Methodology for Borrow Material

UPGRADING OF APPROXIMATELY 104KM OF ROAD D104/D791 CHIPATA TO MFUWE IN EASTERN PROVINCE METHODOLOGY FOR BORROW MATERIALS 1.0 SCOPE This method statement covers the work involved in obtaining borrow materials for work under this contract, including negotiations with Owners of the land on which borrow areas are situated, clearing the site, stripping and disposing of excess overburden, excavating selected material for use in the Works, and finishing-off the borrow areas. 2.0 NEGOTIATIONS WITH OWNERS AND AUTHORITIES We shall be responsible for all negotiations with and compensation of owners for all borrows pits that we shall identify and prescribe. However, for those that are identified and prescribed by the Employer (Consultants), we shall be exempted from all obligations and costs in respect of negotiations with and compensation of the Owners of the land on which the borrow areas are situated. 3.0 USE OF BORROW PITS Having concluded (verbally and in written) all the necessary negotiations with the Owners of the ground on which any borrow pit is situated, we shall open such a borrow area. The notification to the landowners will be at least 7 days before prospecting and the Engineer will also be informed accordingly. 4.0 4.1 OBTAINING BORROW MATERIALS General Borrow materials shall be obtained from approved sources of supply listed and described on the borrow-pit plans, or from such other sources as may from time to time be tested and approved by the Engineer.

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4.2

Use of borrow materials The decision as to which source of supply of borrow material shall be used at any time shall rest with the Engineer, and we shall at any stage of the work use that approved source of supply which in the opinion of the Engineer is the most suitable in regard to the quality and quantities of the various types of available materials and the ultimate cost of the work to the Employer. Should there be need to obtain material from sources other than those shown on the borrow-pit schedule, we shall excavate the necessary trial holes, and take such samples and conduct or have conducted such tests as are deemed to be necessary by the Engineer. We shall submit the results and sufficient details to the Engineer to satisfy him that the quality and quantity of the material available in the proposed borrow area are acceptable for the intended use, all at our own expense. Compensation to Owners and arrangements for taking any material shall be in terms of the Project Specifications. Approval of borrow pits or borrow areas shall apply only to those portions of the pit or area from which acceptable material can be obtained or produced. We shall organise our operations in any approved pit or borrow area or portions thereof with a view to using the material for the purpose envisaged. We shall plan our exploitation of the borrow pits in such a manner that the various types of materials excavated can be selected and loaded directly for use. When this is unfeasible for reasons beyond our control, material to be stockpiled for later use shall be loaded, transported and temporarily stockpiled as ordered by the Engineer and as determined in Clause 3203 of SATCC specifications. No material reserved for a specific purpose shall be used for any other purpose without the written approval of the Engineer.

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4.3

Borrow materials obtainable in the road prism or within the road reserve boundaries Where suitable sources of materials are available in existing cuttings and side drains, or anywhere else in the road prism or within the road reserve boundaries, such materials shall be used for the construction of fills, pavement layers and shoulders, if approved by the Engineer.

5.0 5.1

OPENING AND WORKING ON BORROW PITS AND HAUL ROADS Removing topsoil Prior to opening a borrow pit, we shall ascertain from the Engineer whether the removal of topsoil is required and shall then remove and stockpile such topsoil as instructed by the Engineer. This work shall be carried out, measured and paid for in accordance with the provisions of Section 5700 of SATCC specifications.

5.2

Clearing and grubbing Clearing and grubbing of borrow areas will be measured for payment in accordance with the provisions of Section 1700 SATCC before excavation is commenced, but only in the following cases, unless otherwise directed by the Engineer: (i) In borrow areas located in plantations. (ii) In borrow areas where large trees with trunks exceeding 1.0 m in circumference as defined in Section 1700 are found. (iii) In borrow areas without any excess overburden but where the removal of grass, shrubs and roots is required. Unless the clearing and grubbing of a borrow area have been prescribed by the Engineer in writing, no payment will be made for clearing and grubbing such borrow area. This applies particularly to borrow areas opened for obtaining rock or sand used in the construction of stone-pitching, concrete work, crushed-stone base or sub-base, permeable subsurface drain material or surfacing.

