P2W-4020-CMS- 00X-00

CONSTRUCTION METHOD
STATEMENTS DATE 2023/4/20

KINGDOM OF LESOTHO

THE LESOTHO HIGHLANDS DEVELOPMENT AUTHORITY

CONSTRUCTION OF POLIHALIDAM AND APPURTENANT WORKS

CONTRACT LHDA NO.4020

METHOD STATEMENT FOR SPILLWAY CHUTE

P2W-4020-CMS-001 Document preparation, Name Signature

verification and approval

Approved by Concrete Manager
Verified by Technical Dep Manager
Checked by Assist civil Engineer
Designed by Assist civil Engineer

Document Revision table

Date Revision No. Description of modifications/revisions

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TABLE OF CONTENT
1. SCOPE............................................................................................................................................. 1
2. LOCATION OF WORKS....................................................................................................................... 1
3. DEFINITIONS & ABBREVIATIONS........................................................................................................ 2
4. REFERENCE DOCUMENTS.................................................................................................................. 4
4.1 LEGISLATIVE REFERENCE:................................................................................................................ 4
4.2. CONSTRUCTION DRAWING (DESIGN MaM JV):.................................................................................5
4.3. CONSTRUCTION DRAWING (SUNJV):............................................................................................... 6
5. RESPONSIBILITIES............................................................................................................................. 6
6. EQUIPMENT.................................................................................................................................... 8
7. CREW ORGANIZATION AND MANPOWER......................................................................................... 10
8. MATERIALS.................................................................................................................................... 12
9. DESCRIPTION OF WORKS................................................................................................................ 13
9.1 ELIMINARY ACTIVITIES................................................................................................................. 14
9.1.1. SURVEYING............................................................................................................................. 14
9.1.2. MATERIAL DELIVERY AND STORAGE........................................................................................... 15
9.2. DRILLING AND BLASTING............................................................................................................. 16
9.2.1 Blasting controls, Warning and Monitoring..................................................................................16
9.2.2 Management Measures............................................................................................................. 17
9.2.3 Blasting Procedure..................................................................................................................... 17
9.2.4 Blasting Sequence of the Spillway............................................................................................... 18
9.3. STEEL CUTTING, BENDING AND FIXING......................................................................................... 19
10. QUALITY CONTROL....................................................................................................................... 23
10.1. INSPECTION & TESTING............................................................................................................. 23
10.2. Blasting Quality Control............................................................................................................ 23
10.3. FOLLOW UP & EVALUATION...................................................................................................... 23
11. SAFETY AND ENVIRONMENTAL MEASUREMENT..............................................................................24
11.1 GENERAL SAFETY RECOMMENDATIONS........................................................................................ 24
11.2 LAWS AND REGULATIONS........................................................................................................... 25
11.3 START OF WORK SAFETY MEETING............................................................................................... 25
11.4 BLASTER & ASSISTANTS CERTIFICATION / LICENSES.......................................................................26
11.5. TRANSPORTATION OF EXPLOSIVES.............................................................................................. 26
11.6 STOCK CHECKS........................................................................................................................... 27
11.7 EXPLOSIVES ACCOUNTING........................................................................................................... 27
11.8 LOSS OF EXPLOSIVES................................................................................................................... 27
11.9 THEFT OF EXPLOSIVES................................................................................................................ 27
11.10 INCIDENTS / FIRST AID EQUIPMENT............................................................................................ 27
11.11 EMERGENCY MANAGEMENT..................................................................................................... 28
11.12 HAND TOOLS AND EQUIPMENT ................................................................................................. 28
11.13 LADDERS AND SCAFFOLDING / WORKING AT HEIGHT...................................................................29

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11.14 USE OF MOBILE EQUIPMENT / MOBILE CRANES..........................................................................29

11.15 STACKING AND STORING........................................................................................................... 30
11.16 FALLING ITEMS / MATERIAL....................................................................................................... 31
11.17 HOT WORK.............................................................................................................................. 31
11.18 BARRICADING........................................................................................................................... 31
11.19 WEATHER................................................................................................................................ 32
11.20 PPE......................................................................................................................................... 32
11.21 GENERAL................................................................................................................................. 32
12. ENVIRONMENTAL MEASUREMENT................................................................................................ 33
12.1 STORAGE................................................................................................................................... 33
12.2 HOUSEKEEPING & DISPOSAL........................................................................................................ 33

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1. SCOPE

The present method statement covers the various steps related to the Construction
of the Spillway Chute under LHDA Contract No. 4020 - Construction of Polihali Dam
and Appurtenant Works (LHDA 4020) taking into account the requirements for
construction of the forecast in the technical specifications (Section 8 “Chapter 4 –
SURFACE EXCAVATIONS”, “Chapter 6 – BLASTING”, “Chapter 12 - FORMWORK”,
“Chapter 13- REINFORCEMENT” and “Chapter 14- CONCRETE”). The aim of the
document is therefore to give, based on the information available, clear indication on
the work phases and the best and the most exhaustive description of the methods. It
is understood that this document is a working tool that may be modified or adjusted
during the construction, in accordance with the actual situation on the spot and the
progress of the work.

2. LOCATION OF WORKS

Spillway Chute forms part of the Polihali Dam permanent works related to the
Contract 4020. This will be a reinforced concrete side structure and will be a 98 m
long frontal ogee spillway with 40 m wide concrete chute and flip bucket discharging
into an excavated plunge pool. The spillway chute will be provided with two aeration
slots.

Figure 1: Spillway Chute Plan View

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Setting Out of the Spillway Structures are as per Drawing “P2W-4020-X-S-X-0101- A shown in
figure 1.

3. DEFINITIONS & ABBREVIATIONS

a) B.o.Q: Bill of Quantities

b) CoC SC: Conditions of Contract Clause/Conditions of Contract Sub-Clause
c) CMS: Construction Method Statement
d) FC: Fixed Charge
e) LHDA: Lesotho Highlands Development Authority
f) LHWP2: Lesotho Highlands Water Project Phase II
g) m a.s.l.: Metre above sea level
h) O.G.L: Original Ground Level
i) MMS: Management Method Statement
j) MPC: Measurement and Payment Clause
k) MaMJV: Matla a Metsi Joint Venture
l) OH: Over head
m) OH&S: Occupational Health and Safety
n) PPE: Personal Protective Equipment
o) RL: Height above mean sea level
p) SCH: Specification Chapter
q) SANS: South African National Standard
r) SABS: South African Bureau of Standard
s) TRC: Time-Related Charge
t) UG: Underground
u) "Structural concrete": is any class of concrete which is used in unreinforced (mass concrete),
reinforced, pre-stressed or precast concrete construction, which is subject to stress and which is
required to comply with SCH 14.6.
v) "Non-structural concrete": is composed of materials complying with the Specifications which
are used only for filling voids and for similar purposes.
aa) "In-situ structural and mass concrete": means concrete cast in-situ from the payment or
dimension lines and levels given on the Drawings or as directed by the Engineer.
bb)"Backfill concrete": means concrete cast in-situ beyond the lines where directed by the
Engineer.
cc) "Formed surfaces": are faces which have been cast against formwork.

