkalis, salts and
other organic or Substances and shall conform to the requirements of clause 8402(d) of std.
Tech. Specification. The source of water for mixing concrete and mortar shall be approved by
the Engineer.

3.5 Cement

Cement used for structures shall be either ordinary Portland or Sulphate resisting cement
complying with the requirements of AASHTO M-85 or blended hydraulic cement complying

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with the requirements of AASHTO M-240.

3.6 Steel Reinforcement

Reinforcing bars shall comply with NZS 3402P and/or deformed steel bars for concrete shall
conform to the requirements of AASHTO M 31 (ASTM A615).

3.7 Prefabricated Concrete Pipe

Pre-cast concrete pipes used for the construction of culverts shall be manufactured in
accordance with the requirements of AASHTO M-170 (ASTM C 76 or ASTM C 118) or AASHTO M-
242 and shall be the Class as described in the Contract.

Concrete used for the construction of culverts is as indicated in the drawings in accordance
with the requirements of Division 8400.

Reinforcement used for the construction of pre-cast or in-situ concrete culverts shall be steel
reinforcement complying with the requirements of Division 8300

3.8 Backfilling

The material for the backfilling of Retaining walls or pipes shall be selected material of at
least sub base quality. Where the excavated material is not of adequate quality, selected
material shall be imported for this purpose.

4.0 Constructions

4.1 Prefabricated pipe culverts shall be installed under either:

a) " Trenched conditions" where the units are laid in a trench excavated below existing
ground level or in a trench excavated in previously constructed sub grade and, if
necessary, sub base layers; or

b) '' Embankment conditions'' where the units are laid approximately on the existing
ground surface and the sub grade is then constructed on either side and over the culvert.

As a general rule, all prefabricated pipe culverts shall be constructed under trenched
conditions. The only exceptions shall be those permitted by the Engineer.

4.2 Any sections of existing wing walls approach slabs and headwalls which may obstruct
any new work shall be demolished and removed.

4.3 Concrete pipe culverts and drains shall be laid on Class B or Class C bedding as shown
on the Drawings and/or as directed by the Engineer. But when rock or hard
foundation is encountered Class A bedding type with concrete cradle should be used
in conformity with the details shall on the plans and the requirements of Technical
Specifications.

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4.4 Large selected stones for headwall of the culvert /Retaining wall shall be laid with
the largest dimension in the horizontal plane stones shall be individually placed to
bread joints and to provide a minimum of voids, and shall be firmly bedded against
adjoining stones. The stones shall be wetted and the voids shall be filled with 1:3
cement; sand mortar the headwall of the culvert shall be constructed up to invert
level first and after laying and jointing of the pipes headwall shall be completed as
per line and level of approved drawings and as per Division 8905.

4.5 The pipes shall be laid hard up against each other so as to obtain tight joints. The
inside of the pipes shall be smooth with no displaced joints. All pipes shall be laid
true to line and level Joints shall be either Portland cement mortar with cement to
sand ratio of (1:3) or as prescribed by the Engineer.

4.6 Inlet and outlet structures for prefabricated culverts as well as catch pits shall be
constructed in accordance with the details shown on the Drawings and as per clause
3211.

4.7 Weep holes shall be constructed as per clause 8706 and drawing and shall be cleaned
of mortar and any other clogging material that may have entered during
construction. Care shall be taken to construct weep holes staggered in horizontal and
vertical direction.

4.8 The walling shall be kept moist for a minimum period of four days after completion.

4.9 Backfilling alongside and over pipes shall be placed and compacted in layers not
exceeding 150 mm after compaction, to a density of at least the density required for
the material in adjoining layers of fill sub grade and sub base. The density of
backfilling in excavations mad in the natural ground shall be at least 95% of modified
AASHTO density. Backfilling shall be carried out simultaneously and equally on both
sides of a pipe to avoid any unequal lateral forces.

4.10 Grouted stone pitching, with minimum thickness of pitching 150mm, shall be done
as per drawing and as per clause 3403 (b) with cement: sand of (1:3) or as specified
in the drawing or as directed by the Engineer.

4.12 The side drain Type ''A'', ''B'' & ''C'' shall be constructed as per approved drawing and
as per project specification with cement: sand 1:3

4.13 Gabion structures shall be constructed as per drawing and as specified in Division
9100 or as directed by the Engineer.

5.0 Design, erection and removal of formw ork:

5.1 All formwork shall be in accordance with division 8200 of the specification and will
be got approved by the Engineer.

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5.2 The design of scaffolding shall be done for construction of retaining wall of height
more than 2m and got approved by the Engineer.

6.0 Production, Transportation, Laying and Curing of Concrete

6.1 The concrete of appropriate mix shall be produced at site using tilting concrete
mixers with weigh batching arrangements.

6.2 The concrete shall be placed through chutes/ manually by head load.

6.3 Curing shall be effectively done by covering the concrete surfaces with gunnies and
wetting at close intervals by sprinkling of water or by pending.

7.0 Personnel employed for execution and supervision

7.1 Structural inspector, Material Inspector, Surveyor and Lab. Tech from Consultant's
side and contractor's technical staff.

8.0 Tests and sampling procedures

8.1 The sampling of all materials as per specifications shall be collected and tested in
the laboratory established at site for this project.

9.0 Equipment Details

9.1 Excavators: one excavator for making foundation trenches

9.2 Pump: Pump of sufficient capacity to drain out water
9.3 Mixing of Concrete: Portable concrete mixers with weigh batcher shall be used
9.4 Compaction of concrete: Needle vibrators / plate vibrators shall be used for
effective compaction of concrete.

10.0 Safety, Environment Etc.

10.1 As effective and requisite measures shall be implemented to ensure full satiety to
all the concerned work force, force, machinery & general public.

10.2 Effective and sufficient care will be taken to minimize damage to the environment
and cleanliness will be given the utmost importance.

11.0 Diversion of w ater.

11.1The requisite and efficient methods will be adopted to suit the need of diverting
water without adverse effect on the environment.

11.2 Approval of the Engineer will be sought prior to the implementation of any method.

12.0 Activities:

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12.1 prerequisites:

12.1.1 Obtain & check latest construction drawing

12.1.2 The location of structures shall be marked and get checked by the Engineer’s
representative
12.1.3 The benchmarks shall be established after connecting with the GPS
benchmarks in the region.
12.1.4 The grid levels are recorded and got verified by Engineer's representative.
12.1.5 The correct length of culverts is calculated and joints are planned with
reference to the structure on the existing carriage way.
12.1.6 The working drawings of structures are prepared as per ground requirements
and approval of Engineer is sought.
12.1.7 The approval for the appropriate concrete mix design is obtained.
12.1.8 The approval is sought for quality/ source of RC Pipes and other construction
materials.
12.1.9 The design of shuttering/scaffolding completed and drawing prepared and
approval of the Engineer is sought
12.1.10 The layout is set out and beacons are established and protected.

