PT Report Ce Ii

UNIVERSITY OF DAR ES SALAAM
COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF STRUCTURAL AND CONSTRUCTION ENGINEERING
PT II (CE 200) REPORT YEAR 2022
PROJECT: DESIGN AND BUILD OF AN ELECTRIFIED STANDARD GAUGE
RAILWAY (SGR) LINE FROM MWANZA TO ISAKA (249km MAIN LINE AND 92km
SIDING/PASSING LOOPS) ON ALIGNMENT PARALLEL TO EXISTING METER
GAUGE RAILWAY (MGR)
NAME: KASSIM, MALIYAT HAIDARI
REGISTRATION NUMBER: 2020-04-03542
DEGREE PROGRAMME: BSc CIVIL ENGINEERING
DATE OF STARTING: 18th JULY 2022
DATE OF FINISHING:
SUPERVISOR’S NAME:
SUPERVISOR’S SIGNATURE: _________________
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TABLE OF CONTENTS
Abstract ............................................................................................................................................. 3
ACKNOWLEDGEMENTS.............................................................................................................. 5
LIST OF ABBREVIATIONS........................................................................................................... 6
CHAPTER 1: PROJECT OVERVIEW ............................................................................................ 7
1.0 INTRODUCTION..................................................................................................................................... 7
1.2 ORGANIZATION CHART ......................................................................................................................... 7
1.2 TRC COMPANIES, MISSION, VISION AND VALUES. ............................................................................... 8
MISSION ...................................................................................................................................................... 8
VISION ......................................................................................................................................................... 8
VALUES........................................................................................................................................................ 8
OBJECTIVES ................................................................................................................................................. 8
1.3 PROJECT INFORMATION................................................................................................................. 9
1.5 TECHNOLOGY INVOLVED.............................................................................................................. 9
CHAPTER 2: GENERAL DETAIL, LOGBOOK AND WEEKLY SUMMARY ........................ 11
Week 1 ...................................................................................................................................................... 12
Week 2 ...................................................................................................................................................... 17
Week 3 /4.................................................................................................................................................. 25
2.2. MAIN ACTIVITIY OUTLINE FOR THE WEEKS 3 & 4 ...................................................... 30
2.2. Construction of drainage and livestock culverts ....................................................................... 35
2.3. CONSTRUCTION METHOD.................................................................................................. 36
Week 5-8 ................................................................................................................................................... 39
2.4. MAIN ACTIVITIY OUTLINE FOR THE WEEKS 5-8 .......................................................... 47
CHAPTER 3: SPECIFIC REPORT................................................................................................ 58
3.1. EARTHWORKS............................................................................................................................... 58
3.1.1. Technical Preparation ................................................................................................................ 58
3.1.2. Site Preparation .......................................................................................................................... 58
3.2. Main activities............................................................................................................................... 59
3.3. Skills and manpower..................................................................................................................... 64
Chapter 4: Miscellaneous................................................................................................................ 67
Annexes........................................................................................................................................... 69
REFERENCES/ BIBLIOGRAPHY................................................................................................ 75
1
LISTS OF TABLES AND FIGURES
Figure 3: the slump achieved for the casting of bridge decks......................................................... 14

Figure 4: Formwork preparation for the casting of the bridge decks ............................................. 15
Figure 5: Proctor machine, conducting all compaction for the mold ............................................. 19
Figure 6: graph showing the relationship between dry density and moisture content.................... 21
Table 1 of results: for Dry Density-moisture content relationship ................................................. 22
Figure 9 An excerpt of the bar bending schedule including all the displayed specifications ......... 30
Table 2: allowable tolerances in the cutting and bending of reinforcement bars ........................... 31
Table 3: bending allowances for bent steel..................................................................................... 31
Figure 10: steel bar cutting machine............................................................................................... 32
Figure 11: steel bar bending machine ............................................................................................. 32
Figure 12: steel bar stock, the bars are secured with bending wires and inscribed using marker on
their aluminum labels. the bar marks are used to indicate the type of stock prepared, .................. 33
Figure 13: steel fixing and erection of scaffolds along the drainage culvert at KM 157+730 ....... 35
Figure 14: design drawing for the B-B section for the box culvert at KM 156+000...................... 36
Figure 15: bottom slab reinforcement secured in steel formwork onset of inspection, concrete is
casted afterwards............................................................................................................................. 37
Figure 16 a completed box culvert along KM 156+000 ................................................................. 38
Figure 19: concrete batching plant.................................................................................................. 47
Figure 20: testing temperature and viscosity for a concrete sample from the plant, ...................... 48
Table 5: increase in strength with respect to setting time............................................................... 48
Figure 21: plotted graphs from data obtained from CBR tests ....................................................... 53
Table 3 of results on CBR test ........................................................................................................ 54
Figure 16: GPS base and rover ....................................................................................................... 60
Figure 23base plate, digging steel rod, spoon, brush, and calibrated sand as used in field density
test. .................................................................................................................................................. 62
Figure 17: a water bowser | Figure 18: a wheel loader ................................................................... 62
Figure 20: roller/compactor machine | Figure 24: dumping trucks ................................................ 63
Figure 24: borehole drilling by wash borehole drilling technique.................................................. 64
2
Abstract
This report entails the detailed presentation of the entire 8-week courses of training that took place
during the Practical training (PT II) program for the year 2022. The training took place in the
railway construction project along Mwanza-Isaka.
The project is described as the DESIGN AND BUILD OF AN ELECTRIFIED STANDARD
GAUGE RAILWAY (SGR) LINE FROM MWANZA TO ISAKA (249 KM MAIN LINE
AND 92KM SIDING/PASSING LOOPS) ON ALIGNMENT PARALLEL TO EXISTING
METER GAUGE RAILWAY (MGR). This project is considered to be part of the phase 1, lot 5
of the construction of the Standard Gauge Railway (SGR) which began in Dar es salaam.
The training program was allocated to the Tanzania Railway Corporation (TRC), a government
institution and the client of the project. Thus, the training was handed over to KORAIL JV, the
project consultants who were the inspectors for all the project activities. Thus, the consultant then
assigns all trainees onto the supervision to the contractor.
All site works were fully coordinated and handled by the contractor; the China Civil Engineering
Company Corporation (CCECC) in a joint venture with another company, China Railway
Company Corporation (CRCC). The contractor is thus responsible for the employment,
supervision and overseeing of all design engineers, technicians, surveyors, site foremen, machine
operators, drivers and laborers. The contactor is also accountable to the safety and welfare of all
the staff on site and thus equally expected to employ safety officers.
All activities done on and off site are done in accordance to the Environmental, Social, Health and
Safety (ESHS) regulations as assigned, inducted and overseen by their respective officers.
Each day is commenced with a toolbox meeting, which is done and coordinated by the officers, of
which various ESHS requirements are gone over, reminded and various misconduct previously
observed or expected are addressed.
The project being “design and build”, it implies that both design preparation as well as design
execution were conducted by the contractor. That being said, the training process under the
contractor involved reviewing the developed designs, understanding the prepared designs,
execution of the design and inspection of the completed design.
The project locations are determined by the designations of respective chainages along the entire
design corridor was to be aligned. The chainages begin at KM 0+000 and are assigned every 20m
throughout the line.
The first week of training took place in Lot 1, along Dar es salaam-Morogoro; mainly Ilala
Batching plant (KM 0+000) and the overpass at Pugu station (KM 20+000) while the procedures
and area for relocation was being put in place. This was 15th of July through 20th of July at which
the training was relocated to lot 5 i.e. Mwanza- Isaka for which the rest of the training was done.
Since most of the training was spent in lot 5, most of the main activities described in the report
will base on the said vicinity.
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The Mwanza-Isaka project is divided into 4 sections as explained below;
1. Section 1: 58.55 km from Isaka (KM 129+450) to old Shinyanga (KM 188+000)
2. Section 2: 68.0 km from Shinyanga (KM 188+000) to Malampaka (KM 256+000)
3. Section 3: 65.0 km from Malampaka (KM 256+000) to Fela (KM 321+000)
4. Section 4: 64.014 km from Fela (KM 321+000) to Mwanza central (KM 367+014)
In this part, the second week of training took place along section 2, while the rest of the training
took place in section 1 and section 0. All trainees were put under the supervision of consultants
that were the site inspectors.
The entire project involved mainly structural works (construction of culverts, steel production and
fixing), quality control (laboratory materials testing and documentation) and embankment
construction. This lasted for the remaining course of training, 21st of July through 10th of
September.
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ACKNOWLEDGEMENTS
Sincere gratitude to every single facilitator that led to the successful conduction of the training as
well as the completion of this report. Below are some of the key facilitators without whom this
project would have been in vain;
Under the Tanzania Railway Corporation management, this has been greatly facilitated by the
following;
 The Director General, Mr. M. Kadogosa
 The SGR Project Manager, Eng. M. Machibya
 The SGR Lot 1 Deputy Project Manager, Eng. T. Komu
 The SGR Lot 5 Deputy Project Manager, Eng. C. Kalisti
 The SGR, Lot 5, section 1/section 0 (Shinyanga - Isaka) supervisor, Eng. O. L. Julius
Under the KORAIL JV management, the project was greatly facilitated by the following;
 The earthworks inspector, for section 1 Eng. E.M. Lyaruu
 The structural engineer for section 1, Eng. E. Shuma
 The Materials inspector for section 1, Eng. B. Mfinanga
 The deputy materials inspector for section 1, Eng. I. Shaban
 The surveyors for section 1, Mr. H.M. Mchingamao
Along with all technicians from whom maximum support was received.
From the CCECC-CRCC JV management, immense gratitude is to all technicians, skilled,
semi-skilled and unskilled laborers that had offered all the support that eventually led to
the completion of the training and the documentation of the report.
Additional gratitude to the University-assigned external supervisor(s);