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dd) "Free surfaces": are horizontal or inclined surfaces less than 15 degrees from the horizontal
produced by screeding or troweling to the level and finish required.
ee) "Pour": refers to any particular unit or part thereof which is concreted in a continuous
operation, and also to the volume which has to be filled in a continuous operation. Pours in
vertical succession are also referred to as "lifts".
ff) "Water/cement ratio": is the mass of the free water in the mix divided by the mass of
cementitious material in the mix. Free water is the water in the mix excluding water absorbed by
the aggregate but including moisture in the fraction of the fine aggregate passing the 4.75 mm
sieve.
gg) "Characteristic strength": (CS) means the specified 28-day cube strength (150 mm cubes)
below which not more than 5% of the test results may be expected to fall.
hh) "Specified excavation line" or "Payment line" means the excavation profile given on the
Drawings or determined by the Engineer for the Works, within which no unexcavated or
loose material shall occur after the excavation is complete except as allowed within the
specified tolerances. It is also the line to which payment for excavation will be made.

ii) “Controlled blasting” means the use of a drilling and charging pattern that has the purpose

of limiting overbreak and damage to the rock outside the payment line and comprises closer
spacing of the perimeter holes plus reduced decoupled charges in these holes. It also
comprises the use of delays in detonating the various rows of holes in the drilled pattern to
limit vibration velocities. The four principal techniques of controlled blasting are smooth
blasting, pre‐splitting, line drilling and trim blasting. Normally, only smooth blasting is used
underground and the other techniques are used in surface excavations.
jj) "Smooth blasting" means the drilling of a number of closely spaced parallel holes along the
required final excavation surface, with a suitable burden/spacing ratio, loading all the holes
lightly with a decoupled, uniform continuous charge of small diameter explosive, and
detonating all these charges simultaneously, after the detonation of the main production
blast.
kk) “Decoupling” means that the diameter of the charge is smaller than the diameter of the hole
so that an annular air space is provided around the charge. This air space absorbs some of the
initial explosive energy and reduces the magnitude of the initial high‐pressure impact
that is responsible for the crushing of the rock immediately surrounding the hole.
ll) "Pre‐splitting" means the drilling a line of closely spaced parallel holes of appropriate
diameter, spaced not more than ten times the hole diameter or 600 mm, whichever is the

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smaller, and charging the holes with an appropriate amount (decoupled if necessary) and
type of explosive to shear the rock, to form a pre‐split surface along the line of drill holes.
Either all the holes in a pre‐split line shall be drilled, charged and detonated simultaneously
prior to drilling the production holes for the excavation adjacent to the pre‐split line, or pre‐
splitting shall be accompanied by delaying detonation in the production holes to allow the
pre‐split holes to fire first. The first line of production holes next to the pre‐split face shall be
lightly charged to ensure that the pre‐split line is not damaged when the charges in the
production holes are detonated.
mm) “Line drilling” comprises drilling a line of holes of appropriate diameter spaced not more
than twice the hole diameter to form a surface of weakness along which the rock will break.
Blasting is not permitted in the line drilled holes, and the first line of production holes next
to the line drilled holes shall be lightly charged to avoid damage to the line drilled break
surface.
nn) “Trim blasting” comprises the separate removal of a protective zone of rock that has been
purposely left within the specified limits of excavation for flat areas and shallow slopes.
Drilling for trim blasting shall consist of a regular pattern of holes at appropriate spacings and
angles and to accurate depths. The holes shall be lightly charged and detonated in relays to
lift the rock progressively to form the final excavated surface without damaging the
surrounding rock.
oo) “Overbreak” means any excavation that extends beyond the payment line, irrespective of the
reason for such excavation. Overbreak shall be minimized by using an accepted
controlled blasting technique.
pp) “Enlargement” means the additional excavation carried out to enlarge an existing excavation
to a new payment line.

4. REFERENCE DOCUMENTS

4.1 LEGISLATIVE REFERENCE:

- EXPLOSIVES PROCLAMATION 1958 AS AMENDED BY THE EXPLOSIVES (AMENDMENT) ACT 1966

- EXPLOSIVES REGULATIONS 1959 AS AMENDED BY EXPLOSIVES (AMENDMENT) ACT 1972.
- MINE HEALTH & SAFETY ACT (MHSA) (ACT 29 OF 1996)

- OCCUPATIONAL HEALTH & SAFETY ACT (OHSA) (ACT 85 OF 1993) EXPLOSIVE ACT (ACT 26 F
1956)

- MHSA CHAPTER 4, EXPLOSIVES REGULATIONS OF 2015

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- 2003 EXPLOSIVES REGULATIONS UNDER THE OHS ACT

- EXPLOSIVES REGULATIONS PUBLISHED UNDER THE EXPLOSIVES ACT OF 1956

CONTRACT LHDA NO.4020 – PART II WORK REQUIREMENT – SECTION 8_SPECIFICATIONS:

• 00 Scope of Works
• 01 General
• 02 Survey and Setting out
• 03 Dealing With Water
• 04 Surface Excavations
• 05 Underground Excavations
• 06 Blasting
• 07 Rock Support
• 08 Borrow and Quarry Materials
• 09 Secant Pile Wall
• 10 Dam Embankments
• 11 Drilling and Grouting
• 12 Formwork, Waterstops, Bridge Bearings
• 13 Reinforcement
• 14 Concrete
• 15 Structural Steel and Other Metal Work
• 16 Access Roads
• 17 Fencing
• 18 Drainage
4.2. CONSTRUCTION DRAWING (DESIGN MaM JV):

- P2W-4020-X-S-X-0101- A

- P2W-4020-X-S-X-0102- A

- P2W-4020-X-S-X-0103- A

- P2W-4020-X-S-X-0105-A

- P2W-4020-X-S-X-0106-A

- P2W-4020-X-S-X-0007-A

- P2W-4020-X-S-X-0008-A

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- P2W-4020-X-S-X-0010A-A

- P2W-4020-X-S-X-0010B-A

4.3. CONSTRUCTION DRAWING (SUNJV):

Reference is made to all the correspondence up to date. Reference is also made to all the
Construction drawings that are going to be issued from the present date on for the approval of
the Engineer. As will be indicated in the casting phases to be submitted and approved by the
Engineer, Contractor is going to submit, if required, for each section, dedicated drawings related
both to concrete outline as well as reinforcement details. It has to be evident that the drawings to
be used both by the Contractor and the Engineer must refer to the latest revision officially
transmitted.

5. RESPONSIBILITIES

The responsibilities for the implementation of the present Method Statement are assigned as
follows:

Contractor’s Representative: He has the responsibility to approve this document upon its
verification of full compliance with all applicable Contract requirements, alongside with the
provisions of the Law in force, in terms of health, safety and environmental matters, which may
be likely to have an influence or to be dealt with during the execution of the Works. He is
responsible for the implementation of the overall activity on Site both on a Construction and
HSSE point of view.

Project Manager: He prepares the Method Statement. The Contractor’s Chief Engineer shall
verify the document as drafted. He must check its technical consistency in terms of i) Works
scheduling, ii) Resources availability and iii) Analysis of possible interference's with other
production activities to be concurrently carried out on the area as of the Works. He is responsible
for the internal distribution of i) the present Document, ii) latest shop drawings approved and iii)
overall technical details to all the departments (Contractor and Subcontractor) which are involved
in the construction activity in subject. He cooperates with the Site Manager and the Quality
Manager in order to establish proposal of non-conformities treatments (if any) and relative
corrective and preventive actions.

