MANAGEMENT PLAN

AND
CONSTRUCTION METHOD STATEMENT

Tender Name: - K-HILL PROPERTY DEVELOPMENT, INFRSATRUCTURE

DEVELOPMENT AT KGALE LAKE CITY - GABORONE

Tenderer/Contractor: - GIANT BUILD CONSTRUCTION (PTY) LTD

Employer: - K-HILL PROPERTY DEVELOPMENT (PTY) LTD

Author: GIANT BUILD CONSTRUCTION (PTY) LTD

Author: GIANT BUILD CONSTRUCTION

VERSION HISTORY
Document
Date Document Revision History Document Author/Reviser
Version

Oct., 2021 CW 1.0 Tender Submission

APPROVALS Approver Name and Title Approver Signature

Oct., 2021 CW 1.0

Table of Contents

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i. General Execution Plan......................................................................................................................5
a) General Plan of Site Arrangement...................................................................................................5
b) General Plan of Site Utilisation........................................................................................................5
1.1 Location of the Site Camp........................................................................................................5
1.2 Land Board Matters / Surface Rights....................................................................................5
1.3 Site Office Features and their Functions.............................................................................5
1.4 Site Management Office Structure and Roles.....................................................................5
1.5 Site Mechanical Workshops and Plant Facilities...............................................................6
1.6 Site Materials Testing Laboratory...........................................................................................7
1.7 Concrete Batching Plant...........................................................................................................7
1.8 Site Stores.....................................................................................................................................7
1.9 Materials Procurement and Storage......................................................................................7
1.10 Deliveries from Commercial Sources...................................................................................8
1.11 Accommodation for Site Staff.................................................................................................8
1.12 Borrow Pit Acquisition and Mining Licenses......................................................................8
1.13 Haul Roads..................................................................................................................................10
1.14 Mobilisation of Plant and Equipment..................................................................................10
1.15 Site Practice................................................................................................................................10
1.16 Completion and Restoration of the Site.............................................................................11
c) General Plan of Protection of the Site and Environment.......................................................11
1.1 Safety, Health and Environment............................................................................................11
1.2 Protection of Services Where Required.............................................................................13
1.3 Storm Water Drainage..............................................................................................................13
1.4 Waste Management and Pollution Prevention Control..................................................13
1.5 Traffic Management Plan........................................................................................................14
d) General Provision of Utilities and Services................................................................................14
1.1 Site Power...................................................................................................................................14
1.2 Communication.........................................................................................................................14
1.3 Toilet Facilities...........................................................................................................................15
1.4 Fuelling Arrangements............................................................................................................15
ii. Construction Method Statements.................................................................................................16
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a) Structural Components....................................................................................................................16
1 Chambers........................................................................................................................................16
2 Reinforced Concrete Reservoir:...............................................................................................20
3 Sump Tank.......................................................................................................................................29
4 Underground Sump......................................................................................................................33
5 Concrete Production, Transportation and Placing:.............................................................36
5.1.1 Construction Works.........................................................................................................37
5.1.2 Concrete Curing................................................................................................................38
5.1.3 Quality Assurance Documentation..............................................................................39
6 Formwork:.......................................................................................................................................39
6.1.1 Health & Safety:................................................................................................................40
6.1.2 Quality:................................................................................................................................40
6.1.3 Construction Works.........................................................................................................41
7 Steel Fixing:....................................................................................................................................42
7.1.1 Health and Safety:............................................................................................................43
7.1.2 Quality Control:.................................................................................................................43
7.1.3 Construction Works.........................................................................................................44
8 Joints in Concrete Works............................................................................................................46
8.1.1 Joint Construction............................................................................................................46
b) Pipelines...............................................................................................................................................48
1 Setting Out for Site Clearance:..................................................................................................48
1.1 General Procedures.............................................................................................................48
1.2 General setting out procedure..........................................................................................49
1.3 Setting out for Bush clearing............................................................................................49
1.4 Setting out Levels.................................................................................................................50
1.5 Excavations setting out......................................................................................................50
1.6 Setting out Pipelines and Valve Chambers...................................................................50
1.7 Setting Out Pump Station and Buildings.......................................................................51
1.8 Electrical / Mechanical / Electro Mechanical Works...................................................51
2 Earthworks......................................................................................................................................52
2.1 Site Safety...............................................................................................................................52
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 2.2 Site Clearance & Top Soil Removal:................................................................................52
2.3 Soft Excavation:....................................................................................................................54
2.4 Pipe Bedding..........................................................................................................................57
2.5 Backfilling Pipe:....................................................................................................................58
2.5.1 Primary or Initial Backfill................................................................................................59
2.5.2 Secondary Initial Backfill................................................................................................59
2.5.3 Final Backfill.......................................................................................................................59
2.6 Blasting for the Works:.......................................................................................................60
2.7 Pipe Jacking:..........................................................................................................................66
3 Pipe Laying.....................................................................................................................................75
3.1 Pipe Handling, Transport and Storage:..........................................................................75
3.2 Pipe Laying.............................................................................................................................79
3.3 Thrust blocks.........................................................................................................................80
9 Sequencing of pipelines, chambers and fittings.................................................................81
10 Tests..............................................................................................................................................81
10.1 Water for Testing...................................................................................................................82
10.2 Progressive Testing during Construction.....................................................................82
10.3 Tests on Completion............................................................................................................82
10.4 Hydrostatic Pressure Testing............................................................................................83
10.4.1 Requirements for determining the test pressure....................................................83
10.4.2 Test procedure...................................................................................................................84
10.4.3 Test duration......................................................................................................................85
10.5 Disinfection.............................................................................................................................86
10.5.1 Disinfection Procedures.................................................................................................86
10.5.2 Medical Screening and Clothing..................................................................................86
10.5.3 Tests on Other Materials.................................................................................................87
11 Building Works...............................................................................................................................88

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i. General Execution Plan

a) General Plan of Site Arrangement

Refer to Appendix 1 of this Project Management Plan for the general plan of site
arrangement for the contractor’s camp, contractor’s and Engineer’s office.

b) General Plan of Site Utilisation

1.1 Location of the Site Camp
The main site office space will be about 1.5 hectares. The main camp site shall house the
offices for the management staff- Engineer and Contractor, the laboratories, the mechanical
workshop, the stores and the concrete batch plant and precast concrete yard (refer to
proposed site layout plan attached). The site office shall be equipped with all the plant,
equipment, spares, communication facilities, power and water and personnel complement
necessary to manage the contract efficiently. The camp sites shall be de-bushed, with
preservation of some big and/or protected trees, cleared of topsoil which will be stockpiled
for later re-use. The earthworks shall then be done to ensure full drainage of the site and for
the driveways, parking and building platforms as per the approved drawings and
specifications.

1.2 Land Board Matters / Surface Rights

The Contractor will agree with the Engineer on the positions of the site camps, offices,
borrow areas and material storage areas. The Contractor will dermacate these areas and
apply for surface rights with the Balete Land Board or the developer as the case may be.
Lease agreements are signed off. The Contractor will seek the approval of Department of
Environmental Affairs for clearance to proceed with site clearing and erection of the
necessary site facilities.

1.3 Site Office Features and their Functions

The site office will be managed by the Project Manager who will report to the Project
Director. The Project Manager will have authority of the site, its management, directing the
Contractor’s progress works, communication with the Employer, Engineer and all
stakeholders and delivery of the end product.

1.4 Site Management Office Structure and Roles

The contractor’s offices will be of the Park home type portable offices and/or FSM type
buildings erected on site on concrete floor slabs. The site layout plan shall be drawn on site

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and approved by the Engineer. A tentative layout is provided in this Project Management
Plan to give a general picture of anticipated requirements.

The enclosed organogram details a comprehensive personnel complement to ensure that

the contract is well managed and that the site staff will be able to deal with any challenges
that may be encountered during the contract period. The Contractor’s supervisory staff
details of qualifications and experience are enclosed elsewhere. Our key personnel possess
the required qualifications, experience and knowledge to execute this contract and any
training needs identified during construction for non-key personnel shall be addressed as
required trough in-house onsite training, outsourced to private practitioners or through CITF
Trust Fund development programmes. The site staff will be well supported from the Head
Office in Gaborone. One of the key area for results delivery is constant communication
between site, head office and the Project Engineer. This will ensure a smooth flow of the
planning, work execution and timeous response to queries and site instructions from the
project team. All areas of risk will be reported to head office on a daily basis to ensure that
all sections of the site team are well integrated and coordinated. The workshop will require
continuous backup support and adequate supplies of spares and lubricants to avoid lengthy
breakdowns that may halt the progress of works for long periods of time. To this end the site
workshop team will prepare daily inspection reports and condition surveys of all plant and
machinery on site and ensure servicing is carried out timeously at the manufacturer’s
specified service intervals. Unforeseeable site conditions will be notified to the Engineer
upon realising any situation that may hamper the progress of the works whilst alternative
arrangements are being considered.

1.5 Site Mechanical Workshops and Plant Facilities

The workshops shall be located at the Contractor’s office yard located at site office and will
comprise two offices for the Workshop Manager and his mechanics, two containers for
spares store, with a double volume dome structural steel workshop covered with roofing
sheets and the boiler’s workshop. The workshop shall be headed by the Workshop Manager
and assisted by the plant mechanics to keep the plant in working order. The Workshop
Manager shall report directly to the Project Manager. The workshop located at the site will be
capable of carrying out major repairs. A suitably large stock of spares will be held on site so
as to minimise down time. Concrete slabs shall be constructed at the workshop service bay.
The oil separator facility and used oil storages shall be constructed in accordance with the
applicable standards. Diesel will be obtained from the fuel dealers and stored in over ground

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tanks located at the workshop at the site office. The fuel will be carted to site in fuel bowsers
and all wheeled machines shall be filled up from one common point to manage spillages,
only tracked machines shall be filled at the places of work. Spillages shall be treated without
delay and this shall be achieved by stocking considerable amounts of chemicals to deal with
these.
The workshop shall be equipped with light welding and fabrication equipment and a qualified
welder, and only the heavy/specialised welding/fabrication shall be done at the commercial
workshops in Gaborone. The plant and equipment for the works shall be as per the plant
schedule enclosed elsewhere.

1.6 Site Materials Testing Laboratory

A site testing laboratory will be established on site and operated by the contractor’s Materials
Tcehnician, and the laboratory shall be equipped to carry out all the necessary testing
required in the contract. The Contractor’s Materials Technician shall have experienced
materials technicians to assist him and the Engineer will be allowed access anytime to carry
out his inspections of the laboratory and the equipment.

1.7 Concrete Batching Plant

The concrete central batching plant shall be established on site at a location agreed with the
Engineer. The batching plant shall be 1No. Karoo batch plant fed by weight batching. The
concrete materials shall be stored in the batch plant yard in an approved manner and the
site shall be fenced off and manned at all times. The batch plant shall be able to produce up
to 25m3/hour and therefore shall be adequate to meet the site demand. Concrete shall be
ferried to site in concrete mixer trucks and dumpers and discharged at the final positions.
The 500R concrete mixer will be established on site for small mixes and for take over if any
of the batch plants is broken down.

1.8 Site Stores

Sensitive materials, such as cement, pipes, fittings, etc. will be protected from the bad
weather elements. The stores shall comprise of four containers some for tools and the other
for materials and shall be located at the office yard. A formal inventory control system will be
implemented, to ensure that perishable materials are used on a “First In First Out” basis, and
to ensure that due consideration is given to lead times, so that materials are in stock when
required. The site stores shall be controlled by a competent store keeper.

1.9 Materials Procurement and Storage

o The Engineer’s approval of the suppliers and materials shall be sought prior

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 to placing any orders as a quality control measure.
o All the materials shall be delivered to site within a sufficient period before
they are required to allow for inspection by the Engineer.
o The stores shall be made of steel containers with shelves where required,
adequate to store all the materials and tools as may be necessary.
o Only sensitive materials and tools shall be stored in containers and inventory
control system shall be implemented.
o The other construction materials shall be stored inside the site offices yard.
o The pipes and pipe fittings shall be stored in covered areas to prevent
damage by the ultra violet rays.
o Cement for concrete works and brickwork will be ordered on demand and
delivered to site on palates and covered tarpaulins. This will be evenly
offloaded along the road length to requirements.
o The materials shall be used on first in first out basis

1.10 Deliveries from Commercial Sources

All suppliers of commercial materials will be arranged through head office and site
personnel. All suppliers will be issued with a site location map showing the access route and
site contact person. Where witnessing, acceptance and approval of delivery of materials is
required, the Engineer will be invited to witness, sample as necessary and have the
necessary testing carried out. Product test certificates will be collected and copies issued to
the Engineer. The site will ensure that will materials will immediately be offloaded at the
respective storage and the delivery vehicles dispatched back on time.

1.11 Accommodation for Site Staff

The Contractor’s key staff shall be housed in rented accommodation in Gaborone and
Ramotswa. The Contractor’s staff shall be transported to site in a staff buses. The busses
shall transport staff to and from work from all main villages where the Contractor’s staff will
be accommodated. All the labour sourced locally for this contract will be expected to provide
their own accommodation at their cost.

1.12 Borrow Pit Acquisition and Mining Licenses

The Contractor will engage an Environmentalist Consultant to make the necessary
clearances with Department of Environmental Affairs. The Prospecting license will be
applied for through the Department of Mines. The Royalties stipulated therein will be paid on
a monthly basis at the rate of extraction of gravel and fill materials.

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 o Obtain surface rights from the Land board on land authority.
o Survey the area and prepare a plan with Coordinates and the total area of
the proposed site you are applying for.
o If the area has been sufficiently prospected and that no other person has
exclusive rights over that area, an application for a prospecting waiver from
Department of Geological Surveys is launched.
o After that man application for a Mining License after completing your
prospecting programme is done.
o Submit coordinates of the area applied for to Department of Geological
Surveys to check if the area is within a Prospecting, Retention or Mining
license and consent of the holder will be sought.
o Prepare an archaeological assessment of the area covered within the
proposed mining area and submit the report to Department of National
Museum and Art Gallery requesting for a clearance.
o A request for a clearance from Department of Wildlife and National Parks is
lodged.
The boundaries of the borrow pits shall be set out as per the mining licenses and shall
be marked with steel pegs and/or corner poles. The borrow pits will not be fenced; the
cleared bush shall be pushed to the boundaries followed by the top soil then over
burden. These soil berms shall act as barriers to storm water and boundary at the same
time. There will be defined access routes to and from the borrow pits as may be
necessary, and where the in and out routes are in one, the road width shall be at least
three time the width of the widest truck. The in-pit haul roads gradients shall not in any
way be steeper than 8%. There shall not be any built structures at the borrow pits and
the machines and the borrow pit shall be guarded by manned security 24 hours a day.

The borrow pit site boundaries shall be set and the area shall be fenced to keep out the
animals and people from the area. There shall be some offices and plant workshops at
the borrow pit site and these shall be placed as far from the operations area as possible
to avoid interruptions during drilling and blasting operations if required.
Operation Plans
The field investigation shall determine the materials quality and this shall dictate the
extraction plans. Where the materials exist in different classes, each class of material
shall be excavated and stockpiled in separate stockpiles. The borrow pit extraction
plans shall be drawn after the completion of the filed investigations. But generally, the
excavations shall be done using the bull dozers and the side/edge slopes shall be
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maintained at 30%. The excavation shall be done in stage depths of 3m per stage or as
may be dictated by the materials profiles. The haul roads inside the pit shall be so
designed that the incoming and outgoing traffic do not interfere with each other. The
bottom of the pit shall be as level as possible for smooth passage of haul
trucks.
1.13 Haul Roads
The Contractor will construct haul roads along the pipeline route and to and from borrow pits
for site use. Dust suppression measures will be applicable as per the contract. A detailed
traffic management plan is attached as part of this submission.

1.14 Mobilisation of Plant and Equipment

Giant Build Construction will hire some of the plant required for the works from other service
providers to ensure there is adequate resources to complete the works. This equipment will
be mobilised to site within 14 days.
 Equipment will be mobilised to site transported on lowbed vehicles in fully assembled
conditions where weight and height restrictions are not exceeded.
 Where the weight and height restrictions do not permit, the relevant equipment will be
transported as dismantled kits to be reassembled on site.
 Clearance will be sought from the Department of Roads, Transport and safety for
payment of waybills.
 The equipment available locally within Botswana will be transported to site within 14
days.
 The major construction plant will be deployed to site in accordance with the plant
deployment schedule proposed in this submission. Over and above deploying the
right plant in the right numbers the Contractor will endeavour to have a well-
established and managed site workshop as well as the required spares to attend to
operation and maintenance requirements.
Where the work progress requires for additional plant, this will be hired from local plant hire
companies within Botswana as guided by Economic Diversification Drive procurement
policies.

1.15 Site Practice

Industrial Relations
The industrial relations policy for the project will observe at least the following principles:
 Equal opportunity policy.
 Sound and harmonious relations between management and the workforce.
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  Freedom of association.
 Freedom to organise.
 Recognition of Trade Unions which are representative of the workforce.
 Collective bargaining in terms of agreed procedures.
 Observance of labour legislation, including wage orders.
 Support for recognised industry structures.
 Formal disciplinary procedures.
 Formal grievance procedures.
 Amicable dispute resolution.

1.16 Completion and Restoration of the Site

The Contractor shall at completion of the works, take down all temporary structures, fences,
concrete slabs, access roads, earth dams etc. and rehabilitate all the sites to acceptable
environmental condition as much as possible. The re-usable materials such as roofing
sheets, windows, timber fences, etc. shall be salvaged for future use. The rubbles and other
unusable materials from all these shall be disposed at the council dumping sites in the area.
The compacted areas shall be scarified using the motor grader to a certain depth, at least
200mm, and plant back the top soil to promote vegetation grow and give nominal
compaction to give it stability against erosion. The temporary dams will be filled with soil, in
layers compacted to at least 90% Mod AASHTO for lower layers and given nominal
compaction on the final layers. All temporary culverts will be removed and the water courses
opened up for free drainage. The borrow pits and the camp sites will be rehabilitated as per
the relevant method statements and the requirements of the EIA. All the temporary licenses
and permits given shall be returned as required to the issuing offices/owners and clearance
certificates for camp sites, borrow pits and quarries obtained from the relevant authorities.

c) General Plan of Protection of the Site and Environment

1.1 Safety, Health and Environment
All new staff and labour will be required to participate in a compulsory pre-entry induction
course, designed to impart Safety, Health and Environment and Security information before
commencing any works on site.

The general safety of the site and the successful completion of the works is wholly
dependent on the commitment of the site management to safety, health and environment.
The site management is required to provide strong leading role towards positive safety,
health and environment performance. The SHE manager/ officer shall be responsible for the
day to day running of the entire site SHE issues. The SHE officer shall have safety
11
representatives and Site Engineers to assist him in achieving the site safety requirements.
The Contractors Project Manager remains ultimately responsible for the safety of the site
and of the employees.