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5.3

Excess overburden We shall advise the Engineer in good time, before any excavation at such borrow area is commenced, of his intention of starting to use a borrow area in order that a survey of the site can be made for the purpose of computing the quantity of excess overburden, if any, to be removed. No removal of overburden or other quarrying operations shall be proceeded with until agreement has been reached between the Engineer and us regarding the quantity of such overburden. Unless, under exceptional circumstances, the clearing and grubbing of the borrow area is required to be done first, the excess overburden shall be measured only after this work has been completed. As instructed by the Engineer, excess overburden shall be moved to the outer limits of the proposed borrow area, and, if this area is enlarged later on, the excess overburden shall be moved further to the new outer limits, or, where possible at that stage, replaced into the borrow pits.

5.4

Excavating borrow material Borrow material shall be excavated within the limits of depth and area shown on the borrow-pit plans or as directed by the Engineer, and in a manner that will not prejudice the use of the material for the intended purpose. Where any borrow pit contains different types of materials in separate layers which require to be mixed to produce a suitable product, the materials shall be excavated over the full depth of the approved working face in one operation without the different types of materials being separated. We shall take all reasonable precautionary measures so as to avoid contamination of the suitable borrow material by the inclusion of clayey or otherwise unsuitable material from the floor of the borrow pit, the overburden, any unsuitable layers, or areas beyond the approved limits of the borrow area. During loading, any hard oversize material which will not break down during processing on the road shall be excluded as far as is practicable.

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Methodology for Borrow Material

During borrow operations, and especially when excavating material near the floor and outer boundaries of the borrow areas, we shall plan our operations so as to reduce, in so far as is possible, the amount of earth moving work that will be necessary for finishing-off the borrow pits. Indiscriminate excavation without due regard to the desired final shape of the borrow pit will not be permitted. The material in borrow pits shall be blasted or ripped and excavated in a manner that will ensure the effective breaking-down of the material in the borrow pit before it is loaded. Rip able material which tends to break into large blocks shall be cross-ripped. 6.0 SELECTING THE MATERIAL We shall use materials strictly in accordance with the purpose for which they have been approved and in accordance with the details as indicated on the Drawings or as directed by the Engineer. During our activities in borrow pits or cuttings, we shall ensure that approved materials are not unnecessarily polluted with unsuitable material or that approved materials are not unnecessarily wasted. Where unnecessary pollution or wastage of suitable material has occurred, we shall supply other suitable material at our own cost. 7.0 STOCKPILING THE MATERIAL We shall plan our activities in such a way that materials excavated from borrow pits and cuttings, in so far as is possible, can be transported direct to and placed at the point where it is to be used. However, where utilising materials in this manner is impracticable, and, if so instructed by the Engineer in writing, it shall be temporarily stockpiled for later loading and transportation to where it will be used. Stockpiling areas and maximum heights of stockpiles shall be indicated or approved by the Engineer. Before any stockpiling of material may be done, the site shall be cleaned, and all loose stones or any vegetation or other material which may cause pollution shall be removed. During use, the lower 100 mm of stockpiled material shall not be utilised for construction. After the stockpiled material has been removed, the site shall be reinstated as closely as possible to its original condition, and the surface shall be lightly scarified to promote vegetation growth.

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Methodology for Borrow Material

8.0 8.1

BREAKING-DOWN THE MATERIAL FROM CUT AND BORROW Breaking-down the material in cuttings and borrow pits The material from cuttings and borrow pits shall be broken down in the cuttings or borrow pits to the specified maximum sizes, depending on the use envisaged for the material, before it is loaded and hauled to the road. Material intended for crushing need only be broken down sufficiently to permit acceptance by the crusher. If, in the opinion of the Engineer, our working methods are such that unnecessarily large quantities of oversize material are produced, he may give instructions to change the methods in order to produce less oversize material at our own cost. Care shall be taken not to load oversize material and to bring it onto the road. However, where this is nevertheless done, the oversize material shall be removed from the road or broken down further to the required size on the road. breaking it down. The Engineer may also require oversize materials to be used for other purposes, such as for rock fills instead of

8.2

Further breaking-down of pavement and fill material brought onto the road Pavement material brought onto the road shall be further broken down to the sizes as specified for each layer by using normal grid-rolling. Any oversized material shall be removed by hand, and/or constructional plant as provided in Clause 3210.