Construction Manager: He is responsible for the overall supervision and planning of the works
during the execution phase. He has the responsibility to share the issuing of this document with

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the Technical Service Manager. He must monitor availability of the planned resources, in
accordance with the method statement’s requirements. He must record the “day-to-day
progress” through the information collected from the Site Departments. Considering possible
changes in the physical/environmental/geological conditions on which the Contractor’s
assumptions are based, the Construction Manager shall monitor the actual situation as
encountered during the execution of the work.

Plant Manager: He assures that routine and special maintenance are done for all plants,
machinery and equipment. The Plant Manager is responsible for overall emergency planning
within the facility, for activation of the plan in event of an emergency, and for termination of
emergency procedures under the plan, with return to normal operations. The Plant Manager is
also responsible for decision making during emergency operations. He will often delegate some of
these responsibilities, particularly those involved with emergency planning, which are normally
delegated to the Safety Committee members. Since emergencies can occur in the absence of the
Plant Manager, he must designate an authorized alternate to activate, implement, and terminate
emergency response plans in his absence. This alternate should be the senior administrative
manager or supervisor on duty at the time the emergency occurs. Only the Plant Manager, or his
designated alternate, should have the authority to activate or terminate emergency response
plans.

Concrete Supervisor: The appointed Concrete Works Supervisor provides daily activities to be
executed in accordance with the provisions of the Method Statement itself as well as following
the planning established by the Site Manager, to whom he will directly report. He will also be
responsible for assuring the continuous availability of equipment, materials and personnel to the
entire duration of the work.

Chief Surveyor: He carries out, together with his staff (field surveyors & assistants), i) as-built
survey of the excavated surface, ii) definition of suitable benchmarks and/or control points on the
excavated surface for the setting out, iii) verification of the Formwork alignment and iv) as built of
the final concrete outline. He must inform immediately the Technical Manager and the Quality
Control Manager about any discrepancy with design details if any, encountered during the
surveying activity. As indicated in the list of activities depicted in the next paragraph.

Safety and Environmental Manager: He is responsible for the following:

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(i) Assesses safety risks associated with the works and assist the drawing up of the Method
Statement;

(ii) To provide a safety program and its implementation in line with construction work
program;

(iii) To assure by his staff that all personnel in execution of work shall be aware of safety
rules & regulations and equipped with adequate safety equipment and / or PPEs:

(iv) Identifies the significant environmental aspects associated with work;

(v) Ensures that all waste management procedures are adhered to, including the
segregation of waste.

(vi) Execute routine inspections as determined/specified in the Risk Assessment

document, which shall be issued and approved by the Employer prior to any construction
activity related to the Works to commence.

Emphasis during the execution of the works shall be put on the following aspects:

 Management of solid waste generated by the Works;

 Management of wastewater generated by the Works;
 Conditions of workplace(s) according to health standards and regulations as applicable to the
Works
Quality Manager: He prepares the QCM and checks its implementation, involving in these
activities, all the relevant site structure organizations. He coordinates and controls the QC
activities, by his staff (Quality Control Engineers and/or Inspectors). He coordinates both the
execution and recording of the QC inspections of the ongoing works and the registration of the
non-conformities. Coordinates with the Sun JV Management all necessary actions to solve them.
He assures that the results of the QC inspections planned in the QCP are adequately recorded in
the standard format forms.

Quality Control Engineers/Inspectors: They have the responsibility to carry out the controls
related to the activities depicted in the present method statement and punctually record the
results of their inspections. Reference shall be made to the latest revision of the Shop drawings
distributed by the Technical Manager.

6. EQUIPMENT

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The following tools, equipment, machinery and consumable must be available in the store
/workshop in order to carry out the different activities described in this Method Statement.
Each Sections’ Chief involved in the construction phases and fixing activities is responsible to
verify the quantity of material required and, as per schedule of work approved and
distributed, he has to arrange the sufficient stock of material to avoid any possible delay in the
defined Programme of Works.

Machinery:

Table 1: List of Machinery to be used at the Dam Spillway

Item Description Specification Unit Quantity

1 Excavator CAT 330 No. 4
2 Water Bowser HOWO 371 No. 2
3
3 Dump Truck 18m , HOWO 371 No. 20
4 Road Roller XG620H No. 2
5 Wheel Loader LW500FN No. 3
6 Truck Mounted 14T FLAT TRUCK WITH 4 No. 1
Crane MOUNTED CRANE
7 Flat Truck HINO 4T No. 2
3
8 Diesel Bowser 10m , HOWO 290 No. 1
9 Bull Dozer SD32W No. 2
10 Compressor 750W No 1
11 Engasol 250W No. 2
Compressor
12 Drill Rig 45 Ton No. 4

Minor tools and consumables:

- Hand Drilling machines and drilling bits (both for concrete and steel)
- Concrete Vibrators - Grinding machines
- Grinding disks (both for concrete and steel)
- Concrete Chisel
- Hammers
- Trowels
- Shovel
- Pickaxe
- Tirfors (20ton chains’ length 25,00 m) or Electrical winch

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Tools and equipment may change according to the needs and progress of works. Extension of
service lines system will follow the progress of the work as follows:
• Electrical line (medium voltage) and transformers.
• Water line
• Compressed air
• Lighting and power supply (low voltage)
All the electrical equipment, such as distribution boards, generator stations and transformers will
be protected, as feasible as possible, from excessive dust ingression and water splashing. Tools
and equipment may change according to the needs and progress of works. A dedicated
maintenance plan is going to be defined by the Plant Department. It comprehends and records
overall interventions and inspections carried out on daily basis according to working hour of the
relevant machinery. The maintenance Programme is going to be strictly supervised by the
Workshop Manager, leading the mechanics ‘crew as well as maintenance engineer at the Site
Plant Office.
Machinery refilling will be done at the designated fuel station (location: Working Area – Third
Platform) or directly on the relevant excavation benches/platforms by the means of a Diesel tank
according to the nature of the Machinery and/or the working shift timeline.

7. CREW ORGANIZATION AND MANPOWER

Personnel is going to be subdivided in different teams, which shall work on a day and night shift
(simultaneously whenever required), with the aim to speed up all the activities related to
structures’ construction. HSE officer and Quality officer will follow all the various activities and
team, highlighting to Concrete Supervisor and Site Manager risk of temporarily interference
(different from permanent ones clearly identifiable) to be avoided. Each team will be also
completed by enough labourers for any simple handling or other simple tasks.
I TEAM: BLASTING TEAM
 Magazine Master
 Blaster
 Drill Rig Operator
 Explosives van driver
 Blasting Assistants
II TEAM: SURFACE, CONSTRUCTION JOINTS CLEARANCE AND PRELIMINARY ACTIVITY
• General Hands
 Surveyor (if enquired in case of further design verification)