12.2 Main Activity:

12.2.1 RFI is initiated.

12.2.2 The bed at founding level is made good to the required compaction to support
the structure either by excavating or filling with approved material to
required level and lines and inspected by the Engineer.
12.2.3 The existing structure is dealt with as scheduled. If dismantling is envisaged
the pre-measurements are recorded and submitted for checking by the
Engineer's representative.
12.2.4 Bed concrete is laid and cured as planned and checked by the Engineer.
12.2.5 Masonry work for headwall completed up to invert level including catch pit in
u/s side if required and levels checked
12.2.6 Shuttering is made and the cradle concrete is poured and vibrated.
12.2.7 Prefabricated pipes laid and jointed and got checked by the Engineer.
12.2.8 Masonry headwall construction completed and checked by the Engineer.
12.2.9 The inlet & outlet protection works are constructed and checked by the
Engineer.
12.2.10 Side drains constructed and checked by the Engineer.
12.2.11 The surroundings are cleared of all surplus stocks, waste materials etc., and
cleaned.
12.2.12 The structure is finished as per specifications including necessary markings.

13. Construction Tolerances

13.1 The tolerances of different structural components shall be within the limits as
specified in Division 8000 of specification.

14. Test Frequency

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14.1 All required tests shall be conducted at the specified frequencies or as directed
by the Engineer

5.8 STRUCTURES (RC BOX /SLAB CULVERT AND BRIDGES)

1.0 Scope

The Scope covers the work in connection with the construction of In-situ RC Box Culvert, RC
Slab Culverts and Bridges as per the line and levels shown in the approved drawings and
specifications.

2.0 Reference Documents

2.1 Specification

 Division 3200: Culverts

 Division 3400: Pitching, stone work and Erosion Protection
 Division 8200: Formwork
 Division 8300: Steel Reinforcement for structure
 Division 8400: Concrete for Structures
 Division 8700: Bridge Bearings
 Division 8000: Construction Tolerances for Structures
 Division 8900: Stone Masonry Structures
 Division 10116: Testing of Construction Water
 Division 10106: Testing of Construction Concrete


2.2 Draw ings

 Bench Mark List Summary

 Working Drawings

2.3 Inspection and Test plan

 As per RFI

3.0 Materials

3.1 Aggregates

(i) Both course aggregated (stone and fine aggregates (sand) shall comply with the
requirements of AASHTO M80 Class A and M 6 Class B respectively.

(ii) Aggregates shall not contain deleterious amounts of organic materials such as grass,
timber or similar materials. The maximum amounts of deleterious substances are given in

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table below:

Table 5-29: Maximum Amount of Deleterious Substances

Maximum Percentage by Mass

Item
Fine Aggregate Coarse Aggregate
Material Passing 0.075mm sieve 2.0 1.0
Lightweight material 2.0 2.0
Organic matter 0 0
Clay lumps 1.0 0.5
other deleterious substances 2.0 1.0

The sum of the percentage of all deleterious substances in aggregate as delivered to the
mixer shall not exceed 3 percent for fine aggregate and 2 per cent for coarse aggregate.

(iii) Both course aggregates (stone) and fine aggregates (sand) shall comply with the
requirements as per tables given below:

Table 5-30: Grading of Fine Aggregate

BS ERA/AASHTO ASTM
Grading
Requirement Requirement Requirement
BS, Sieves Sieves size,
% passing % passing % passing
size mm
10.00 10mm 100 100 100
5.00 4.76mm 89-100 95 - 100 95-100
2.36 2.38mm 60-100 68 - 86 80-100
1.18 1.19mm 30-100 47 - 65 50-85
0.60 0.60mm 15-100 27 - 42 25-60
0.30 0.30mm 5-70 9 - 20 10-30
0.15 0.15 mm 0-15 0-7 2-10
0.075mm. -- 0 -2.5 ---

Table 5-31 Nominal Size and Grading of Coarse Aggregate

Nominal Percentage of total mass passing sieve

Size (mm) Sieve size (mm)
31.25 25 19 12.5 10 4.75 0.075

25 90-100 0-20 0-2 - 0-0.5

20 100 80-100 10-40 0-4 0-0.5

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Nominal Percentage of total mass passing sieve
Size (mm) Sieve size (mm)
10 100 90-100 40-70 0-15 0-0.5

Note: passing 0.075mm sieve should not exceed 3% in any case tested as per AASHTO T11 for
concrete work.

Table 5-32: Required Properties of Aggregate

Test Fine Aggregate Coarse Aggregate

Flakiness index (BS872 part 105.1) Not Applicable 35%
Los Angeles abrasion loss at 500 revolutions
-- ≤ 40%
(AASHTO T 96)
Soundness loss % (AASHTO T 104) (a) 10, (b) 15 (a) 12, (b) 18
Alkali aggregate Reactivity (ASTM 289) Non-Reactive Non-Reactive
Passing 0.0.75mm sieve (AASHTO T 11) Maximum 3% Not Applicable
Adherent Coating value (FLH T512) <1%
Sand Equivalent (AASHTO T 176) >75 -

Notes :(a). When tested with Sodium Sulfate, (b). When tested with Magnesium sulfate,

3.2 Water shall be clean and free from detrimental concentration shall conform to the
requirements of clause 8402(D) of standard technical specification.

Table 5-33 Criteria for Inorganic Impurities in Water Used to Manufacture Concrete

Standard Test Methods and

Properties Specification
Specification

AASHTO T-26, SABS method

PH 7 to 9
113

Chloride content (Cl2), AASHTO T-26, SABS method

400 ppm
max 202

Reinforced concrete: 400

ppm
Sulfates (SO3) content, AASHTO T-26, SABS method
Pre-stressed concrete: 400
max 212
ppm
Mass concrete: 1,000 ppm

Alkali carbonate and AASHTO T-26, SABS method

1,000 ppm
Bicarbonates, Max 837

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Standard Test Methods and

Properties Specification
Specification

Reinforced concrete: 1,500

Total dissolved solid, Max AASHTO T-26, SABS method 84 ppm
Mass concrete: 3,000 ppm

Total percentage of solids AASHTO T-26, SABS method

2.25 %
by weight, Max 113

Conductivity @ 25°C SABS method 213 330mS/m

Organic Impurities 300 ppm (applicable if pH < 5) Chemical Oxidation Demand

Sugar ---- Negative

3.3 The cement used shall be Portland cement conforming to the requirements of AASHTO
M 85

3.4 Reinforcement shall be deformed steel bars conforming to the requirements of AASHTO
M31

Table 5-34 Reinforcement bars requirements

Tensile Yield
Type of Nominal Elongation
Strength, strength, Size of bars, mm
steel sizes, mm % , min.
Mpa, min. Mpa, min.
11 10
Sizes
Grade 40 420 280 12 13, 16
≥10mm
12 19
9 10, 13
9 16, 19
Sizes
Grade60 620 420 8 22, 25
≥10mm
7 29, 32
7 38, 43, 57

3.5 The material of formwork shall conform to the Division 8200 and/or as mentioned in
drawings.

3.6 Filter material behind structure shall conform to clause 3107 of technical specification.

3.7 The material for the backfilling shall be selected material of at least sub bade quality or
otherwise specified in the drawing. Where the excavated material is not of suitable
quality, selected material shall be imported for this purpose.

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4.0 Concrete Mix Design

4.1 Classes of Concrete

Table 5-35 Classes of Concrete

Cylindrical Strength
Classes of Concrete Nominal Size (mm)
(N/MM2)
A 25 25
C 15 25
Y 25 20
Lean Concrete 10 20
All structural concrete work shall be class 'A’, ’C’, ’Y’ and lean concrete having
characteristic compressive strength of 25,15,25 and 10 Mpa respectively. Concrete for
bridge railing shall be class 'Y' and shall conform to 8703 ERA Technical Specifications shall
be followed.