Personnel Protective Clothing will be made available to the entire workforce, and in addition,
dust masks, goggles, gloves, gumboots and waterproofs will be issued where appropriate.
Safe working practices will be adopted. Care will be taken to ensure the issue of proper tools
and safety equipment, and ensure the correct usage thereof. All equipment, plant, tools and
machinery will be properly maintained and operators will be instructed in correct operating
procedures. The operations areas shall be marked hard hat areas and no employee shall
enter without hard hats on, and other safety notices will be erected where required, such as
at fuel issuing points. Fire fighting facilities will be provided in accordance with the risk
assessment requirements and clearly marked. The employees will be educated on
environmental issues such as snake bites, animal attacks, environment protection etc. No
open fires shall be allowed on site. Each crew on site shall have a safety representative and
a first aider equipped with all necessary first aid kits.
We have adequate Engineers who will assist the SHE Officer to educate our site staff to
overcome any prohibitions and statutory provisions relating to health and safety.

All services, including potable water, sewerage and refuse collection will be operated in a
manner designed to prevent disease, insects and vermin. All ablutions, kitchens, mess halls
and other facilities will be cleaned regularly, and will be properly ventilated. Standing water
will not be permitted. Condoms will be made available to all employees. Regular meeting
will be held to educate the workforce on HIV / AIDS and other sexually transmitted
infections. The site staff shall utilise the available health facilities available in and around
Molepolole for treatment of any ailments and/or injuries that may be sustained on site. Any
major referrals shall be taken to Gaborone hospitals which is accessible from all the villages
along the project route. The Contractor shall have fully trained first aid staff assigned to each
section of 50 people or more to attend to any emergencies on site before the patient is taken
to the health facilities. We shall also provide an ambulance manned by 2 paramedics on site
covering the whole site for serious medical emergencies.

All quality control which is necessary in terms of the contract, or which is required by way of
good practice, will be carried out using correct methodology. Responsibility for the QA/QC
function on site will rest with the QA/QC manager and the Project Manager.

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1.2 Protection of Services Where Required
It was observed during the site visit some services which cannot be relocated will need
protection during construction. The services include private farm fencing, existing
structures – buildings, working in close proximity to the water lines, crossing of existing
roads, working in proximity to communication towers, existing boreholes etc.

1.3 Storm Water Drainage

The Contractor will ensure that all areas within the site and at the camp site are well drained
and natural water courses are not impeded through material stockpiles or windrows. During
the construction of the works all efforts will be made to keep an updated daily weather record
and review weather forecasts for planning the works accordingly. The works will be
protected through temporary construction of mitre drains that will drain water into open
ground or farmland with the respective owners’ consultation. Every effort will be made to
complete each day’s section of constructed pipework sections during rainy season to avoid
damage from collected stormwater.

At the end of construction of the works prior to demobilisation all temporary haul roads,
bypasses and hard stand platforms from the contractor’s camps will be obliterated by
scarifying lightly to allow promote rain water percolation and natural vegetation cover. The
borrow pits will be rehabilitated in accordance with the specifications and formed to collect
rainwater on the lowest points for future cattle and wildlife watering holes.

1.4 Waste Management and Pollution Prevention Control

There is a specific detailed method statement on how the waste shall be managed during
the course of the contract and the environmental protection plan for this contract; these can
be referenced where more detail is required. The contractor shall provide adequate waste
collection bins at strategic points covering all areas of work and waste shall be collected
effectively and disposed of at designated waste disposal sites in the vicinity of the project
location. The contractor’s environmental officer and his team which includes the SHE crew
and site foremen shall ensure that the waste is disposed into waste collection facilities at all
times. All the waste shall be handled, stored and disposed of in accordance with the
regulations of Department of Waste Management and Pollution control and the Employer
and any other applicable legislations and/or bye laws.

The employees shall also be provided with portable chemical toilets where access to the
permanent latrine facilities is not possible. These toilets shall be placed at all work fronts to

13
ensure that the employees do not get tempted to use the unacceptable facilities. The
employees will be trained through safety and environment talks on how to handle waste and
to look after the environment. All the fuel/oil containers shall be bunded to avoid any
seepage into the ground that may pollute the underground water. The construction vehicles
shall have designated routes away from the public roads where possible to reduce
interference and/or environmental impacts. The construction plant will be regularly serviced
to reduce the amounts of fossil gases emitted into the atmosphere from the plant and
vehicles engines to minimise the air pollution.
Dust will come from the plant and equipment working on site and driving along access roads
and haul roads. Most of the dust caused by plant and equipment on site will be controlled by
the sprinkling of water using water carts on the project. All the employees will be issued with
the relevant PPE and will be trained on its safe use thereof. The batch plant shall be located
away from the flood lines and/or drainage lines. The sludge from the batch plant shall be
trapped into proper sludge storage facilities and shall be maintained to avoid pollution of the
storm water.

1.5 Traffic Management Plan

The traffic management plan will be updated with maps showing access to the site from the
A1 road to the site camp, offices, workshop and the various locations within the site. The
maps will be drawn up to true coordinates and will be helpful in guiding suppliers and site
staff in getting their orientation correct at all times. The traffic management plan will also
focus on the regulation of traffic movement within the site for both the Contractor’s vehicles
and through traffic within the project Villages. For this tender the traffic management plan
has been prepared and is attached to the Project Management Plan.

d) General Provision of Utilities and Services

1.1 Site Power
Power will be provided from the BPC sources in the vicinity of the site and shall be
reticulated within site to supply the offices, laboratories, workshops, batch plant etc. where
this is not possible and/or proves uneconomical, power will be generated from 50KVa
generators or bigger as may be designed by the contractor’s electrician. There will also be
some backup generators as may be required for power outages.

1.2 Communication
Telephones for communication with head office and other stakeholders will be from the
Botswana Telephone Network. Communication within site personnel shall be by means of

14
radio network and cellular network. We will also connect the fax machines and internet
facility from the local internet suppliers for use by site office.

1.3 Toilet Facilities

The Contractor shall provide water borne latrine facilities with conservancy tanks and
portable chemical toilets for use at the site of Works. Portable toilets along the works will be
relocated with the progression of the works. These will be serviced and cleaned regularly to
maintain a high standard of hygiene for the site staff. The camps shall be fenced with
security fencing and equipped with all necessary safety and fire fighting equipment. All
camps shall have 24 hour manned security.

1.4 Fuelling Arrangements

Fuel storage facilities will be constructed near the contractor’s workshops with satellite
storage facilities at the quarry. Bunded wall construction (0.5m to 1.5m height) with a
concrete base will be made for the fuel tanks with capacity to hold the greater of at least
110% by volume of the largest tank or 25% of the combined tank volume. Deliveries by
suppliers to site will be as per the site requirements. All vehicles will fuel at the storage
facility located near the workshop. Fuel deliveries to site will be through diesel bowsers for
heavy plant at borrow pits or parked at site.

A vehicle lubrication bay and mobile lubrication unit will also be provide to service the
equipment at the workshop and on site. Spill kits will be available for use on site in the event
of plant breakdowns and leakages.

15
 Bulk fuel Tank in bund wall containment.

ii. Construction Method Statements

a) Structural Components
1 Chambers
Purpose:
This method statement describes the sequencing for the construction of concrete chambers
with associated pipes, pipe fittings, valves, control valves and meters. The types of
chambers being discussed here are for:
 Isolating valves for uPVC
 Isolating valve chambers
 Scour valve chamber
 Air valve chamber
 Non-return valve
 Inlet flow control valve chamber
 Flow control valve chamber
 Flow meter type 1, 2 and 3 chambers
 Motorised valve chamber
 Isolating and control valve chamber – 200 dia.
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References: Project Specifications , Supply and Delivery of Valves, SANS 1200 G, SANS
1200 L, Conditions of Contract, Book of Drawings as provided with the tender documents. .

Materials: Aggregate, Cement, Sand, Reinforcement, Formwork, pipes, fittings, valves,

meters, control valves, air valves.

Personnel: Project Manager, Site Agent , Quantity Surveyor, Land Surveyor, General
Foremen, Unskilled, Semi-Skilled and Skilled Labourers, QC Engineer / Materials
Technician, Tradesmen, Charge Hands, Plant Operators, Drivers, SHE Officer, Trades
Foreman / Charge Hand.

Plant: Mobile Crane, TLB, Flatbed truck, Tipper trucks, Roller compactor, Concrete vibrator,
immersion type, Concrete Mixers

SHEQ
 Toolbox talk to sensitise workers on possible dangers associated with working
on the concrete construction sites
 Full PPE to be worn by all workers at all times
 First Aiders and SHE Officer to be available full time on site to monitor the
works.
 All equipment to be serviced and maintained regularly. All service registers
are to be kept in the SHE File.
 Sampling testing and grading of aggregates
 Preparation of concrete mix designs
 Signing off of relevant QC inspection forms
 Cement purchased from local suppliers should be delivered to site in bags
covered with tarpaulin. Usage will be on a first in first out basis. No cement
will be kept on site for a period exceeding 3 months. Cement will be stacked
on palates lifted off the ground.
 Pre-start inspections are made on all machinery.
 Precast concrete measurements are calculated from the drawings.
 Sourcing of the pipe fittings, valves and associated pipework.
 Formwork is sourced and delivered to site.
17
  All works are inspected, checked and approved by the Project Engineer on a
continuous basis.
 Factory tests and certificates will be managed by the Quality Control Engineer
through the Quality Control Test Plan by the Project Manager.

Responsibility
 The Site Agent 1 will oversee this work and will be assisted by the Site Agent,
Materials Technician and the Concrete Foreman. The Project Manager has
overall oversight of the progression of the works and is assisted by the project
team.

Construction Works
 EIA and AIA approvals for commencement of excavation are sought.
 Ensure the pipe is already installed up stream or down stream or both sides.
 Setting out and excavation is carried out to the specified dimensions and
extents of the structure. Check dimensions of excavations.
 The types of valves used on this project include Gate Valves, Butterfly Valves,
Air Valves, control valves and flow meters.
 Procure the Project Engineer’s and Environmentalist’s approval to proceed
with the works.
 The concrete plant is erected together with the cranes and concrete pumps
and tested.
 Setting out of all concrete structures will be carried out as detailed in the
method statement for setting out.
 Excavation for the foundations is carried out, the trench bottoms and sides
trimmed, watered, compacted and blinding is cast. All foundation trench levels
are set out prior to casting the blinding.
 The setting out and levels are checked and approved by the Project
Engineer’s Surveyor.
 Pipework is covered and protected at all times during excavation.
 Formwork for floor slab, steelwork and starter bars for walls is installed.
 Formwork is erected on the sides and floor slab. The shutters are set out to
square and level and aligned to the correct orientation as per the drawings.
Shutters will be purchased from a local supplier, UNI-Span who will be
responsible for the preparation of the formwork design. The Project Engineer
will approve all the works at every stage. Trained and skilled formwork teams
18
 will be employed. Local staff employed in the villages will also receive training
during the course of the project.
 Reinforcement will be assembled to the floor starter bars for the walls.
 The steel fixers will be local Citizen steel fixers including the shutter hands
and foreman.
 Prior to casting any concrete the Project Engineer is invited to inspect and
approve/disapprove the pre-concrete works preparations.
 The concrete is prepared at the mixer and transported to the site using
concrete trucks.
 Testing to be done includes: slump test for workability, concrete test cubes (6
number) will be collected per 50m3 of concrete cast and tested through
destructive – compression testing at 7, 14, 21 and 28 days. All batches of
cubes cast will be clearly labelled and dated together with information on
location of structure and time the concrete was cast.
 Concrete floor slab is poured. The concrete will be poured by pump and
mobile crane and concrete bucket where necessary. The concrete will be
vibrated with mechanical pokers as it is poured.
 The concrete is levelled using straight edge tampering tool. Wood float finish
is applied to the concrete by a skilled bricklayer.
 The top of the slab is cured by applying sand and keeping it moist at all times
for the full 21 days of curing.
 After the concrete is cured and the cube crushing tests have proved to comply
with the specifications the shutters are stripped and cured as per
specification.
 Connect all puddle pipes, valves and fittings and make stand on temporary
plinths.
 Scaffolding is erected for safe access whilst constructing walls.
 The wall formwork is assembled and erected first on one side to allow for the
steel fixing to be completed on the walls.
 The reinforcement is fixed as per the drawings.
 Spacer blocks are positioned as on the outer and inner wall of the
reinforcement.
 The formwork is closed around the reinforcement, levelled, plumbed and the
walls are squared off and aligned to the true position.
 Water bars and concrete joints are inserted at the positions shown on the
drawings.
19
  The concrete is then cast into the walls in one lift using the tremie pipe. Cast
concrete to walls. Walls may be cast in one lift and the use of tremie's will be
incorporated to prevent the concrete from segregating. The concrete will be
poured using the mobile crane. The concrete is vibrated as it is being cast in
layers.
 The concrete is levelled off with a straight edge. The tops of the walls are
floated to wood float finish.
 The concrete is cured with water and moist sand for at least 21 days or as
directed by the Engineer.
 The wall formwork is stripped and cured as per specification.
 The formwork sections are moved to the next chamber. The process is
repeated until all the chambers have been cast. Waterproofing is applied to
the outside of the chambers prior to backfilling and compaction.
 Backfilling is done to the levels specified on the drawings behind walls in
150mm layer thickness and compacted to specified densities as per
specification.
 The precast concrete cover slabs will be placed by a mobile crane

Documentation
 Approved concrete mix design
 Approved setting out and commencement of the work
 Approved inspections – signed Request for Inspection: reinforcement, formwork,
spacers, slump and workability
 Approved completed works
 Approved test results – concrete cube crushing

2 Reinforced Concrete Reservoir:

Prior to starting any new activity, a ‘Notification to Start Activity’ (NSA) form shall be
submitted to the Engineer for approval.

The details for the reinforced concrete reservoir are given on drawing numbers
KLC/CIV/372, KLC/CIV/373 and KLC/CIV/374. Setting out of the tank position will be done
by the Surveyor. The Engineer will be requested to approve the setting out for the tank
position.

The sequence of activities for construction of the reinforcement shall be:

20
  Clearing and grubbing as applicable
 Setting out horizontal and vertical controls and approvals by the Engineer
 Excavation trimming and compaction of insitu and approvals by the Engineer
 G5 gravel backfill and compaction to formation layer and approvals by the Engineer
 Blinding concrete and approvals by the Engineer
 Base slab steel fixing, wall starter bars, column starter bars, placing washouts and
formwork and approvals by the Engineer
 Casting base concrete and approvals by the Engineer
 Steel fixing to walls and columns
 Formwork to walls and columns including support framework and working platforms
including placement of fitments that are embedded in the concrete walls and
columns.
 Casting concrete to walls and columns in appropriate lifts as per specification.
 Stripping wall and column formwork
 Formwork and steel fixing for reservoir roof.
 Concreting reservoir roof
 Curing of concrete is an ongoing process at each stage of the concrete pour.
 Admixtures and water bars for water proofing will be placed by a waterproofing
specialist.

2.1 Setting Out

 The limit of the working space may be set-out on the ground (the limit shall include
working space around the foundation for casting retaining walls and waterproofing
works). Or shall be marked temporary structures such as a side rail as reference, in
accordance with the approved drawings.
 Over-excavation - Care will be taken not to excavate below the required level (the
excavation shall include 75mm for the thickness of blinding or no fines concrete
finished off with plaster, approved 25x15mm sealant).

2.2 Compaction
 The bottom of the excavation will be cleared from debris and extraneous material.
 The formation level willl be sprinkled with water to achieve the required O.M.C for the
soil, which shall be then compacted by means of a vibrating compacting roller or a
vibrating plate compactor.
 The compacted area will be tested to determine the degree of compaction (i.e. not
less than 95% of M.D.D).
21
  To determine the Safe bearing pressure of soil under footing Plate Load Test shall be
conducted as instructed by the Engineer.

2.3 Consultant’s Approval

 No permanent works activities shall be carried-on in the compacted areas, prior to
receiving approval from the Engineer.

2.4 Anti-termite Treatment

 Anti-termite treatment shall be applied according to the applicators approved method
statement and covered with one layer of 1000 gauge polythene sheet.

2.5 Blinding Concrete

 Blinding concrete to the approved mix design shall be poured to thickness of 50mm
in all horizontal areas.
 The blinding shall be finished to a uniform level. The surface of the blinding concrete
shall be steel float finished, and smooth enough to receive the approved water-
proofing membrane.

2.6 Backfilling & Compaction

 The surrounding area of lift pit shall be back filled in layers not exceeding 150 mm,
using approved material and compacted not less than 95% of M.D.D. up to the
bottom level of blinding under slab on grade.

2.7 Preparation
 Areas to be placed with concrete shall be maintained in clean condition, free from
trash, debris, sand and other foreign matters.
 In hot weather conditions, area to be placed with concrete shall be suitably covered
and protected by tarpaulin sheet placed 20cm above the reinforcement. Water shall
be sprayed on forms, reinforcement and base prior to pouring the concrete.
 Prior to placing, following items shall be checked by respective site supervisor:
o Survey check review: deviation of line, grade, plumb and location of
embedment.
o Final clean up.
o Joint preparation.
o Dampness of surface to receive concrete
o Site Agent shall initiate Concrete pour record & Inspection Request.

22
Design of Joints
This is perhaps one of the most important consideration for purpose of construction and
serviceability of the storage tank. Construction joints will be planned carefully with respect to
the "day's work", vertical lifts increment and curing. Unplanned stoppage due to rain,
equipment breakdown, or for whatever reasons will be costly and remedial works are usually
ineffective. Movement joints due to curing, short and long term shrinkage, expansion and
contraction, or even possibility of structure subsidence will be considered and provided
carefully. Both construction and movement joints will be synchronized. Joints are shape
dependent, and will be kept to simple shapes to make it easier to predict best positions of
joints.

Preparation of Foundation
 The existing ground, surrounding the tank extending not more than 300mm, or as
decided on site to suit, will be carefully over-excavated to a uniform & reasonably
level finish, using power tools, excavator, ripper or suitable tools to the designed
foundation levels.
 Where over excavation has occurred, the filling will be done with granular material
compacted to 98% MOD AASHTO or with mass concrete as agreed with the
Engineer.
 Foundation Levels will be re-checked by the Surveyor for level accuracy.
 Internal ground slabs will be constructed in individual panels as per construction
joints in the drawings. The sides consist of 12 panels with curved edges while the
central panel consist of one continuous slab/footing. The outer panels made up of
foundations of retaining walls, will be constructed in 12 individually panels. The exact
number of panels will be discussed with the Engineer and be subject to approval on
site.

Anti-termite Treatment
 Anti-termite treatment shall be applied according to the applicators approved method
statement and covered with one layer of 1000 gauge polythene sheet.

Formwork
 Plywood Formwork will be placed according to panels in alternate sequence, such
that when one panel sets, it's sides will be coated with bitumen and used as
23
 "formwork" for continuing panels. Bitumen will be used to coat the Formwork as
release agent.
 Formwork may be reused twice depending on conditions.
 For curved sides, thinner plywood formwork in single layer will be used. They will be
bent slightly to suit the radius of the tank & fixed onto timber frame. Where bending
cannot be achieved without cracking the formwork, small straights of 600mm will be
used to form the incremental curve.

Reinforcement
 The reinforcement will be fixed with spacers at the bottom to allow for the cover and
from the top reinforcement adequate cover is left, with discontinuity at joints.
 The reinforcement will be tied into a grid and will be bent at joint slightly if equipment
permits, or if not practical, additional bent & lap bars will be used, allowing for cover
at all sides.
 Mesh reinforcements is held in position by shaped concrete block or purpose made
rebar seat. Pass through is not permitted.
Waterstop
 Waterstop will be constructed at all joints as per drawing.
 The water stop will be placed in position in accordance with the design preferrably
installed horizontally at mid-level, from top slab level, using 2-part split formwork, well
clamped together to prevent movement during concreting works. The stop-end will
terminate at mid-point of the water-stop. Care will be taken at water-stop intersection
to ensure adequate overlap.
 Manufacturer's recommendations for the water-stop fixing will be used where
applicable.