8.3

Milled material Milled material need not normally be broken down further unless so specified or instructed by the Engineer.

8.4

Control at borrow pit We shall be responsible for controlling our operations at every borrow pit where material is being excavated to ensure compliance with all the requirements of Subclause 3105(d) of SATCC specifications. We shall carry out sufficient tests on the material being excavated from the borrow pit to satisfy ourselves that the quality of the material will comply with the specified requirements for the particular layer for which it will be used.

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Methodology for Borrow Material

If there is any doubt concerning the quality of the borrow material being excavated at any time, we shall notify the Engineer immediately, and in any case before such material is brought onto the road. The results of all the tests carried out shall be submitted to the Engineer on request. The Engineer will, after further testing or inspection if necessary, instruct us regarding the use of the material in the borrow area, or he may order the borrow pit to be finished off and abandoned. 9.0 CONTROLLING THE MOISTURE CONTENT OF MATERIALS Reasonable precautions shall be taken to prevent material in borrow pits, excavations, stockpiles and on the road from becoming excessively wet as a result of rain or groundwater or storm water. In view hereof, the excavation of borrow pits and cuttings shall, as far as possible, be so planned and executed as to prevent the damming-up of water in the borrow pits or cuttings. Some temporary drainage shall also be provided where necessary for this purpose. During the rainy season, material spread over the road shall be spread with a proper cross slope, and, if not directly compacted, it shall be rolled several times with a flat-wheeled roller in order to let the water runoff and not penetrate the material unduly. Care shall also be taken not to allow the water to dam up against material heaps, windrows, or any spread material. Where material, despite proper precautionary measures, on account of its in situ moisture content, is nevertheless too wet to comply with the requirements in regard to moisture content during compaction, the material shall be dried up until it is adequately suitable for compaction. However, where the Contractor has taken all reasonable precautions to keep the material dry and to dry it out where necessary and it is nevertheless impracticable to dry out the material as required, the Engineer shall: a) permit the material to be compacted at a higher moisture content, subject to the required dry density being achieved; or b) declare the material to be unsuitable and instruct that it be not used, and, if already on the road, be removed at the appropriate compensation and replaced with suitable material.
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Methodology for Borrow Material

10.0 LAYER THICKNESSES AND SPREADING THE MATERIALS 10.1 Fills The layer thickness of fills will generally be determined by the maximum size to which the material can be broken down in the borrow pits and cuttings, and thereafter when it can be processed on the road itself. The layer thickness will therefore normally be based on the pre-estimation of what the maximum size will be to which the material can be broken down, and shall be such that the maximum size specified in clause 3200-4 of SATCC will be more or less equal to the layer thickness after compaction. The maximum layer thickness (after compaction) required shall be 200 mm, but layer thicknesses as little as 100 mm will be permitted. In order to prevent the layer thicknesses from being determined by the presence of isolated large fragments, the Engineer may require such isolated fragments to be removed from the road, as determined in Clause 3210. The Engineer may also agree to the material being compacted in layers in excess of 200 mm or the maximum fragment size, provided that he is satisfied that the material will be properly compacted. Layer thicknesses shall be agreed on in advance between the Engineer and the Contractor. Where a new layer is constructed on an existing or already constructed fill and the new layer will be less than 100 mm in compacted thickness, the existing fill shall be scarified to such a depth as will give a layer thickness after compaction of not less than 100 mm of the new plus the scarified material together. Where coarse material is to be processed in layer thicknesses which make mixing by road grader impracticable, the material shall be so excavated, transported and dumped that it will be properly mixed after dumping and exhibit a minimum segregation of fine and coarse material. Such material shall be placed to the correct thickness by end tipping, and the surface levelled by bulldozer, after which some fine material shall be spread on top of the layer and worked into the depressions on the surface.