4.2 Material Testing

The materials shall be tested as per specification of the Technical specifications and all
test results shall be submitted to the Engineer for approval

4.3 Cement Content

The cement content shall be taken for the trial mix design to provide adequate
workability with low water/ cement ratio (not more than 0.5 in any case) so that the
concrete can be completely compacted with the means specified. The cement for any
class of concrete shall not exceed 550 kg/m3 of concrete.

4.4 Trial mixes:

After approval for the materials to be used, trial mixes shall be made 60 days in advance
prior to use and compacted as per specification in the presence of the Engineer; using
the same type of plant and equipment as will be used for the works with concrete of
designed proportions to prove and establish the workability, strength, water/ cement
ratio, surface criteria, etc. methods of transporting fresh concrete and the compaction
equipment shall be tested for approval.

Trial mixes for any class of concrete required for the works shall be made and submitted
to the Engineer for approval, before the construction works are started. Based on trial
mixes, information regarding concrete mix design for each class of concrete shall be
prepared, for the approval of the Engineer together with the test results.

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After the proposed mix has been approved, no variations shall be made to the mix
proportions, or in type/source, size and grading of any of the constituents without the
written consent of the Engineer. The following information to be supplied with the mix
design

 Estimated minimum compressive cube strength in MPa after 28 days

 Maximum Nominal size of the aggregate (CA and FA) used in the mix and %
proportion of each aggregate constituent,
 The type and proportion of the cement in the mix,
 Details of Admixture used (if any),
 Water/ Cement ratio,
 The slump obtained.

5.0 Design, Erection and Removal of false w ork /formw ork:

5.1 Formwork shall be designed to be sufficiently rigid to ensure that the specified
dimensional tolerances can be achieved under the combined action of self-weight, dead
loads and imposed loads as well as the additional loads resulting from the rate of
concreting, the lift cast in one operation and the method of placing and compaction. The
detailed design calculation and drawing of false work shall be submitted to the Engineer
for approval as per specification.

5.2 False work shall be erected in accordance with the approved drawings incorporating such
modification as required by the Engineer as per specification Division 8200.

The joints between contiguous formwork elements shall be tight fit and where necessary the
joints shall be caulked, taped or packed with a sealing gasket. Paper, cloth or similar
material shall not be used for this purpose.

5.3 False work and formwork shall not be removed for the appropriate minimum period of
time as given below in the Technical Specifications Clause 8204(d).

6.0 Excavations of Foundations

6.1 The excavation of the foundation bed shall be made true to the line and levels of the
approved drawings. The compaction of bed and bed material at founding level shall be
checked and shall be compacted and tested as per the speciation. The Engineer's
approval of all excavations for all structures shall be obtained prior to commencing any
bedding.

6.2 The area shall be kept clean and free from water during excavation and concreting by
making diversion channels, pumping and other means No pumping will be done during
the placing of concrete unless it is carried out from a suitable sump pit separated from
the concrete work.

7.0 Cutting, Bending, Placing and Fixing of Reinforcement

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7.1 Bar bending schedule drawing shall be prepare and submitted to the Engineer for
approval at least six weeks in advance of actual construction.

7.2 Cutting and bending of reinforcement shall be carried out as per approved bar bending
schedule

7.3 Reinforcement shall be positioned as shown on the Drawings and accurately secured in
positions within the tolerance given in sub-clause 8303(d) of the Technical specification
by tying with 1.6 or 1.25 mm diameter annealed wire or by the use of suitable clips.
Spacer bars hall be provided with the same material of reinforcement at adequate
spacing to keep the bars in position.

7.4 The minimum cover shall be as shown on the Drawings where no covers indicated, the
minimum cover shall not be less than the appropriate values shown in Table 8303-1 of
the as small as possible, consistent with their use and be of approved design and
material.

8.0 Production, Laying and Curing of concrete.

8.1 The concrete of appropriate mix shall be produced at site using concrete mixers with
weigh batching of ingredients. The mixing of concrete shall be carried out as specified in
clause 8405 of Technical Specification.

8.2 The concrete is laid in place through chutes / head loads from the concrete mixers after
approval of shuttering and reinforcement by the Engineer. Concrete shall not be allowed
to fall freely through height of more than 1.5m.

8.3 Concrete shall be compacted by means of vibrators. Internal vibrators shall be capable of
producing not less than 10.00 cycles per minute and external vibrators not less than
3,000cycles per minute. Sufficient stand by vibrators shall be held available in case of
breakdown.

8.4 Construction joints shall be provided as per clause 8407 and as approved by the Engineer.

8.5 Curing is effectively done by covering the concrete surfaces by gunnies and wetting the
gunnies at close intervals or by pending. The curing period shall be continuous for at
least 5 days for concrete made from Portland cement. Clause 8410 of technical
specification to be referred for further details.

8.6 Finishing of concrete All concrete products shall be finished as shown in the drawing and
as per clause 8409 of specification to the satisfaction of the Engineer. Clause 8409 of
technical specification to be referred for further details.

8.7 Process Control

The process control shall mainly comprise of the following:

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(i) Cement: bulk or bagged cement used for concrete, mortar or grout shall be sampled by
taking one grab sample representing not more than 100 tons of cement manufactured in and
uninterrupted process and stored in one lot. The sample shall be tested for all the
requirements given in AASHTO M 85 by the methods given in that Standard.

(ii) Testing of aggregates: Coarse aggregates shall be tested for grading once for every 100
m3 delivered on site and fine aggregate once for every 50m3 delivered or more frequently if
ordered by the Engineer.

(iii) Strength of Concrete: Testing of 28 day crushing strength of concrete shall be controlled.

A test shall be the average test average test value for three tests of cubes prepared from the
same batch of concrete, the samples being consolidated in the molds by rodding as per BS
1881 or AASHTO T 106.

(v) Control charts: A system of control charts shall be instituted: depicting test results of all
concrete 28-day strength and where applicable accelerate crushing strengths.

(vi) Provision of Records

Written records in the form of concrete pour card/shall be maintained which will provide the
following:

1.0 Date on which each section was concreted class of concrete time taken to place the
position of the section of the works.
2.0 Daily maximum and minimum temperatures.
3.0 Nature of samples and dates on which taken, including identification marks.
4.0 Results of tests on samples taken and description of concrete section represented by
samples.

These records shall be maintained in a form agreed to by the Engineer and shall at all times
be up to date and available to the Engineer for inspection.

9.0 Construction of Expansion Joints and filler Joints:

9.1 Material for Expansion joints including sealing materials shall conform to clause 8704 (C)
and as approved by the Engineer.

9.2 Priors to manufacture of expansion joints, detail drawings shall be submitted to the
Engineer for approval.

9.3 Preparation of joints shall be made after removal of the temporary filler material or
breaking out of the excess concrete the inside faces of the joint shall be wire brushed or
grit blasted to remove all laitance and contaminants the joint shall thereafter be
cleaned out and blown out with compressed air to remove all traces of dust.

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9.4 All joints to be installed as per approved drawings and shall be accurately dimensioned to
ensure compliance with.

9.5 Filler joints shall be accurately formed to the dimension shown and filler material
specified on the drawings. The filler shall be secured in position not to displace during
concreting.