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III TEAM: STEEL FIXING

• Supervisor
• Steel fixers
• General hands (assistance for the steel fixers)
• Welders (dedicated if required by the Foreman)
• Mobile Crane Operator (dedicated)
• Forklift Operator (dedicated)
• Crane Truck driver
IV TEAM: SCAFFOLDING ASSEMBLING
• Supervisor (to be trained by the appointed Subcontractor’s Representative before
proceeding with relevant tasks)
• Carpenters (to be trained by the appointed Subcontractor’s Representative before
proceeding with relevant tasks)
• General hands (assistance for the carpenters
• Crane Truck driver
• Mobile Crane Operator (dedicated)
• Forklift Operator (dedicated)
The number and qualification of the personnel may change according to the needs, machinery to
be temporarily operated and progress of works. The teams here-above mentioned will be
opportunely organized to face a double shift and they will be supervised both by Sections’ Chief
as well as by the Production Manager in order to cope with the different site needs. Relevant
Supervisors will meet at the start/end of each shift together with the Construction Manager in
order to finalize and discuss the activities to be carried out. A weekly programme is going to be
submitted to the Engineer in due time and officially confirmed daily. Since during the activities
dedicated teams and crews will work simultaneously, specific attention shall be paid in order to
avoid interference that could cause accidents. Daily dedicated DSTI meetings are going to be held
by the Supervisor of each Site Section at the presence of HSSE Department representative.
Machinery’s Operator involved during activities described in the present document must:

• be trained and certified by Contractor/Third Party for the equipment that they operate.
• have a valid equipment operator’s license and certified for that specific equipment by a
competent person.
Copies of the certifications shall be maintained on Job site by Contractor and made available to
Engineer (upon request). Since most of the activities related to the Spillway Concrete casting will

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require the use of lifting Equipment, before proceeding with any operation Contractor will verify
the knowledge of the relevant operators in using computer control system installed in the
Machinery. This will highly reduce the risk of possible critical accidents. All the lifting equipment
operators, as well as riggers, must know the universal hands’ signs for a correct understanding
and acting, some of which ae highlighted below.

Figure 2: Machinery Operator – Hand Signs

8. MATERIALS

The materials involved in the blasting are:

‐ Emulsion explosive, emulsion cartridges (from approved supplier)

‐ Watergel cartridges (from approved supplier)
‐ Pentolite boosters (from approved supplier)
‐ Ammonium Nitrate blasting agent – ANFO.
‐ Detonating cord.
‐ Non electric delay detonators.

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‐ Non electric delay detonators.

‐ Non electric delay detonators.
‐ Non electric delay detonators.
‐ Instantaneous electronic detonators
‐ Cast boosters.

9. DESCRIPTION OF WORKS

In the present paragraph, all the activities as well as the sequence Contractor intends to follow
during the construction of the spillway will be highlighted. This includes the initial drilling and
blasting, as well as the mucking process. Kind reference shall further be made to all the drawings
prepared by the appointed Formwork designer which will be submitted to the Engineer. It will
include all the preliminary activities which shall start well ahead of the construction process itself
as soon as the excavation process related to the Spillway Structures are completed. They can be
listed as follow:

• Clearance of the foundation level;

• As built survey of the excavated area defining the elevation of the blinding level;
• Preliminary surveying activities related to steel fixing and setting out for formwork placing;
• Receival of the Formwork elements and establishment of a dedicated and protected area
where they must be stocked; and
• Receival of steel reinforcement.
Each activity listed above may start once the following activities are completed:

✓ All personnel complete Safety and Environmental induction

✓ Supervisor attend the DSTI with all relevant employees before starting of each shift

✓ All personnel strictly connected with the Formwork System operation complete the training

to be carried out by PERI Representative

✓ Temporary fencing installation along the site perimeter is completed to avoid unauthorized

personnel entrance

✓ Safe access into working area and platforms is guaranteed

✓ Area is widely illuminated (night shift)

✓ Ensure that there is temporary storage for reinforcement and relevant elements for

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execution of the activities

✓ Installation of safety signs and Health and Safety precautions according to the

Specifications

✓ Installation of safety tags on all the scaffolding access towers

✓ Provision of survey benchmarks in suitable locations

✓ Equipment will be maintained in good operating condition

✓ All the materials to be used for the relevant works shall be already identified, approved and

available at the workplace.

✓ Concrete mix design approved by the Engineer

Before Contractor starts with the casting activities, pre-requisite activities, to be fully checked off,
are as follows:

1. Excavated foundation Layout to be checked as specified on the drawings and respecting

tolerances forecast by technical specifications.

2. Approval of concreting sequence, steel reinforcement detailing, Formwork System, procedures

and/or techniques as described in this document;

3. Steel reinforcement cut, bend and delivery to the dedicated storage area;

4. Formwork manufacture and delivery; As far as all the assembling procedures, the activity is
going to be supervised by a SUN JV Representative who is going to verify all the frame’s
connection instructing personnel about different operations and checking for the correct and safe
use of the System. The present Supervisor is going to attend a training period together with
relevant Formwork Representatives. The following paragraphs relate to main subjects described
and are listed as follows:

1. PRELIMINARY ACTIVITIES

2. DRILLING AND BLASTING

3. EXCAVATION

4. STEEL CUTTING, BENDING AND FIXING

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9.1 ELIMINARY ACTIVITIES

9.1.1. SURVEYING

Prior to the start of works related to casting of Spillway Structures, following completion of
excavation as per design, a detailed survey of the underground area shall be carried out at the
presence of the Engineer and a report, including pictures of the future construction area, has to
be prepared as per specific requirement of 4020 Contract. During the Survey, contractual project
beacons and benchmarks shall be used together with additional control points (if any defined by
the Contractor Chief Surveyor) with the aim to define the suitable position and vertical alignment
of concrete structures in subject. Tolerances allowed are the ones clearly identified in the Section
8 Technical Specifications.

9.1.2. MATERIAL DELIVERY AND STORAGE

As far as Formwork System elements and Steel Reinforcement bars are concerned, they are going
to be delivered to the Site by the appointed Suppliers. Each consignment of product is loaded,
wedged and secured at the factory to avoid damages during the transit (Supplier is fully
responsible till the load has been accepted by the Contractor). According to the supplier lead time
and to the construction schedule, a suitable storage area has to be defined (i.e. fenced Carpentry
yard). In case the existing concrete slab cannot stand all the delivery a secondary and temporary
area must be identified, fenced, secured, and it has to be as flat as possible, hard, drained and
free protruding rocks and/or miscellaneous debris that could damage or compromise elements
stability during their storage and/or handling procedures. As far as steel reinforcement bars is
concerned, Suitable storage area for steel reinforcement must be provided, as close as possible to
the area of casting to avoid several handling that can misplace steel bars. Area must be widely
compacted and fully protected from running and/or standing water The storage area/yards is
going to be identified and set up to ensure that the quality of the reinforcement does not fall
below acceptable limits before its placement at site. To ensure this, SUN JV Store Manager and/or
Concrete Supervisor must verify and assure that:

1. The material is always be kept off the ground (minimum 450mm) by supporting by timber
and/or concrete pad to prevent damage and accumulation of dirt, rust and other deleterious
matter;

2. The material is going to be covered with polyethylene sheets whenever possible. Indeed,
reinforcement must be protected from any external miscellaneous agent that can affect its
mechanical properties (corrosion, pitting, cracks, laminations or other defects) or geometry;

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3. Storage facilities are such as to permit easy access for inspection and identification;

4. Reinforcement bundles downloaded from the trailer and stored are clearly tagged with bar
schedule and bar mark reference

On the arrival to the Site, the Contractor (through his own identified Representatives) must be
present in order to monitor the material delivery. A quick inspection of each load should be made
(before offloading commences) with the aim to identify how the load has travelled and whether
any damage has occurred. Only when satisfied with the quality and the quantity the Contractor
representative shall approve the delivery. At this stage the ownership of the delivered goods
passes from the Supplier to the Contractor. It’s advisable to avoid handling elements repeatedly
in order to reduce the risk of damages or minor elements misplacing.