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Methodology for Borrow Material

10.2 Pavement layers All material placed in position before compaction shall be spread evenly over the entire surface of the layer concerned, and the quantity of material spread shall be such that every layer will comply with the specified requirements for thickness when measured after compaction. The layer thickness shall comply with the requirements as indicated on the Drawings and in the Project Specifications. Spreading material in restricted areas may be done in any manner approved by the Engineer, on condition that the required level and grading standards can be attained. Where the compaction apparatus used is of such a nature that the material in thicker layers cannot be properly compacted, the Engineer may instruct that material be placed and compacted in layers as thin as 75 mm. Where the thickness of any existing pavement layer requires to be supplemented and the thickness of the added material after compaction will be less than 100 mm, the existing layer shall be scarified to a depth that will give a layer thickness of at least 100 mm after compacting together the loosened existing and added material. In the case of gravel bases and sub-bases, the Engineer may direct the existing layer to be broken down to its full depth. 11.0 PLACING AND COMPACTING OF MATERIALS Any oversize material which cannot be broken down to the required size shall first be removed from the road and then disposed of or used as may be prescribed by the Engineer. The material shall then be sprayed with water, mixed, and compacted as described hereafter. 11.1 Spraying and mixing (i) General Requirements Before the material is compacted, it shall first be thoroughly mixed by grader or other suitable plant so as to obtain an even mix of the various types of materials and to spread the fine and coarse material evenly throughout the mixture. If necessary during the mixing process, water shall also be sprayed evenly over and mixed into the material to bring it to the correct uniform moisture content. The moisture added shall be just sufficient to bring the material to the optimum moisture content for the compacting equipment being used and the compaction required, provided that, should
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the moisture content of the material be in excess of 2% above the optimum moisture content for modified AASHTO density, it shall be compacted only when so approved by the Engineer. (ii) Additional Requirements In Respect Of Work In Restricted Areas The Engineer may, in restricted areas, permit to spread, water and mix the gravel or crushed stone in a windrow next to the pavement excavation. Care shall be taken not to damage existing surfacing and not to pollute the mixed material with other deleterious material. Irrespective of the layer concerned, the mixing shall be of such quality that a uniform mix will be obtained at all times to the satisfaction of the Engineer. 11.2 Compaction (i) General Requirements Compaction shall be carried out in a series of continuous operations covering the full width of the layer concerned, and the length of any section of a layer being compacted shall, wherever possible, be not less than 150 m nor more than can be properly compacted with the available equipment. The Engineer reserves the right to order the contractor to reduce the length of any layer compacted in any single operation if the proper compaction of such layer is not being achieved. The types of compaction equipment to be used and the amount of rolling to be done shall be such as to ensure that specified densities are obtained without damage being done to lower layers or structures. During compaction the layer shall be maintained to the required shape and cross-section, and all holes, ruts and laminations shall be removed. (ii) Additional Requirements In Respect Of Work In Restricted Areas Suitable equipment and methods acceptable to the Engineer shall be used in restricted areas so that the required densities will be obtained throughout the thickness of the layer. If necessary, the layers shall be placed in thicknesses which are less than the specified layer thickness, as determined in Sub-clause 3207(b) of SATCC specifications.
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Methodology for Borrow Material