Concreting
 Concrete pour will utilize pumps direct from Concrete Mixer Trucks for speed and
ease of delivery. At least 2 concrete vibrators will be used at any one time. Where
pumps are not available, or breakdown, manual delivery via wheel-burrow will be
used. To ensure continuity of pour, both contingencies will be provided for. Water
proofing additives for water proofing and making the concrete water tight will be
added to the concrete in accordance with the design and approval of the Engineer.
 During concreting, care will be taken to ensure concrete beneath the water-stop is
well vibrated and filled, to avoid voids and weakness.
 Slabs &foundations will be constructed simultaneously. Where vertical walls are to
24
 extend up, lap bars, construction joints & water-stops will be placed first.
 Internal circular panel slabs & foundation will be constructed first, starting from one
side of the base, and progressing on alternate panels to the other finishing sides.
Thereafter, the outer ring Retaining wall slabs will be constructed with vertical lab
bars, water-stops & joints.
 Once concreting is completed, it will be covered with one layer clear polythene sheet,
and constantly watered with fine spray for a minimum of 3 days. Once concrete has
cured the minute line marks left by polythene sheets may be additionally surface
grind to smoothen out.

2.8 Concrete Placement

 Upon arrival of transit mix truck at site the delivery note will be checked for the actual
details like time of batching, quantity, mix type, approved mix design, variation in
weighing of materials, water cement ratio & slump checked regularly to the
satisfaction of the Engineer.
 Concrete Temperature shall be measured using Thermometer and the maximum
allowable temperature of concrete shall be 32 degree centigrade.
 One set of six (6) cubes for each 50 cum. Or fraction thereof of each concrete class
placed in any one day or for each 450 sq.mtr of surface area placed.
 One specimen shall be tested at 7 days and 4 specimens shall be tested at 28 days.
One specimen shall be retained in reserve for later testing, if required. Two
specimens tested at 28 days shall be field cured. All others shall be laboratory cured.
 Slump test shall be carried out for each concrete load at point of discharge and one
for each set of compressive strength test specimen.
 Air content test as per BS 1881 part 106, pressure method; shall be carried out one
test for each set of compressive strength test specimen.
 Durability test for concrete shall be done as specified and when directed by the
Engineer.
2.9 Formwork
 All formwork shall be properly secured, supported and protected from collapse during
the concreting exercise.
 Formwork shall be placed plumb to dimensions and levels as per the design and
specifications.
 A stripping compound that is no staining shall be applied on all the formwork.
 Formwork shall be struck off after the specified period has elapsed for each section
of the reservoir.
25
2.10 Reinforcement
The reinforcement shall be placed as detailed in section 8 of this document.

2.11 Placing of Concrete

 No concrete shall be placed during sand storm or rain.
 No water shall be added to the mixer truck after batching.
 Site Agent shall take immediate steps to notify the Engineer when a cold joint is
imminent and shall assure that the required method of correcting it is adopted as
detailed on the drawings.
 Pump car, bucket and chute will be used as placing equipment as appropriate.
 Chutes shall be used for drop of concrete greater than 1.0mtr in case of thin walls
and 2 meter in other work. In case of slab work it shall be 250-500mm.The slope of
chutes should be constant and steep enough to permit concrete to flow continuously
down the chute without segregation(1:2 or 2.5 slope)
 Concrete shall be deposited in horizontal layers to a compacted depth not exceeding
450mm and in a manner to avoid inclined construction joints.

2.12 Procedure for compaction of concrete

 Concrete shall be consolidated by mechanical vibrators. The vibrators shall be
adequate in number of units and power of each unit to properly consolidate all
concrete.
 In consolidating each layer of concrete, the vibrator shall be operated in a near
vertical position, and the vibrating head shall be allowed to penetrate under the
action of its own weights. Vibrator shall be allowed to remain inside the concrete for
sufficient time to obtain proper consolidation of concrete.
 The vibrator should penetrate rapidly to the bottom of the layer and at least 4 inch
into the preceding layer.
 Vibrators shall not be used to move or spread concrete.
 Concrete shall be placed as soon as practicable after mixing and while sufficiently
plastic for full compaction.
 Concreting during hot weather (Temperature greater than 40 deg. Centigrade) shall
be avoided as much as possible to prevent the occurrence of severe thermal effects.
 After concrete placing, Site Agent/Supervisor shall record relevant details on the
format ‘Concrete Pour Record’ in presence of Engineer.

26
Construction of Circular Walls
 The Vertical Circular Walls is constructed in 5 vertical increment panels and 12
circular segments, with construction joints as per the design.
 Metal scaffolding & Timber platform & staging will be constructed on both sides of the
wall. The staging will be used to brace &support the formwork and at the same time
provide working platform.
 Formwork shall be made of clean metal sheet factory curved to appropriate radius for
external & internal surfaces and cut to fit. The formwork will be held in place by
external brackets welded and/or nailed to the timber staging. Joints between panels
will be close fitted either nailed to staging and/or bolted together by brackets. The
lower formwork will extend into old concrete kicker or walls by not less than 50mm,
with firm fit, while the upper will be level flush with the horizontal joint. Key Joint will
be made with water-stop as per drawings. The vertical sides of wall will be formed
with specially shaped metal sheet by 2-part split to allow for vertical water-stop as per
drawing.
 Vertical & horizontal reinforcements will be laid as per drawing and held in position by
shaped concrete block or purpose made rebar seat from external wall, with no pass-
through into any internal walls or joints.
 Where a pass-through rebar seat is required, a purpose circular plate will be welded
at mid-point. Alternatively, where required, the bars will be temporarily held in place
during concrete vibration, and subsequent withdrawn on completion of vibration and
opening in formwork sealed immediately.
 A non-staining release agent will be applied onto the clean metal sheet formwork.
 Concrete will be cast via pump delivery starting from one end of the panel, spread
horizontally, vibrated and incremented accordingly until to horizontal joint and water-
stop.
 Once casting is completed, exposed concrete surface will be toweled smooth and
covered with one layer polythene sheet, wetted and cured.
 Once surface is cured, joints will be painted with 2 coats bitumen subject to
Engineer’s approval.
 Formwork will be dismantled in 10 days, or as appropriate, for next panel
construction.
 The process is repeated until the whole 12 panels for each horizontal wall is
completed.
 The procedure is repeated for next increment of wall height, until the roof level, with
adjustment to formwork shape for internal surface each panel.
27
  Once formwork is stripped, the surfaces are checked carefully for honeycomb,
irregularities, or blemishes. Repairs will be carefully made to the surface by touching
up. Any honeycomb surface will be further treated with an approved brush-on
sealant.
 Internal walls will be natural finish while external walls will be smoothen out and
painted.

Construction of RC Columns
 RC columns will be constructed in 2 stages, each 3.675m, with staging to suit.

Construction of RC Roof Slab

 Temporary staging using the RC Columns as support would be made consisting of
timber joists or where practical, steel H-beams, or a combination of both, which will
support plywood formwork. Alternative, metal staging will be erected and plywood
formwork supported by a series of timber joists & braces.
 Contraction Joints are also made for roof slab, similar to base slabs, with the
exception that the bars are continuous through joints.
 Concreting procedure will be similar to base slabs.
 Reinforcements are tied with concrete or rebar seats, with or without pass through.
 Curing procedure will be similar to base slab.
 Formwork will be removed progressively as the slab is cast.
 A mobile staging will be made to touch up the underside of roof slab. It will be
maintained as natural finish.

Embedded Items

 Anchor bolts, Pipe sleeves, Conduits for electrical works, drains, curb and trench
angles, and other inserts as shown on the design drawings shall be placed, secured,
and protected during placement of concrete.
 Engineers of relevant discipline from the Sub-contractor side shall check installation
of embedment.
 Care will be taken to ensure discontinuity or if unavoidable, use of appropriate
approved joint sealant would be used.

Prior to starting any new activity, a ‘Notification to Start Activity’ (NSA) form shall be
submitted to the Engineer for approval.

28
2.13 Finishes
 Concrete finishes shall be as required in specification and shall be free from voids,
honey combing or any other defects.
 All concrete shall be power floated to produce smooth even finish unless otherwise
specified. Hand trowelling shall be carried out to surfaces of footings, beams etc.

2.14 Curing
 During and after placement, concrete and the exposed surface of fresh concrete shall
be protected from wind, high temperature and rain. Curing shall start as soon as free
water has disappeared from the concrete surface after placing and finishing.
Concrete surface shall be initially covered by only polythene sheet. Then after
required hardening, place the wet hessian cloth and cover with polythene sheet.
 Concrete shall be cured for a minimum of 7 days. Curing compound, if used, shall be
approved by the Engineer.

2.15 Concrete Repair

 Repair method of defective concrete shall be determined or selected by Consulting
Engineer or in accordance with the disposition of issued Non Conformance Report.
3 Sump Tank
Prior to starting any new activity, a ‘Notification to Start Activity’ (NSA) form shall be
submitted to the Engineer for approval.
3.1 Earthworks
3.1.1 Excavations setting out
 Topsoil shall be stripped to a depth of 150mm.
 Profiles for excavations shall be set out at an offset of at least 2.5m from the edge
line and shall be on either side of excavation pit for easy control of excavation levels.
 The alignment shall be marked with a different coloured soil for visibility to the
excavation operator. A checker/spotter will be available at all times.
 The excavation levels shall be set on these profiles using nail and/or batter boards.
 The profiles shall be salvaged as soon as the excavation has been completed.

3.1.2 Excavation
 After setting out of the foundations excavation using a TLB will commence.
 Excavations will be done accurately cut to the lines and levels shown on the
drawings and approved by the Engineer.

29
  Any formation which becomes waterlogged or otherwise spoilt shall be cleaned out
and reformed to the original level at the expense of the Contractor and to the
satisfaction of the Engineer before any further material is placed.
 The Contractor will provide all timbering, sheet piling and other supports as are
necessary for securing the sides of trenches and excavations and will be responsible
for their safety.
 Excavation shall be deposited clear of all footpaths, roads, paved areas and lines of
services.
 The insitu material shall be scarified and mixed with water and re-compacted to 90%
MoD AASHTO at 1% OMC.
 One layer of 150mm G6 gravel is placed and compacted to 93% Mod AASHTO at
OMC.
 One layer of 150mm G5 gravel is placed and compacted to 95% Mod AASHTO at
OMC.

3.2 Concrete, Reinforcement and Formwork

Details for concrete production, transportation and placing is detailed in section 5 of this
report. The method statement for Formwork and Reinforcement are detailed in sections 6
and 7 respectively.

Upon completion of excavation, the foundation trenches are prepared by:

 Trimming of foundation base and sides

 Compaction of insitu material
 Compaction of hardcore backfill
 Installation of formwork
 Installation of reinforcement and holding down bolts
 Concreting the bases

3.3 Structure
3.3.1 Assembly and Erection
 The GMS framework is fabricated at the specialist subcontractor’s work shop in
Gaborone.
 Delivery of the steelwork shall normally be in 30 ton semi-trailer trucks on just in time
delivery sequence in order to alleviate site congestion, and minimise double handling
and on site damage.

30
  For transport and delivery to site of bolts, nuts and washers the following shall be
noted:
o They shall be provided with adequate packing, sufficiently protected to avoid
damage during transport.
o In the case of high strength bolts, both bolts and nuts shall be adequately
greased each package shall contain only one type of bolt, nut or washer of
the same diameter, length and quality.
o Each package shall be provided with a label, indicating the manufacturer’s
mark, the type (bolt, nut and washer), the quality and the number.
o High strength bolts are indicated by colored labels, according to the type and
quality.
An inspection of the foundation, to check the levelling and alignment of the anchor bolts,shall
be made before erection commences.

A fixed levelling point and three fixed alignment points shall be established for this purpose.
Errors in the foundation identified at this stage, shall be corrected using packer plates. The
foundations shall be cleaned prior to erecting the steelwork. The site supervisor shall ensure
that the cavities for holding down bolts are completely free from contamination.

Works at a height shall be minimised by the use of sub-assembly units where practicable.
Where sub-assembly shall be carried out on site, it shall be done behind the lifting
equipment in order that the assembly can be lifted straight off the ground and into position.

During lifting damage shall be minimised on the paint treatment by the use of softwood
packers and to ensure that the load will not slip as it is being lifted and that the sling-chains
or wires are not damaged.

Where the structure needs additional rigidity during erection temporary stiffening shall be
used to ensure the rigidity of structure until the permanent connections are made.

3.3.2 Holding Down Bolts

Movement tolerances are accommodated in the foundation to ensure that correct alignment
takes place. After checking and confirming that holding down are acceptable, typical 100 mm
x 100 mm steel packs (1-20 mm thick) or similar are placed on the base to the required level.

Bolting Connections on Site

Before carrying out any bolted connections checks shall be made to ensure:

31
  The bolts, nuts and washers to be used shall be exactly as indicated on the
drawings.
 Bolts, nuts and washers shall be cleaned and undamaged.
 The parts to be connected shall be cleaned and without defects.
In connections with tapered flanges, tapered washers shall be placed under the nut, the bolt
or both. In the case of a hole with a vertical axis, the bolts shall be inserted from above, with
the nut at the bottom.

3.3.3 Galvanized Mild Steel Tank Assembly

Installation of Galvanized Mild Steel Water Tank will be carried out by specialist contractor
based on the following steps and shall be done in accordance with the approved shop
drawings and specification and approved material submittal.

 Proper coordination with main Contractor is done to ensure exact dimensions of the
base plinth of the Galvanized Mild water tank mountings and floor plan for the
structural. Markings shall be done for reference.
 Working inside Galvanized Mild Water tank will not proceed unless all safety
regulations and procedure are met for a Confined Space.
 All major components of the tank will be checked for completeness and available as
illustrated on water tank cutout list attached in the material submittal.
Step -1: All the panels are identified using the parts list.

Step -2: The drain panel will be fixed on the bottom of the tank base which is shown on the
approved material submittal and registered manual of the manufacturer guides and layout
the exact location to be confirmed prior to assembly.

Step -3: The manhole cover will be fixed on the roof of the tank. But it can be fixed after all
the side walls and base of the tank is assembled should be fixed above the inlet connection
to facilitate access to the ball valve if required

Step -4: The side panels of the tank at 1.5 meter high or more are designed to receive the
inlet and outlet and overflow connection flanges.

Step -5 Inlet and outlet and overflow are coordinated with given elevation of the incoming
piping network.

Step -6 The sealant is placed between the side panels which are subsequently bolted
together to the final tank height.

Step -7 The roof panels are bolted together and the vent pipe is placed at the highest point.

32
Step -8 The GMS step ladder is erected and bolted onto the structural frame and the tank.

3.4 Tests
Tests that will be carried out on the storage tanks include hydrostatic pressure testing and
disinfection.

3.4.1 Water Tightness Test

The procedure for testing for leakages is described in section 13 of the WUC Design
Standards DS 0295. The tank is filled with water at a prescribed rate and then examined
after 24 hours to ensure there are no cracks, pinholes, or other discontinuities in the
metalwork. The second purpose of the test is to confirm the mechanical strength of the tank.
If there are weak spots they will be evident when the tank is full of water, and far less
detrimental to workers and the environment. The final, and most critical observation made
during a hydrostatic test is the integrity of the foundation that supports it. The foundation is
one of the leading causes for tank damage. While the tank is full of water settlement can be
observed and measured in a controlled environment confirming its ability to withstand the
weight of a full tank and provide baseline measurements for comparison over time.

3.4.2 Disinfection
For disinfection, the procedures prescribed in section 12.2.2 of the WUC Design Standards
DS0295 and section 10.3.13 PSDP: Disinfection Procedures (Water Utilities
Corporation) of the Contract Specifications will be applicable. Upon completion of water
tightness testing, the tank is drained.

4 Underground Sump
Drawings referenced for this construction include drawings numbers S1130 to S1136 series
as provided with the tender documents. The proposed drainage scheme for the new sump
includes a pumping chamber and a cavity drain sump. The detailed methodology for
constructing the concrete sump is similar to the casting of the concrete reservoir, the only
difference being that the sump is rectangular whilst the concrete reservoir is circular in
shape. The reinforced concrete underground sump of capacity 2500m3 will be constructed
as follows:

Excavation

 Setting out will be as per the drawings and approval of the Engineer.
 Excavation will be to the design levels and imported compacted backfill required.
 Insitu material is scarified, water, mixed and compacted to 93% MoD AASHTO.

33
  Imported G5 gravel materials is used to backfill in 150mm lifts and compacted to 95%
MoD AASHTO.
 Upon reaching the formation level with the gravel backfill, excavation for the
underground drainage is carried out forming a trapezoidal shape.

Concrete Works

 50mm concrete blinding is cast as detailed in Section A-A of drawing number S1130.
 The 110mm diameter perforated geo-pipe is laid to connect to the 1250mm diameter
inspection manhole chamber located outside the sump footprint.
 The 19mm coarse aggregates are laid around the geo-pipe to fill the trench.
 The 75mm thick no fines concrete layer is placed and the surface finished off with
plaster.
 Concreting of the 250mm thick slab is done after the erection of formwork and
reinforcement.
 Columns will be cast in 4 lifts, each lift being 1200mm high.
 External sump walls will also be cast in lifts of 1200mm height to give a total of 4 lifts.
 The roof slab is cast last leaving openings for the equipment access.
 Approved waterproofing admixtures will be added to the concrete as required by a
specialist.
 Where a waterproofing membranes are required these will be installed by the water
proofing specialist.

Joints

 Saw cut joints will be set out within 24 hours of casting the concrete and cut with a
saw cutter to the specified depth and widths.
 Joint treatment will be carried out to seal of the joints immediately after.
 Expansion joints will be constructed as per the drawing details and water bars are
placed as specified.
 Construction joints will be executed in agreement with the Engineer and the
necessary water bars will be placed accordingly.

Formwork

 Formwork is laid around the bas slab to allow for a concrete thickness of 250mm that
will be cast above the no fines concrete.

34
  The formwork will be will supported within the sump pit (which would have been over
excavated to allow for working space) and constructed to lines and level and plumb
ness.
 No movement of the formwork will be permitted during concreting and it should be
laid in a manner to sustain the wet concrete loads and vibration during poking.
 Setting out for the circular column bases will be marked on top of the no fines
concrete.
 Staging, formwork and walkways will be placed around each column, bracing and
supporting it. Steel circular sections of formwork will be used to shutter the steel
reinforcement.

Cat Ladder

 HD bolts for the cat ladder are marked out, positioned within the reinforcement and
cast within the concrete
 The cat ladder is installed through the equipment access in sections and bolted onto
the HD bolts.

Reinforcement

 Setting out for the column footings is done and starter bars are placed within the slab
base as required.
 The design steel reinforcement will then be fixed in the slab (this will be checked by
the Structural Engineer prior to concreting) above the no fines concrete.
 The starter bars for the columns will be spliced once the slab and base concrete is
being cured preferably within three days.

Embedded Items

 Anchor bolts, Pipe sleeves, Conduits for electrical works, drains, curb and trench
angles, and other inserts as shown on the design drawings shall be placed, secured,
and protected during placement of concrete.
 Engineers of relevant discipline from the Sub-contractor side shall check installation
of embedment.