9.2. DRILLING AND BLASTING

This section covers the various steps of blasting activities under LHDA Contract No. 4020 ‐
Construction of Polihali Dam and Appurtenant Works (LHDA 4020) taking into account the
requirements from technical specifications (“SCH 4 ‐ SURFACE EXCAVATIONS & “SCH 6 ‐
BLASTING”).

9.2.1 Blasting controls, Warning and Monitoring

Blasting shall meet the requirements of the South African Explosives Act (Act No 41 of 1958) and
a permit will be required from the Lesotho’s Mines and Geology. The use of explosives are
described and discussed in SCH 6. Blasting of rock outcrops at the spillway section will result in
vibration damage to nearby properties, flying rock and noise disturbance. Blasting management
will therefore require: - Benchmark monitoring (dilapidation survey)
- Notification of residents and warning system
- Clearance of humans and livestock from the area and definition of a no-go area during
blasting where there is risk of fly rock.
The blasting subcontractor and/or SUN JV will undertake a dilapidation survey of all properties
around the site. The objective will be to provide a benchmark or baseline of the condition of
nearby structures in order to enable monitoring of any claims for damages linked to blasting
activities. The target will be all structures within 500 m of the blasting area included and fully
reported in the dilapidation survey.

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9.2.2 Management Measures

It was mentioned previously that blasting on the site may result in the development of cracks on
nearby properties. To provide a record of pre-blast conditions as a benchmark for monitoring or
incidents that are recorded, the blasting subcontractor will conduct a Dilapidation survey to be
undertaken of any structures within a 500 m radius of blasting areas. This is to be done in the
form of colour photographs, video surveys, and shall provide a record of the following features:
- Identification of the owners and tenants
- General type of construction, foundation type, age and use
- Photographs shall be provide the location and date and shall show signs of settlement orstress
cracks, signs of poor construction, areas of standing water adjacent to the site wet for extended
periods and signs of settlement and tilting.
The blasting Sub-contractor shall perform a location survey of all off-site buildings and surface
features around the work sites within the survey limits specified herein. A qualified and
experienced land surveyor, satisfactory to the Engineer, shall perform the location survey and
survey plans shall be prepared including on and off-site buildings. All buildings shall be uniquely
identified and/or numbered and the dilapidation survey and monitoring reports shall refer to the
buildings identifications throughout the project.
9.2.3 Blasting Procedure

 Notify relevant parties at least 24 hours in advance as to the date and time of the blast

 Before ordering explosives check that the required number and depth of holes have been
drilled.

 Order the required number of explosives and detonators.

 Store cell phone’s safely in office while working or handling explosives

 No naked lights, flames or smoking allowed near explosives

 Receive explosives on site. A cornered off area is to be dedicated for this. Sign boards are to
be displayed to warn bystanders that explosives are being handled.

 The blaster to fill in the pre and post blast inspection report document

 Transport explosives into the jacking excavation within a rubber elephant foot bag to the
point of application.

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 Place blasting warning signs and warning flags man to warn public.

 Charge drilled holes with explosives. Any leftover explosives are to be removed from the
workings in an approved elephant foot bag.

 Connect blasting cable and check continuity of the circuit.

 Blasting activities will be pre-warned through the use of sirens sounded for a full 5 minutes
before, and 1 minute after blasting has occurred.

 Blasting Sub-contractor shall station personnel on roads and elsewhere with red flags to
prevent persons, animals and traffic entering or remaining within the danger zone. Care shall
be taken to ensure that all possible approach routes to the danger zone are covered by these
warning arrangements.

 Check that all persons and vehicles are a safe distance from blast area. (600 m or more as per
blasters discretion)

 nitiate blast.

 After blasting, no person shall approach the area until it has been examined by the blasting
supervisor or other responsible person and declared safe.

 Remove blasting warning signs and flags

 After the 30 minutes re‐entry period, check for and treat misfires and check that the blast
area is safe to enter.

 Complete and file the pre and post blast inspection report

 Explosives shall be stored in site magazine; any unused explosives will be destroyed as per
explosive regulations with the approval of the Inspector of Explosives

9.2.4 Blasting Sequence of the Spillway

The excavation sequence of the spillway will be in two folds. The first section, entails the
excavation through drilling and blasting from the lowest points, that is from elevation 1917 m to
elevation 2013 m. The access road used for the equipment will be TR8 and TR16. First lift for the
blasting, at the lower level will be done to the full spillway width, in 50 m long sections. Once the
first blast has been completed along the whole longitudinal section of the spillway, the
subsequent blasts will be carried out in half widths, in 50 m long sections as well.

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The next section will be from elevation 2017 m to 2070 m. Excavation through Drilling and
blasting method will proceed using the access roads TR 5 and TR 5-1. When the last section of
the blasting is reached the material will be moved along haul road TR 4 to the designed
stockpiles or spoil areas. The works shall be executed in both sections simultaneously. Survey
levels for the blaster shall be done to a design slope for each of the benches. this must be done
so that the drainage can be maintained.

9.3. STEEL CUTTING, BENDING AND FIXING

As mentioned previously, the cutting and bending activities of steel reinforcement bars are going
to be carried out at the designated Unik Construction Laydown Area, by the employees of Unik
Construction. During the fabrication, Unik Construction’s Quality Department will plan, according
to the production rate and with the aim to verify following requirements:

a) Steel Reinforcement Bars (straight to be worked out) are be stacked in the supplier’s steel yard
with a minimal clear off the ground (suggested 450 mm) and covered with polyethylene sheet to
protect from moisture;

b) The bars’ cut length is marked by the supplier personnel with a steel measuring tape;

c) Shapes, diameters and lengths of the bars is according to construction drawings approved by
the Engineer.

d) The bar is going to be cut with a shear line cutting machine;

e) Steel reinforcement is going to be received from the supplier and be cut and bent on Site in
accordance with SANS 282;

f) Reinforced bars, once the required number is cut and bend, shall be bundled and tagged with
bar mark number, shape code according to SANS 282 and stocked for delivery to the Spillway
area;

g) Stirrups, Chair bars and general cranked bars, shall have bends with substantially constant
curvature;

h) The bending radius “r” shall be the one indicated in the bar list. If a value is not specified, the
minimum values listed in SANS 282 will strictly be followed;

i) Bars template shall always be available for the Engineer’s spot inspection and/or comparison.

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Once delivered to the Site, Quality Control Department, as well as Store Department
Representatives, must follow up, together with SUN JV Material Engineer, inspection of all
reinforcement received (Permanent Material), verifying its compliance with design details as well
as material properties As far as reinforcement testing is concerned, the Contractor is going to
submit tests certificates for each batch or bundle (bars of the same type, nominal size and cast
number, delivered at one time or bound together for delivery purposes). All manufacturer's test
certificates (MILLS Certificates must be stored and recorded by Quality Department)., batch
reference labels and quality control certificates shall be retained by the Contractor and noted
against each bar mark number at the time of cutting and bending. This information shall be
copied to the Engineer on weekly basis.