10. Protection and Allied w ork

10.1 The protection work like apron and pitching shall be constructed in accordance with
the details Shown in the approved drawings and as per Method statement

10.2 Weep holes shall be provided as per drawing and shall be cleaned of mortar and
any other clogging material that may have entered during construction.

10.3 Filter media shall be constructed simultaneously with backfilling as per grading
specified.

10.4 Backfilling behind the abutments, wing walls and return walls shall be placed and
compacted in layers not exceeding 150mm thick after compaction to a density of at least
the density required for the material in adjoining layers of fill sub grade and sub base.
The density of backfilling in excavations made in the natural ground shall be at least 95%
of modified AASHTO density backfilling shall be carried out only after the structures
attain full strength and after obtaining permission from the Engineer.

11.0 Personnel Employed for Execution and Supervision

11.1 Structural Engineer, Surveyor from the consultant side and technical staff from
contractor's side.

12.0 Tests and Sampling Procedures

12.1 The sampling of all materials as per specifications shall be collected and tested in the
laboratory established at site for this project.

13.0 Equipment Details

13.1 Excavators; one excavator for making foundation trenches

13.2 Pump; pump with sufficient capacity to drain out water
13.3 Concrete Mixers: Concrete mixers with weigh batcher having water measuring system
shall be used
13.4 Vibrators: Needle Vibrators/ Plate Vibrators shall be used for effective compaction of
concrete
13.5 Transit Mixers: To carry the concrete from one fixed batching stationed to the site

14.0 Safety, Environment, etc… :

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14.1 All effective and requisite measures shall be implemented to ensure full safety to all the
concerned work force, machinery &general public.

14.2 Effective and sufficient care will be taken to minimize damage to the environment and
Cleanliness in all works will be given the utmost importance.

14.3 The requisite and efficient methods will be adopted to divert the traffic

15. Diversion of w ater:

15.1 The requisite and efficient methods will be adopted to suit the particular need of
diverting the water channel.

15.2 The approval will be sought prior to the implementation of any method.

16 Activities:

16.1 Prerequisites:

16.1.1 Obtain & check latest construction drawing.

16.1.2 The location of structures shall be marked and got checked by the Engineer's
Representative.
16.1.3 The benchmarks shall be established after connection with the benchmarks.
16.1.4 The grid levels are recorded and got verified by Engineer's representative.
16.1.5 The hydraulic data are verified and HFL Marked on the ground.
16.1.6 The working drawings of structures are prepared as per ground
requirements and approval of Engineer is sought.
16.1.7 The bar bending schedule is prepared as per the approved drawing and
approval of Engineer is sought
16.1.8 The approval for the appropriate concrete mix design is obtained.
16.1.9 The design of shuttering/scaffolding completed and drawing prepared and
approval of the Engineer is sought
16.1.10The layout and beacons are established and protected.

16.2 Main Activity

16.2.1 RFI is initiated.

16.2.2 The bed at founding level is made good to the required compaction to support
structure either by excavating or filing with approved material to the required
level and lines and checked by the Engineer.
16.2.3 Shuttering is ready for checking and Bed concrete is laid
16.2.4 Shuttering along with reinforcement placed and the concrete for bottom slab is
Poured and vibrated after approval
16.2.5 The shuttering is erected in lifts for side wall/abutment of Box/bridge and
Reinforcement is tied in position as per drawing and checked.
16.2.6 Concrete side wall/abutment of Box/bridge are poured in lifts of suitable height
and vibrated.

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16.2.7 The shuttering is made to support the top slab of box/deck slab of bridge and
Reinforcement is tied in positions per drawing and checked.
16.2.8 The slab concrete is poured, vibrated and cured. The formwork is removed
after due time as per norms and blemishes, if any, are made good.
16.2.9 The kerb and hand railing are erected as per drawing and specification
16.2.10 The expansion and filler join are placed.
16.2.11 The protection and other allied work is completed
16.2.12 The surroundings are cleared of all surplus stocks, waste materials etc. and
cleaned.
16.2.13 The structure is finished as per specification including necessary
markings, etc.

16.3 The structure is complete

17. Codes and standards

17.1 The test shall be carried out as per technical specification and with the following
Standards:

Table 5-36: Codes for Standards for Testing Concrete

Test Standard
Sampling AASHTO T141
Compressive strength AASHTO T152, T23 and T126
Slump ASTM C 143
Air content AASHTO T 152
Unit weight AASHTO T 152

17.2 Test Frequency for Aggregate

The minimum frequency shall be as given in Table 5-37 for the various tests.

Table 5-37 Testing Frequency of Aggregates

Description Type of test Remark

Grading + Material passing no .200 0ne test per 50m3 and at least
Aggregate for concrete sieve once a week
(Sand and Coarse Flakiness Index, FI - do -
aggregate) Once a month, or as warranted
Los Angeles Aberration, LAA
by change in quality of material
Adherent coating Value - do -

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Description Type of test Remark

Organic impurities - do -
Sand equivalent, SE - do -
Soundness
Specific gravity and absorption - do -
0ne test per 50m3 and least
Fineness modulus, FM
once a week

17.3 Tests on Concrete

(i) Compressive strength: the procedure of sampling, Manufacture of test 150 mm cubes
storing, curing and testing shall be in accordance AASHTO Standards.

(ii) Consistency (slump test): The test method described in ASTM C 143 shall be followed and
shall be conducted minimum three times (i.e. at start, intermediate and before finishing) for
every concrete pouring.

Table 5-38: Minimum Sample Size of the 150mm cubes for Structural Concrete

Description Type of test Remark

Q’ty of concrete,
No. of sample
m3
1-5 1 set (3 cubes)
Casting concrete 6 - 15 2 sets
cylinders 16 - 30 3 sets
31 - 35 4 sets
Cement 4 sets + one additional sample
51 and above
Concrete for each 50m3 or part thereof
7 days compressive
At 7 Days
strength
Slump test 1 test per 5m³ but not less than 2 testes /day
Temperature of
1 test per 5m³
placed concrete

18 Construction Tolerances

18.1 Tolerances for reinforced concrete structure and reinforcement shall be in

accordance with the Requirements of clause 8000 of Standard Tech. Specifications
except where such tolerances are reduced by the Engineer.

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6 REPORTING AND RECORD K EEPING

6.1 REPORTING

6.1.1 General Reporting Guidelines

In the course of the services, the Resident Engineer shall ensure the timely submission of at
least the reports required by the TOR with further refinements/details /additions proposed
by the Consultants and agreed by the Employer. The number of copies of the reports shall be
as required by the TOR or any agreed modifications there to. Additional supplementary
reports, which are not covered under this proposal, may also be submitted to address specific
and important issues in the course of the services based on the consultants’ recommendation
and/or the Employer’s request.

All the supervisory staff shall duly be made aware that poorly presented reports may possibly
spoil all efforts and are problematic for the review by a third party. After all, what remains
as permanent records of the project are the reports regardless of the thoroughness of the
investigation or analyses. Hence, the RE/ARE shall give adequate emphasis towards ensuring
a consistent and standard reporting by all staff concerned.

6.1.2 Contents of Project Reports

All project documents shall at least address the contents required by the consultancy
contract (the TOR as well as the consultants’ proposal). The necessary checklists and optional
items to be included in the report have been included in the consultants’ proposal and hence
are not repeated herein.