Dr. S. Rimoy | Dr. J. Elvis; whose unrequited guidance and subject matter rectification was
highly useful in the completion of the training.
Gratitude is to the moral and material support of our parent throughout the progression of the
training. Lastly, greatest thanks is to the Almighty, for strength, ability and all that was done to
make this possible.
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LIST OF ABBREVIATIONS
TRC- Tanzania Railway Corporation
GoT – Government of Tanzania
KORAIL JV- Korea Railway Joint Venture
CCECC - China Civil Engineering Company Corporation (CCECC)
CRCC - China Railway Company Corporation (CRCC).
ESHS – Environmental Social, health and Safety
MGR – Meter Gauge Railway
SGR – Standard Gauge Railway
PPE – Personal Protective Equipment
MDD – Maximum Dry Density
PI – Plasticity Index
OMC – Optimum Moisture Content
NMC – Natural Moisture Content
CBR – California Bearing Ratio
QC – Quality Control
HEC-RAS – Hydrological Engineering Centre- River Analysis System
GSM-R – Global System for Mobile Communications - Railway
GPS – Global Positioning System
RoW – Right of Way
HSE – Health Safety and Environment
AREMA – American Railway Engineering and Maintenance of way Association
BS – British Standard
CML – Central Materials Laboratory
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CHAPTER 1: PROJECT OVERVIEW
BACKGROUND AND JUSTIFICATION
1.0 INTRODUCTION
Tanzania Railway Corporation (TRC) is a state corporation that established under the Railway
Act No. 10 of 2017 with the core manmade of providing an efficient and effective rail transport
service, manage and develop rail in structure and safety and security in Tanzania mainland.
Therefore, during my industrial Practical Training, I have trained more about EARTHWORKS,
STRUCTURAL WORKS like UNDERPASS, SO, CONTROL QUALITY (QC), and
CONCRETE WORKS
1.2 ORGANIZATION CHART
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1.2 TRC COMPANIES, MISSION, VISION AND VALUES.
HISTORICAL BACKGROUND
The History of Tanzania Railways Corporation can be traced back from 1948 after the
establishment of the East Africa Railways and Harbors Corporation (EAR&H). East African
Railways and Harbors Corporation (EAR&H) was a company that operated railways and harbors
in East Africa from 1948 to 1977.
The Tanzania Railways Corporation is a state-owned enterprise that runs one of Tanzania's two
main railway networks. When the East African Railways and Harbors Corporation was dissolved
in 1977 and its assets divided between Kenya, Tanzania and Uganda, TRC was formed to take
over its operations in Tanzania.
MISSION
We understand our client’s goals, and embrace them as our own, experience, integrity and
dedication to deliver superior solutions to the world’s energy, environment and infrastructure
challenges.
VISION
To solve the challenges of making the Earth a better place to live community by community and
project by project.
VALUES
 Safety
 Quality
 Integrity
 Creativity
 Accountability
 Teamwork
 Passion
OBJECTIVES
The object is to construct a whole rail network into new Standard Gauge Rail (SGR). The
construction of the central railway standard gauge involves the use highly advanced technology and
power which enable increase of speed from 30km/h as of now to 160km/h. Moreover, the new
Standard Gauge railway line will also increase axle load from 13tons to 35tons.
The Standard Gauge central line will be built into phase, phase one will be from Dar as salaam to
Mwanza (1219km) which is also implemented in lots as follows:
Lot 1: Dar es salaam-Morogoro (205 km main line and 95 km sidings/passing loops),
Lot 2: Morogoro- Makutupora (336 km main line and 86 km sidings/passing loops),
Lot 3: Makutupora- Tabora (249 km main line and 122 km sidings/passing loops),
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Lot 4: Tabora- Isaka (133 km main line and 29 km sidings/passing loops),
Lot 5: Isaka – Mwanza (249 km main line and 92 km sidings/passing loops sidings/passing loops).
The project has a modern signaling and Telecommunication (ST) system based on European
Railway Traffic Management System (ERTMS-II) and GSM-R.
1.3 PROJECT INFORMATION