The following requirements shall be strictly followed:

 Reinforcement shall be clean and freed from all loose rust, mud, dust, oil or any other
hazards that can reduce bond between concrete and reinforcement

 During the reinforcement’s handling, it must be packed and then lowered down in bundles
properly tied, up to the bottom of portal platform area

 Steel reinforcement is delivered to the work area using a forklift or crane truck (according to
shape, quantity and weight to be carried out);

 Steel reinforcement is lifted and located onto the several working platforms as well as
alongside construction joint surface wherever and whenever its standing affects the
personnel safety access and operation;

 Manual handling of reinforcement will be the last option and will be carried out by personnel
having prior experience in reinforcement handling. Steel Fixers foreman must ensure that
the reinforcement will not be roughly handled, dropped from a height, or subjected to shock
loading or mechanical damage

 Before proceeding with reinforcement fixing, each single bundle must be checked as well as
the Bar position (according to shop drawings) must be clearly marked with dedicated tags

 No flame-cutting of high-tensile steel bars shall be permitted, except with the written
approval of the Engineer.

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 “Cut to fit” reinforcement is allowed only when it’s clearly indicated in the construction
drawing (previously approved by the Engineer) or otherwise instructed by Engineer
Representatives on Site

 Surveyors shall mark the installation elevation both for internal and external layers (if
required by the Supervisor). The survey team shall moreover assist throughout all these
activities by providing suitable reference points, controlling the actual position of the cages
already installed and instructing any adjustment or relocation of the rebars (if strictly
required by the Supervisor)

 Starter rebars will come off the planned construction joints and will lap subsequently with
the elevations and with the adjacent blocks to be poured;

 Reinforcement cannot protrude the concrete cover; cover must be as indicated in the
relevant shop drawings;

 Minimum spacing centre to centre of parallel bars should be as per design;

 Binding wire must be Dia. 1,60 mm black annealed mild steel will be used for tie reinforcing
bars;

 Steel Fixers can use different tie configurations to join rebar together and hold it in the
proper spacing and in place as the concrete pours. Each one has its particular use, such as for
speed, climbing, or twist prevention. The ends of all tying wires must be turned into the main
body of the concrete and not allowed to project towards the surface. As depicted in Figure 3
the ones identified by the Contractor are as follow:

✓ Type “A” – Snap tie or Simple tie: The wire is simply wrapped once around the two crossing
bars in a diagonal manner with the two ends on top. These are twisted together with a pair of
side cutters until they are very tight against the bars. Then the loose ends of the wire are cut off.
This tie is going to be used used mostly on floor slabs.

✓ Type “B” – Snap tie (with a round turn): this tie is made by going about 1 1/2 times around the
vertical bar, then diagonally around the intersection, twisting the two ends together until the
connection is tight, but without breaking the tie wire, then cutting off the excess. The present tie
system can be used only along horizontal surface or connection with supports bars

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✓ Type “C” – Double-strand simple tie. This tie is a variation of the simple tie. Since it is especially
suggested for heavy work, the present type of tie would be the most used during the fixing
activities of the Spillway steel reinforcement bar.

Figure 3: Tie’s Types

✓ Type “D” – Saddle or U tie: the wires pass halfway around one of the bars on either side of the
crossing bar and are brought squarely or diagonally around the crossing bar with the ends twisted
together and cut off. This tie can used on special locations, such as connection of horizontal bars
with vertical ones used for support

✓ Type “E” - Saddle or U tie with a twist: this tie is a variation of the saddle tie above depicted
and it’s highly preferred for diameters higher than 20 mm. The tie wire is carried completely
around one of the bars, then squarely across and halfway around the other, either side of the
crossing bars, and finally brought together and twisted either squarely or diagonally across.

✓ Type “F” - Cross tie or figure eight tie. This type of tie has the advantage of causing little or no
twist in the bars

 Concrete spacer blocks are going to be made with 10 mm maximum size aggregate
guaranteeing the same strength and material source as the surrounding concrete. They are
going to be place with a minimum density of 1 No/m 2 (location it’s anyway depending on the
actual formwork alignment) in order to guarantee a minimum concrete cover of 75 mm
(unless otherwise indicated in the shop drawings approved by the Engineer). Concrete

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spacers blocks are formed in specially manufactured moulds and the concrete compacted on
a table vibrator. Once completed blocks must be cured in water for at least 7 days.

 The use and the type of mechanical couplers, where required in the terms of the scope of
work (shop drawings submitted), it’s subject to the written approval of the Engineer. Test
certificates from an approved recognized testing authority to the Engineer are going to be
submitted to the Engineer together with relevant data sheets. Connections are going to be
made strictly in accordance with the manufacturer’s instructions

Once all reinforcement bars are securely and accurately fixed in positions as per approved shop
drawings and whole steel reinforcement’s cage/layout is fixed and supported so as to retain its
correct position in the forms during the process of placing and consolidating the concrete, before
proceeding with the Formwork System final alignment, SUN JV Quality Department must
promptly inform the Engineer for an official inspection. Upon Engineer’s approval, dedicated
team can proceed with the formwork placing operations

10. QUALITY CONTROL

10.1. INSPECTION & TESTING

As per Quality Control Manual, SUN JV is going to strictly monitor, on a quality point of view, all
the phases depicted that can be summarized as follow:
- Approval of Permanent Materials;
- Steel reinforcement fixing - Inspection and Approval of Pouring prior commencement of the cast

- Fixing of required embedded mechanical parts

- Concrete Placing
Relevant checks to perform are listed in the various checklist attached to the Quality Control Plan,
which include forms such as Pre-Concrete Pouring checklist.

10.2. Blasting Quality Control

‐ Each blasting operation will be established as per specific plan issued by Technical Office and/or
Blast Foreman, including area, exact position and depth of the drilled holes.
‐ Based on the above‐mentioned plan, before ordering explosives check will be performed on the

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required number and depth of holes have been drilled.

‐ The blaster to fill in the pre and post blast inspection report jointly with the QC
engineer/inspector.
‐ QC Section will record and file the pre and post blast inspection report.

10.3. FOLLOW UP & EVALUATION

Production personnel will establish the daily/weekly reports, related to the performed tasks. The
result of row data collection would be shared with Reporting Section for data processing and
submitted to the Management for check and for any further decision. The following documents
shall be used to assess and evaluate the progress of the works:

- Site Daily Report

- Daily Construction Status Report
- Weekly Construction Status Report
Designated Supervisors for each area shall prepare Daily Reports and Weekly Reports while the
Site Manager evaluates and follow up on the progress of the work based on the Site
Establishment Construction Schedule.

11. SAFETY AND ENVIRONMENTAL MEASUREMENT

11.1 GENERAL SAFETY RECOMMENDATIONS

It is important to note that the following will be rigorously implemented by SUN JV during the

first six months of the Contract.

(a) More time spend on Induction of all new employees particularly the local affected persons.

(b) On the job training/coaching done by and supervisors.

(c) More visible and effective training on the floor level.

(d) Regular Safety tips and hints as well as tool box talks by Supervisors - Safety department

personnel to play an advisory role in this regard.

(e) Discipline by line management - leading by example and enforcing safe working practices. (f)

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Prompt, positive and participative resolutions on issues raised by Safety department personnel

and workers alike.

(g) Early establishment of job specific procedure and dissemination of such information.

(h) Risk profiles for all tasks and jobs to be performed and ensuring that Safety, Hygiene and

Environment are the integral part of all the Method Statements.

(i) Specific Health, Safety, Hygiene and Welfare Audits conducted by Senior Management.