As a rule of report preparation, all site staff shall be well informed regarding the following
standard report writing guidelines.

 Before preparing any report, the outline shall be defined in the form of table of
contents. This will ensure complete coverage of all desired elements and avoids
redundant topics or ideas.
 All reports shall have Table of contents, List of Figures and List of Tables similar to this
QAM. MS word software shall be used to prepare the reports
 All reports shall be prepared as much, in an objective manner, as possible
 All major reports shall be preceded with an executive summary to allow a simple and
fast referencing of the objective, coverage and findings of the report.
 The RE shall ensure proper filing of supplementary documents like calculations,
drawings and communications. Also, proper cross referencing between different
documents shall be in place
 The RE shall ensure that all reports are checked by a sufficient number of relevant
personnel
 The RE shall ensure that the Employer will be the sole owner of all reports and
documents pertaining to the project

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6.2 SITE INSPECTIONS, DAILY REPORTS AND DIARIES

6.2.1 Site Inspections

To ensure the Contractor’s strict contact compliance, it is mandatory that all personnel
charged with inspection responsibilities properly prepare themselves in advance through
detailed study and understanding of the Plans and Specifications. On-site observations of the
field engineer’s activities and procedures will be made by the RE to ensure compliance with
plans and Specifications.

The field engineer’s activities will be determined by the Contractor’s construction activities,
and they will be notified of these in advance based on Request for Inspection (RFI) submittals
from the Contactor.

A sample of the RFI is given in Annex B (Form No. SI/05 and/or SI/06)

The inspectors are authorized to inspect all work done and material furnished. Such
inspection will extend to all parts of the works and to the preparation, fabrication or
manufacture of the materials to be used. The field engineers are not authorized to alter or
waive any provision of the contract conditions or documents.

The supervision staffs are responsible for keeping the Resident Engineer informed as to
progress of the work and the manner in which it is being done, and also to call the
Contractor’s attention to any non-compliance with the drawings or specifications. You are
not authorized to approve or accept any portion of the work, or to issue instruction contrary
to the plans and specifications, or to act on behalf of the Contractor. The inspectors have
authority to reject unsatisfactory workmanship, defective materials and to recommend
suspension of any work that is being improperly performed, subject to approval by the RE.

6.2.2 Daily Inspection Reports

A Daily Report must be completed by each inspector (Annex B3, Form No. SR/01). These daily
reports will be reviewed and compiled by the RE and will constitute part of the final Project
documentation submitted to ERA.

The daily report from each inspector must include but not be limited to the following items:

(a) Quantities of work performed under their inspection, such as cubic meters of
material acceptably placed etc;
(b) Site instructions given,
(c) Unusual or unsatisfactory conditions;
(d) Delays encountered;
(e) Number of men or man-hours employed;
(f) Equipment, Plant, methods used by the Contractor;
(g) Tests performed to satisfy quality control, and as samples taken;
(h) Weather conditions and effect on the works; and
(i) Daywork records, if any.

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6.2.3 Field Inspection Diaries

Each supervision staff will keep personnel Diary Notebook to accumulate during the day all
data used to prepare his Daily Report.

Notes made in their Diary Notebook will be recorded neatly, clearly and will be dated, signed
and in sufficient detail to be clearly understood. This Diary Notebook will also include the
field engineers working hours and work location details for each day.

The supervision staff Diary Notebook must be properly identified, indexed and periodically
turned in to the RE for his review and safekeeping.

The Daily Report will contain quantities of work satisfactorily performed each day under their
inspection. These quantities will be based on measurements if the quantity is for a particular
section of work that is complete or based on an estimate if the work is ongoing. Sketches
with dimensions and calculations should be attached to the Reports as required.

Mechanical Plant and Equipment should be inspected periodically.

6.2.4 Record Keeping

Proper record keeping is perhaps the most important item for projects of this nature not only
for proper control of current jobs but also for settling future disputes in respect of quality,
time and cost. Hence, suitable procedures of record keeping are defined along with this
manual and thus the RE/ARE shall ensure to adopt such established procedures.

 Complete and accurate records of the amount and quality of the work performed are
required. They document that work is performed in accordance with the plans and
specifications and assure the Contractor receives proper payment for his work.
Records also provide a means to maintain control of the work during construction and
document the reasons for decisions and actions taken.
 Project records must be sufficiently clear and complete to be understood by people
unfamiliar with the details of the project. The importance of maintaining adequate
and proper records cannot be overemphasized. Memory cannot replace valid
permanent documents.
 It is particularly important to have a record of any problems on the job (such as
nonconforming work or changed conditions). This record should include any
instructions given to the Contractor, or agreements made with him, to resolve the
problem. Remember that the records have legal importance if there is a claim or
other contract dispute.
 Forms are available for nearly all materials tests and for inspectors’ daily reports. Pay
item books and diaries may be organized somewhat differently on every project. You
should know what records you are to keep and in what form before you begin work on
any project; ask your supervisor.

Proper record keeping encompasses the following major items which are defined for the
project in the subsequent sections.

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 Breaking down of project records into major components
 Breaking down of such major components into suitable sub-records (As
appropriate, each sub-record may in turn be broken down)
 Suitable numbering of the records/files
 Preparation of summary pages (record registers) for each of the records
 Define proper record keeping system for both hard outputs and electronic copies
of all draft and final documentation.

6.2.5 Breakdown of Records

The records are broken down into:

 Summary of Registers
 Administration
 Standard Forms (unfilled)
 Preliminaries
 Earthworks
 Unbound Pavements
 Concrete, Minor drainage and slope Protection Works
 Bridges
 Ancillary Works
 Utilities
 Diversions
 Safety
 Reports and Records
 Measurements
 Topographic survey
 Date Order of Files (All originals)

6.2.6 Communication within the Consultant

Project staff shall communicate using special memos, which are suitably referenced. The
referencing shall be in such a way that each staff ensures sequential memo numbering
starting 1 like Memo # RE/02 to mean the second memo written by the RE. The RE shall also
ensure proper registry of all memos on the Memo Registry Template.

All intermittent staff who travels to site shall write a report to the RE upon the completion of
each trip. Such memos shall include the dates, jobs performed and any findings during the
period.

6.2.7 File Numbering System

The basis of a good filing system is that someone from outside should be able to locate a
specific item quickly and easily. Simply filing every piece of information in date order will
quickly become bulky in all but small projects of short duration.

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Hence, a standardized file numbering system shall be devised to cover all project activities

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7 STAFF ORGANIZ ATION

7.1 CONSULTANTS’ ORGANIZ ATION

In order to effectively address the requirements of this specific project, a project

organization is proposed that includes major components consisting of:

 The field based Main Project Team consisting of Engineers, Technicians And Field
support staff directed by and reporting to the RE,
 Project Management that is responsible for overall contract management and
administration,
 Head Office support: The HO support is responsible for providing expertise and as
logistics support,

7.1.1 The Main Supervisory Team

The main project personnel (who will either permanently reside at site or who are assigned
intermittently) are composed of professionals and sub-professionals from both the main
Supervisory team (leading Consultant) and the Associated/Joint Ventured/Sub-Contracting
Consultant to make best use of the available resources from the firms.

