1 Purpose

To document the method and processes to be used to achieve the construction of

22km of Machongwe - Rusitu Mission Road and Stabilization the slopes of all rock
cuts along the route. Ensure that the construction is done according to the clients’
specifications and agreed best practice standard.

2 Scope
This method statement covers:

i. Clearing of all unsuitable materials/cleaning of shoulders, removal of grass a

and shrubs from existing road.
ii. Clear overburden from gravel pits and stockpile adjacent
iii. Stockpile gravel
iv. Set out to follow existing alignment both longitudinally and transversely as well
as establishing profiles on either side of the road.
v. Scarify, proof roll insitu material and compact
vi. Load, dump, spread and compact selected gravel on two bases of 150mm each
to required densities. Cleaning of existing drainage structures.
vii. Finish to required profile and finish.
viii. Prime the constructed base
ix. Construction of Bus stops and Bell mouths (Kerbed)
x. Construction of additional pipe culverts
xi. Construction of a shelvert
xii. Construct 19/9.5mm Double Seal using unprecoated seal stone
xiii. Construction of gabion walls and mattresses on some rock cuts/ catch fences.
xiv. Erosion protection works (lined catchwater drain; bolsters; lined side drains;
stone pitching; sub-soil drains)
xv. Supplying and installation of guardrails where obstructions appear more
dangerous than what a guard rail will be or on the outside of curves with Radii
less than 300m without recovery areas.
xvi. Supply and apply white and yellow road markings with cat eyes to appropriate.
xvii. Fix and Supply Road Signs that are SATTC Compliant
3 Distribution
Control Copy No. Issue: Name Location/ Area No. of Copies
Master Project Quality File Site Office
01 Client Client Office
02 Site Agent File Site
03 Head Office Head Office

4 References
Drawing/ Document Description Reference No. Revision
Drawings TBA
SATTC Specs for Roads & Bridges 1998 Edition
MOT Standard Spec

5 Plant & Equipment

Description Capacity/ Model Quantity
Dozer D7 1
Tippers 15m3 10
Graders 140G 4
Single Drum Vibrating Roller 12t 2
Pneumatic Roller 18t 2
Water Bowser 16000L 4
Bitumen Distributor 12000L
Chip spreader 1
Rotary Broom/ Drag Broom Z/T 1
Front End Loader 1
TLB 1
Excavator 1
Road Marking Machine 1
Utility Vehicles Double & Single Cabs (ISUZU) 4
Flat Truck 7 Tonner 1
Brooms & shovels 1
6 Monitoring & Measuring Equipment
Description Degree of Accuracy Quantity
Laboratory Equipment As Specified 1 Set
Bitumen Distributor Dipstick 1
Automatic Level Machine Manufacturer’s Specs 1
Thermometer 0.5°C 1
Spirit Level Manufacturer’s Specs 1

7 Safety Requirements
Benchmark Method Statement Safety Risk Assessment Required
Format Y/ N/ NA
Y/ N/ NA
Excavation Permit Y
Confined Space Work SWP Y
Hazardous Material SWP Y
Hot Work N/A N/A
Hand Tools SWP Y
Power Tools N/A N/A

8 Materials
Material Estimated Quantity Certificate Required
Y/N
Insitu Material TBA No
Imported Gravel From BOQ Y
Aggregates From BOQ Y
Kerbing TBA No

9 Method
9.1 Survey and Setting Out
In order to achieve the required longitudinal and traverse profiles, fixed controls shall
be established ahead of construction works.
These shall be situated at both sides on the road and shall be placed at 40m intervals
on stretches and 20m or less at curved areas. Level Control shall be achieved by
means of use of a stringline pulled tight between profiles and a boning then fixes the
road level at vertical offsets at a layer under construction. As Built records shall be
recorded and monitored post construction.

9.2 Clearing of the Road Reserve

Clearing shall be done in the confines of pegs established during setting out. A grader
shall remove of all trees, bush, other vegetation, rubbish and all other objectionable
material, including the disposal of all material resulting from the clearing and grubbing.
It shall also include the removal and disposal of structures that obtrude, encroach upon
or otherwise obstruct the work. Due to reasons of difficult terrain of this road, the
construction of diversions is not feasible, clearing shall be done in half widths to allow
traffic to use that half of the road not under clearing. The length of the half-width under
clearing shall be kept to a minimum, with provision for traffic travelling in opposite
directions to pass at frequent intervals. This shall be facilitated by a traffic
management plan which shall be put in place when works commences.