Curing of Concrete

Curing plays an important role on strength development and durability of concrete.

35
  Curing will be done immediately after concrete placing and finishing, and involves
maintenance of desired moisture and temperature conditions, both at depth and near
the surface, for extended periods of time.
 Properly cured concrete has an adequate amount of moisture for continued hydration
and development of strength, volume stability, resistance to cracking, and abrasion
and scaling resistance.

Hot Weather Concrete Construction

The precautions may include some or all of the following:

 Moisten subgrade, steel reinforcement, and form work prior to concrete placement.
 Erecting temporary wind breaks to limit wind velocities and sunshades to reduce
concrete surface temperatures.
 Cooling aggregates and mixing water added to the concrete mixture to reduce its
initial temperature. The effect of hot cement on concrete temperature is only minimal.
 Using a concrete consistency that allows rapid placement and consolidation.
 Protecting the concrete surface during placement with plastic sheeting or evaporation
retarders to maintain the initial moisture in the concrete mixture.
 Providing sufficient labor to minimize the time required to place and finish the
concrete, as hot weather conditions substantially shorted the times to initial and final
set.
 Fogging the area above the concrete placement to raise the relative humidity and
satisfy moisture demand of the ambient air.
 Providing appropriate curing methods as soon as possible after the concrete finishing
processes have been completed.
 Adjusting the time of concrete placement to take advantage of cooler temperatures,
such as early morning or night time placement.

Tests
Tests that will be carried out on the underground sump include hydrostatic pressure testing
and disinfection. Test on construction materials – concrete and aggregates will be as
described in section 6 of this documents for concreting .

5 Concrete Production, Transportation and Placing:

Purpose:
This method statement describes the production, transportation and placing and curing of
concrete for the project. The method statements below are general and apply to each
respective component of the works as detailed in the works breakdown structure and as
36
detailed on the construction drawings and specifications.
Responsibility:
The Site Agent is responsible for this work and will be assisted by the General Foreman,
Concrete Foreman, Formwork foreman, Steel fixing foreman and the team leaders working
on each activity related to the construction of the concrete works and structures.

SHEQ
 Toolbox talk to sensitise workers on possible dangers associated with working on the
concrete construction sites
 Full PPE to be worn by all workers at all times
 First Aiders and SHE Officer to be available full time on site to monitor the works.
 All equipment to be serviced and maintained regularly. All service registers are to be
kept in the SHE File.
 Sampling testing and grading of aggregates
 Preparation of concrete mix designs
 Signing off of relevant QC inspection forms
 Cement purchased from local suppliers should be delivered to site in bags covered
with tarpaulin. Usage will be on a first in first out basis. No cement will be kept on site
for a period exceeding 3 months. Cement will be stacked on pallates lifted off the
ground.
 Pre-start inspections are made on all machinery.
 Precast concrete measurements are calculated from the drawings.

5.1.1 Construction Works

 Where precast concrete member dimensions do not permit transporting over long
distances the site will prepare a platform of compacted gravel where forms are built to
dimensions and reinforcement is erected and the concrete cast in situ and cured for 28
days.
 Procure the Project Engineer’s and Environmentalist’s approval to proceed with the
works.
 Composition of concrete shall comply with that specified in the approved Mix Design.
Batching, mixing and delivering of concrete shall be performed in accordance with the
trial mix approved by the Engineer for the supply of Ready Mix Concrete.
 The concrete plant is erected together with the cranes and concrete pumps and tested.
 The concrete mix designs are done at early stage of the project with materials from
commercial suppliers e.g. PPC Quarries and or Belabela Quarries for aggregates. All
37
 aggregates will be transported in 30 tonne trucks to site.
 A continuous mix Karoo batching plant is erected on site. The concrete will be mixed
and dispatched to site using mobile concrete mixers. A standby concrete batching plant
shall be allowed for when batching concrete mix for the reservoir.
 All concrete should be placed within an hour of leaving the batching plant before
setting starts.
 Communication between the batching plant is maintained throughout the day to ensure
that only required volumes of concrete are batched in a day work.
 Prior to casting any concrete, the Project Engineer is invited to inspect and
approve/disapprove the pre-concrete works preparations.
 The concrete is prepared at the mixer and transported to the site using concrete trucks.
A minimum of 100 m3 of concrete is targeted to be cast daily.
 Testing to be done includes: slump test for workability, concrete test cubes (6 number)
will be collected per 50m3 of concrete cast and tested through destructive –
compression testing at 7, 14, 21 and 28 days. All batches of cubes cast will be clearly
labelled and dated together with information on location of structure and time the
concrete was cast.
 Concrete floor slab is poured on site. The concrete will be poured by pump and mobile
crane and concrete bucket where necessary. The concrete will be vibrated with
mechanical pokers as it is poured.
 The concrete is levelled using straight edge tampering tool. Wood float finish is applied
to the concrete by a skilled bricklayer.
 The top of the slab is cured by applying sand and keeping it moist at all times for the
full 21 days of curing.
 After the concrete is cured and the cube crushing tests have proved to comply with the
specifications the shutters are stripped and cured as per specification.
 Concrete for water retaining structures shall be 35MPA/19mm concrete. High quality
aggregates shall be used to reduce the water demand to 175 l/m 3 maximum and a
maximum cement content of strength concrete mixes 450kg/m3.

5.1.2 Concrete Curing

A curing compound shall be applied and covering exposed surfaces with protective
polythene sheeting to completely enclose the cast element within 1 hour after finishing.

Vertical or sloping faces of wall elements shall be cured by applying curing compound within
1 hour after stripping formwork and immediately afterwards enveloping the element with
38
polythene sheeting.

The curing compound will comply with the requirements of ASTM C 309-74 “Liquid
Membrane forming Compounds for Curing Concrete” Type 2. Suitable spray equipment will
be used to apply the compound.

Concrete surfaces shall be finished off as specified in regards to the type of floated finish to
be applied. The choice of formworks will also be done based on the specified surface finish.

5.1.3 Quality Assurance Documentation

 Cement factory material data sheet.
 Test results for aggregates: tests will be conducted for all concrete aggregates
delivered to site.
 Test of water: test of water from designated boreholes will be done every six months.
 Mix design as approved.
 Copy of respective batching and cast tally book.
 Cube test result.
 Water tightness test results for water retaining structures.
 Quality assurance form: The following QA forms shall be used.
 Concrete release form.
 Slump test record form.
 Concrete strength results form.
 Post concrete inspection form.

6 Formwork:
Purpose:
The purpose of this Method Statement is to control the specification input on the concrete
formwork.
Scope of Works:
This method statement describes the works to be done under this section defined as
concrete shuttering. This section deals with concrete shuttering in relation to all civil
structural works under this contract.
Shuttering activities required in the following sections of the works:
 foundation bases to all structures
 valve chambers
 water pipeline thrust blocks
39
  building foundations, floor slabs and beams
 beams
 slab edges
 columns
 walls
 roofs
 plinths
 pump stations

Responsibility:
The Site Agent is responsible for this work and will be assisted by the Site Engineers, The
responsibility for the works is placed on the Concrete team and the Concrete Foreman. The
team includes the operators, section leaders, survey team and the formwork team.

6.1.1 Health & Safety:

 Toolbox talk to sensitise workers on possible dangers associated with working
on the concrete construction sites is conducted daily
 Ensure that all employees have undergone pre-employment site safety
inductions.
 The employees to be briefed on major risks associated with the works.
 Conduct the pre-task risk assessment every time prior to starting works.
 The Contractor shall adhere to and follow the recommendations of the Clients
EIA.
 Ensure that the shutter hands are qualified and experienced.
 Full PPE to be worn by all workers at all times
 First Aiders and SHE Officer to be available full time on site to monitor the
works.
 All scaffolding be inspected by an accredited and qualified scaffolding
inspector.

6.1.2 Quality:
 All equipment to be serviced and maintained regularly. All service registers
are to be kept in the SHE File.
 Signing off of relevant QC inspection forms
 Formwork will be done as per the Professional Engineer’s approved drawings
requirements
40
  The Engineer will approve the formwork upon inspection on condition that all
formwork requirements of the contract have been satisfied.
 The Foreman to submit request for final inspection and obtain approval of the
works upon completion
 The signing off should be done on the designated form and signed off on the
Quality control Plan.
 Pre-start inspections are made on all machinery.
 Precast concrete measurements are calculated from the drawings.

6.1.3 Construction Works

General
Concrete form work to be used shall be of any of the two types depending on the
nature of the structure or structural member to be constructed, volume and pressure
of wet concrete and specified surface finish.
All concrete finish shall be as specified in sub-clause 4.3.1.8 SANS 2001 as follows
a) Rough: all external surfaces more than 150mm below ground level or concealed
or internal surfaces not exposed to the view.
b) Smooth: all surfaces not described in (a).
c) Special off-form surface finishes shall be as shown on the drawings
The type of formwork to be used in this contract are as follows:

 Timber formwork
 Steel formwork
All timber shutters shall be treated and free from any defect that may undermine the
required surface finish or shape of the concrete.

All steel shutters shall be free from any deformation, bends, wraps or uneven welds
and shall be free form dust or any chemicals that may have effects on concrete.

All shutters shall have sufficient strength to withstand the pressure resulting from
placement and compaction of the concrete and shall have sufficient rigidity to
maintain the specified tolerances.

 Ensure presence of the latest “approved for construction” drawings

 Identify and obtain specification approved shuttering
 Erect scaffold if required and inspect
41
  Ensure that the reinforcement has been approved
 Ensure that the formwork design has been approved by the Engineer
 Ensure that the correct form work is used for the specified design finish
 Ensure that the formwork is treated properly with approved release agent
compatible with the concrete finish quality

Work activities
 Set out the position of formwork as per the drawings
 Erect the formwork starting with the inner faces
 Erect the formwork on the outer faces
 Install all corner chamfers as required
 Install the spacers where necessary
 Install the bracers for support
 Ensure that all joints are sealed tightly to prevent local honeycombing and
leaching of concrete
 Call for inspection then pour concrete on approval of formwork
 The formwork shall remain in place, after all the concrete has been placed in the
relevant lift, for the appropriate minimum period of time given in table 2 of SANS
1200G, taking into account the prevailing weather conditions

7 Steel Fixing:
Purpose:
The purpose of this Method Statement is to guideline with relation to the fixing of
reinforcement steel.
Scope of Works:
This Method Statement describes the works to be done under this section defined as
concrete shuttering. This section deals with concrete shuttering in relation to all civil
structural works under this contract.
All shuttering activities required in the following section.
 foundation bases to all structures
 drains and channels
 valve chambers
 water pipeline thrust blocks
 pump station
 building foundations, floor slabs and beams
 beams
42
  slab edges
 columns
 walls
 roofs
 plinths

The Site Agent is responsible for this work and will be assisted by the Site Engineers. The
responsibility for the works is placed on the Concrete team and the Concrete Foreman. The
team includes the operators, section leaders and survey team and the formwork team

7.1.1 Health and Safety:

 Toolbox talk to sensitise workers on possible dangers associated with working
on the concrete construction sites is conducted daily
 Ensure that all employees have undergone pre-employment site safety
inductions.
 The employees to be briefed on major risks associated with the works.
 Conduct the pre-task risk assessment every time prior to starting works.
 The Contractor shall adhere to and follow the recommendations of the Clients
EIA.
 Ensure that the shutter hands are qualified and experienced.
 Full PPE to be worn by all workers at all times
 First Aiders and SHE Officer to be available full time on site to monitor the
works.

7.1.2 Quality Control:

 All equipment to be serviced and maintained regularly. All service registers
are to be kept in the SHE File.
 Sampling testing and grading of aggregates
 Preparation of concrete mix designs
 Steel fixing will be done as per the Project drawings requirements, using
binding wire to tie in rebar crossings and cover blocks to give cover for rebar
inside formwork.
 The Project Engineer will approve the steel fixing upon inspection on
condition that all steel fixing requirements of the contract have been satisfied.
 The Foreman to obtain approval of the works upon completion.
 Signing off of relevant QC inspection forms
43
  Formwork will be done as per the Professional Engineer’s approved drawings
requirements
 The Engineer will approve the formwork upon inspection on condition that all
formwork requirements of the contract have been satisfied.
 The Foreman to submit request for final inspection and obtain approval of the
works upon completion
 The signing off should be done on the designated form and signed off on the
Quality control Plan.
 Pre-start inspections are made on all machinery.
 Precast concrete measurements are calculated from the drawings.
 Steel shall at the time of placing be free from loose or powdery rust, scale, oil,
or other coatings that may reduce the bond between steel and surrounding
concrete, affect the durability of the concrete, or initiate corrosion of the
reinforcement. If any substance other than water is used to lubricate
formwork, every precaution shall be taken to avoid contamination of the
reinforcement by such substance.
 The steel shall be tagged to identify them with drawings and bar sizes and
marks.

7.1.3 Construction Works

 Materials
Ensure presence of the latest “approved for construction” detailed design
drawings.
Reinforcing bars shall comply with the relevant requirements of SANS 920 and
the requirements of the scope of work.
Welded steel fabric shall comply with the relevant requirements of SANS 1024,
as specified in the scope of work. The welded steel fabric shall also be
manufactured in accordance with the Project Specifications. Welding of steel
reinforcement will not be permitted.
Steel shall be stacked off the ground to prevent distortion and shall be
protected from aggressive environments and contamination. Reinforcing shall
be stored per the Manufacturers recommendations.
Ensure that the setting out has been approved.
 Bending
Reinforcing bars shall be bent to the dimensions shown in the construction
drawings.
44
 Bars shall not be bent hot.
Reinforcement shall not be subjected to mechanical damage, rough handling,
dropping from a height or shock loading.
Bend the steel in accordance with the drawings, only minimum steel will be
bent on site for accuracy and to avoid wastage.
 Fixing
All reinforcing at the time of placing of the concrete, shall be free from rust,
scale, oil and other coatings.
Reinforcement shall be positioned as shown in the construction drawings and
maintained in those positions.
Reinforcement shall be secured at sufficient intersections to avoid displacement
of bars by tying at intersections with annealed wire of nominal diameter 1.6mm
or 1.25mm.
Reinforcement shall be supported in its correct position by means of chairs or
spacers. These spacers shall be of a suitable material, shape and design.
Spacers shall be durable, not lead to corrosion and shall not cause spalling of
the concrete cover. Concrete spacer blocks manufactured on site shall not be
used.
Fix steel using the approved binding wire, tightly bound around nodes at bar
intersections.
Ensure the minimum specified cover to reinforcement by use of approved cover
blocks. Reinforcement shall be supported in its position by means hangers or
saddles, and aligned by means of chairs and spacers of approved design and
shall be maintained in those positions until concrete is poured.

 Cover
The exposure conditions shall be classed as severe as per the specifications.
The concrete cover over reinforcement shall be given in Table 3 of SANS 2001-
CC1, but shall not be less than 50mm for any given class of concrete.
Documentation
 Approved reinforcement schedule as received from the suppliers
 Approved spacing and placed and tied steel including spacer blocks.
8 Joints in Concrete Works
This method statement is prepared for the construction and detailing on site of the various
types of joints for the concrete works. This includes construction of: construction joints,
expansion joints, contraction joints. Water tight joints shall be constructed with a water bar
45
as detailed.
The procedures to be adopted are as follows:

Cleaning Surfaces
Laitance on the surface must be removed from the concrete in order to ensure that a good
bond will be achieved when fresh concrete will be placed against it. Following methods may
be used for removing laitance from the top of walls and columns unless specified otherwise
in the contract:
 Washing and Brushing - The easiest way is to brush off the laitance while the
concrete is still fresh but has stiffened slightly. Brushing shall be commenced
between one to two hours after placing of concrete. Site operatives shall have
brushes with soft and hard bristles so that it can be used depending upon stiffness of
concrete. Care shall be taken that the brushing shall not be harsh which will dislodge
the coarse aggregates. In case laitance has hardened but is still green, a wire brush
will be used.
 Air and Water Jet: Laitance can be removed by directing a jet of air and water onto it.
This method can be used up to six hours after placing or possible longer but the site
operative must make his own judgement while adopting this method. This operation
will not start too soon because it might dislodge coarse aggregate particles.
 Mechanical Scabbling: If laitance is too hard to be removed by wire brushing,
mechanical scabbling can be tried using small percussion power tools. This method
can be applied after 3 days when concrete has hardened sufficiently. Care will be
taken not to weaken the coarse aggregates.

8.1.1 Joint Construction

Formwork:
Formwork for subsequent concrete pours must be accurately aligned and well fixed so that
there is no grout leak which results into discoloration and honey combing. Strips of foam
rubber or polyurethane unless specified otherwise can be fixed around the edge of the
hardened prepared joint.

Watertight Construction:
For watertight construction, flexible water bars of specified details will be used. Care will be
taken while concreting so that all water bars are securely tied to avoid its folding during
concreting.
Cold Joints:
46
Cold joints occur during the concreting operation when a delay in placing adjacent concrete
has occurred and earlier concrete placed has stiffened.

A simple test can be used to determine whether concreting can proceed. The poker vibrator
is embedded into the existing concrete to examine the condition of concrete. Where the
action of the poker has left a distinct hole, concreting operations will not continue. In this
case the joint face can be prepared by one of the methods described above for horizontal
construction joints.
Placing the Fresh Concrete:
Particular care shall be taken while placing and compacting new concrete on or against the
old:
 Any dirt or dust from the surface of the hardened concrete shall be removed
preferably with a compressed air hose. As a safety precaution site operative will wear
safety goggles. This cleaning will be done before new formwork is fixed because not
only access be easier than but also dirt might otherwise stick to the new formwork.

 While fixing a new formwork extra dirt is created which can be cleaned after
removing a stop end – which will make it easy to be swept or blown away.

Joint Sealing:
Where the structural component containing the joint is to be exposed to the external
environment, the joint has to be sealed to prevent ingress of water. For type and method of
application the contract specifications and/or manufacturer’s instructions are applied.

Documentation
Following documentation and forms will be maintained as a minimum pending on Quality
Assurance Plan requirements and contract specification.
 Contract and/or approved workshop drawings.
 Manufacturer’s test certificates (in case of sealants and waterbars).
 Request for Engineer’s consent/approval.

b) Pipelines
1 Setting Out for Site Clearance:
Introduction: The purpose of this Method Statement is to outline the general survey and
setting out procedures and to ensure that the resources and competency to carry out the
works safely and efficiently are in place.