7.1.2 Project Management

The basis of forming an appropriate project management system is to clearly define lines of
communication and appropriate checking and reporting of each project element. To achieve
this, the organization of the project management is set up in such a way that the project
team has access to the combined resources of the member consulting firms.

The management of the project team will be the responsibility of the RE/ARE and all other
individual team members are required to report to them. The CRE is accountable for
technical, quality, budget and schedule performance of the project.

The RE/ARE will be provided with overall supervision and assistance from the head offices.
The head office coordinators will ensure that all logistics and head office backup support is
provided to the field team in a timely and efficient manner during all phases of the project.
The project organization chart shown overleaf (Figure 7-1) provides a quick reference to the
basic framework. The lines of communication indicated on the chart are developed to ensure
direct flow of information between the different parties and individuals.

7.1.3 The Management Frame Works

The construction supervision consultant will ensure that high quality of construction is
achieved and that all works are undertaken as per approved engineering designs and
specification as specified in the contract document.

This will be achieved by ensuring effective real-time supervision and monitoring by the
Supervision Team. The Team will carry out all routine construction supervision duties.

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CLIENT [ERA]

CONSULTANT
Engineer/Project Coordinator/Co-Project Coordinator,

Head Office Support: Technical, Head Office Support: Admin.

Other Technical Support Administrative Support
Resident Engineer Finance and Other Logistics

Secretary

Deputy Resident
Engineer

Structural
Environmentalist Highway
Geotechnical Hydrologist/ Claims Pavement
Engineer
+ Engineer,
Hydraulics Senior
+ Engineer Expert + Material Quantity
Engineer Surveyor Road Safety and Safety Audits
JE JHE Engineer Surveyor
JSE JCE Specialist
+

JME
Right of Way Management Specialist

Drafts Person Structural Soil & Lab. Technicians (2) Junior Surveyor (2) Works Inspectors (2) Materials Inspector (2)
Inspector (2)
Surveyors (2) Surveyors (2) (2) Lab. Technicians (2 x 2)
(2)
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Effective coordination between members of the team will be ensured through periodic review
meetings so that common problems and remedies are known to each member of the team.

7.1.4 Quality Cycle

Quality Management of a job is a cyclic process. The quality cycle starts with quality Control
measures prior to actual Construction activities. It runs during construction stage and quality
Audit of the results achieved and Identification of defects and establishing of their causes. It
ends with suggestion of remedial measures their execution and ensures their implementation
against recurrence of the defects.

7.1.5 Staff and Responsibilities

The assigned duties and responsibilities of each staff are annexed.

7.1.6 Monitoring and Evaluation of The Performance of The Consultants’ Team

The Consultants will consistently monitor the performance of the supervisory team including
monitoring of the RE through the head office project coordinator and that of the remaining
supervisory staff by the RE.

7.1.6.1 Monitoring of Consultants’ Personnel by the Resident Engineer

The Resident Engineer will be responsible for the following tasks with respect to his
supervising staff:

 As part of this Project QA System, the RE shall provide duties and responsibilities of
each member of the team. Each staff will accordingly receive the list of duties and
responsibilities as well as deliverables (e.g. reports. inspection sheets, diary,
measurement sheets) etc. expected from him with the relevant schedules.
 The RE shall also ensure the ethical and moral obligations and responsibilities
addressed in this QAM. This QAM has clearly defined the moral requirements of the
supervisory staff such as avoiding conflict of interest.
 Each member of the team shall be provided with standard forms for field survey,
inspection, data collection and reporting. The forms may be modified based on
comments from the relevant staff to take care of actual needs.
 The RE shall conduct weekly meetings to monitor the performance of each staff in
the previous week and to discuss on better supervisory activities. The plan for the
coming week will also be discussed.
 The RE shall monitor the performance of each staff at quarterly intervals. The
evaluation shall take care of individual’s motivation to work, technical capability,
ethical and, reporting quality, team spirit, attendance, improvement of skill, etc.

The DRE/ARE will also be actively involved in evaluating the supervisory staff. Other key staff
members like the PME, HE & SE will evaluate the technical adequacy and other performance
measures for the staff working under them. The responsibilities of each staff in respect of
monitoring the supervisory team will be issued to each member of the team along with the
Quality Assurance Manual.

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The staff evaluation sheets shall be copied to the consultants’ head office (to the Project
coordinator) and that will be part of the files on each staff.

7.1.6.2 Monitoring of the Chief Resident Engineer by The Head Office Coordinator
The RE will also be adequately monitored and evaluated by the Consultant’s head office
(immediate project supervisor/coordinator). As ethical quality of the Resident Engineer is
perhaps the single-most important obligation, it is the consultants’ belief that technically
and ethically proven Team Leader will only be recruited for the post. Monitoring of the
technical adequacy and motivation to site and office works of the RE will also be given
serious consideration. The project Coordinator will review the reports prepared by the RE
and provide the necessary comments as appropriate.

The Inspector may be responsible to inspect construction work on several places that could
be progressing simultaneously. If that it is unable to assign other Inspectors to those sites and
multiple priorities prevent the Inspector from being in more than one place at the same time,
the Inspector, with input and guidance from Engineer, must implement a “just in time”
inspection process. The Inspector may include the following, or other processes, in the “just
in time” process:

 Verify the sequence and timing of each Contractor’s work from the current project
schedules and discussions with the Contractor,
 Identify the construction processes that are most critical for inspection, if inspection
needs are concurrent,
 Discuss, with the Contractor(s), the planned methods and procedures for each planned
activity to assure that the Contractor is aware of, and plans to utilize and assure,
acceptable materials, methods, and workmanship,
 Use the Quality Assurance Program to help assure quality materials and workmanship.
(Also refer to the discussion on Quality of Materials and Works in ERA Technical
Specification, 2013)
 Identify key points, in each of the simultaneous activities, at which the Inspector can
review the work and fundamentally assure that the work is properly accomplished
with acceptable quality,
 Identify and implement methods to gather and assure acceptable quantity information
and documents, including Memo/Material Delivery forms and measurement of work
performed.

7.2 GENERAL RESPONSIBILITIES OF THE SUPERVISOR

 Know the plans and specifications for the items you are inspecting, including
specifications specific to the project (special provisions, etc.)
 Be alert for any potentially unsafe conditions or any situations that may delay
construction and report them to your immediate supervisor,
 Identify nonconforming work or materials as early as possible; anticipate problems
where possible. Notify the Contractor immediately and make a record of it. Follow up
on corrective work and make a record of it too. If the Contractor can’t or won’t fix
the problem, notify your supervisor,

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 Avoid any inspection, testing, or other activity that could be construed as the
Contractor’s responsibility. If you don’t, the Contractor may not be held accountable
for his work if there is a claim or other contract dispute,
 Be prepared to make inspections and tests promptly. Do not make hasty or premature
decisions. The Contractor is expected to give you adequate notice of when he will be
ready for inspection and testing,
 If specifications don’t cover a particular situation or tolerances seem unrealistic,
contact your supervisor for guidance. Report problems you can’t handle and see that
they get resolved before an expensive and time-consuming correction is required,
 Assure that the Contractor has properly located, laid out, and marked the facility,
structure, or operation to be constructed,
 Assure that material(s) to be incorporated in the work meets contract requirements
and the Contractor has properly performed all required testing,
 Assure that the Contractor performs its work as required by contract and the work is
producing a product with the qualities required by contract,
 Assure that the work or processes do not violate contract restrictions, including
restrictions for protection of the environment and restrictions set by statutes, laws, or
ordinances,
 Measuring the work, or assuring that measurements are taken and recorded, and
preparing Source Documents, as work is performed, to justify payment. This includes
assuring that the Contractor performs check weights, as required, when material is
paid by mass,
 Acting as the representative of the Employer, in communications with the Contractor,
the public or other interested parties. This involves responding to questions or
concerns from the Contractor and others,
 Recording information about the project and its happenings in the Project Diary,
 Daily Progress Report or another appropriate document.