PROJECT OBJECTIVE
The main objective of the project is to construct Standard Gauge Railway (SGR): Mwanza – Isaka
(LOT 5) with improved capacity, reliability and cost-effective transportation over the Central
corridor as a whole.
PROJECT STAKE HOLDERS

 CLIENT: Tanzania Railway Cooperation (TRC)
P.O. BOX 76959, Dar Es Salaam
 SUPERVISION CONSULTANT: KORAIL – JV; A Joint Venture of Korea Rail Road,
CHEIL Engineering, UNITEC Civil Consultant Ltd, Dong – Myeong, Multi – Tech
Consult, BARSYL, SSF Ingenieure and Rina Consulting S.P.A
 CONTRACTORS:
Main Contractor: China Civil Engineering Construction Company(CCECC) and China
Railway construction company(CRCC).
 CONTRACT NO:
➢ CONTRACT SUM: USD 1,326,077,288.76(inclusive of 18% VAT)
➢ PROJECT FINANCED BY: Government of the United Republic of Tanzania
➢ PROJECT CONTRACT COMMENCEMENT DATE: 15th may 2021
➢ PROJECT CONTRACT COMPLETION DATE: 14th may 2024
1.5 TECHNOLOGY INVOLVED
High technology was involved in most of the activities this included;
• Computerized batching of concrete and shotcrete.
• The use of total station for levelling and GPS for setting out
coordinates.
• Hydro seeding technology to plant vegetation on Railway embankment slope to improve soil
against erosion.
• Mobile crane to carry heavy equipment and materials.
• Pre-casting of box culverts, in-situ casting of concrete by using a concrete pump, and funnel for
catenary pole foundation.
• The use of geotextile material for soil improvement.
• The use of cuber machine in constructing drainage ditches and filling sub ballast and ballast
layers.
• The use of drone to map areas.
• The use of lightweight deflectometer to determine the dynamic deformation modulus.
• The use of strain gauges to check the deformation of pile foundation in Static Pile Loading Test.
• The use of HEC-RAS software to perform Hydrology study.
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PROJECT SIGNBOARD
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CHAPTER 2: GENERAL DETAIL, LOGBOOK AND WEEKLY SUMMARY
The SGR project at its preliminary stages involved multiple civil works which were divided in
accordance to the mode of specialization. The official commencement of training as per a pre-
prepared schedule began on the second week after the area of training had been relocated to lot 5.
The stretch began from the chainage KM 129+000 (section zero) at Isaka to KM 366+000 (section
4) at Mwanza. The activities involved included the following;
STRUCTURE
 Reinforcement cutting and bending (at the steel yard)
 Reinforcement fixing
 Formwork preparation in steel and timber boards
 Formwork fixing
 Erection and fixing of scaffolds and props
MATERIALS DESIGN, TESTING AND QUALITY CONTROL
 Concrete mixing (batching)
 Concrete casting
 Formwork removal, remedial works and concrete curing
 Soil & structure laboratory
EARTHWORKS & ENGINEERING SURVEY
 Setting out of structures
 Setting out of embankment and level control
 Dumping, mixing and compaction of earthworks
MISCALLEONOUS
 Environmental, safety, health and social guidelines
 Manufacture of pre-stressed concrete sleepers
 Report writing
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Week 1
Weekly Report No 1 from 18/07/2022 to 23/07/2022
Day Brief description of work performed Hours
Office introduction and orientation 1
Monday Brief explanation of the project 4
Visit of MGR port link site 3

Tuesday Rock filling and concrete slab layout 3
Visit of Pugu station overpass 3
Wednesday Field density test at Pugu site using Toxiller machine 3
Concrete on site mixing and determination of slump, temperature and 4

Thursday viscosity.
Concrete casting at Ilala site 3
Meeting with Dar es salaam resident engineer to discuss relocation to 6
Friday lot 5
Training relocated to lot 5. Received instructions to report at the head -

Saturday office at Malampaka camp.
Total hrs. 41
Sequence of operations for main job: concrete casting and formwork

No Operation Tools, Machinery, Equipment
1 Precast concrete arrived in truck mixers from Truck mixers
batching plant
2 Concrete cubes were taken for testing; cubes for Cubes mold, medium cone and small
compressive strength, slump test and flow was cone, tape measure and base slab.
determined.
3 Concrete was poured into ready-made steel form- Steel reinforcement bars, binding
work and consolidated using external electrical wires, steel formwork, generators,
vibrators. vibratory compactors.
4 Curing process was done by the use of chemical Acrylic concrete curing compound
substance that was sprayed onto casted concrete.
Signature Training Officer Date
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DETAIL OF THE MAIN JOB
Figure 1: sequence of operations in the batching plant
Figure 2 FLOW TABLE AND CONE SLUMP USED IN SLUMP TEST (dimensions in mm)
DATE DRAWN NAME CHECKED DATE NAME