47
References: Botswana Roads Department Standard Specification for Roads and Bridge
Works, Project Specifications, Detailed Design Drawings, Conditions of Contract, SANS
1200 Series, Occupational Health and Safety Act
Activity: Survey and Setting Out
Materials: Pegs (Steel & Wooden), Cement, Concrete
Plant: Survey Equipment (Total Station, GPS, Dumpy Level, Staff, Rods, Prisms), Concrete
Plant, measuring devices, all associated equipment.
Personnel: Project Manager, Site Agent, Civil Engineer, Electrical Subcontractor,
Mechanical Subcontractor, Mechanical Electrical, Electrical Engineer, She Officer, Surveyor,
Semi-Skilled and Unskilled Labourers
1.1 General Procedures
 Chainmen will be employed as required. If unskilled personnel are engaged to work
with the Surveyor they will be trained regarding the requirements.
 Identify existing services from marker posts and expose as required. Check with
Water Utilities Corporation and other utility providers for their as built drawings for
existing services.
 Verify the existing national trigonometric beacons and establish the construction
bench marks and construct temporary bench marks as may be appropriate. Secure
the temporary benchmarks in concrete to avoid disturbance.
 Ensure presence of the latest “approved for construction” detailed design drawings.
 Verify the Engineer’s setting out data for any discrepancies.
 All bench marks that might be affected by the works will be referenced in consultation
with the Engineer.
 Ensure that the survey equipment is in good working condition and has valid
calibration limits and certificates.
 Enter and save all the setting out information in the setting out device
 Engineer will be informed where the setting out will be carried out in a particular week
through the weekly programme that will be submitted and/or as may be arranged with
the Engineer on site.
 The Surveyor will set out working servitude boundary / pipeline corridor.
 Setting out of positions of major structures will be carried out. This includes the
houses, pipeline routes, location of pump station, standby generator houses,
electrical gear and SCADA etc.
 The working servitude boundary is fenced off.
 Identify and agree with Engineer’s staff on movement / removal of obstacles and any
other structures.
48
  Search for services in servitude and protect / relocate as necessary in liaison with the
relevant authorities and the Engineer’s instruction.
 Vegetation is stripped and top soil is removed (+/- 150 mm) and stored in manner
and at location agreed with Engineer where it can be preserved till end of
construction. This is done at the pipeline, maintenance road and the borrow pits.
 Identify protected trees with the Environmentalist ensure they are not disturbed.
 Material obtained from clearing, grubbing and demolition of structures is spoiled at
dumping sites as directed by Engineer.
 Request for final inspection from Engineer prior to submitting request for excavation

1.2 General setting out procedure

 Set the Total Station or GPS base station over a known benchmark.
 Sight to the next control point for orientation.
 Sight to the next known control point for control.
 Set out the points using the information provided by the Contractor’s Design
Engineer and mark the set points on the ground using pegs and chevron tapes.
Ensure that the pegs are flush with the ground to avoid being a hazard to the
environment.
 All changes in vertical and horizontal alignment shall be staked out, setting out for top
soil removal and bulk excavation shall have an offset from the alignment and some
intermediate points to a distance safe from machine disturbance.
 All the pegs that denote the position of a corner or column will be labelled
accordingly.
 Sight to the known control point at the end of the process and/or during the process
as a control to eliminate possible survey errors.
 Request the Project Engineer to check the setting out for approval.

1.3 Setting out for Bush clearing

 Bush clearing limits shall be as set out as per the contract specifications and/or
drawings and where applicable, offsets shall be set-out from the external lines of the
building using coordinates supplied.
 The offsets shall be marked out by profile poles painted white at the top half to
enhance visibility.
 The off sets shall be at least 2.5m from the edge of the area to be cleared to avoid
damage and disturbance during clearing.

49
1.4 Setting out Levels
 Set up dumpy level
 Sight to a known control point and record the reading in the survey book
 Set up levels as provided by the Engineer or Contractor’s Design Engineer and/or
pick levels at pre-marked points as the case may be
 Sight to the known control points at the end of the process and/or during the process
as control to eliminate possible survey errors.
 Reduce the levels and check for variations to known control points
 If the variations are within the allowed deviation limits, the survey may be accepted
but if the variations are out of the acceptable deviation limits, then the survey shall be
re-done

1.5 Excavations setting out

 Profiles for excavations shall be set out at an offset of at least 2.5m from the edge
line and shall be on either side of excavation pit for easy control of excavation levels.
 The alignment shall be marked with a different colored soil for visibility to the
excavation operator. A checker/spotter will be available at all times.
 The excavation levels shall be set on these profiles using nail and/or batter boards.
 The profiles shall be salvaged as soon as the excavation has been completed.

1.6 Setting out Pipelines and Valve Chambers

 Prior to commencement on site the depth and location of all underground services
will be confirmed and their location clearly marked on the surface at 20m centres.
 Coordinates, Levels, built in items, reference to standard details are checked. Notes
on the drawings have to be read and understood.
 The Contractor’s Surveyor will ensure that Control stations have been checked,
levels are 2 peg tested and that they have current instrument calibration records.
 Each page of the field book is to be titled and dated correctly.
 Back sight checks are to be carried out for each level setup, and when observing the
orientation. The horizontal distance and coordinates are verified for accuracy to
ensure that the control stations have not been disturbed.
 Check the start valve inverts and use the design inverts to set up the excavation
profiles.
 The pipe inverts will be checked at 20m intervals using the excavation profiles for
vertical control. Quality Assurance forms are completed daily and signed off with the
Engineer.

50
  The valve chamber standard details are checked e.g. if step irons or ladders are
required, falls across the chambers, correct frame and cover etc.

1.7 Setting Out Pump Station and Buildings

 The latest construction drawings are available on site.
 The correct setting out data has been received, verified and is being used on site.
 The necessary materials are prepared (i.e. pegs, nails, rope or line, hammer, tape,
marking tool etc).
 Site clearance is carried out to the specified extents.
 The position of each pump station is set out and the building levels are marked on
the profiles.
 The four corners where we have the proposed pump station dimensions are set out
using pegs.
 Excavation and setting out profiles are set out offset 2m from the edges of the
construction lines for the pump station.
 The excavation depths are set out on the profiles with allowance for boning and a
boning for checking excavation depths is prepared.
 From the plan details, the width of excavation to be done is also marked by line with
pegs at appropriate positions. However the excavation width is then marked by lime
or by with furrow with spade. This is applicable for the construction of the houses.
The pump stations excavation will be bulk excavation.
 The digging or excavated depth will be as per the construction drawings.

1.8 Electrical / Mechanical / Electro Mechanical Works

All equipment data sheets, MSDS, catalogues, workshop drawings, PI & D, process flow
charts, commissioning test plans are prepared at the project onset and submitted for Water
Utilities Corporation ensure timeous approvals prior to the commencement of construction
activity.
Documentation
Approval of the Engineer should be obtained immediately after the works have taken
place and prior to the successive activity. The signing off should be done on the
designated form and signed off on the Quality control Plan.
Approved horizontal alignment and positions of pipelines, valve chambers and
structures.
Approved level controls.

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2 Earthworks
2.1 Site Safety
 Trench collapses can occur in any soil and may result in worker deaths.
 In unbraced or unsupported excavations, proper attention should be paid to sloping
the trench wall to a safe angle.
 All trench shoring and bracing must be kept above the pipe.
 The length of open trench required for coupled pipe sections should be such that
bending and lowering the pipe into the ditch does not exceed the manufacturer’s
minimum recommended bend radius and result in kinking.
 The trench width at pipe grade should be as per the Engineer’s design.

2.2 Site Clearance & Top Soil Removal:

Introduction: The purpose of this Method Statement is to align the methodology for the site
clearance, topsoil removal and removal of all obstacles covered under site clearance in the
project specifications and/or as may be instructed by the Project Engineer during
construction.
Specification: Botswana Standard Specification for Road and Bridge Works, Project
Specifications and Drawings, SANS 1200 C
Activity: Site Clearance & Top soil removal
Materials: N/A
Plant: Graders, Front End Loaders, Tipper trucks, TLB’s
Personnel: Project Manager, Site Agent, Civil Engineer, Measurement Engineer, She
Officer, Surveyor, Semi-Skilled and Unskilled Labourers
SHEQ
 The SHE Officer and First Aiders to be available on site and monitor the activities.
 The Site Agent to verify quality control processes are being adhered to.
 Ensure that all employees have undergone safety, security and site inductions and
medical examinations as may be required.
 SHE toolbox talks shall be carried out on a daily basis to sensitize and educate the
operatives of the SHE issues.
 Brief employees on the major risks associated with the works.
 Check the Client’s EIA for any issues of archaeological interests and any other
considerations such as protected species and dust nuisances that need attention.
 Ensure that the Engineer’s instructions with regard to the extents of clearing,
obstructions such as fences to be removed, services, affected private properties
and/or protected trees to be preserved are in place.
52
  All employees shall wear appropriate PPE.
 All Quality Control Registers are updated.
 All SHE File registers are updated.

Responsibility
 The responsibility for the works is placed on the earthworks foreman and earthworks
team headed by the Site Agent. The team includes the Site Engineer 2 numbers,
Land Surveyor, operators, section leaders and survey team.

 The Project Manager remains ultimately responsible for the works above the Site
Agent. The Project Manager is responsible for studying and reviewing the
methodology to keep abreast with the technology and latest developments and/or
SHE requirements.

Methodology

Preparation Work
 Ensure that the Project Engineer has approved setting and all the Project
Engineer’s special instructions are in place prior to commencement of
the works.
 Ensure that all underground services that may be affected are located and where
applicable, exposed and/or relocated.
 Agree with the Engineer the proposed stockpile area locations.
 Photographs of services and properties likely to be affected will be taken in
consultation with the Engineer and the affected parties before construction
begins.
 Get the Engineer’s instructions/approval for the trees to be removed.

Work Procedure
 Fences within the construction area shall be removed by hands prior to
commencement of the works.
 Mark all existing services with timber profiles painted with bright color paint.
 Mark the lines of areas to be cleared with ranging rods at least every 100m.
 Line men shall be engaged to ensure that the working widths are not exceeded
during the bush clearing process, and to locate all services and obstacles that
may have been unseen during approval of setting out.
 A front end loader or similar approved equipment shall be used for bush clearing.

53
 Grubbing for large trees shall be done by the front end loader during clearing and
for smaller trees, grubbing shall be done by means of pickaxes and machetes.
 Where large trees are to be taken down in built up areas or where services exist,
such trees shall be taken down by cutting from top downwards to avoid damage
to third party properties.
 The debris from the clearing shall be bulldozed to the borders of the working
widths and shall be loaded and transported in tipper trucks and disposed off at
designated disposal areas.
 The earthworks foreman on the site will ensure existing services, such as
pipelines, poles of BPC, private properties etc. are protected.
 A request for inspection of the cleared and grubbed area shall be submitted by
the contractor prior to commencement of topsoil removal.
 Depending on the Project Engineer’s instructions, ground levels shall be picked
and recorded and submitted to the Project Engineer for approval and record
before topsoil removal
 The topsoil will be removed by means of grader as may be applicable and loaded
onto trucks to a temporary stockpile area located by the Project Engineer.
 The top soil shall be removed to the specified depth by ripping and blading to
windrow, controlled by survey profiles or by pushing to temporary stockpiles.
 Surveyor to check the levels after the removal of topsoil and submit for approval.
 The Contractor shall submit a request for inspection to the Project Engineer.
Documentation
 Environmental authorisation from Department of Environmental Affairs to proceed
with the clearing works
 Approval of the Project Engineer should be obtained immediately after the works
have taken place and prior to the successive activity. The signing off should be
done on the designated form and signed off on the Quality control Plan.

2.3 Soft Excavation:

Purpose: The purpose of this Method Statement is to outline excavation method
requirements throughout the contract.
Specification: Botswana Standard Specification for Road and Bridge Works, Project
Specifications, SANS 1200 D, SANS 1200 DB
Activity: Excavation
Materials: lime, cement
Plant: Excavators, tipper trucks, loaders, water bowsers, TLB, picks and shovels
54
Personnel: Project Manager, Site Agent, Civil Engineer, She Officer, Land Surveyor,
Quantity Surveyor, General Foreman, Pipeline Foreman, Semi-Skilled and Unskilled
Labourers,

SHEQ
 All employees to undergo site safety induction prior to commencement of the works.
 All employees to attend the safety talks on daily basis.
 Employees to be briefed on all major risks associated with the works.
 Pre-task risk assessment to be conducted every time prior to starting works.
 The Contractor shall adhere to and follow the Clients EMP for any endangered
plants that should be avoided and any other consideration that needs attention.
 Obtain permit to excavate from the Project Engineer using Project Quality Plan
Excavation Application sheet. (to be submitted together with M.S for approval).
 The Contractor supervisor shall check for ground stability before workers can go
inside the trench.
 Dependent on the degree of instability of the ground, the trench would be battered to
a slope of 1:1 to a stable level to reduce the risk of collapse. Alternatively, the trench
sides would be shored against any possible collapse.
 Back excavation is done where loose collapsible material is encountered along the
trench line.
 Spoil areas to be treated in accordance with the employer’s EMP and/or existing
regulations.
 The works to be protected in accordance with the contract requirements.
 Archaeological artifacts shall be dealt with by site observation and reporting any
finding to the Project Archaeologist immediately. Archaeologist’s reports will also
assist with information on the location of archeological findings.
 Ensure that haul routes are in good drivable conditions and dust suppression plan to
be in place.
 Ensure the stability of the excavations during and after excavations.
 Ensure adequate ventilation is available in the trenches to carry away dust and
exhaust fumes from the equipment and plant.
 All open trenches to be barricaded at all times.
 All employees to wear PPE.

Responsibility
 The responsibility for the works is placed on the Site Agent (Water), earthworks
55
 foreman and earthworks team headed by the Project Manager. The team includes
the operators, section leaders and survey team and general workers

 The Project Manager remains ultimately responsible for the works above the Site
Agent (Water). The Project Manager is responsible for studying and reviewing the
methodology to keep abreast with the technology and latest developments and/or
SHE requirements. The Project Manager is supported by the Site Agent, Health and
Safety Manager and Materials Technicians to conduct the works.

Methodology
Preparatory Work
 Ensure presence of the latest “approved for construction” drawings are received
from the Contractor’s Design Engineer.
 Ensure that the survey equipment is in good working condition and has valid
calibration limits and certificates.
 Ensure that the setting out has been agreed with the Project Engineer and all
necessary survey works have been completed.
 Ensure that all the affected private properties have been identified and protected.
 Ensure that the services have been identified and marked on the drawing with the
help of the service providers and the Project Engineer’s instructions are in place
regarding protection and/or relocation of services.
 Ensure that the excavation permit is in place prior to any excavation works.
 Ensure that there is adequate drainage around the excavations to avoid flooding.

Work activities
Hand Excavation
 Hand excavation shall be used for locating the underground services and where the
use of machines is not possible.
 The Earthworks Foreman to mark the extents of the area to be excavated and the
service position to be exposed and/or relocated
 Dig carefully to dimensions using the picks and shovels until the service is located
 Open the service and mark with wooden profile the actual position of the service and
backfill with sand at least 200mm above the service for protection.
 Barricade the excavations using approved methods.

Machine Excavation
 Set out the controls and mark the extents of excavations on the ground.
56
  Excavate to lines and depths as set out using the hydraulic excavator. The depth and
width shall be controlled continuously using the dip stick and excavation levels.
 Select materials and stockpile on one side of the trench, where feasible, that may be
used for selected backfill as instructed and/or indicated in the geological report.
 Where required, excavate and load directly on to tipper trucks and haul to
stockpile/spoil.
 Ensure that the bottom of the excavations is fairly level for pipe bedding preparations.
 Pick the trench bottom levels and width as may be required and submit to the
Engineer for approval.
 All hard rock removal shall be done in accordance with the requirements of the
contract.

2.4 Pipe Bedding

 Pipe bedding material shall be sand or gravel in accordance to the requirements.
 The bedding shall he placed after the trench bottom is compacted to provide proper
support.
 Minimum compaction of the bed shall be 90% Standard Proctor Density (70% of
maximum relative density for crushed rock, crushed stone or gravels).
 The bed must be over-excavated (manual digging is enough) at each coupling joint
location to ensure that the pipe will have a continuous support and does not rest on
the couplings.
 However, this area must be properly bedded and backfilled after the joint assembly is
completed.
 Where the trench bottom soil can be cut and graded without difficulty, pressure pipe
may be installed directly on the prepared trench bottom.
 For pressure pipe, the trench bottom may undulate, but must support the pipe
smoothly and be free of ridges, hollows, and lumps.
 In other situations, bedding may be prepared from the excavated material if it is rock
free and well broken up during excavation.
 The trench bottom should be relatively smooth and free of rock. When rocks,
boulders, or large stones are encountered which may cause point loading on the
pipe, they should be removed and the trench bottom padded with 150mm thick of
tamped bedding material.
 Bedding should consist of free-flowing material such as gravel, sand, silty sand, or
clayey sand that is free of stones or hard particles larger than one-half inc

57
2.5 Backfilling Pipe:
 When gravel or crushed stone is used as backfill, immediate backfilling after joining is
desirable, as it will prevent two serious hazards, floating of pipe and thermal
movements.
 Floating of pipe can damage the pipe and create unnecessary reinstallation costs.
This may not be the case in this project as the water table is not encountered.
 Thermal movement caused by exposure to the elements can cause the loss of seal
due to movement of several lengths acting on one joint.
 Proper selection, placement, and compaction of pipe zone backfill are important for
controlling the vertical deflection and are critical for pipe performance.
 Attention must be paid so that the backfill material is not contaminated with debris or
other foreign materials that could damage the pipe or cause loss of side support.
 During backfilling, the granular material should flow completely under the pipe to
provide full support.
 A blunt tool maybe used to push and comp act the backfill under the pipe.
 Proper backfilling should be done in 150 mm to 300mm lifts depending on backfill
material and compaction material, 300mm lifts will be adequate since gravel is
relatively easy to compact. Sand needs more compaction effort.
 After the pipes have been laid, the trench refilling is to commence with approved fill in
compacted layer not exceeding 150mm unconsolidated thickness. Each layer shall
be well compacted by hand with iron rammers weighting not less than 5 kg until the
trench has been filled to a height of 300mm above the top of utility.
 The remainder of the trench is then to be refilled in the compacted layers not
exceeding 300mm unconsolidated thickness. Each layer is well compacted, with
power rammers, vibrating plate compactors or other mechanical means of a type to
be approved until the ground is thoroughly consolidated.
 200mm thick layer of backfill above the pipe aggregate surround shall be laid and not
be compacted fully to avoid chances of pipe damages.
 The remainder of the fill material shall be placed in layers of not greater depth than
300 mm compacted thickness with light mechanical 1 Ton roller.
 The compaction of sandy backfill is most easily accomplished when the material is at
or near its optimum moisture content. When backfilling reaches pipe spring-line, all
compaction shall be done first near the trench sides and proceeds towards the pipe.
 It is recommended that placing and compacting of the pipe zone backfill is done in
such a way as to cause the pipe to ovalize slightly in the vertical direction.
 Trenches are not to be backfilled until all required test are performed on the utilities
58
 and verified by the Engineer.
 To permit the proper consolidation of backfill into the voids behind trench sheeting
and supports, trench sheeting shall be withdrawn gradually as backfill progresses in
depth along the trench.

2.5.1 Primary or Initial Backfill

 This backfilling will be done by hand.
 This zone of backfill provides the primary support against lateral pipe deformation.
 To ensure such support is available, this zone should extend from trench grade up to
at least 75 percent of the pipe diameter.

2.5.2 Secondary Initial Backfill

 The basic function of the material in this zone is to distribute overhead loads and to
isolate the pipe from any adverse effects of the placement of the final backfill.

2.5.3 Final Backfill

 As the final backfill is not an embedment material, its nature and quality of
compaction has a lesser effect on the flexible pipe.
 However, arching and thus a load reduction on the pipe is promoted by a stiff backfill.
 To preclude the possibility of impact or concentrated loadings on the pipe, both
during and after backfilling, the final backfill should be free of large rocks, organic
material, and debris.
 The material and compaction requirements for the final backfill should reflect sound
construction practices and satisfy local ordinances and sidewalk, road building, or
other applicable regulations.