7.3 FAMILIARITY WITH PROJECT AND CONTRACT DOCUMENTS AND REQUIREMENTS

The Inspector must become familiar with all documents for the project and contract. Those
include, but are not limited to:

 Project plans,
 Project special provisions and supplemental standard specifications,
 Standard specifications that relate to the project,
 Changes to the contract documents, including plans and specifications,
 Permits and permit requirements relating to the project, including environmental
concerns and restrictions (discussed below),
 Right of Way obligations,

7.4 AUTHORITY OF THE INSPECTOR/ SUPERVISOR

 The inspector has the authority to approve materials and workmanship that meet the
contract requirements.

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 Approval should be given promptly authorizes the inspector to reject work or
materials. The inspector must keep the PME informed of any material rejection. The
inspector must thoroughly document the reason for rejection and the amount of
material rejected.
 The Inspector does not have the authority to order the Contractor to stop his
operation. Authority for the issuance of a stop order should be left to the judgment of
the CRE.
 The inspector does not have the authority to approve deviations from the contract
requirements.
 The inspector should not require the Contractor to furnish more than what is required
by the plans and specifications, nor allow anything less.
 The inspector should not under any circumstances attempt to direct the Contractor’s
work; otherwise, the Contractor may be relieved of his responsibility under the
contract.
 Instructions should be given to the Contractor’s supervisors, neither to his workmen
nor his subcontractors.

7.5 RELATIONSHIP WITH THE CONTRACTOR

 You should maintain a professional, agreeable, and cooperative attitude with the
Contractor and his work force.
 Your goal should be to help build a good facility within the contract time, not to
hassle and delay the Contractor.
 Avoid familiarity and accept no personal favors from the Contractor.
 Tact should be used when pointing out deficiencies to the Contractor and his staff.
 Your behavior can improve or disrupt the relationship between the Contractor,
inspection personnel and the Employer.
 Don’t let personality differences or your opinions of the Contractor interfere with
your working relations with him.
 Don’t pre-judge the Contractor. Begin with the premise that the Contractor is fair-
minded and intends to do a good job.
 Honor commitments made during partnering with the Contractor
 Criticism on or off the job of the Contractor or the Contractor’s employees by the
inspector is unwarranted and hurts Contractor relations.
 If you make a wrong decision, admit it. It is recognized that no one is perfect.
 Be courteous to the public and respect their rights. The resulting good public relations
will benefit all concerned.
 Never get involved in the Contractor’s labor relations. This is the Contractor’s
responsibility.
 Inspect work as needed and required by being aware of the project schedule,
discussing the planned work with the Contractor, and openly communicating with the
Contractor,
 Utilize good communication skills in order to develop and maintain a good working
relationship,
 Discuss expectations and requirements, before a work process starts, to verify that
the Contractor understands the contract requirements for the work process as well as

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other expectations, such as quality of the materials or work, traffic control, safety,
etc.,
 Act in a courteous, but firm manner,
 Not operate or adjust the Contractor’s equipment,
 Communicate only through the Contractor’s appointed representative,
 Assure that all communications are productive and will result in timely responses and
actions,
 Respond in a timely manner to all requests, commitments, and needs

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8 COST CONTROL

8.1 INTERIM PAYMENT STATEMENT

The Contractor shall submit an interim payment statement in five (8) copies to the Engineer at

the end of each month.

The Contractor’s interim payment statement shall include the following:

 The value of the Permanent Works executed;

 The value of variations executed;

 The value of works executed under the “project facilities”;

 The value of works executed under the “Day Works”;

 The value of works executed under the “Detour and Traffic Management works”;

 The value of works executed under the “Social, Health and Safety”;

 The value of works executed under the “Road Furniture and Environmental works”;

 The value of Price Fluctuation;

 The value of Materials on site;

 Amount of retention to be withheld;

 Repayment of Mobilization Advance;

 Amount of the reimbursement to the Contractor;

 Calculation sheets (To be agreed after determination of the project activities);

 Summary sheet;

 Back-up data.

The Employer’s Representative shall on receipt of the said application for Interim Payment,

approve or amend it and thereafter issue an Interim Payment Certificate within 14 (fourteen)

days, certifying the amounts due to the Contractor, to the Employer.

No Interim Payment Certificate shall be issued for a sum less than Birr, seven million (ETB

7,000,000) as stipulated in the contract.

8.2 PRICE FLUCTUATION

The amount to be included in the IPC in respect of changes in cost and legislation shall be

determined using the formula given in sub-clause 70.3 of the Conditions of Particular
Application, Part II.

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Weightings and indices to be applied to the price adjustment formulae are given in the Appendix

to Bid in the Contract.

8.3 MATERIALS ON SITE

The Contractor is entitled to be paid in respect of materials stocked on site and intended to be

incorporated in the Permanent works, under sub-clause 60.3 of the Conditions of Particular

Application, Part II.

The Contractor’s shall regularly submit records of orders, receipts, and delivery on site,

manufacturer’s certificates and specifications to the Resident Engineer. Records of consumption

of materials shall also be submitted to the Resident Engineer. The Quantity Surveyor shall take

weekly inventory of the stock of materials on site.

8.4 VARIATION ORDERS

Variation Orders may arise as a result of changes due to unforeseen conditions during the

contract period. The Employer’s Representative can issue the necessary variation orders to the

limits mentioned under sub-clause 2.1 of the Conditions of Particular Application, Part II, but

only after receiving specific prior approval from the Employer.

8.5 RETENTION MONEY

The Employer is entitled to withhold ten percent (5%) of Interim Payment Certificates up to five
percent (5%) of the Contract Price, less Provisional Sums.

8.6 REPAYMENT OF MOBILIZ ATION ADVANCE

The RE shall start recovering the Mobilization Advance after certification of thirty percent

(30%) of the Contract Price, less Contingencies, specified Provisional Sums and Day Works.

The Advance shall be recovered by deducting forty percent (40%) of the amount of the monthly

Interim Payment Certificated.

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9 CLAIMS
9.1 GENERAL
Claims are formal demands in writing made by the Contractor for additional payment or

extension of time that in the Contractor’s opinion are outside the scope of his contract and

pursuant to any clause of the contract.

Some situations that may give rise to claims are as follows:

 Disputes over quantities;

 New work items;

 Interpretation of the specifications;

 Failure to give possession of site within the specified time limit;

 Delay of issue of drawings or instructions by the Employer’s Representative;

 Delay in approval;

 Adverse physical obstructions or condition;

 Variations;

 Delay in payment by the Employer;

 Acceleration of works;

 Remedies;

 Suspension of work by the Employer/the Employer’s Representative, etc…

9.2 PROCEDURE FOR DEALING WITH CLAIMS

Condition of Particular Application and General Conditions of Contract of this Contract, Sub

Clause 53.1, stipulate the formal procedure for claims.