24/07/2022 MHK Maliyat HK
13
Location: Ilala site (KM 0+000), Dar-es-salaam
Main activities:
Concrete mixing and casting for bridge decks for the section along Ilala site.
Tools and equipment:
 Truck mixers
 Slump cone
 Tape measure
 Steel plate
 Steel formwork
 Steel bars
 Wheelbarrow
PROCESS
The concrete arrived in drum mixer trucks which was then tested on site for slump and
flow. The concrete specification included a strength of 45MPa consolidated through
external vibration by electric means. The concrete temperature was at 28C hence
considered to be optimum temperature for casting and pre-stressing.
Pre stressed concrete was used in which tension was originally introduced into the steel
structures before the concrete was poured in. Pre-stressed concrete is useful in high
strength structures with over 100 years’ design age since they can be built to withstand
high pressure without failure through simple process. After pouring, the concrete was
tested and found to achieve a slump of 180mm with low viscosity.
Figure 3: the slump achieved for the casting of bridge decks
The concrete mixture was transported through a pump and poured into ready-made steel
formwork with built-in external vibrators. the formwork consisted of built in external
vibrators capable of offering consolidation of the structure.
14
Figure 4: Formwork preparation for the casting of the bridge decks
6 concrete cubes were also taken from site for crushing to determine the compressive test
of the cubes to help determine the design strength.
Man power required:
 Machine operators for pump, vibrators, steel fixers, and cranes used to carry the
formwork.
 Laboratory technicians for conducting lab tests.
 Concrete casting engineers for supervision
Challenges encountered
 Noisy surroundings
 Excessive exposure to the sun
 Proximity of the site to civilian areas
Measures to tackle the challenges
 Protective wear is enforced to avoid heavy sunstrokes from repetitive exposure
 Signs are placed along the area to make all nearby civilians aware.
Health and safety measures to be considered during site work
 Observing all the Personal Protective Equipment (PPE) during work: safety boots,
protective helmet and visible reflector need be worn at all times. Masks or protective
clothing should be worn to avoid inhalation of heavy heat exposure and dust.
 Steering clear of heavy machinery under operation and avoiding all possible blind spots;
movable cranes along the batching plant do not brake at close range. Care should be taken
to avoid being run over. The formwork also operates with inbuilt vibrators which require
short working hours to avoid silicosis.
 Resting when needed is also recommended since many working hours in the sun can result
to fatigue, dizziness, fainting and/or muscle failure.
 All injuries must be attended by a practitioner as early as possible to avoid fatal cases.
 The Environmental, Social, Health and Safety (ESHS) are always available on site, if any
of the respective issues arise, they should be consulted.
15
Social and environmental measures to be considered during site work
 Dumping of wastes onto the site areas should be avoided, all garbage should be taken
away for collection.
 All setbacks encountered on site should be directed to the foreman, who will in turn report
them to the site manager if the issues cannot be resolved.
 The Environmental, Social, Health and Safety (ESHS) officials are always available on
site, if any of the respective issues arise, they should be consulted.
16
Week 2
Arrival and orientation of Lot 5 site 3
Monday Meeting and introduction to resident engineer at Lot 5 4
Aggregate grading and PSD at materials lab for determination of MDD 5

Tuesday Meeting for general overview of SGR project for Lot 5 3
Determination of relative density and relative absorption of sand 4
Wednesday Completed Proctor compaction test to be used for MDD and CBR 4
Tensile strength test for steel bars 2
Obtained 15-25mm and 45-63mm aggregates from Seke quarry for testing 3
Thursday Obtained steel bar samples from Seke steel yard for testing 4
Conducted Los Angeles Abrasion(LAA) test 5
Determination of soil’s Atterberg limit and Plasticity Index (PI) of the soil using 1
Friday cone penetrometer. 4
Conducted test for clay lumps and friable particles 3
Relocated to Lohumbo camp 4
Saturday Briefing on activities at Lohumbo steel yard 4
Total hrs. 53
Sequence of operations for main job: Maximum Dry Density (MDD) test.
No Operation Tools, Machinery,
Equipment
1 A sample prepared (grading by quartering method) was taken from  Trays
which 5 samples each weighing 6000g was obtained from passing  Mold and base
through 37.5 mm sieve. plate
2 Three 300g samples were obtained and used to determine Natural  Compaction
Moisture Content by drying in the oven for 24 hours. hammers (2.5 kg
3 5 samples of 6000g were soaked for at least 2 hours with different and 4.5 kg)
amounts of water from 6%, 8%, 10%, 12% and 14%  Oven
4 The weight of an empty mold was taken, and later that of the mold filled  Digital balance
with the soaked sample. The first sample was compacted by 62 blows  Water
with 4.5 kg hammer in 5 layers; the second sample was compacted by 62
blows with 2.5 kg hammer in 5 layers; the third sample was compacted
into 30 blows with 4.5kg hammer in 3 layers
5 The weight of the compacted sample with the mold is recorded and used
to determine the bulk density and dry density. Hence a graph of dry
density against moisture content is plotted.
Signature: Training Officer Date
17
Detail of the main job
Proctor compaction test is used to determine the value of Maximum Dry Density (MDD) and
Optimum Moisture Content (OMC). The sample is then placed into three sample molds and whose
compacted molds are used in the CBR tests of the sample.
Drawn Date Name Checked Date Name

M.H.K 25/07/2022 Maliyat HK
PROCTOR COMPACTION TEST (CML 2000, et al.)
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Location: Malampaka Camp KM 251+000
Main activities: Site orientation & soil laboratory
During soil lab training, the following activities took place;
Sample source: KM 330+900 – KM 331+340
Aim: determination of Maximum Dry Density (MDD) from the relationship between dry density
and Natural Moisture Content (NMC) of the soil samples Materials:
 Trays
 Mold and base plate
 Compaction hammers (2.5 kg and 4.5 kg)
 Oven
 Digital balance
 Water
Figure 5: Proctor machine, conducting all compaction for the mold
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Sample preparation
5 samples of each 3 kg passed through the 20 mm test sieve were prepared using 1 litre mold.
Each sample was boxed thoroughly to give a range of moisture contents. Each of the portions is
then sealed in an airtight container and cured for a minimum of 4 hours.
Procedure
1. Weight of the mold with its base plate is recorded as m1
2. The extension collar is attached the mold is placed on a solid base.
3. A quantity of moist soil is placed in the mold such that when compacted it occupies a little
over 1/3 of the height of the mold body.
4. The rammer is placed with guide on the material in the mold. The rammer handle is lifted
until it reaches the top of the guide and then released to drop freely resulting to a blow.
5. The process is repeated to achieve 30 blows into each of the layers then the extension
collar is removed, edges straightened and a new mass is recorded as m2.
6. The compacted soil is then removed and a sample is taken from which Natural Moisture
Content will be determined.
7. The remaining of the sample is the discarded.
COMPUTATIONS FROM THE TEST
1. Bulk density of the compacted specimen, = × (kg/m3 )