(j) Awareness Campaigns, in the form of posters, advertising of information and rules, videos,
workshops etc. are implemented.
(k) Incentive Schemes - in the form of a token or otherwise and also ensuring that accident
prevention is incorporated in the bonus scheme where necessary.

11.2 LAWS AND REGULATIONS

All the local laws and regulations’ will be managed as described in the following Chapter. The
project will be undertaken, as a minimum, in accordance with the following requirements.

- Lesotho Workmen’s Compensation Act;

- Lesotho Labor Code (Order 24 of 1992) and Labor Code (Amendment) Act of 2006 and
Regulations, particularly Part V and VII and the Sixth Schedule of the Labor Code of 1992 (also
referred to as the Labor Code Order);
- Lesotho Mine Safety Act (Act 4 of 1981). I
n addition to the above Lesotho legislation, the SUN JV shall also comply with the requirements of
the following:
- South African Mine Health and Safety Act (Act 29 of 1996) and Regulations;
- South African Occupational Health and Safety Act (Act 85 of 1993) and Regulations;
- Relevant IFC Performance Standards;
- Project Health & Safety Plan;
- Project Environmental Plan.

11.3 START OF WORK SAFETY MEETING

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- Prior to any work starting, all personnel should report to the Site Supervisor for Safe Work
Procedure, Risk Assessment, Method Statement, Emergency response and MSDS training;
- Supervisor to complete DSTI and to make sure all employees understand the safety
requirements and to sign the DSTI;
- Safety Officer to attend meeting and inspect and sign DSTI;
- If there is a change in task being performed, DSTI to be reviewed with employees;
- Supervisor to inspect all employees PPE to make sure they have all their PPE and correct PPE
with them, and the condition of the PPE;
- Random alcohol testing to be performed by the Safety Officer and recorded on the DSTI;
- Prior to any work starting the construction area will be identified & HSE signage or corporate
signage will be positioned accordingly where required.

- Supervisor to ensure that a site safety notice board is available for relevant safety documents,
toolbox talks, procedures etc that can be placed on and available for employees to read.

11.4 BLASTER & ASSISTANTS CERTIFICATION / LICENSES

‐ Blasting activities (including transportation) may only be carried out by competent and licensed
persons who have been appointed in writing.
‐ The originals of the licenses for all licensed employees of the Sub Contractor involved in
Blasting / Explosives will be kept on site.
‐ Each license holder shall carry a certified copy of his or her license on his / her person when at
work. All blasting licenses / certificates shall be valid for the period required on Site.

It is further anticipated that the excavation and blasting phase will be the most severe. Daily rock
blasts will be kept within prescribed acceptable vibration standards. PPS meters shall be set up at
strategic positions around the site to monitor the shock felt by adjacent properties. All blasts shall
where necessary, be covered with heavy-duty rubber mats and soil over-burden to prevent ‘fly
rock’ damage beyond the site boundaries.

11.5. TRANSPORTATION OF EXPLOSIVES

‐ Only sufficient explosives for immediate use may be transported to the working face.
‐ Explosives shall be transported in containers and vehicles specifically designed for this purpose.

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Containers and vehicles shall be clearly marked and a Competent Person shall accompany each
load transported.
‐ No vehicle will be allowed into the Explosives Magazine, except the approved vehicles used for
delivery and transportation of explosives.
‐ Only licensed, trained and authorized drivers allowed to operate any vehicle which has to
transport explosives and a Competent person shall accompany each explosive load
‐ Vehicle transporting explosives must be properly identified
‐ Any oil / chemical spill must be cleaned up immediately.
- Contaminated ground to be removed and stored in containers for removal

11.6 STOCK CHECKS

‐ The Blaster shall ensure that an explosives stock check is carried out on a monthly basis.
‐ Any discrepancies shall be reported in accordance with legal requirements.
‐ Records of stock checks shall be maintained by the Blaster and shall be made available for
inspection by the Engineer.

11.7 EXPLOSIVES ACCOUNTING

‐ The Blaster shall maintain accurate records of explosives issued, explosives expended and
current stocks. For explosives expended, the responsible Blaster shall record the specific items
and quantities expended and shall certify that they have indeed been expended.
‐ These signed records must be reconciled against stock figures at the end of each Month, and
any discrepancies shall be investigated.

11.8 LOSS OF EXPLOSIVES

‐ If the Blaster suspects that explosives have been lost, a complete stock check shall be carried
out without delay.
‐ If the loss is confirmed, the matter shall be reported immediately to the Engineer.
‐ The loss will also be reported to the Lesotho Police, who will determine what follow‐up action
must be taken.

11.9 THEFT OF EXPLOSIVES

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‐ If explosives are stolen, the area where the theft occurred shall be secured immediately without
being disturbed.
‐ The details shall then be reported to the Engineer and the Lesotho Police, who will determine
what follow‐up action must be taken.

11.10 INCIDENTS / FIRST AID EQUIPMENT

- Every incident / injury / near miss must be immediately be reported to site Safety Officer for
investigation and to complete incident report as required;
- A fully stocked first aid kit will always be placed on site;
- An appointed person first aider will always be based on site;
- First aid kits will be regularly inspected and inspection recorded to ensure all contents are
compliant.

11.11 EMERGENCY MANAGEMENT

- Emergency contact details to be placed on site;

- Emergency assembly point to be identified and sign placed for employees to assemble at in case
of an emergency;
- Employees will ensure that before commencing work on any site, that they are familiar with the
sites fire and emergency procedures;
- Fire extinguishers to be placed where hot works are being done;

11.12 HAND TOOLS AND EQUIPMENT

- Where necessary, applicable personal protective equipment shall be worn when

using hand tools;

- All tools/equipment (Drills, Grinders, welding equipment, cutting equipment, hand tools,
Ladders) being used for assembly or other works, to be inspected before use, and recorded in
required registers;

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- Damaged tools/equipment to be removed out of service and NOT be used;

- No damaged electrical cable on tools / equipment or any extension are allowed, or will be used;
- Loose clothing, jewelery or gloves that could get caught in the tool shall not be worn when
operating powered tools;
- Operators of powered tools who have long hair shall keep their hair tied up;
- The power source shall be disconnected from the tool before making any repairs, servicing,
adjustments, or replacing attachments such as drill bits, angle grinder disks;
- Correct hand tools for the job shall be used, e.g. screwdrivers shall not be used as chisels.
- Pliers shall not be used as hammers;
- All hand tools used in elevated areas, that may be dropped or fall to lower levels shall be fitted
with safety lanyards and attached to solid structures or in the case of podges, scaffold keys etc.,
attached by wrist lanyard to the user;
- Purpose built tools and equipment may not be used unless a risk assessment has been
conducted and authorized by the Engineer;

11.13 LADDERS AND SCAFFOLDING / WORKING AT HEIGHT

- Any person required to work higher than 1.8 m, must wear and use a safety harness tied to a
secure point;
- Ladders to be inspected before use and recorded in a register;
- Scaffolding to be inspected and a safe to work label to be placed on scaffold before any person
allowed to climb / work on scaffold
- Any person required to work on a ladder, the ladder will be placed on a 1-4 angle, extend 1 m
past landing, will be placed on secure / level ground and if not tied down will be held by a person
standing at the bottom of the ladder;
- Any work performed from a ladder, employee will wear and use a safety harness and hook onto
a solid anchor point where required;
- Use safety harnesses is mandatory when working at height of 1.8 m except where solid
handrails have been installed;
- Working above other personnel is prohibited unless adequate precautions are in place
- Do not throw tools or equipment from height;
- All material that needs to be used, will be properly stacked/stored so as not to fall down or
cause a tripping hazard.