Upon receipt of a ‘Notice to claim’ from the Contractor, the Employer’s Representative should;

 Acknowledge the notice of claim, to the Contractor;

 Investigate contemporary records including supporting data on site, including

photographs if necessary;

 Decide whether the ground and the amount of claim are reasonable or justified;

 Forward copies of the Contractor’s claims and all correspondence regarding the claims to

the Client and to the Claims Expert of the Consultant.

The Resident Engineer should maintain a register of all received and expected claims and shall

keep Claims Expert informed of all developments. The Claim Expert will in turn advice the

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Client in respect of Claims.

9.3 EX TENSION OF TIME

If delays have been incurred, which are likely to cause delayed completion of the project, it will

become a priority issue for the Contractor to seek extension of time. This is necessary to reduce

or eliminate the amount he will otherwise have to pay as liquidated damages by not completing

on time.

FIDIC conditions clauses 44.1 entitle the Contractor an extension of time for completion of the

works in the event of;

 The amount and nature of extra or additional work;

 Any cause of delay referred to in these conditions;

 Exceptionally adverse climatic conditions;

 Any delay, impediment or prevention by the Employer;

 Other special circumstances which may occur, other than through a default of or breach

of contract by the Contractor or for which he is responsible.

The Employer’s Representative must remember that granting additional time is likely to mean

increased project costs granting less or no liquidated damages as well as possible consequential

claims from the Contractor.

9.4 PARTIAL TAK ING-OVER OF THE WORK S

The Employer’s Representative may, upon a request from the Contractor, issue a Taking-Over

certificate for any section or part of the permanent works that is completed before time, after

getting the Employers consent.

9.5 PAYMENT OF RETENTION MONEY

Upon the issue of the Taking-Over Certificate with respect to the whole of the works, one-half

of the retention Money shall be certified, by the Employer’s Representative, for payment to the

Contractor. If the works are taken over in sections, the percentage of the first half of the money

released following the issue of Taking-Over Certificate for a Section, and it passing all tests,
shall be the percentage value of the Section. Moreover, the Contractor may substitute the

remaining retention money with an on-demand bank guarantee in a form and from a source

acceptable to the Employer, as stated in under sub-clause 60.6 of the Conditions of Particular

Application, Part II.

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Otherwise, upon the issue of a Taking-Over Certificate with respect to a section or part of the

permanent works, only such proportions thereof as the Engineer determines having regard to the

relative value of such a section or part of the permanent works shall be certified by the Engineer

for payment to the Contractor.

Upon expiration of the Defects Liability Period for the Permanent Works, the other half of the

retention money shall be certified by the Employer’s Representative, for payment to the

Contractor.

9.6 STATEMENT AT COMPLETION (FINAL ACCOUNT)

Within 84 days after the issue of the Taking-Over Certificate in respect of the whole of the
works, the Contractor shall submit to the Employer’s Representative a Statement (eight Copies)

at Completion in detail as required by the Employer’s Representative. After review by the

Employer’s Representative and amendment by the Contractor, the Employer’s Representative

shall certify payment by the Employer.

9.7 COMPLETION REPORT

While preparing a Taking-Over Certificate, the Employer’s Representative shall prepare a

Completion report. The completion report shall include the following:

 Project Description (purpose, scope and dimensions),

 Project data (historical data on contract, financial sources, etc.),

 Monthly certificates,

 List of equipment,

 Claims, variation Orders and Addenda,

 Project Organization’

 List of Minutes of Meetings,

 Quality and Time evaluation,

 Major problems encountered and measures taken,

 Construction photographs,

 List of “As-built” drawings,

 Final Account.

9.8 “AS-BUILT” DRAWINGS

The Contractor shall prepare and submit two (2) copies of “As-Built” drawings for the approval

of the Engineer. The drawing should provide information regarding all aspects of the Works,

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both visible and concealed, to enable future maintenance and modification of design, thus

avoiding expensive site measurements, investigations and examination. The Contractor shall

obtain the consent of the Employer’s Representative as to their size, the referencing system and

other pertinent details.

These drawing shall include-

 Full details of the works as actually executed;

 True position of all culverts, drains;

 Records of all modifications;

 A summary of different materials of construction used and locations.

 Cross sections showing different materials used in embankment construction,

 Positions of relocated utility installations, if any, etc.

9.9 DEFECTS LIABILITY PERIOD

The Defects Liability Period, which is 12months, is calculated from the date of substantial

completion of the works certified by the Employer’s Representative.

The Contractor shall carry out the work listed in the Taking-Over Certificate. In addition, the

Contractor shall execute all such work of amendment, reconstruction, and remedying defects

that arise during the Defects Liability Period, as the Employer’s Representative instructs.

9.10 FINAL TAKING-OVER CERTIFICATE

Upon expiration of the Defects Liability Period and after the completion of any remedial works

requested by the Employer’s Representative, and subsequent final inspection and acceptance of

the Works, the Employer’s Representative shall issue a Final Taking-Over to the
Client/Employer with a copy to the Contractor.

The issuing of the final taking-over certificate implies that the duties and responsibilities of the

Contractor in fulfilling the Contract are complete and approved.

9.11 FINAL STATEMENT

Not later than 56 days, after the issue of the Final Taking-Over Certificate, the
Contractor shall submit to the Employer’s Representative for consideration a draft Final
Statement with supporting documents showing in detail, and in the form approved by
the Employer’s Representative;

 the value of all work done in accordance with the contract, and

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 Any further sums which the Contractor considers to be due him under the
Contract.

The Contractor shall, after the Employer’s Representative approval of the draft, submit
to the Employer’s Representative the Final Statement.

Upon submission of the Final Statement, the Contractor shall submit to the Employer,
with a copy to the Employer’s Representative, a written discharge confirming that the
total of the Final Statement represents full and final settlement of all moneys due to the
Contractor.

After receipt of the Final Statement, the Employer’s Representative shall issue to the
Employer (with a copy to the Contractor) a Final Certificate.

9.12 Handing Over of Records and Documents

The Resident Engineer shall arrange to hand over copies of all records and documents prepared

and/or generated during the execution of the project to the Employer’s/Client, as required by the

contract.

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10 CONCLUSION

The Quality Assurance system presented above covers the quality assurance and documentation

of all aspects of the works and is easy to be audited at any time. The more one uses this QA

System the easier it becomes.

This Quality Assurance system comprising a combination of process control and end product

control will be adopted in this project.

As this Quality Assurance Manual covers information and data registry formats, it is perfectly

possible to be used before construction works, i.e. during the design review proceeding, for

Drainage structures inventory and classification, Construction material investigation, Road

inventory, surveying works, Drainage structure condition survey, etc…

Generally, it can be concluded that the purpose of this manual is to define and describe the

quality assurance plan and to provide general procedures that ensure all activities performed

during the execution of the project are in compliance with the relevant specifications.

An additional purpose of this document is to present the quality assurance plan to our clients and

to inform them what specific controls and programs are in effect in order to assure quality of the

executed works.

Concerned personnel are expected to implement all procedures of this quality manual and to

follow explicitly all quality policies and test methods unless prior permission for deviation in

writing is received from ERA.

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11 ANNEX

11.1 DUITIES AND RESPONSIBILITIES

11.2 STANDARD FORMS

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