Where;
m1= mass of the mold and base plate (g)
m1 = mass of the empty mold (g)
V = volume of the mold (cm3)
r
2. Dry density d= (kg/m3 )
Where w is the moisture content of the soil (%)
3. The graph of dry density against moisture content is plotted, at the maximum point of the
graph which gives the MDD, its corresponding value of moisture content gives the Optimum
Moisture Content (OMC).
4. On the same plane, graphs corresponding to 0%, 5%, and 10% air voids calculated from the
equation;
d =
r r
Where;
d = dry density (kg/m3)
s = particle density (kg/m3)
w = density of water (kg/m3)
Va = volume of air voids in the soil
w = moisture content in the soil
20
Figure 6: graph showing the relationship between dry density and moisture content, the MDD
value is obtained at the peak of the curve. its corresponding moisture content value gives the
OMC
21
Table 1 of results: for Dry Density-moisture content relationship
PROJECT: DESIGN AND BUILD FOR STANDARD GAUGE RAILWAY LINE FROM
MWANZA TO ISAKA (341 KM)
Dry Density - Moisture Content Relationship
KM 330+900- DATE
LOCATION 23-Jul-2022
331+340 SAMPLED
SOURCE OF MATERIALS: B/PIT KM 335+000 DATE TESTED 29-Jul-2022
DEPTH: (m) TESTED BY Maliyat HK
SAMPLE No.: S 3-219 CHECKED BY Eng. Nassoro
LAYER 9th Layer
VISUAL SOIL DESCRIPTION:
TEST METHOD CML TEST 1.9, Ref: BS 1377: Part 4: 1990
Bulk Density Determination
Test No. 1 2 3 4 5
Weight of sample g 3000 3000 3000 3000 3000
Water Added g 2% 4% 6% 8% 10%
Weight of mold + sample g 5044 5166 5257 5252 5198
Weight of mold g 3080 3080 3080 3080 3080
Weight of sample g 1964 2086 2177 2172 2118
Volume of mold cm^3 949 949 949 949 949
Wet density kg/m^3 2070 2198 2294 2289 2232
Moisture Content Determination
Container No. FR GED RM KA BL
Weight of wet soil + Container g 316.2 331.2 330.2 339.2 345.2
Weight of dry soil + Container g 307.1 317.1 311.1 314.1 314.1
Weight of moisture g 9.1 14.1 19.1 25.1 31.1
Weight of Container g 35.1 36.2 37.1 38.5 38.6
Weight of dry soil g 272 280.9 274 275.6 275.5
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Maintenance
1. The molds must be kept clean with smooth inside walls.
2. The rammer must be free of sticky materials
Man power required:
1. Material technicians for documentation and conducting experiments
2. Materials laborers for sample preparation
3. Materials engineer for data inspection and provision of conclusive results
Man power required:
formwork.
 Remote areas for sample sourcing
 Dusty and inconvenient site areas
 Adequate transport is provided to ensure timely retrieval of samples.
 Personal Protective Equipment (PPE) is ensured to have been worn at all times.
Health and safety measures to be considered during laboratory work
protective helmet and visible reflector need be worn at all times. Masks need to be worn
wherever there’s exposure to heavy dust.
 Care needs to be taken while operating the proctor hammer to avoid injury from impact.
Gloves need to be worn throughout operation to avoid severe abrasion.
 Resting when needed is also recommended since continuous working can result to fatigue,
dizziness, fainting and/or muscle failure.
23
24
Week 3 /4
Cutting and bending of reinforcement bars of type BL015 and UR022 8
Monday
Review and writing of daily and weekly reports 4

Tuesday Review of design drawings for box culvert km157+730 4
Visiting of completed box culvert km133+00 4
Wednesday First aid induction at Isaka camp 4
Cutting and bending of reinforcement bars of type BR035 and BR022 5

Thursday Review of design drawings 3
Formwork fixing at km133+00 5

Friday Review for the design of the reinforcement at km133+00 4
Saturday Design review of the design drawings of the box culverts at km133+00 6
and km157+730
Total hrs. 47
Sequence of operations for main job

1 Method for tying the bar was determined  Pincers
2 Each bar was placed in its respective position in  Steel bars
accordance to the layout design, marked in their  Metal wires
positions.
3 Bars were tied so as they remain in their correct
position to receive desired strength
4 Type of tie to be used was selected (saddle ties
were used)
5 The bar was chaired using concrete for support.
6 The bar configuration was observed on placed.
25
Figure 7: DIFFERENT BAR SHAPES AND SPECS AS EXPLAINED IN THE BAR BENDING
SCHEDULE
The culvert design drawing consists of reinforcement detail that explain all the types of steel bars to be
placed into the structure. The main job is to determine the property of each steel bar detail such as size,
spacing, shape, dimensions, number per member and location in each slab so as to get its position in the
structure.
At the completion of each structural section, the structure is inspected so as to make sure the placement
was done to design. Any inaccuracy detected to exceed the allowable discrepancy was rectified before
the site could be cleared to proceed with concrete casting.
DRAWN DATE NAME CHECKED DATE NAME

M.H.Kassim 06/08/2022 Maliyat HK 06/08/2022
26
Figure 8 the bar bending schedule as used in the design drawings to determine the specifications
for each respective steel bar
27
Weekly and daily report writing 6
Monday Design interpretations for km157+00 4
Fixing of reinforcement bars along the shear key, secured the bars of 8
Tuesday type UL022 and UL024
Vertical and sidewall reinforcement bars were fixed and secured. Bars 8
Wednesday of type UL017 and BL022 were fixed
Fixing of hook-shaped steel bars along the main bridge and left apron. 7
Thursday Inspection of steel structure for design review 5
Arrival of structures at box culvert km157+00 2

Friday Formwork base drilling and earthing rod was fixed. Securing of loose 8
fittings along the structure
Clearing the structure of binding wire chips using compressor 2
Saturday Formwork fixing along expansion joint LHS of the culvert 4
Inspection of the wing wall 4
Total hrs. 60
Sequence of operations for main job: culvert inspection

1 The bottom slab was measured first
2 The type of bar laid was identified  Tape measure
3 The spacing between the given bar was measured
4 The total length of the series was measured This helps
identify the correctness in the number of bars laid
5 The obtained data was compared to the bar bending

schedule for confirmation.
6 The process is done for main bars, distribution bars, wing

wall, vertical walls and top slab
7 The observed setbacks were rectified as per the

recommendation by the structural engineer.
28
DETAIL OF THE MAIN JOB
The construction of the box culvert at KM 157+730 is explained in the design above. The represented part
is a reinforcement plan view from the cut section of the right apron from the expansion joint.
After the completion of steel fixing a long a particular culvert, inspection was done so as to determine
whether the structure was built in accordance to the design. Any structural blunders were redone as per
instruction. After inspection, the site was then allowed to proceed with concrete casting.
M.H. Kassim 13/08/2022 Maliyat HK 13/08/2022
29
2.2. MAIN ACTIVITIY OUTLINE FOR THE WEEKS 3 & 4
STRUCTURAL WORKS
 Reinforcement cutting and bending (at the steel yard)
 Formwork fixing
Reinforcement cutting and bending (at the steel yard)
Location: Lohumbo main contractor’s camp KM 150+000
Preparation of reinforcement bars
Steel bars are prepared through cutting and bending steel stock present at the steel yard. These
steel bars are used as structural reinforcements in livestock and drainage culverts to be constructed
along the site area. Reinforcements come in various shapes, sizes and lengths in accordance to the
specifications in the bar bending schedule. The shapes, size and dimensions of the bars are
obtained from the bar bending schedule present in the design drawing.
Figure 9 An excerpt of the bar bending schedule including all the displayed specifications . These
properties are used by the steel fixers to make stock preparation for the reinforcement bars as per
requirement on the structure
Method of measurement of bending dimensions
Dimensions are added or taken into account on the stock bars in consideration to the shapes and
final appearance requirement.
The tolerances for cutting and/or bending dimensions shall be in accordance with Table below and
shall be taken into account when completing the schedule. The end anchorage or the dimension in
parenthesis in the shape codes shall be used to allow for any permissible deviations resulting from
cutting and bending.
30
TOLERANCES
CUTTING AND BENDING PROCESS TOLERANCE (mm)
Cutting of straight lengths (including +25, -25
reinforcement for subsequent bending)
Bending
< 1000mm +5, -5
> 1000mm to < 2000mm +5, -10