12.0 PLACING AND COMPACTING THE MATERIALS IN LAYER THICKNESSES IN EXCESS OF 200 mm AFTER COMPACTION (only applicable in the case of fills) 12.1 Soft-material fills Materials which readily break down to a maximum size of 200 mm shall be compacted in layers not in excess of 200 mm after compaction, and spraying, mixing and compacting the material shall be executed as described in Clause 3208 of SATCC specifications for pavement layers. In the case of cohesion-less sand, the layer thicknesses may, however, be increased to as much as 300 mm, and spraying and mixing the material may be omitted or limited in so far as is practicable, all, however, subject to the required density being achieved over the full depth of the layer. In this case efficient vibratory rollers shall be used for compacting the sand. 12.2 Hard-material fills Should the material used for fills be of such a nature that, during the breaking-down effort as described in Sub-clause 3204(b), it does not readily break down to a maximum size of 200 mm or less, the material shall be spread as described in Subclause 3207(a) and processed as follows: The material shall be sprayed and mixed as described in Sub-clause 3208(a), but, should this be impracticable on account of the thickness of the layer, these processes may be omitted on condition that the material be thoroughly mixed and placed as described in Sub-clause 3207(a) (last paragraph). The material shall subsequently be compacted in accordance with one of the methods described in Section 3300, depending on the method directed by the Engineer. 13.0 DISPOSING OF OVERSIZE MATERIAL All oversize materials removed from the road in terms of Sub-clause 3204(a) and all excess fill removed from the road in terms of Sub clause 3207(a) shall be disposed of at our own cost or, with the approval of the Engineer, may be used for other suitable purposes. Oversize pavement material left over after application of the provisions of Sub-clause 3204(b) and removed from the road in terms of Clause 3208, shall be loaded and disposed of as determined by the Engineer and will be paid for subject to
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the provisions of payment Item 32.04. Where, however, such material is used directly for any construction work, the Contractor will be entitled only to compensation at the rate in respect of the construction item in question. All reasonable precautions shall be taken not to place on the road any material which cannot be broken down to the required size by processing on the road. This shall be avoided by proper selection during excavation in the cuttings or borrow pits. If such material is encountered in cuttings, it shall be spoiled directly or used as prescribed by the Engineer. 14.0 DRAINAGE AND PROTECTION 14.1 Compacted Layers The compacted layers shall be adequately drained and shaped to prevent water from standing on or along or scouring the completed work. Windrows shall be removed to facilitate the drainage of water from the surface. No material for a subsequent layer may be placed if the underlying layer has been softened by excessive moisture. In cases where pavement layers are replaced over a section of the road width, or where pavement layers are widened and the new layer is more or less permeable than the adjacent existing layer, for example in the case of a stabilised layer next to an untreated layer, it may be specified, or the Engineer may instruct that pavement subsoil drainage be installed in accordance with the details indicated on the Drawings or determined by him. 14.2 Protecting borrow pits Borrow pits shall be continuously protected against the ingress of surface water, and we shall construct such temporary banks as may be required for diverting surface water, and, in so far as is possible, our operations shall be planned in such a way that the borrow pit will be self-draining. Where this is not possible, borrow pits shall be dewatered by pumping. We shall be solely responsible for keeping borrow areas dry and ensuring that borrow material is sufficiently dry when required for use. 14.3 Access roads Access roads shall be constructed and surfaced appropriately as required and shall be provided with temporary ditches and culverts of sufficient sizes to ensure that the
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Methodology for Borrow Material

existing drainage of the area is not restricted. We shall obtain the Engineers prior approval to the sitting of junctions of access roads with existing roads and shall comply with the Engineers conditions of access particularly regarding clearance of obstructions to provide adequate sight lines, temporary drainage or culverts and the provision of signs and traffic control. The provision of access roads shall not be measured for payment. 14.4 Private access roads Where materials from a borrow pit are hauled on private access roads, such roads shall be maintained properly to the satisfaction of the Engineer during borrow operations at the borrow pit. No additional payment will be made for this work. 15.0 FINISHING-OFF BORROW AREAS AND HAUL ROADS 15.1 Borrow areas On completion of operations in a borrow area, we shall reinstate the entire area so as to blend it with the surrounding area and to permit the re-establishment of vegetation. For this purpose the borrow area shall be shaped to even contours without any slopes being steeper than 1:3, except where the Engineer so permits in specified cases. All material in and around the borrow area, whether spoil from roadbuilding operations, excess stockpiled material, oversize material left in the borrow pit, material resulting from clearing and grubbing operations or excess overburden, shall be used or disposed of as directed by the Engineer. Solid waste and rubbish may not be dumped into the borrow area. Material incapable of supporting vegetation shall be buried and used for shaping the borrow area and shall subsequently be covered with soft material. All available soft material shall be spread evenly to the prescribed thickness, and where sufficient material is not available for so covering the entire area, the remaining portions shall be scarified along the contours so as to avoid undue erosion. The shaping and finishing-off of the borrow pit shall be done in such a manner that the borrow pit will be properly drained wherever practicable, and, where required, the Contractor shall place earth banks to divert surface water from the borrow area. If so directed, the borrow area shall be fenced
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Methodology for Borrow Material