Measurement
 Excavation shall be classified in 3 categories, vis, soft excavation, intermediate
excavation and hard rock and these classes shall be agreed with the Engineer
during excavation.
 Hard excavation shall be broken down in to smaller particles before it can be
excavated.
 Materials that may not be suitable for re-use shall be disposed off at the Engineer’s
discretion.

Documentation
59
  Approval of the Engineer should be obtained immediately after the works have taken
place and prior to the successive activity.
 The signing off should be done on the designated form and signed off on the Quality
control Plan.
 Quantities of excavated volumes should be signed off with the Project Engineer.

2.6 Blasting for the Works:

Purpose: This method statement describes methods that will be employed for rock
excavation on the project.
Specification: Department of Mines (also Licensing Authority), Explosives Act of
Botswana :Chapter 24:02, Drawings, Specifications, Conditions of Contract, AEL (1993):
Safe and efficient blasting in open cut mines, quarries and construction. New Vaal
Symposium.
Activity: Removal of rock by blasting
Materials: Explogel explosive cartridges and / or Anfo
Plant: Pneumatic crawler drill rigs, radios for communication, excavator with drilling tool
Personnel: Blasting Foreman/Blaster, Blaster assistants, Drillers, assistants , labourers ,
SHE Officer, PRO, guards.
SHEQ
 All employees to undergo site safety induction prior to commencement of the
works.
 All employees to attend the safety talks on daily basis.
 Employees to be briefed on all major risks associated with the works.
 Pre-task risk assessment to be conducted every time prior to starting works.
 The Contractor shall adhere to and follow the Clients EMP for any
endangered plants that should be avoided and any other consideration that
needs attention.
 Obtain permit to excavate from the Project Engineer using Project Quality
Plan Excavation Application sheet. (to be submitted together with M.S for
approval).
 The Contractor supervisor shall check for ground stability before workers can
go inside the trench.
 Notify all relevant occupants/owners of surrounding farms and households of
blasting.
 The blasting sub-contractor will appoint a licensed, qualified and registered
Blasting Foreman as per the requirements of the Department of Mines and
60
 approved by the Engineer.
 Permits and notices are scheduled at least 7 days in advance with the
Department of Mines requirements
 The blasting subcontractor will put in place suitable noise and dust
prevention measures and complete the demolition work in the minimum time
possible.
 Blasting will be conducted in an organized and controlled manner and in
accordance with the Explosives Act and Regulations. The Blaster is
responsible for the blasting activities and for the procuring the necessary
Blasting Permits as required in the Act.
 Warning signs will be erected at blasting sites. A warning siren will be
sounded off prior to any blasting activity.
 The Risk Registers, SHE File Registers and Quality Control Registers will be
updated

Construction
General Blasting Rules

 Blasting may only take place once a day, unless otherwise agreed to by the
the Project Manager.
 Blasting is strictly forbidden after sunset, if however the blasting could not
take place, the sleepover of the blast should be done in accordance with
approval by the relevant persons according to legislation.

 Any charged up holes or misfires, which need to sleep over to the next day,
must be demarcated and guarded for the period of exposure.

 Blasting procedures may only be carried out by an appointed competent

blaster, who is the holder of a valid blasting certificate.

 For all blasts, the client & blasting officials must ensure that all persons are
evacuated further than 500 meters from the blast.

 When cover or controlled blasting is done, a safe evacuation distance will be

agreed upon and communicated by the responsible blaster and the Project
Manager in accordance to applicable legislation, site rules and client
requirements.

 All persons in the surrounding area of the blast or within range of potential fly
rock, including geologists and contractors working within or around the blast
61
 area, must be informed of the intention to blast by the Client & Blaster on the
day of the blast.

 The people concerned must inform the Drilling & Blasting Foreman if they will
be around the blast site within half an hour prior to the blast, depending on
the agreed blasting time. They must be cleared to the 500m line before
blasting takes place.

 For all blasts, the siren will be sounded five (5) minutes before setting off the
blast.

 No charges shall be fired if the visibility is poor because of mist, smoke, rain
etc. or during high winds.

Drawing and Transportation of Explosives

 The Blaster will determine the volume of rock on site and calculate required
quantities of explosives. Orders are issued to the supplier for the quantities
required.
 The quantities of required explosives for that blasting session will be collected
from the magazine stores by the Blaster and signed off in the presence of a
Department of Mines Official. No one will have access to the magazine at any
given time. Security will be on guard 24 hours a day.
 Records of all explosives in store will be reported to the Department of Mines
on a daily basis.
 A permit to transport the permits will be secured and the transport vehicle will
be clearly marked and escorted to site by security vehicles as per regulations.
The transport vehicle will have red flags and warning stickers.
 Storage of blasting materials will be in an aluminium case and separated
from the blasting accessories which will be stored in a plastic case. Both
cases will be locked when not in use.
 Transportation of explosives to the works will be in accordance with the
Explosives Regulations.
 Evacuate the blasting area of all people and animals and inspect the area.

Introduction:
Where blasting is required in close proximity of existing infrastructure, underground fibre
optic cables, Microwave towers and live BPC overhead cables and pylons, structures and
buildings to the blast area, there is need to reduce or minimise the effect of ground vibrations

62
resulting from the blast will be considered. These vibrations will be measured using a vibro
recorder, which measures the peak particle velocity (or PPV) of the ground through which a
blast induced energy wave passes through.
The reduction of ground vibration or ppv’s will be achieved by reducing the amount of
explosives that is detonated at any one time. This will be achieved by drilling small charge
holes by hand and increasing the number of delays used when tying up or connecting the
blast holes so that the ppv readings would be negligible resulting in little or no ground
vibrations being transferred to the adjoining structures.
Chemical fracturing or the use of jack hammers (Excavator fitted with a pegger) will be used
at areas to close to existing services and structures as per site observation.
Photographs of all structures in close proximity of any blast areas will be taken to ensure a
record is kept to track any potential damage.

Explosives Selection
During the dry season and for pipeline blasting far from the villages, Anfex will be used with
6 g/m detonating cord and 25 x 200 cartridge explosives as primer.
During the rainy season, an equivalent charge of bigger 65 x 560 cartridges will be used on
the pipeline. Within 300m of private houses, 500 / 25 ms handimasters shall be used to
replace the detonating cord and 65 x 560 cartridges used instead of Anfex.
For small diameter drill holes, 25 x 200 cartridge size will be used, with cord and 25 ms
relays placed accordingly, depending on the distance of the blast from the nearest
damageable structure.
All blasts will be initiated electronically using Instantaneous Electronic detonator, to avoid the
waiting/burning period - hence greater risk of inadvertent entry - when using nonelectric
initiation methods such as the safety fuse.
Drill and Blast Pattern
In shallow trenches, the drilling burden and spacing will be in the order of 500m x 500m to
ensure good fragmentation, hence greater excavation productivity.
For the pipeline drilling, the initial burden and spacing at powder factor 1 will be designed.
However, there will be some scope for blast parameter optimization after trial blasting and
monitoring of the excavation productivities on site.
Since drilling will be through the overburden, drill penetration and output data will be also be
used for ‘fine tuning’ the drill and blast pattern, taking into consideration the geological
conditions along the project servitude.
Besides the topography and geology, the drill and blast pattern shall also be adjusted to
compensate for nearby structures and services to achieve the desired explosives energy
63
ratio to break the rock without causing any structural damage to these.
Drill pattern must be approved by the Engineer prior to blasting.
Ground Vibration Control Plan
When blasting is to be done in a built up area, blast - induced damage to houses will be
managed by varying the explosive charge mass per unit delay through controlling the mass
of explosives firing at any one time.
Two types of relays will be used
i. in the bush, the 25 ms surface relay with detonating cord for blasting and
ii. in the built-up areas, 25 ms surface / 500 ms down hole shock tubes
The resulting ground vibrations from a blast can be measured using a properly calibrated
vibrometer. Accordingly, for each blast, a ppv reading and distance from point of
measurement shall be read in the Engineer’s presence before printing the same in the blast
report form (See Annexure 1) and getting it duly signed.
Flyrock Control Plan
It is expected that since drilling will be through overburden material, this will have the effect
of mitigating against this problem. A balanced blast design incorporating a stemming length
of 20% of the charge depth shall be used. Additional covering the blast with gravel up to 1.2
x charge depth shall effectively eliminate this problem.
Because the overburden depth shall vary with the trench topography, drillers log book shall
be relied on to calculate the required cover and stemming heights for the different rock
profiles encountered.
Stemming material shall be of good quality graded stone in the size range of 4 to 12 mm, for
the blast hole diameter of 63 mm.
Fire Control Plan
After the re-entry period for each blast (typically 5 minutes) has elapsed, the blaster shall
inspect the area for any indication of fire or fire hazard.
Drilling and blasting occur when the pipeline centerline has been bush cleared; therefore
there will minimum dry vegetation left to increase the fire hazard. By design, explosives
vaporize, as opposed to smoldering, at the instant of detonation minimizing fire risk.
As a precautionary measure, the blaster shall pick up any plastic shock tubing left over from
the initiation system for later burning and also ensure that the initiating detonator is placed
within on cleared ground with a minimum radius of 2m.
Noise Control Plan
Since all blasts will be covered for flyrock, this precaution will automatically take care of any
resulting noise levels. Detonating cord used as indicator for complete detonation, commonly
referred to as “policemen” on site, shall be secured to a stick and buried on the cover to
64
dampen noise levels. No noise threshold has been specified in the contract and noise is
unlikely to be an issue of concern.
General Blasting Safety
Blasting sites have to be secured at all times. Blasting operations will not start in areas that
are not properly fenced. To this end reference is made to the Department of Mines
procedures for (i) code of conduct for blasting employees, (ii) standard blasting procedure
and (iii) misfire handling procedure.
Our blasting teams will be issued with the following list of personnel protective equipment
(PPE) and site safety boards: Heavy duty gloves, ear plugs, overalls, steel toe boots, hard
hats, dust masks, first aid kit, red flags, green flags, danger blasting warning signs and
sirens. Employees will be apprised on relevant safety issues by way of toolbox talks prior to
the start of each blasting operation. Movement onto and around the drill rigs will be clearly
spelt out.
Portable magazines will be set up on site to the required legal standards and licensed
accordingly. Explosives shall be transported in a licensed roadworthy explosives truck by
personnel licensed and authorised to operate the means of transport. All explosives-
handling related activities shall be under the direct supervision of licensed blasters. Our
blasters will be appointed in writing to various work activities (such as magazine master and
blasting foreman) as required by the Explosives Regulations of Botswana.
Conclusion
In conclusion, Blasting Sub-Contractor shall follow the safety regulations as contained in the
Explosives Regulations of Botswana and the Contract Blasting specifications, in addition to
our own Code of Conduct for Blasting Operations to ensure an incident free blasting
contract.
The Sub-Contractor shall maintain a blasting quality control programme on site to manage
the following critical variables: drilling accuracy, blast design parameters – burden, spacing,
blast hole charge loading, stemming, firing sequencing /timing, ground vibrations and fly
rock. Our aim remains to ‘get the required levels right first time’ without compromising any
safety rules.
Documentation
 Department of Mines approval of Blasting Foreman personnel appointments.
 Department of Mines approval of blasting activities.
 Signed off condition survey records for pre and post blasting activities for all adjacent
and neighbouring structures up to 100m radius. The owners and authorities will sign
off the records.

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2.7 Pipe Jacking:
Purpose: This method statement describes the method to be employed for the pipe jacking
where cutting a trench across the existing road is not possible.

References: Project Specifications, SANS 1200DB, SANS 1200G, SANS 1200 HA, SANS
1200 L, Conditions of Contract, Drawings, Botswana Standard Specification for Road and
Bridge Works

Plant: Herrenknecht AVND2000AB Slurry TBM, Pipejacking frame and launch pad, Spoil
separation plant, Intermediate jacking station (if required), Clean slurry feed pump, Clean
slurry feed lines 125DN, Slurry spoil pump(s), Slurry spoil lines 150DN, Control cabin,
Launch seal arrangement, Mechanical pipe brake at launch portal, Pipe lubrication injection
system, 60T crawler crane, Compressor 250cfm, Grout/Bentonite mixing and pumping
equipment, Power generation equipment, Electrical distribution cabin, Fuel storage and
distribution, 2.1m id jacking pipes (standard), 2.1m id jacking pipes (with lubrication injection
ports), MDF packing for pipe jounts, Bentonite slurry, Flocculating additives for separation
plant, Cement & PFA Excavator, Dewatering Pumps, Concrete Mixer (or concrete trucks),
Genset, Dump Trucks, Sideboom, Welding Machines
Materials: uPVC pipes and steel sleeve pipes
Personnel: Project Manager, Site Agent, Site Engineer, , She Officer, Land Surveyor,
Quantity Surveyor, General Foreman, Concrete Foreman, Semi-Skilled and Unskilled
Labourers,

Responsibility: The Site Agent shall have overall responsibility for ensuring these activities
are carried out and coordinated professionally. The supporting project team will include the
Land Surveyor and the Site Engineers and Foremen.

SHEQ
The following Health, Safety and Environmental issues will be addressed during the
preparation of the technical and safety method statements and during the construction of the
works. The construction phase will contain general information regarding Health, Safety and
Environmental concerns. These issues, as well as detailed specifics, will be contained within
the activity method statements for the construction of the pipe jacking works.
 Get AIA/EIA clearance to work within the road reserve
 Provide all the plans, drawings, sections, layouts and method statement to the
Engineer for approval
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  Contact Roads Department and provide them with the plans, layout and method
statement for the proposed pipe jacking and get their clearance and approval.
 Provide details of equipment to be used for the pipe jacking to the Engineer and to
Roads Department for their approval
 Carry out a risk assessment of the thrust boring work
 Prepare confined space working method statement
 Monitoring of air quality – ventilation
 All personnel to be made fully aware of the safety implications of working within a
shaft and tunnel environment
 Temporary works designs to be checked and signed off by China Civil - Buildco JV
JV temporary works engineers. All internally designed temporary works to be
checked and signed off by an independent professional engineer not directly involved
in the project
 Lifting operations to be properly planned, monitored, certified and implemented
 All personnel to be fully qualified to perform their duties
 All equipment to be certified as required
 All personnel to receive adequate training where necessary
 All personnel to attend shift start safety briefing
 Permit to Work system to be operated where necessary
 Oil and fuel storage regime to be strictly controlled
 Appropriate discharge consents to be obtained for disposal of any surface or
groundwater
 Monitoring of compliance with waste disposal licence for spoil disposal

CONSTRUCTION
It is envisaged that the works will be carried out on a dayshift only basis, monday to friday,
with weekends utilised for maintenance work only. This will limit the number of vehicle
movements required each day and avoid potential disturbance to local residents during the
night and at weekends.
Prior to commencing the pipe jacking, the following will be investigated:
1. Investigate if high water table and difficult soil conditions exist as this may require
special work.
2. Verify that the ground is firm to avoid jacked pipe subsiding in soft ground. this will be
done by carrying out a geotechnical investigation. trial pits, testing and a report will
be prepared and submitted to the engineer for approval prior to commencing.
3. Investigate for unexpected subsurface obstacles / services / rock as these may
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 cause difficulties while jacking.
4. Experienced operators and well organized construction work will be provided through
engaging experienced teams to carry out the work.
5. Locate the drive shafts is important in a suitable location as this may affect the
surrounding ground.

The Works Will Progress According To The Sequence Outlined Below:

Fig 1: Typical arrangement of pipe jacking.

 All chambers will be located outside of the road reserve.

 In order to facilitate tunnel break out and the retention of groundwater, slurry
and lubricating fluids during pipejacking, a concrete portal structure will have
been constructed as part of the shaft construction works.
 The portal will have a circular opening of 2.64m diameter and will be fitted
with retaining clamps required to hold the flexible seals.
 Excavation for the pipejack will be carried out using a Herrenknecht
AVN2000AB TBM, operating in closed ‘slurry mix shield’ mode.
 The TBM will be operated remotely from a Herrenknecht TBM control cabin
on the surface in the site compound.
 The TBM will be equipped with a mixed ground cutting head capable of
excavating through rock layers and boulders as well as the clay.
 The TBM will also be equipped with a rock crusher between the muck
chamber and the slurry intake pipe to break up any large lumps of rock into
smaller particles able to be carried in the slurry lines.
 Excavated material will pass through the openings in the cutting wheel into

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 the muck chamber and will mix with the incoming slurry.
 The slurry/spoil mixture will be pumped to the surface through a 150mm dia
pipeline to a spoil separation plant. The spoil will be separated from the slurry
by passing through a sequence of coarse and fine screens followed by
desanding hydrocyclones.

 Removal of very fine particles will be achieved by off line circulation through a
centrifuge. Cleaned slurry will be returned to the slurry holding tank for reuse.
Separated spoil will be loaded on to tipper lorries for disposal offsite.
 The ‘slurry mix shield’ system allows the operator to control the support
pressure on the excavated face by a combination of adjustments to the slurry
feed and removal rates together with adjustments to the pressure in the
compressed air ‘bubble’.
 The support pressure will be set to exclude groundwater and provide some
support to the ground at the face

Work Control

During the works, soil conditions, groundwater, line of pipes, breaks and deformation of
pipes need to be monitored constantly.

Safety Control

The working environment is harmful and dangerous, rules and regulations on safety need to
be observed tightly. In addition, necessary equipment needs to be installed for the health of
workers. Workers need to be trained to be aware of the safety and their health should be
well monitored.

Risk areas identified include:

 Poor ventilation
 Unforeseen water table conditions
 Unforeseen poor / soft ground conditions
 Risk of collapse – unstable ground conditions
 Every effort will be made to ensure that pollution of the surrounding ground and
environment is avoided

Hazards and Risks

The hazards associated with horizontal boring machines include entanglement at the
rotating chuck and cutting tools. Crushing or trapping may also arise from other moving
parts, eg from the moving table. The automated nature of tunnel boring machines means

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that additional risks to safety may be present as machine movement is not always reliable or
predictable.

Injuries may occur during:

 machining observation;
 setting and adjustment; or
 swarf removal.

To mitigate these risks the following measures will be implemented:

1. Operator

Operators of drilling, tracking and support equipment will be competent or supervised by a

qualified operator. Operators will have continuous 2 way radio contact with the driller locator
and product side personnel to coordinate the drilling operation. Back up radios or spare
batteries should be available.
2. Support

Support personnel should be briefed by the operator upon arrival, and must follow and
maintain all safety procedures throughout the job. Support personnel and visitors must be
informed of hazards, their responsibilities, and any restrictions of activities.

3. Training

China Civil – Buildco JV and/or support worker shall ensure all personnel are properly
trained and equipped.
4. Planned Emergency Response

The HDD Operator and/or support worker shall follow procedures set out below under
“Response to Events” in the event of a utility strike as dictated by each individual bore.

Pre-Construction

Prior to the start of construction, the Operator and/or support worker shall complete the
following:
 Work Area Familiarization: The Operator and/or support worker shall familiarize itself
with the work area and the technical requirements of the plans.
 Utility Locates. The Operator and/or support worker shall request utility locates and
complete all other utility coordination requirements.
 Complete an On-Site Hazard Assessment: include the following:
o Discuss specific hazards and procedures;
o Discuss location of emergency facilities;

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 o Discuss evacuation plan and emergency procedures Brief all personnel,
subcontractors and visitors as they arrive
o Record discussions and attendees. It is imperative that site-specific hazards
identified and appropriate safety procedures are discussed, as every site has
unique safety issues that need to be addressed. Crews should be aware of
specific safety and emergency procedures.