> 2000mm +5, -25
Length of bars in fabric 25 or 0.5% of the length
(whichever is greater)
Table 2: allowable tolerances in the cutting and bending of reinforcement bars

Minimum schedule radii and bend allowances
For bent steel, below are some of the specifications to take into account
Normal Bar Minimum Radius Minimum Diameter Minimum end projection P
Size d (mm) for scheduling R of Bending Former General (min 5d Links where
(mm) (mm) straight) (mm) bend <150
(mm)
8 16 32 115 115
10 20 40 120 130
12 24 48 125 160
16 32 64 130 210
20 70 140 190 290
25 87 175 240 365
Table 3: bending allowances for bent steel.
1. Straight bars: A Stock bars are supplied in 12 m notional lengths in diameters of 12 mm

and above in original manufacturers bundles. Tolerances for stock lengths shall be subject
to BS4449: 2005
The dimensions are labeled A, B, C, D, E in accordance to the number of dimensions
present.
2. Hooks: in accordance to minimal tolerance and allowable dimensions, hook specifications
can be expressed in the equation below,
A+0.57B + (C) - 1.6D
where B shall not be less than 2(r + D). Neither A nor C shall be less than P nor less than
(B/2 + 5D).
The tensile strength of steel bars used is determined through steel strength tests
conducted in the structure laboratory. The table is available (see Annex 2)
31
Tools and Equipment used
1. Steel bar cutting machine: used to cut stock bars into required sizes to be bent
into suitable shapes
Figure 10: steel bar cutting machine

2. Steel bar bending machine: used to bend the cut bars into sizes originally
specified in the bar bending schedule.
Figure 11: steel bar bending machine

Other equipment used in the steel yard include bending wires, aluminum labels, markers, wooden
planks and lifting cranes.
32
Figure 12: steel bar stock, the bars are secured with bending wires and inscribed using marker on
their aluminum labels. the bar marks are used to indicate the type of stock prepared,
Man power requirement
1. The machines require operating technicians to assist in cutting and bending of
reinforcement bars.
2. Laborers are required as per capacity in movement and stocking of steel bars in the
machine and transferring to stockpiles.
3. A foreman with ability to instruct the drawing specifications to the technicians from the
bar bending schedule.
4. An engineer for supervision is required
Safety guidelines on operating a rebar bending machine
1. The rebar bending machine must have product specifications, certificates of conformity
and maintenance records, it should be installed on a stable ground, and its cable insulation
is good.
2. Both the belt pulley and the exposed gear must have a protective cover.
3. Before using, it is necessary to check whether the shock protector works effectively,
whether the blade has cracks, and that the nut for fixing the blade is firm and not loose.
4. When the machine does not reach the normal speed, it cannot cut the material. When
cutting the material, the operator's hand should only be placed on the side of the rebar
which is near the worker's body, and the two ends of the rebar should not be cut with both
33
hands. When the long rebar is cut off, the other side should be especially helped by a
professional person to stabilize the reinforcement.
5. When operating, we should use both hands to hold the reinforcing brand aim at the edge
of the knife. When the blade comes down and there’s little press, it is necessary to press
the steel bar immediately, so as to avoid hitting the end with the end up.
6. When cutting short material, the length of one part held in the hand should not be less
than 40 cm, and the distance between the hand near the blade and the blade should be kept
more than 15 cm. If the part which held by hand is less than 40 centimeters, the short rebar
must be pressed down by the casing to prevent injury when cutting.
7. The cutting materials should be cleaned in time. It should be stacked in order according
to different specifications.
8. When we operate the machine, it is strictly prohibited to use hand to remove the broken
ends and debris near the edge of the knife directly. The people around the machinery who
are not professional are not allowed to stay.
9. Re-bars and red-burning rebar whose diameters exceed the mechanical regulations
should not be cut. When multiple bars are cut off at one time, the section of rebar must be
converted.
10. When it is found that the mechanical operation is abnormal or the abnormal sound or
the blade is skewed, the machine should be stopped immediately. Workers should pull the
sluice, break the power, report the repair of the machine repair personnel, and not repair it
without authorization.
1. Inadequate glove supply
2. Stock rebars are not stored in a closed space. Exposure of reinforcement to air for a long
time can lead to imminent corrosion.
Measures to mitigate the challenges
1. Rebars were made in real time at the required quantities to prevent overstaying. For high
quantity stock, white sheets were used to cover the stock for future use.
2. Glove supply was ensured by frequent toolbox supplies to all staff.
34
2.2.Construction of drainage and livestock culverts
A culvert is defined as a structure that can be designed hydraulically to take advantage of
submergence to increase hydraulic capacity. Box Culvert is a reinforced concrete structure
used as drainage under the road work. In other words, it is a small structure of less than 6m
span between faces of abutments. On the other hand, minor bridge, if the length of the
span is greater than 6m
Culverts are used:
 where bridges are not hydraulically required,
 where debris and ice potential are tolerable
 Where it’s considered more economical than a bridge (including guardrail and safety
concerns).
During the course of training, the culvert constructions that were fully supervised took
place at the following location KM 133+000, KM 156+830, KM 157+730, KM 168+000,
169+530, KM 173+940, KM 175+140 and the following activities were constituted;
 Formwork fixing
Figure 13: steel fixing and erection of scaffolds along the drainage culvert at KM 157+730
The above figure shows the section span of the culvert.
It is a rigid frame structure and simple in construction. So, it is Suitable for non-perennial streams
where scrub depth is not significant but the soil is weak. However, due to the strength of the
concrete floor, water direction can be changed when a large amount of water is expected
35
CONSTRUCTION METHOD
1. Setting out
2. Site clearing and excavation
3. Preparation of foundation
4. Casting of concrete blinding
5. Reinforced concrete structure construction
i. Fixing re-bars of bottom slab of box barrel, wing walls & side walls
ii. Formwork for bottom & apron slab
iii. Concrete casting on the bottom apron and slab
iv. Fixing Rebars for U Trough (Wing walls) & Box Barrels Walls
v. Formwork for wing walls, side walls & top slab with head walls
vi. Fixing rebars for top slab & head wall
vii. Pouring concrete for wing walls, box barrels walls & box barrel top slab
with head walls
viii. Formwork removal, curing & waterproofing of concrete
6. Installation of perforated drainage pipe
7. Backfill
8. Scour protection
9. Scour protection with gouge riprap
Figure 14: design drawing for the B-B section for the box culvert at KM 156+000
Steel reinforcements require thorough inspection before any additional procedure can take place.
On approval, the reinforcements are secured with formworks to allow the casting concrete to take
place.
36
Figure 15: bottom slab reinforcement secured in steel formwork onset of inspection, concrete is
casted afterwards
37
1. Waterlogging at the bottom of the excavated pits.
2. General condition of working materials; the pincers used in steel binding did not have
sharp cutting edges,
3. Presence of excessive cut out pieces of the binding wire at the base of the reinforcement
structure.
Measures imposed to mitigate the challenges
1. Care was taken to avoid wet patches present on the pits; water hogs the base of the safety
boots making it inconvenient to work.
2. Toolbox meetings handled all challenges regarding equipment and were changed regularly
3. Compressor was required for use before casting of concrete so as to rid the structure of any
additional scrape pieces.
Figure 16 a completed box culvert along KM 156+000