9.3 Stockpiling
Prior to stockpiling, gravel prospection shall be done and assessment of quality of the
gravel shall also be done. A prospection report together with a supporting Gravel Pit
Plan shall then guide stockpiling operation. Great care shall be taken to avoid spoiling
gravel with overburden. Stockpiling shall be done using a dozer and volume of each
stockpile shall be measured before use.

9.4 Scarify Insitu Material

Once proof rolling is done, if suitable, insitu material shall be scarified and compacted
to 90% Mod AASHTO. Level control shall be strict at this stage to avoid challenges on
the uppermost pavement layers. Field Density tests shall be conducted and recorded
for analysis post construction. The construction shall be done in half widths same as
in sub-clause 9.2. in case of unsuitable material approved fill material shall be imported
and shall be compacted true to subgrade levels as per design. In the event of a high-
water table subsoil drains shall be installed before base 2 construction.
9.5 Base 2 Construction
• Obtain results from EXCO Laboratory to confirm density of compacted insitu
material
• The construction of base 2 shall be done in half widths same as in sub-clause
9.2 and shall include construction of bell mouths and bus stop construction
• Load, haul and dump to achieve 150mm compacted thickness of 150mm to full
road width
• Spread, mix and compact (by 12t rollers) dumped material to 96% Mod
AASHTO to give a working with of 7m.
• Finishing to the required profile shall be done by a skilled operator ensuring that
there are no biscuits layers.
9.6 Culvert Construction (Trenching Method)
• Setting out shall be done prior to excavation as per the drawings.
• Excavations shall be done in half widths same as in sub-clause 9.2.
• The widths of excavations shall be sufficient to allow the proper laying, bedding
and backfilling of culverts. The widths of the excavation for each type and size
of culvert shall be as shown on the Drawings.
• Headwalls shall be constructed as well as stilling basins at every inlet of the
pipe culvert. These shall be stone pitched.

9.7 Base 1 Construction

• Obtain results from EXCO Laboratory to confirm density of compacted base 2
material.
• The construction of base 1 shall be done in half widths same as in sub-clause
9.2 shall include construction of bell mouths and bus stop construction.
• Load, haul and dump to achieve 150mm compacted thickness of 150mm to full
road width.
• Spread, mix and compact (by 12t rollers) dumped material to 98% Mod
AASHTO to give a working with of 6.8m.
• Finishing to the required profile shall be done by a skilled operator ensuring that
there are no biscuits layers.
9.8 Production Control
The planned production per day shall be about 600m of a compacted layer in less
steep terrains and 250-400m in much steeper terrains. This shall be achieved by
means of two compaction sets each having 2 graders.

9.9 Surfacing
9.9.1 Priming
• Set out prime line
• Ensure the surface is clean, free from loose material as per ITP
• The smoothened base layer shall be sprayed with water to suppress any dust
that may be available and to enable prime to bond well to the base
• Use dipstick to determine quantity of prime in the BD’s Tank
• Flush the BD nozzles in tray to check if nozzles are spraying correctly
• Position B.D 5-10 away from the starting point
• A minimum of 1.0 m of reinforced paper or other suitable approved material
shall be used at all joints at the beginning and end of all sprays in order to obtain
a neat start and cutoff.
• Record ground and prime temperature before spraying commences
• Once this is done spraying can commence.
• Remove tobacco paper on joints immediately after spray
• Record the dipstick reading after spraying to determine the quantity of prime
sprayed. From this you can determine the application rates of any section being
sprayed. Repeat the cycle. This can be MC30/TP7.
• Allow for prime to cure (MC30-4days, TP7-7days) prior to application of tack
aggregate.
• The priming shall be done in half widths shall be done in half widths same as in
sub-clause 9.2.