Specific Hazards
1. Underground Underground hazards to consider include:
 Electrical power cables, which can cause serious injury or electrocution if
connected
 Fiber optic cables carry laser light signals, which can cause eye damage
 Low-pressure sewage and storm water. These pose a unique hazard potential
if a gas or electric line installation has been installed that has intersected the
sewage line without detection. Subsequent maintenance or repair activity
could cause a gas leak, explosion, or electrocution
2. Verify Utility Locates
 The location of all identified utilities must be verified using non-destructive
methods of excavation. The bore profile must be designed to maintain
acceptable clearances between underground utilities and structures, and the
final reamed hole. Possible migration of the back reamer from the pilot bore
toward the utility, due to excessive steering or a tight radius, must be carefully
considered when establishing clearances. As easements become increasingly
congested, it may be necessary to increase the easement widths to
accommodate demand for new utilities.
 If there is any risk to the utility from the drilling activity, a window must be
excavated at or near the utility to visually monitor the potentially hazardous
situation. A vacuum unit is required to remove the drilling fluid during this
process, and high pressure drilling fluid hazards must be addressed. If the
bore passes closely by a utility, it may be necessary to continuously monitor
the separation after the drill head or reamer passes the window as the drill
string or product pipe may subsequently contact the utility during the
completion of the installation.
 Communication is a critical ingredient of any successful horizontal directional
drilling project. It is imperative that the drill locator and the drill rig operator
have an understanding of the job prior to commencement of the work. They

71
 should walk the planned borepath with the tracking equipment to evaluate any
potential fields of electromagnetic (active) interference and look for signs of
reinforced concrete or other possible passive interference that may hinder the
operation, and discuss the identified hazards.
 During the actual boring process, if abnormal readings are found with the
tracking equipment, the contractor should stop, back up, and verify previous
readings prior to commencing the bore. This is critical; as deviation from the
planned bore profile could result in an underground utility strike. Care must
also be taken during the pullback to ensure that utilities are not damaged due
to the upsizing by the enlarged back reamer and possible straightening of the
bore during back reaming and product installation.
3. Traffic Control (Pedestrian and Vehicle)
 Necessary traffic control must be maintained throughout the project. Typically,
mobilization, demobilization, material handling, and intermittent movement of
mobile equipment require traffic control if the activity conflicts with vehicle or
pedestrian traffic. Traffic control includes permits, planning, notification, flag
persons, warning signs and barricades. The work area, particularly around
the drill rig and entrance/exit pits, must also be secured to prevent
unauthorized entry. Emergency vehicles and buses must have access during
construction.
4. Drilling Unit
 If the drilling unit is equipped with an Electrical Strike Sensing System, its use
should follow manufacturer’s recommendations. The system may include
audible and visual warning alarms, grounding mats, and personal protective
equipment. Electrical sensing stakes must be driven into the ground and the
strike alert system tested prior to operation.
5. Overhead

Overhead hazards include:

 Overhead lines must be avoided. Overhead lines are of particular concern
during mobilization/demobilization, while handling drill pipe, or loading and
unloading heavy equipment. Always maintain a safe separation between
equipment and power lines. If necessary, place highly visible markers on
either side of the overhead hazard or designate an individual to notify
equipment operators as they approach.
6. Surface

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 Surface hazards to include:
 Manholes within the drill area should be opened and inspected, without entry,
to determine the underground utility it services. The direction of flow in a
sewer should be checked to determine the approximate grade. This
information can be used to project depth of the utility where the bore is being
made
 Wires attached to poles should be assumed to be live
 Out buildings (i.e. storage sheds) should be checked to determine if they
have electrical wires or other utility services that may not be marked on any
plans
 Gas barbeque grills, outdoor lighting, etc. should be identified and services
confirmed
 Ditch line depressions in the landscape or obvious changes in vegetation may
reveal previous excavation and should be investigated
 Road repairs may indicate the presence of recently installed or repaired
utilities
 Marker signs or casing vents at or near property lines indicate underground
hazards
 China Civil - Buildco JV shall check local regulations and proper due diligence
should be taken to verify the existence of existing water pipelines etc.

During Construction

While the work is being performed, the Operator and/or support worker shall complete the
following:
1. Calibration and Tracking: The Operator and/or support worker shall calibrate the
tracking and locating equipment at the beginning of each work day and maintain a
calibration log.
2. Monitoring and Recording: The Operator and/or support worker shall monitor and
record the alignment and depth readings provided by the tracking system and when
precise alignment control is necessary.
3. Maintain Drilling Fluid Circulation: The Operator and/or support worker shall maintain
drilling fluid circulation throughout the process including the initial pilot hole
installation, and the reaming and back pull process. The pull back shall not exceed
the fluid circulation rate capabilities.
4. Back-reaming: The Operator and/or support worker shall back-ream as required to
accommodate the product size. Compaction reamers are not permissible. The

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 Operator and/or support worker shall plan the back pulling operations carefully to
ensure that all back pulling operations can be completed without stopping and within
the permitted work hours.
5. Clearances. The Operator and/or support worker shall maintain all required
clearances and offsets from existing utilities.
6. Documentation: The Operator and/or support worker shall at all times and for the
entire length of the alignment be able to demonstrate and provide the horizontal and
vertical position of the alignment, the fluid volume used, return rates, and pressures.
7. Inspection: The Operator and/or support worker shall inspect the work and
surrounding area to ensure damage has not occurred to existing utilities due to
construction operations.

Response to Events

If an existing utility is struck during the boring operation, emergency procedures must be
initiated to reduce the likelihood of human injury. Procedures to follow in the event of utility
strikes are summarized below by type of utility.
 Electrical Strike If an electrical strike occurs, workers should not move. The voltage
difference between the equipment and the ground, or between a person’s feet may
be sufficient to cause injury or death. Do not touch the machine, drill pipe, water
system, mud-mixing system, or anything connected to the drill as these items may be
highly charged. The drill operator should remain calm and reverse the direction of
advance in an attempt to break contact with the electrical line. BPC, the electrical
utility company must be contacted immediately. The drill operator should follow the
manufacture’s procedure to determine if the drill is electrically charged before
attempting to dismount the drill.
 Gas Strike If a gas line strike occurs, evacuate the area immediately. The drill
operator should shut down all engines and under no circumstance should the
operator attempt to reverse the bore to break contact as further movement may
cause a spark. Emergency services and the gas utility company should be contacted
immediately.
 Fiber Optic Strike If a fiber-optic strike occurs, workers must not look into the cut
ends of the cable, which can cause severe eye damage. Drilling must stop
immediately and the utility owner, Bofinet, must be contacted.
 Communications Line Strike If a communications line strike occurs, drilling must stop
immediately and the utility company, BTC, should be contacted.
 Sanitary/Storm Sewer and Water Strike If a water or sewer line strike occurs, drilling

74
 should be stopped immediately and all bystanders should be warned that a strike has
occurred and that they should stay away. Medical attention should be obtained for
personnel who have come into contact with sewage. As with any strike, the utility
owner should be contacted immediately.

3 Pipe Laying
3.1 Pipe Handling, Transport and Storage:
Purpose: The purpose of this Method Statement is to provides a guideline for the handling,
transport and storage of steel pipelines and uPVC pipelines. The methodology is applicable
for the construction of pumping mains and gravity mains. Steel pipes will require welding and
the procedure for welding is described separately.

Specification: Project Specifications, SANS 1200 series, OHS Act

Activity: Pipe Handling, Transport and Storage.
Materials: 110mm to 315mm diameter uPVC pipes, Fittings, Sandbags, Pumps, Motors,
Valves, Flow Meters.
Plant: Certified Cranes, Flatback Trucks, Chain Blocks, Lifting Rigs and Lifting Belts,
Abrasive Blast equipment, Pipe Clamps for Fit-Ups, Pipe scissors, etc.
Personnel: Project Manager, Civil Engineer, Site Agent, Mechanical Subcontractor,
Mechanical Electrical, Electrical Engineer, She Officer, Surveyor, Semi-Skilled and Unskilled
Labourers
SHEQ
 The SHE Officer is available at all times and inspects the loading and handling
facilities before any activity is done.
 Pre-task briefing and risk hazard awareness is carried out by the SHE Officer.
 The Quality Control Engineer secures the milling certificates and verifies the pipe
thickness, diameter, materials and gets approval from the Project Engineer.
 Site Engineer will arranger and liaise with the Project Engineer for third party
inspection by Engineer’s team of all completed pipework to ensure that the relevant
delivery notes and data packs are in order.
 A skilled and qualified pipe-loading team/rigger with the requisite training and license
as necessary for this job and equipped with the necessary safety equipment in
accordance with the respective site rules & regulations.
 All loading equipment to be in good working order, certified by the Government
Assize Officer for cranes etc. and be equipped with the required safety certificates
etc.

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  Ensure the pipework is fastened down securely onto the truck using suitable ropes
and belts. The ends of every pipe, fitting and special shall be fitted with suitable end
closures as a precautionary measure against damage being caused to the lining
material. The end closures shall prevent the ingress of dirt but allow ventilation
through the pipework.
 The pipework is held in place by pipe cradles and dunnage to stabilise the load.
 Each pipe fitting, special, coupling and valve shall bear the Contract Number followed
by the Item Number given by the Engineer and a Dispatch Number allocated
consecutively by the manufacturer.
 All bends shall be marked as above and the deflection angle in degrees and minutes
painted on the surface.
 Packaged items e.g. bolts and nuts, insertion rings etc. shall be marked with a metal
label bearing the Contract Number and Item Numbers which they are to be used.
 Ensure the loading truck is stationary, parked to level and stable during loading and
off-loading operations.
 Factory Acceptance Testing is done as per the Quality Control Testing Plan approved
by the Project Engineer.

Quality Control Inspections on Site

 Serial numbers of materials will be checked against the relevant delivery

notes and data packs. Discrepancies will be recorded and reported
immediately to the pipe manufacturer.

 Pipe ovality is checked to ensure that it has not been compromised.

 Check that ensure that pipe coating and lining have not been compromised.
Damages identified will be recorded and reported immediately to the pipe
manufacturer.
Responsibilities
Site Agent will be responsible for the supervision of all personnel performing pipe handling,
transport and storage duties as per the specifications, method statement and safety
activities. The Site Engineer will monitor and arrange all FAT testing at regular intervals.

Piping Foreman - The piping foreman will be responsible for the pipe installation, specials,
and fabricated spools as per the approved drawing, as directed per the piping engineer. The
piping foreman will coordinate the rigging crew.
Rigging Crew - The riggers will report to the supervisor and coordinate all activities with the
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foreman, with regard to safe and secure rigging, handling, transport and storage. The riggers
will assist the foreman in the pipe laying process, ensuring safe and damage free lifts.

Procedure
All activities shall be preceded per a risk assessment, safety talk and documented evidence
thereof.

Handling.

All handling shall be carried out on conclusion of a rigging study, risk assessment and clear
instructions as to the importance of safe and damage free handling. The correct protective
slings shall be used and assurance made they conform to certified evidence.

Transport.

Transport shall be made per pre-selected and assessed vehicles certified for such loads.
The pipes will be loaded onto trucks from the suppliers in Gaborone and delivered to the
laydown areas and stored under sheltered environment protecting the pipes from sun
damage. The fittings will be stored at the site office at the laydown yard before being
transported to particular sites for installation. An inspector will be at hand to inspect the pipes
and fittings as they are being delivered.

Handling of nested pipes:

We propose to nest various diameter pipes during transportation. Always lift nested bundles
using at least two pliable ropes.

Always keep nested pipes on site in the original transporting package only.

Stacking of these pipes is not advisable. De-nesting of pipes should be done carefully at pre
allocated station.

Inside pipe may be removed by lifting it slightly with an inserted padded boom to suspend
the section & carefully move it out without damaging the outer pipe.

Offloading

 The pipes will be offloaded such as to keep the load spread evenly along the
pipe trailer i.e. the top pipes will all be offloaded first before any pipes are
offloaded lower down on the trailer.

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  The pipes will be strung along the pipeline servitude at a safe distance from
the construction area to keep them safe from damage.

 The pipes will be offloaded using suitable web slings which will not damage
the coatings and the pipes will be placed on sandbags at least 100mm of the
ground. The pipes will be lifted using the tracked excavator and tractor.
Storage

All storage shall be per the Project specifications in pre-approved areas, seated on
applicable dunnage. uPVC pipes can be stacked easily. Storage shall be allocated to areas
prepare for the purpose and cleared for the necessary safe access. Storage facilities shall
take into consideration the possibility of inclement weather conditions. Continuous visual
inspection shall be performed per the QC so as to identify improper handling, storage or
damage. Should damage be noted, such pipes or items shall be relocated to a quarantine
area for repair. Weather sensitive materials, pumps, motors, control valves electric
equipment will be packed in crates by the suppliers and stored under roof.

The ground area should be relative flat & dry, free of rocks or any other potentially damaging
debris. Place flat timber supports as four meter spacing, to facilitate placement & removal of
lifting slings around the pipe & Stack the pipes on them.

 The pipes will be lifted using the tracked excavator and tractor with trailer.
 Lengths of pipe will be transported to where they should be laid in accordance with
the supplier guidance.
 The topsoil will be stripped and re-used for reinstatement.
 If a possible man-made structure is found, the archaeologist will be called to site to
assess how to proceed.
 Excavation to be performed to the right level with rock being excavated as needed
using hydraulic breaker.
 Bedding will be laid to the correct level at the bottom of trench.
 Pipe will then be placed in position in accordance with the pipe specification and
manufacturer instructions with final connections made.
 The pipes are secured at the ends, fittings and change in direction by means of
end caps protected with thrust blocks.
 A blanket surround is then placed around the pipes up to 300m cover and
compacted to specified densities. Only the joints are left exposed up to 100mm
either side of the joint. All pipe accessories are placed as the pipes are laid e.g.
valves etc.
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  Pipe to be backfilled as detailed in the contract drawings with selected as dug
material.
 Upon completion of all pipe laying and backfilling, the pipelines will be flushed,
swabbed and tested as per the technical specification:
o The pipes are filled with water and pressurized to at least 1.5 x the normal
operating pipe pressure.
o The pressure is maintained constant after switching off the pressurizing
pump and observed for at least 2 hours.
o The Engineer will be present during the pressure testing and on completion
if the test is successful final backfilling to the trench is done.
o The pipeline is emptied of all the water and filled with chlorinated water.
Sampling is done by a dedicated laboratory for water quality testing. If the
dosage is approved then the pipe is emptied and flushed and refilled with
fresh portable water. Further sampling and testing is done to confirm the
quality.
o After receiving the test certificate for the sterilization the pipeline is
connected to the rest of the system under stringent hygienic conditions to
prevent recontamination of the system.

Documentation
 Approval of the Engineer should be obtained immediately after the works have taken
place and prior to the successive activity.
 The signing off should be done on the designated form and signed off on the Quality
control Plan.

Final Site Clearing

 The pipe line corridor is leveled and cleared of any excess spoil heaps and
construction waste on completion of the backfilling works.
 All waste is sorted and disposed of at facilities approved by the Client.

3.2 Pipe Laying

 The pipes will be lifted by hand and laid out against the section of the trench that is
ready for construction.
 Heavier, larger diameter pipe will require handling equipment to lift, move, and lower
the pipe into the trench.

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  Pipe must not be dumped, dropped, pushed, or rolled into the trench.
 Appropriate safety precautions must be observed whenever persons are in or near
the trench
 Lengths of uPVC pipe will be transported to where they should be laid in accordance
with the supplier guidance.
 If a possible man-made structure is found, the archaeologist will be called to site to
assess how to proceed.
 Bedding will be laid to the correct level at the bottom of trench.
 Pipe will then be placed in position in accordance with the pipe specification and
manufacturer instructions with final connections made.
 The pipes are secured at the ends, fittings and change in direction by means of
end caps protected with thrust blocks.
 A blanket surround is then placed around the pipes up to 300m cover and
compacted to specified densities. Only the joints are left exposed up to 100mm
either side of the joint. All pipe accessories are placed as the pipes are laid e.g.
valves etc.
 Pipe to be backfilled as detailed in the contract drawings with selected as dug
material.

Typical cross section for pipe earthworks as per details on drawings

3.3 Thrust blocks

RCC thrust blocks will be constructed (common thrust blocks for all pipes including product
lines) at the places of bends, tees & reducer as per the typical details. It is recommended to

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wrap a band of rubber around the pipe prior to placement of any concrete. Rubber should
protrude (25 mm) from the pipe. Rubber thickness 10 mm & of 50 Durometer. Drawings as
given by M/s Pula Consultants (Pty) Ltd will be used for construction. Thrust blocks are cast
as pipe laying progresses. Before the hydrotest all thrust blocks should be completed and
cured at 28 day strength. It is always recommended to have coupling on two edges when
pipe comes out of thrust block.

Documentation
 Approval of the Engineer should be obtained immediately after the works have
taken place and prior to the successive activity.
 The signing off should be done on the designated form and signed off on the
Quality control Plan.

Final Site Clearing

 The pipe line corridor is leveled and cleared of any excess spoil heaps and
construction waste on completion of the backfilling works.

9 Sequencing of pipelines, chambers and fittings

In our initial planning the programme of works has taken into account the need to complete
the pipelines, chambers and fittings concurrently. All pipe fittings and thrust blocks will also
be constructed concurrently. This approach will allow for the pressure testing and
disinfection of the pipelines to be carried out once a section of the pipeline is complete.
To achieve the required production and complete the project on schedule the construction of
pipelines, valves, chambers and fittings has been sequenced to run concurrently. The
approach will enable the following to be effected:
 sections of work are approved concurrently and not partially
 hydraulic pressure testing will be carried out on completed pipeline sections and
reduces duplication of tests.
 disinfection of the pipelines is done for the completed network as per the required
standards
 reduces double handling of the works
10 Tests
A Testing Plan will be prepared at project commencement and forms part of the QC registers
to be used throughout the project.
The tests that will be carried out on the water pipelines and storage tanks include pressure

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tests and sterilization. Other tests on materials will be carried out to include tests on
earthworks and tests on concrete.
The tests to be conducted are summarized below:
 Progressive testing during construction
 Model Testing (where required)
 Factory Acceptance Testing
 Installation Testing
 Tests on Completion
 Dry Commissioning (functional Testing)

10.1 Water for Testing

 The Contractor will source the water for testing from the local boreholes which
have potable water.

 A notice will be given to the Project Engineer of sections of works ready for
testing including dates and times.

 WUC will be notified of the imminent testing in advance and invited to come
and witness.

10.2 Progressive Testing during Construction

 Samples of pipes and fittings will be subjected to FAT at agreed frequencies

with the Project Engineer. The Project Engineer will witness all FAT Tests and
will sign off the approved materials before they are shipped to site.

 Inspection, testing and checking shall be carried out at the manufacturing

plant where the Data Sheets / Test certificates will be prepared and
dispatched to site with the product details.

 Hydraulic testing will be carried out progressively on completed sections of

pipeline. Where tests have been completed successfully backfilling and
compaction will follow immediately.