ESHS guidelines on site works
1. All safety and health concern must be promptly reported to the responsible personnel
2. Personal Protective equipment (PPE) must be worn at all times. Running wires must be
worn to hoist people working above the ground level. Gloves must be worn when lifting
heavy and abrasive objects
3. All concerns on site must be informed to the foreman so that they are immediately relayed
to the required authority.
4. Waste management need be observed at all times on site. All scrapers and leftover pieces
must be disposed accordingly and not scattered on site.
38
Week 5-8
Concrete batching and mixing at Lohumbo camp KM 150+000 6
Monday
CBR test at soil 4
Measurement of Plasticity Index(PI) at soil lab 2
Tuesday Aggregate grading and Particle Size Distribution (PSD) 4
Concrete mixing and batching at Lohumbo camp KM 150+000 2
Wednesday
Concrete casting and the bottom slab of the box culvert at KM 157+730 6
Investigation on the setbacks of the water supply system at the Engineers camp at Lohumbo 12
Thursday KM 150+000
Concrete casting at the bottom slab of the box culvert KM 174+374 6

Friday
Mixing and soaking of samples to be used in the Proctor compaction test 2

Saturday Determination of Maximum Dry Density (MDD) and amount of water required 4
Total hrs. 48
Sequence of operations for main job: Modified Proctor compaction test

1 A sample weighing 18000g , use the value of optimum moisture content Digital balance, water, plastic wash bottle
to determine the amount of water that is going to be required
2 The measured amount of water is used to soak the sample and to be left Tray
in the tray to settle.
3 The sample is placed into the mold and use the 4.5 kg hammer to impart Hammer, proctor compaction test machine,
62 blows on each of the five layers of the sample molds
4 Another sample into the mold but the 2.5kg hammer imparted 30 blows Hammer, proctor compaction test machine,
in each of the five layers of the sample. molds
5 The third sample is placed in the mold and a 2.5kg hammer imparted 30 Hammer, proctor compaction test machine,
blows in each of the three layers of the sample molds
6 The samples were transferred to the curing room and check the initial Water, pressure gauge
gauge pressure of the sample.
7 The gauge pressure five days later was recorded and the samples were CBR test machine
taken for CBR test machine.
39
SIEVES SERIES AS USED IN PARTICLE SIZE DISTRIBUTION
Figure 17: each sample that undergoes grading is passed through

the sieve series so as determine the distribution of soil sizes in the
soil sample.

MHK 20/08/2022 Maliyat HK 20/08/2022
40

Collection of new samples from KM 174+000 for grading and MDD test 4
Monday
Plasticity Index (PI) test at soil laboratory 2
PUBLIC HOLIDAY
Tuesday
Site orientation along KM 174+000 to KM 175+000 5
Wednesday Review of different machines and equipment used in earthworks 6
Preparation of roadbed at KM 173+720 to KM 173+900 6

Thursday Material dumping, spreading, mixing to uniform moisture content, and compaction
to the specified density along the section KM 173+720 to KM 173+900 to 8
introduce the first layer onto the structure.
Introduction to surveying on earthworks, level control 6

Friday Measurement of elevations along the stretch KM 174+900 to KM 174+980 6
Filling of the 7th layer along KM 174+900 to KM 175+000 6

Saturday Setting of pegs along the first layer of KM 173+940 to KM 174+100 4
Total hrs. 53
Sequence of operations for main job: GPS survey

1 The GPS base was set up on a ranging pole and a blue tooth connection GPS base
was established.
2 The rover was set on another ranging pole and was placed on the nearby GPS rover
benchmark and a connection was established.
3 The coordinates and elevation of the benchmark were determined to be GPS rover system
used for alignment
4 The GPS rover was transferred to the embankment later and the old offsets Pegs, digging steel rod, hammer,
and elevations were used to determine the new offset distance. tape measure, calculator and
notebook.
5 Leveling machine was set on a visually able location and set horizontally Level machine, tripod stand.
and the staff was placed at the bench mark.
6 The back site reading at the benchmark was taken followed by each offset Levelling staff
peg and either side of the center.
7 The readings obtained along with the offset distances were used to Booking sheets, pencils, pen,
determine the elevations (reduced level, RL) of each point positioned with calculator and notebook.
the peg as well as center.
41
Detail of the job
Figure 18: cross section of the embankment with its elevation. The slope varies as it rises to reach the
formation top.

42

Induction on concrete sleepers trial production run at Seke Camp KM 12
Monday 231+000
Review and computation of laboratory data 3

Tuesday Writing and filling of daily and weekly schedules 5
Wednesday
Placement of marks for filling directions, inclusion/exclusion of 4

Thursday dipping.
Level control and dumping and mixing of soil material for 6
embankment construction.
Embankment construction at KM 173+720- KM 173+ 920 4
Friday Level control on the compacted embankment 2
SPORT ACTIVITY FOR ALL STAFF

Saturday
Total hrs. 38
Sequence of operations for main job: Sleepers production

1 Cycle production begins
2 The molds were cleaned using release agent  Assembly line for production
3 Steel strands were laid  Concrete mixers and batching
plant
4 Strands were tensioned
5 Concrete were casted in the molds
6 The molds were cured with steam
7 The sleepers were de-tensioned and de-molded
43
Detail of the job
44
Material dumping, spreading, mixing to uniform moisture content, and
Monday compaction to the specified density along the section KM 173+720 to KM 8
173+900 to introduce the first layer onto the structure.
Level control along KM 175+000 6

Tuesday
Concrete casting for blinding at culvert located at KM 175+048 8
Wednesday
Material dumping, spreading, mixing to uniform moisture content, and 8

Thursday compaction to the specified density along the section KM 176+720 to KM
177+940 to introduce the eighth layer onto the structure.
Friday Material dumping, spreading, mixing to uniform moisture content, and 6

compaction to the specified density along the section KM 173+720 to KM
173+900 to introduce the first layer onto the structure.
Report writing, training review of all the work done throughout the training. 8
Saturday
Total hours 42
No Sequence of operations for main job: LAA test