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11.14 USE OF MOBILE EQUIPMENT / MOBILE CRANES

- Only certified, authorized, trained operators to operate Mobile Equipment;

- Pre-shift check to be completed by Operator before operating Mobile Equipment;

- Any person being lifted in a Telehandler basket, must wear and tie his safety harness hooks to
the basket handrail to prevent person from falling out if he/she needs to lean out of basket to
perform task;
- It is forbidden to use a cell phone whilst operating Mobile equipment;
- No person under the influence of alcohol / drugs to operate Mobile equipment;
- Mobile equipment has right of way and employees to stand clear when Mobile Equipment
moves around;
- Mobile Equipment Operators to keep to speed limits. Max 20km/h where employees are
walking or working;
- All Mobile equipment to be fitted with a reverse hooter;
- All Mobile equipment to have a strobe light on;
- All Mobile equipment to haven identification number on;
- Where required, a Flagman will be used to control/divert traffic;
- No maintenance allowed on Earth moving equipment unless done by a trained,
certified Mechanic in an area where there will not be the possibility of spilling oil /grease on
the ground causing contamination;
- No lifting task to be performed without qualified, authorized rigger;
- 2 x guide ropes to be used for high lifts e.g beams, any material that can swing due to windy
conditions;
- No person/s to stand under a load being lifted;
- Keep hands / body parts clear when material/equipment is being lifted to prevent injury;
- Only the Rigger to communicate with Mobile Crane Operator during lifting operation;
- Crane to be positioned on a level, safe surface before operating;
- Simultaneous Operations being carried out
– Supervisors to discuss tasks overlapping with other Contractors and with employees affected;
- Any oil/chemical spill must be cleaned up immediately;
- Contaminated ground to be removed and stored in containers for removal;
- Every Environmental incident must immediately be reported to HSE and ENV Manager and
Safety/Environmental Officer.

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11.15 STACKING AND STORING

- All material that needs to be used, will be properly stacked/stored so as not to
interfere with any traffic, working operations or walkway;
- Barricading to be placed around stacking areas, or work areas if required to keep
unauthorized employees/person away;
- Work area to be kept clean to prevent incidents, and at end of shift area needs to be
properly cleaned for next shift;
- Do not lift on your own more than 25 kg;
- If not sure about weight of item, ask for assistance in picking up item;
- Lift items with your legs, keeping your back strait;
- Keep hands from underneath item when putting item down;
- Never drop an item.

11.16 FALLING ITEMS / MATERIAL

- Where possible items to be positioned at ground/floor level in order that they do not
fall;
- All storage areas will be kept to a minimum;
- Where appropriate heavy items to be stored on the floor than lighter items;
- Items to be securely packaged so they do not spill and fall on raised surfaces;
- There to be no leaning objects;
- Equipment including head protection, foot protection to be worn by those who may
meet falling objects;
- All incidents of falling objects to be investigated to help prevent reoccurrence;
- Ensure that suitable and sufficient information, instruction, training and supervision
for controlling falling objects.

11.17 HOT WORK

Welding and burning operations (hot work) within the tunnels shall be kept to a minimum.
Wherever possible components shall be prepared on the surface and consideration given to
alternative methods such as bolting and sawing. Hot work may be undertaken providing the
following measures are adhered to:
• Only qualified personnel are permitted to perform hot work;
• All gas cylinders shall be transported and kept within steel protective cages;
• Gas bottles shall be fitted with flashback arrestors;

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11.18 BARRICADING

- All applicable legislation concerning barricading shall be complied with at all times.
Barricading shall be erected to:
▪ Prevent persons from making contact with an identified hazard;
▪ Provide warning of the existence of a hazard;
▪ Prevent unauthorized access (by people, vehicles and mobile equipment) into an
area where a hazard exists or where a hazardous activity is being carried out;
▪ Define the boundaries of a hazardous location and / or restricted area; and
▪ Allow a work team to perform hazardous tasks without persons unfamiliar with the
hazard(s) accessing the area.
- Although not limited to these situations, barricading shall be erected or installed:
▪ Around excavations (trenches, pits, etc.);
▪ To protect openings and edges – to prevent persons from falling, all openings and
edges associated with or during the course of construction shall be protected by
sturdy, rigid barriers capable of withstanding a dynamic force of at least 110
kilograms applied in any direction at any point;
▪ To prevent access into areas where overhead work is in progress;
▪ To route vehicles safety through (or around) construction areas; and
▪ To protect members of the public who may be in the vicinity of a work or construction
site (by preventing access).
- In all cases, the erection of barricading shall be a temporary measure. It shall only remain
in place until the hazard is eliminated or the potentially dangerous situation is rectified.
- A barricade shall present a sturdy physical barrier to entering an area. Therefore, plastic
cones, post and chain systems, “danger tape” and “snow netting” will not be accepted as
barricading and may only be used for the purposes of low-risk demarcation. For example,
snow netting may be used for the demarcation of lay down areas.

11.19 WEATHER

- Consideration is to be made of adverse weather conditions, e.g. snow, ice and rain
and Suitable provision made regarding required PPE.

11.20 PPE

- Correct PPE to be worn for task being performed e.g, Hardhat, Overalls, Gloves,
Safety Glasses, Hearing protection, Safety shoes. Additional PPE required for

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specialized tasks
– Welding helmet, Welding Apron & spats, Welding gloves etc;
- Damaged PPE must be replaced immediately;
- Do not throw PPE around on site.

11.21 GENERAL

- No horseplay is allowed on site;

- No fighting is allowed on site;
- No weapons are allowed on site;
- No open fires are allowed on site.
12. ENVIRONMENTAL MEASUREMENT

For all works that are to take place, the following environmental measures shall be considered:
- Appropriate erosion and sediment control measures will be implemented;
- Sediment barriers will be constructed across the entire construction right of way at
all watercourse crossings where necessary to prevent sediment flow into the
watercourse;
- Vegetation and soil will be retained in position for as long as possible, and will only
be removed immediately ahead of construction/earthworks in any specific area;
- Vegetations shall only be removed where essential;
- Diesel generator to be parked far from water course so that if a spill occurs, there is
no spillage into the water course (river);
- No refuelling will take place within the delineated water bodies or within the buffer
zone of 30 m from the water bodies;
- Only use approved diesel cans for refuelling if a Diesel Bowser is not used;
- Any oil/diesel leak must immediately be reported to maintenance department to be
rectified;
- Any oil/diesel spillage will immediately be reported to ECO;
- Spillage area to be immediately cleaned up.

12.1 STORAGE

- No construction materials shall be stored or disposed of within the delineated water

bodies or within the buffer zone of 30 m from water bodies;
- No concrete batching shall take place within the delineated water bodies or within

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the buffer zone of 30 m from the water bodies;

- No refuelling will take place within the delineated water bodies or within the buffer
zone of 30 m from the water bodies.

12.2 HOUSEKEEPING & DISPOSAL

Work areas shall be kept free of mud and debris. Scrap materials in all working areas shall be
removed daily and shall not be allowed to accumulate. All hazardous waste shall be disposed of in
an approved hazardous waste disposal site and a disposal certificate supplied to the Engineer

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