10.3 Tests on Completion

Tests on completion shall commence after the works have been completed and shall
comprise a Dry Commissioning phase to be carried out. The Wet Commissioning Phase will
include two phases, a Local Wet Commissioning Phase and a Remote Wet Commissioning
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Phase. The full pipeline construction team will be on standby at site during the Wet
Commissioning Phase in case any repairs / adjustments need to be carried out to ensure a
successful Wet Commissioning Testing Phase.
10.4 Hydrostatic Pressure Testing
The field pressure test used to test the integrity of the pipe joints which were completed on
site. The test is covered by the SANS 2001:DP2 – Medium pressure pipelines standard. It is
important to check the condition of test equipment like end caps, hoses and pressure testing
machine prior to commencing the test. If equipment leaks, the test will be compromised.
Calibration of test equipment, especially pressure gauges, should be checked. Inaccurate
pressure gauges will not only compromise the integrity of the test, but may lead to over-
pressurization and subsequent damage of the pipeline.
All pipes require large volumes of water to conduct a field pressure test, and a check will be
undertaken to ensure that there is sufficient water available on site prior to the
commencement of the test. All concrete work, like thrust blocks, will be given sufficient time
to reach full strength prior to testing, in order to preserve the integrity.
Temporary end caps fitted for testing purposes will be restrained against end load movement
under pressure. End load forces are high and restraints for end caps shall be able to
withstand these forces. For example, 500 mm class 12 PVC pipe subjected to 18 bar
pressure generates an end load of approximately 18 tons directly onto the end caps.

The pipes also have to be properly backfilled in order to keep them from rising up from the
trench during testing. The joints will be kept exposed, however, as it will make inspection for
leaks much easier and quicker.
10.4.1 Requirements for determining the test pressure
The reason for performing the pressure test is to establish that the pipeline does not leak.
Test pressure is raised above the operating pressure of the pipeline to allow the pipeline to
settle under that pressure and to highlight possible leaks that would otherwise only develop
after some time under pressure. With this in mind, the following requirements for test
pressure are set out in SANS 2001: DP 2. Pressure tests are carried out within the first 8
weeks of installation
First requirement: The test pressure must be 1.5 times the working pressure of the
pipeline, up to a maximum of 10 bar. Above 10 bar, the test pressure must be the working
pressure of the pipeline plus 5 bar. The requirement refers to the working pressure of the
pipeline, i.e. the pressure the pipeline will operate under. It does not refer to the pressure
class of the pipe. For example; a pipeline with an operating pressure of 16 bar should be

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tested at 21 bar (16 bar + 5 bar).
Second requirement: The test pressure must be between 1.25 times and 1.5 times the
operating pressure at any point in the pipeline. This requirement makes allowance for
variation in the test pressure. Due to differences in static head in the test section, it allows
the test pressure to vary between 1.25 and 1.5 times the operating pressure at any point
along the test section.
10.4.2 Test procedure
Once the section of pipeline is ready for testing and the ends have been sealed and
secured, the pipe line is filled slowly, to ensure that air is not trapped during the filling
procedure. It is preferable to fill the pipeline from the bottom to push air out at the top of the
pipeline. A breather will also be left open at the top of the pipeline for air to escape.
If filling the pipeline from the highest point, it is necessary to allow sufficient time for air to
settle to the top before starting the test. It is good practice to leave a filled pipeline for 12
hours for air to settle at the highest point. The air must be removed before commencing the
pressure test.
When determining the test pressure, it is important to consider the location of the pressure
gauge on the pipeline. If the pressure gauge is at the highest point along the test section,
one has to add the static head (vertical height difference in metres between the lowest and
highest points) of the test section to the reading on the pressure gauge.
After pressurizing the test section slowly, the stop ends and thrust blocks should be checked
for movement. If movement is detected, the test must be immediately terminated for repairs
to take place. Once the pipeline has reached test pressure, the joints must be inspected for
leaks. If leaks are found, the pipeline should be de-pressurized, and leaks repaired before
restarting the test.

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Pipelines can sometimes be several kilometres long, it is therefore beneficial to test the
pipeline in sections.
If there are no visible leaks and the pipeline has stood under test pressure for the required
duration, the isolation valve between the test equipment and the pipeline is closed. After an
hour has elapsed, the test pressure is restored and the amount of water needed to do so in
litres is measured. SANS 2001: DP 2 contains equations, depending on the pipe material, to
calculate the allowable amount of water, in litres, needed to restore test pressure in the
pipeline.
As an example we consider a test section of 250mm PVC-U Class 16 pipe, 500m long. The
equation for PVC pipes is as follows: 0.01 x OD mm x Test Length km x √Test Pressure
MPa. Therefore 0.01 x 250 x 0.5 x √2.1 = 1.811 litres. If more than 1.811 litres of water is
needed to restore test pressure, the test failed and one should find the leak before retesting.
10.4.3 Test duration
SANS 2001: DP 2 is specific about the test duration, which specifies that the test duration is
three hours for pipes of nominal diameter 400 mm and above, and between one and three
hours for pipes of nominal diameter below 400 mm. During this time, the pressure inside the
pipe should be maintained by means of a suitable pump.
Once the test duration has elapsed, an additional hour is needed to perform the allowable
pressure drop test. If the pipeline fails the pressure test, the leak needs to be located,
repaired and the test repeated. All air must be bled out of the pipeline before repeating the
test.

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 o The pressure is maintained constant after switching off the pressurizing
pump and observed for at least 2 hours.
o The Engineer will be present during the pressure testing and on completion
if the test is successful final backfilling to the trench is done.

o The pipeline is emptied of all the water and filled with chlorinated water.
Sampling is done by a dedicated laboratory for water quality testing. If the
dosage is approved then the pipe is emptied and flushed and refilled with
fresh portable water. Further sampling and testing is done to confirm the
quality.
o After receiving the test certificate for the sterilization the pipeline is
connected to the rest of the system under stringent hygienic conditions to
prevent recontamination of the system.

10.5 Disinfection
When the network has been fully connected sampling points will be prepared at the
guidance of WUC personnel. WUC personnel will be notified 5 days in advance of readiness
to commence the disinfection.
10.5.1 Disinfection Procedures
The disinfection procedure will follow the pressure testing on a closed network and the
following steps will be taken:
 Swabbing and flushing the main
 Soaking of the main for a minimum period of 20 hours increasing the minimum
concentration of available to 20 mg/l in the mains water.
 Removal of excess chlorine by flushing the main.
 Soaking the main for an additional 20 hours.
 Sampling and testing of the water by laboratory personnel for compliance with the
water quality standards specified in the water quality standards section.

The sampling points will be to the requirements of section 12 of the WUC Design Standards
DS 0295 1995.

10.5.2 Medical Screening and Clothing

All personnel involved in the disinfection of all mains and reservoirs will undergo a medical
examination which carries out the Widal test as well as tests for Cholera and Hepatitis A.
All personnel entering a reservoir will wear overalls, gloves and gum boots previously

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soaked in 5mg/L chlorine solution of HTH.
10.5.3 Tests on Other Materials
Tests on earthworks:
 Sieve analysis and grading for bedding and initial backfill material.
 MDD and OMC for all backfill and bedding materials.
 Atterberg Limits and CBR tests for initial backfill and pipe surround.
 Insitu density testing.

The inspection and test plan for backfilling works summarizes various characteristics to be
checked. The concerned site Engineer shall be responsible to ensure stage wise compliance
for this operation. Materials Technician shall carry out QC checks and reports for inspection
results.
A sample of screened material from site stockpile/laydown material at the site shall be
collected in the presence of The Engineer and shall be sent to the approved laboratory for
testing.
Structural Backfill/ backfill/bedding material for utility trenches shall be identified/stocked/
labeled separately at approved location.
After satisfactory tests, results shall be submitted to The Engineer for approval prior to
proceeding with any kind of backfilling work.
Copies of nuclear gauge certificate, calibration certificate an operator certificate shall be
submitted to the Engineer prior to the commencement of the works.
Compaction test shall be conducted by the technician in the present of the Engineer by the
certified nuclear gauge to ensure that the compaction achieves the 95% of MDD and test
result shall be submitted to the Engineer for the documentation.
Layer thickness and testing frequency shall be as specified.
Test on concrete:
 Tests on coarse aggregates – ACV, 10% FACT tests, durability and soundness
 Concrete mix designs
 Slump tests
o Slump tests (and VSI testing when applicable) shall be carried out at the rate
of one test per load of concrete delivered to the Site, or one test per 10 m³
whichever is the lesser for the first 50 m³ of concrete then at a rate of 1 slump
test for every 50 m³. Slump shall be recorded on the batch ticket for each
delivery wherever applicable.
o In the event of inconsistent slump values, the Engineer may instruct the
Contractor to check the slump test on each truck of concrete at the plant.

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 o The slump requirements to the Sampling and testing for slumps will be carried
out in accordance with relevant Specifications following the ITP and approved
mix design.
 Concrete cube tests at 7, 21 and 28 days.
o All samples and tests will be carried out in accordance with approved ITP and
approved mix design.
o Samples and fresh concrete will normally be obtained from the concrete mixer
during discharge for slump tests and cubes.
o Each sampling will consist of at least 7 specimen cubes; 2 tested at 7 days, 2
tested at 21 days and 2 tested at 28 days as per relevant specification.
Additional samples to be tested at the discretion of engineer.
o A minimum of one sample shall be taken of each mix every day the mix is
used.
o Samples shall be taken at the average rate of one sample every 30 m³ of
concrete or fractions thereof for the first 90 m³, then one sample every 100 m³
of concrete or fraction thereof when continuous concrete production reaches
up to 2000 m3 and later of one sample every 200 m³ of concrete or fraction
thereof when concrete production exceeds 2000 m³.
o A test shall be the average of the strength of the specimens tested at the age
specified. If a specimen shows definite evidence other than low strength, of
improper sampling, moulding, handling, curing, or testing, it shall be
discarded and the strength of the remaining cylinder shall then be considered
the test result.
o If works test specimens fail at 28 days, the Contractor shall suspend
concreting operations and shall not proceed further without approval. The
Contractor shall carry out in-situ testing of the suspect, in the presence of the
Engineer. All defective work shall be replaced and retested to the satisfaction
of the Engineer.
11 Building Works
Methodology

Preparation Work
 Ensure that the mix designs are in place and approved by the Engineer
 Ensure presence of the latest “approved for construction” drawings and set out
the works in accordance with the drawings and any other instructions by the
Engineer
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 Site survey team to confirm with the Engineer the wall setting out, the electrical
and sanitary ware fittings position prior to commencement of construction works
 Ensure that the survey equipment is in good working condition and has valid
calibration limits and certificates
 Ensure that all the building materials are in accordance with the specifications
and have been approved for incorporation in the works as may be required

Work activities

Masonry

 Set out the works in accordance with the drawings and instructions from the
Engineer.
 Install the dump proof membranes where required
 Mix the mortar in accordance with the mix proportions using the concrete mixer
and ensure that the mix has the suitable workability for laying bricks
 The mix shall be measured by volume batching using calibrated buckets or wheel
burrows
 Transport the mixed mortar to the working location using the dumper
 Ensure that the surface where the masonry is to be laid is clean and free of loose
aggregates
 Lay the bricks in approved masonry bond in line with the setting out both
horizontally and vertically
 Ensure that the masonry is laid while the mortar is still plastic
 Install the brick force as specified
 Lay bricks to the lengths and heights acceptable to carry the loading on green
mortar to avoid distortion from the alignment
 Create joints where required in accordance with the specification requirements,
the joints shall take cognizance of stability and structural integrity of the walls and
shall allow harmonious movement of the structure components
 Ensure that the mortared joints between courses of masonry are in accordance
with the specifications
 Masonry over openings shall be laid on top of concrete lintels as specified
 Protect all the newly built masonry work from damage until sufficient strength has
developed

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Plumbing and Electrical fittings
 All the piping, sanitary and electrical conduits shall be done after the walls have
been approved and when the roofing is in progress or in place but before
plastering works.
 Mark the positions of the pipes and conduits on the walls and get approval of the
Engineer
 Chip the walls using the brick hummer and/or grinding machine for the piping and
the conduits
 Fix all the piping and conduits in accordance with the manufacturers
specifications and secure to place using mortar
 Install all the sanitary ware and electrical appliances in accordance with the
drawings and specifications
 Call for inspection prior to plaster application

Plaster and floor screeds and tiling

 Ensure that the walls have been approved and all plumbing and electrical
conduits are fixed to positions
 Mix mortar in accordance with the mix proportions and to the required workability
for the activity to be carried out
 The mix shall be measured by volume batching using calibrated buckets or wheel
burrows
 The surfaces to be plastered shall be free from oils, dirt and any substances that
may affect bonding
 Where specified, the bonding agent may be applied to the walls and floors before
the mortar is laid
 Apply the plaster and the floors to the required thicknesses and finish
 Cure the finished plaster/floor using the recommended curing methods
 Tiling to be installed using approved materials, to lines and levels as per the
specifications.

Steel and Aluminum Fixtures

 Set out the positions for the fixtures as per the drawings
 Install the fixtures as the wall construction progresses and build into place
 Install the fixtures in accordance with the fixture schedule and manufacturer’s
specifications
 Clean the area and prepare the recess for the installation of the new windows. Fit
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 the new window frame into position, ensuring a tight fit and ensuring that the
frame is plumb and square.
 Use packers where necessary to secure the frame in position and then drill
through the frame into the masonry wall for the frame fixings. A minimum of 2
frame fixings should be used on each element of the window frame, though for
long windows additional fixings will be required.
 Once the frame fixings have been inserted and securely fixed /tightened, the
back of the frame should be filled with expanding foam to provide added
protection against the weather, water ingress and from unwanted noise.

Glazing
 Liase with the client prior to the start of works to determine start dates and
durations for the works. Advise the client of the hazards associated with the
works and ensure all materials, parts and equipment have been ordered and are
available for the start of works.
 The works will be carried out in accordance with an agreed programme of works.
 Carry out a visual inspection of the work area to ensure that the required works
are as per the specification and that no additional works or materials are likely to
be required.
 Deliver all parts and materials to site, ensuring that appropriate care is taken
when manual handling large, heavy or awkward shaped objects, such as heavy
glazed units.
 All works are to be carried out in strict accordance with the manufacturers’
recommendations and in the sequence specified by the manufacturer. All work
will also be carried out in strict accordance with Botswana Building Regulations
requirements.
 Before starting work ensure that the correct window sizes have been supplied,
together with the necessary fixtures and fittings.
 Once the windows and frames have been installed, the glazing units can be
inserted. Each unit should be installed and secured into position with the
appropriate beading/seals. The glazed panels can then be carefully lifted into
position, cut resistant grip gloves should be worn at all times when lifting glazed
units and for large panels a minimum of 2 persons should be used to lift and
secure the panels in place. The use of suction lifters should also be used to
provide a safe and secure grip when lifting large and heavy glass panels/units.
 The windows should then be tested to ensure that they open and close smoothly
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 without rubbing or catching, if necessary, the hinges should be adjusted to ensure
a suitable fit.
 The window frame should then be trimmed and sealed both internally and
externally and the area made good.
 Upon completion of the works, CCECC – Landmark JV will remove all rubbish,
scrap and waste materials/packaging from the premises and dispose of
appropriately. Thoroughly vacuum and clean through the area and all transit
routes leaving the property in a clean and tidy state

Roof Structure Construction

 The roof structure shall be designed, manufactured and erected by the specialist
 The trusses shall be built and delivered to site
 Scaffold to be erected around the perimeter of the property by competent
installers.
 Passive fall protection measures by way of a crash deck will be installed
 Trusses to be delivered by lorry and under direction of a banksman guided to
loading area.
 Trusses to be safely unloaded and secured in a vertical position using vehicle
HIAB.
 The mobile crane will be guided into the lifting position by the banksman.
 A crane will raise trusses individual, as per their lift plan.
 The first truss will be positioned and secured to wall plate.
 The remaining trusses will also be lifted into position and temporarily braced
back to the first truss.
 The purlins will then be installed by affixing to the trusses using bolts or nails
depending on the type of trusses used
 The trusses shall then be aligned to final position, braced and fixed in
accordance with the design. Longitudinal bracing will be fixed to the trusses,
ceiling ties and struts.
 The trusses will then be fixed to the walls and gables.
 Sufficient quantities of felt will be transported to the work area.
 The felt will be systematically laid in the direction of the roof gradient with
suitable side and end flaps, and breaking joints between layers.
 The process will be repeated until a sufficient felt layer has been achieved. If any
air bubbles are observed, the felt shall be cut back by the roofing operatives to
the satisfaction of Site Supervisor.
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 Roof batten will be lifted to roof with the crane. Operatives will secure batten at
suitable spaces for tiles.
 Sufficient quantities of roof tiles will be transported to the working area and fixed
to the battens using copper double nails.
 This process will be repeated along the length of the roof and then the ridge tiles
will be cemented into place
 Gable end roof tile edge to be filled with cement mortar.
 Once the work is completed, any surplus material will be safely removed and
operatives will leave the roof via scaffold ladders to the ground level.
 The site will be made good and control handed back to the client.

Ceiling Construction
Plasterboard Ceiling
 All leveling set out coordinates shall be based on the setting out levels on site.
 Once the setting out dimensions are determined, the Mechanical and Electrical
Engineer shall proceed to identify areas of M&E services that requires additional
adjustments. Once completed, the coordinator shall inform the Structural
Engineer on the request for an inspection by The Project Engineer for approval
prior to commencing of any physical works.
 Then installation of the ceiling brackets and hanger rods. Upon completion of the
droppers and hangers, the adjustable suspension brackets will be installed prior
to installing the main top cross rail and TCR to FCR connector and lastly the
furring channels will be installed.
 On completion of the above, the Structural Engineer shall inspect the framing for
any defective or inferior works and shall make all necessary remedial instruction
so as to ensure levelness and a secure and rigid framing has been installed.
 Once all ceiling are completed, the Structural Engineer shall request that the
trades commence all marking and setting out works so as to enable all opening
or penetration be made prior to plastering works.

Exposed Grid Ceiling (MFT)

 Plan the ceiling layout to provide even margins at the perimeter (grid space
for ceiling panels at each end of the ceiling is the same).
 Centre the ceiling both ways to ensure centre lines are at right angles to each
other and main runners are at right angles to purlins or joists.
 Fix wall angle trim to perimeter walls at the correct height of the ceiling and
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 check that they are level. Mitre the wall angle trim (shadow line) around piers
and columns.
 Fix suspension rod brackets to structural framing or concrete soffit to
appropriate height at 1200mm maximum centers in each direction.
 Attach suspension rods (with suspension hangers attached) to suspension
rod brackets previously fastened to supporting members, with rod end bent
down into a hook.
 Attach the main runners to suspension hanger ensuring the hanger hook is
firmly threaded through the top of the main runner.
 Adjust the suspension hanger or rod threaded to set the height of the main
runners to a level line between the wall and wall angle trims.
 Insert cross tee runners intersecting main runners at 600mm centres.
 After suspension components are installed, fix light fittings, air register and
blind boxes. All fittings will be checked for tightness and safety and ceiling
tiles are inserted.

Carpentry, Joinery, Ironmongery and Painting

 The roofing, plastering and tiling should be completed for these activities to
commence.
 Install doors, locks, skirtings, etc, in accordance with the contract specifications
 Apply paint to all the walls, doors etc. as specified to the correct thickness and
quality

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