9.9.2 Tack Coat

• Immediately before applying the tack coat the surface shall be broomed and
cleaned of all loose or deleterious material.
• Where the prime coat (if any) has been damaged, it shall be repaired by hand
brushing or spraying priming material over the damaged portions.
• The prime coat shall be sufficiently dry before the tack coat is applied
 • Weather conditions shall be strictly monitored prior to application as ground
temperatures are also important in sustaining high temperatures before the
stones are chipped.
• Stones for tack are applied just after the bitumen is applied (not more than 3
mins behind). Aggregates and Binder spray rates shall be recorded on as built
records for analysis post construction.
• The use of hand operated equipment for the application of
• Tack coat shall be limited to portions that require kerbing and guttering, bridge
kerb and railing which will be exposed,
• A pneumatic roller compactor shall be used to press the stones to the base for
proper settlement and binding to the road base.
• After the pressing of stones, lose stones are removed by brooming which can
be done manually or mechanically

9.9.3 Seal Coat

• After the brooming of the tack coat bitumen for seal is applied at a given rate
• A pneumatic roller is used to press the stones evenly onto the surface to
make sure they bind to the surface
• Loose stones are wiped off by brooming using a rotary sweeper
• Same laying process for the tack applies to seal laying. Spraying
Temperature, Binder as well as Aggregate spray records are recorded.

9.9.4 Quality Control

• Shape tests shall be conducted before aggregates are procured to site.
Samples shall be taken from the suppliers by EXCO Laboratory team for
assessment and recommendations.
• All bituminous materials shall be tested before use
• Spray sheet records for each spray shall be recorded and shall be signed by
EXCO and Client’s representative.
• Where hold points occur, there will be no work proceeding until the hold points
have been addressed and signed off.
9.10 Drainage & Erosion protection Works
9.10.1 Kerbing
Precast kerbing shall be of the dimensions shown on the Drawings, Precast concrete
kerbing shall be laid with close joints of 3:1 sand: cement mortar at the ends. The joints
shall not exceed 10 mm in width and shall be neatly pointed with a pointing trowel.
Guide-lines and straight-edges shall be used to ensure that the exposed faces of kerbs
are set true to line and elevation. Kerbing around curves shall be laid along the full
curve length before the joints are made, unless otherwise allowed by the Engineer.
Once laying is done, the kerbs shall be painted with P.V.A. In case of curved sections,
they shall be painted in alternate black and white paint. They shall be installed before
surfacing works and they shall be covered with tobacco paper to avoid spoils from
surfacing operations.

9.10.2 Catch water drain

The catchwater drain shall be constructed at the top of rock cuts and this shall be
dependent on the cliff geometry. They shall deflect overland flow from the area outside
the road reserve away from the cut face. They are to be concrete lined or stone pitched
since stones are in abundance.

9.10.3 Side Drains

Side drains shall be constructed beyond the shoulder breakpoint and parallel to the
centre line of the road. In cuts, they shall be used to run water along the toe of a fill to
a point where the water can conveniently be diverted, either away from the road prism
or through it, by means of a culvert. These shall be lined where necessary by either
concrete or through means of stone pitching.

9.11 Guard Rail Construction

Method of construction shall be in accordance to SATCC Standard Specifications for
Roads and Bridges SECTION 5200. The construction shall be as follows:

a. Initial Post Guard Rail Laying

A reference line or the curb line is established and posts are laid alongside the curb
line. Measure the distance, and mark the position of for each post. The holes for timber
posts shall be excavated in such a way that permit proper setting of the posts and
leaving sufficient room for backfilling the hole and tamping the filling.
 b. Erection

If the ground is not possible to pile directly, there is need for digging a hole first and
then bury the post in it. After that, refill the earth to the hole and tamp it. Make sure the
solid level of the tamped soil is as firm as the original soil. Check the verticality degree
with a meter from time to time also check if the post deviates from the planned position.
At least 1.0 m of a post shall be embedded in the ground. The holes shall be backfilled
with a 12:1 soil cement mixture.