off and provided with gates, and top-soiled and/or hydro-seeded as specified in SATCC specifications. The finishing-off of the borrow areas shall be to the entire satisfaction of the Engineer and we shall submit to the Engineer a signed certificate from the landowner or relevant Government Agency stating that the finishing-off complies with all necessary legal provisions. 15.2 Haul roads All haul roads shall be obliterated and their surfaces scarified, earth banks shall be constructed to prevent erosion, and all damaged fences and other structures shall be reinstated, unless otherwise specified. Where materials from a borrow pit are hauled on private access roads, such roads shall be restored to their original condition to the satisfaction of the Engineer when borrow operations at the borrow pit are completed, unless otherwise specified. No additional payment will be made for this work. The restoration of proclaimed roads shall be done in accordance with the instructions of the Engineer and payment will be made in accordance with applicable unit rates. 16.0 DISPOSAL OF BORROW MATERIAL We shall not have the right to use material obtained from borrow pits for any purpose other than for the execution of this contract. He shall not dispose of any borrow material whether processed or not either by sale or donation to any person without the written authorisation of the Employer. 17.0 CLASSIFICATION OF BORROW PITS FOR PAVEMENT LAYERS A schedule of borrow pits showing the estimated quantity of gravel material for base, sub-base selected sub-grade and shoulder to be used from each borrow pit is as shown below. The Engineer shall have the right to decide which borrow pit we shall operate from at any particular stage of the work, to approve new borrow pits during the construction period, to deviate from the estimated quantities shown. GRAVEL MATERIALS FOR

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BORROW PIT UTILISATION

OVER ITEM LOCATION OFFSET BURDEN (mm) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 KEY TAA (FILL) = TESTED AND USED FOR FILL NT = NOT TESTED T= TESTED TAAB= TESTED AND IS IN USE TIP=TESTING IN PROGRESS TAAA= TESTED AND USED FOR ALL LAYERS LUNDAZI RD 0+000 1+500 6+025 6+600 8+200 11+500 16+000 18+850 20+000 24+400 26+000 30+500 32+500 34+650 35+750 41+300 51+500 60+000 61+300 70+000 82+000 87+500 1.5km, RHS 100m, RHS 100m,LHS 200m,LHS 400m,LHS 500m,RHS 350m,LHS 1.5 km, LHS 50m,RHS 100m,RHS 50m, RHS 200m,RHS 150m,RHS 100m,LHS 150m,RHS 150m,RHS 200m,RHS 150m,LHS 250m,LHS 50m,LHS 900m,RHS 160m,LHS 100m,RHS 100 150 100 150 100 100 100 100 150 150 200 100 150 300 120 150 300 200 300 110 350 350 200 GRAVEL SEAM (m) 2 2 2.4 2.2 2 2.5 2.5 2.2 2 2.5 2.3 2 2.2 2.5 2 2.2 2.5 2 2 2.1 2.2 2.5 2.5 AREA (m) 10000 5625 10000 7500 5625 10000 10000 7500 7500 9375 10000 10000 10000 22500 7500 15000 15000 22500 18750 22500 22500 22500 26250 VOLUME (m) 20000 11350 24000 16500 11250 25000 25000 16500 15000 23438 23000 20000 22000 56250 15000 32250 37500 45000 3750 47925 49500 56250 65625 VOLUME (m) 22000 11350 24000 16500 11250 25000 25000 16500 15000 23438 16100 20000 22000 56250 15000 32250 37500 45000 37500 47925 49500 56250 65625 ROAD COVERAGE (SUB BASE AND BASE) (m) 4130 2344 4955 3407 2323 5162 5162 3407 3097 4840 4749 4130 4542 11615 3097 6659 7743 9292 7743 9896 10221 11615 13550 TAAA TAAA TAAA (FILL) TAA(FILL) T(FILL) TAA(FILL) TAAA TAAA TAAB T TIP T TAAA T TAAA TAAA NT NT NT TAAB NT NT NT REMARKS

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