The posts, spacer blocks (if applicable) and guardrails shall be completely erected and
set true to line and level, so that the guardrails will be at the required height above the
level of the completed road shoulder. Where jointed, the end of the guardrails which
overlaps on the side of the traffic shall point in the direction of the traffic movement.
The guardrail shall be suitably braced to prevent any movement, and all bolts shall be
tightened prior to any holes being backfilled. The material shall be mixed with the
correct quantity of water to ensure that the mixture will be placed while at or near the
optimum moisture content. The mixture shall then be placed and thoroughly rammed
in layers not exceeding 100 mm of compacted thickness. The approach ends, where
the guardrail has to be bent down and anchored, shall be constructed as shown on
the Drawings. When the backfilling has been completed and the bracing removed, the
posts shall be rigid and vertical, and the guardrail shall be true to line and level and
firmly fixed to the posts.

c. Reflective plates

V-shaped reflective plates shall be manufactured from 1.5 mm thick mild steel plate to
the dimensions shown on the Drawings. When supplied with galvanised guardrails,
they shall also be galvanised, and when supplied with painted guardrails, they shall
be finished in white baked enamel. The outer surfaces shall be coated with
engineering-grade retro-reflective material which complies with the provisions of CKS
191 in the colours shown on the Drawings. Holes for fixing shall be drilled before the
reflective plates may be galvanised or painted.
9.12 Gabion Wall Construction
Method of construction shall be in accordance to SATCC Standard Specifications for
Roads and Bridges SECTION 2600. The construction shall be as follows:

a. Preparing the foundation and surface

The surface on which the gabion cages are to be laid prior to their being filled with rock
shall be levelled to the depth shown on the Drawings or as directed by the Engineer
so as to present an even surface. If necessary, cavities between rock protrusions shall
be filled with material similar to that specified in Subclause 2602(a) of SATTC
Standard for Roads & Bridges. Where required, a foundation trench along the toe of
the revetment or wall shall be excavated to the dimensions shown on the Drawings or
indicated by the Engineer.

b. Filter fabric

One layer of Grade 3 filter fabric shall be placed where indicated on the Drawings or
ordered by the Engineer. The material shall be placed, in accordance with the
instructions, in strips with a minimum overlap of 300 mm at the joints, and shall be
properly fastened to prevent any movement or slipping while the gabions are being
placed.

c. Assembly

The methods of constructing, stretching, placing in position, wiring and filling the
gabions with rock shall generally be in accordance with the manufacturer’s instructions
which have been approved by the Engineer, but nevertheless sufficient connecting
wires shall be tensioned between the vertical sides of all the outer visible cells to
prevent the deformation of boxes as they are being filled with stone. It is essential that
the corners of gabion cages be securely wired together to provide a uniform surface
and ensure that the structure does not resemble a series of blocks or panels. The
layout and the tolerances for the layout of the boxes shall be as shown on the Drawings
or as instructed by the Engineer.

d. Rock filling
d. i Boxes in retaining walls
Particular care shall be taken in packing the visible faces of gabion boxes, where only
selected stone of the specified size shall be used so as to obtain an even-faced finish.
The boxes shall be filled in layers to prevent deformation and bulging. Boxes shall be
filled to just below the level of the wire braces, after which the braces shall be twisted
to provide tension. Care must be taken to ensure that consecutive layers of cages are
filled evenly to a level surface ready to receive the next course.

d. ii Mattresses used in revetments and aprons

The 0.2 m, 0.3 m and 0.5 m gabions forming aprons and revetments shall be filled by
random stones being packed in the first layer and by selected stones being used for
the top layer so as to resemble normal stone pitching.

10 Hazard Identification and Safe Operating Procedures

Daily safe task Instruction and Safety Talks will be done before works commence.

11 Alternatives Considered
• Construction of catch fences strengthened by cables and poles to intercept and
retain falling or rolling rocks.
• Applying Rock Fall Netting and Shotcrete to Cut Slope.

12 Records
Record of work done shall be in accordance with ITP

Description Internal Ref Responsibility

Inspection and Test Plan ITP/001-Rev0 Site Agent/ Site Engineer
Lab Results Various Site Agent/ Site Engineer
Density Control Summary Sheets Various Site Agent/ Site Engineer
Spray Sheets Various Site Agent/ Site Engineer
Laboratory Result Various Site Agent/ Site Engineer
Survey Report Various Senior Surveyor
As Built Records on Long Sections Various Site Agent/ Site Engineer