1 A 5000g sample is obtained by sieving through a number of sieve-  Trays
series arranged in two.  Container for the
2 The sample is passed through the sieves as; 25mm retained at 19mm, samples
19mm retained at 12.5mm, 12.5mm retained at 4.75mm and 4.75mm  Sieves (25 mm,
retained 2.36mm. 19 mm, 12.5 mm,
3 Initial mass of the sample is determined, the sample is washed and 4.75 mm, 2.36
then put in the oven for 24hours to dry at 105 C mm, 1.7 mm).
4 The sample is then put in the LAA machine and driven into rotations  Oven
set at 500rpm  LAA machine
 Data sheets
5 The sample retrieved is passed through a 1.7mm sieve and the final
aggregate mass was measured.
6 The new mass is subtracted from the old mass and its product with a
100% gives the LAA value for the sample.
45
Detail of the job
LOS ANGELES ABRASION

TEST - LAA
KM
LOCATION: 155+200 SAMPLED DATE: 01-09-22
MATERIALS FOR: CONCRETE TESTED DATE: 05-09-22
ENG.
SOURCE: QUARRY TECHNICIAN: DEBORA
ENG.
SECTION: 1 CHECKED BY: BARAKA
Aggregate Size: 15 -
25 mm
TEST METHOD: CML TEST 2.9 Ref: ASTM C 131 - 06
Mass of indication Sizes
Sieve size (g)
Passing Retained on Grading
A B C D
37.5mm 25mm 1250±25
25mm 19mm 1250±25
19mm 12.5mm 1250±10 2500±10
12.5mm 9.5mm 1250±10 2500±10
9.5mm 6.3mm 2500±10
6.3mm 4.75mm 2500±10
4.75mm 2.36mm 5000±10
Total 5000±10 5000±10 5000±10 5000±10
Sample reference No. 1 2 3

Sample description g Sample Washed Before and After Test
Grading Used g B B B
Mass of sample before test g 5001 5001 5001
Mass retained on sieve
1.7mm g 3457 3457 3457
Mass passing on sieve
1.7mm g 1544 1544 1544
Los Angele Abrasion Value -
LAA % 30.9 30.9 30.9
Average LAA Value % 30.9
Los Angeles Abrasion (LAA) is used to determine the material’s resistance to abrasive affects (wear and tear).
As per ASTM and BS, there’s a minimum required a LAA value requirement for the construction of different
structures.
LAA is sampled in aggregates used in concrete and embankment construction.
M.H.Kassim 10/09/2022 Maliyat HK 10/09/2022
46
2.3.MAIN ACTIVITIY OUTLINE FOR THE WEEKS 5-8
Main activity: Quality control
Location: Materials lab at Lohumbo main camp KM 150+000
Quality control refer to the process of inspecting and ensuring that all the materials achieve the
quality specified in the manual in use. The materials in this project follow multiple specifications
including BS 2000 and AREMA 2000. Thus, it is important that all the materials put to use follow
suit with these specifications.
The main aspects of quality control are explained as follows;
 Concrete mixing (batching)
 Concrete casting
 Formwork removal, remedial works and concrete curing
 Soil & structure laboratory
2.3.1. Concrete mix design, batching and casting
Concrete is prepared using a mix design developed in the structural laboratory. The mix is then
used to prepare a stock supply for cement, coarse aggregates, fine aggregates and water then
mixed through an assembly line and after a thorough mixture is loaded directly onto the mixer
truck.
Figure 19: concrete batching plant. the mixer trucks park directly below the chutes and mixture is
added
47
Concrete transportation and casting
Since concrete is made using trial mixes, the first samples are tested for quality. The following
essentials are tested in concrete;
 Temperature (22 C - 28 C)
 Viscosity
 Slump
Figure 20: testing temperature and viscosity for a concrete sample from the plant, the cubes on
the side are used to prepare samples for the determination of the design strength of hardened
concrete.
On completion, the concrete is tested for slump and decreased slump implies addition of
admixture to increase concrete flow to a suitable design slump.
If the concrete is to be transported to a distant site, more admixtures such as retardants are added
to slow down its setting time. On reaching site, concrete is tested for slump again and then six
cubes are taken to test for design strength in the structure lab.
Concrete design strength requirement
Duration Achieved design
strength
3 days 75%
7 days 90%
21 days 95%
28 days 99%
Table 5: increase in strength with respect to setting time
Tools and equipment used

48
i. Concrete mixers
ii. Cement, water, fine & coarse aggregates
iii. Wheel barrow and spade
iv. Digital thermometer
v. Metal scraper
vi. Base plate and cylinder
vii. Tape measure
viii. Poker vibrators
ix. Cranes
x. Cube-shaped sampling molds
Man power employed
 Concrete technician to supervise the trial mixes
 Machine operator for the batching plant
 Drivers for the truck mixers
CHALLENGES ENCOUNTERED
1. Excessive midday heat resulting to poor concrete setting.
2. Inability to use poker vibrators for consolidation on side walls resulting to slow ad uneven setting
MEASURES TO MITIGATE THE CHALLENGE
1. Concrete casting instructed to be done before noon to avoid the direct exposure to sunlight. White
waterproofing sheets should be put on the structure afterwards to prevent heat absorption.
2. Side walls concrete was spread through manually to help even out the distribution.
2.4.2. CBR test (test no 1.11; CML 2009 et al.)
Objective
The strength of the subgrade is the main factor required to determine the required flexible
thickness for the pavements of roads and railways. The strength of the subgrade, subbase
and base course materials are expressed in terms of their California Bearing Ratio (CBR)
value.
Principle
The CBR value is the resistance to penetration of a 2.5 mm of a standard cylindrical plunger
of 50 mm diameter expressed as a percentage of the known resistance of the plunger to 2.5
mm in penetration in crushed aggregate (taken as 13.2 kN)
References: BS 1377: Part 4: 1990 and TMH 1: 1986: A8
Required equipment
1. Test sieves; sizes 20 mm and 5 mm
2. Three cylindrical metal molds: CBR molds have nominal diameter of 152 mm and a height
of 127 mm. The molds shall be fitted with a detachable base plate and removable
extension. The internal face shall be smooth, clean and dry before use.
3. Two metal rammers of weights 2.5 kg and 4.5 kg
4. A steel rod
Required equipment cont.
5. A steel straightedge
49
6. A spatula
7. A balance, capable of weighing up to 25 kg, readable to 5 g
8. Container for moisture content determination
9. Filter papers 150 mm in diameter
10. Perforated baseplates, fitted to the CBR molds in place of the normal base plate.
11. Perforated swell plates with an adjustable stem to provide a seating for dial gauge.
12. Tripod, mounting to support the dial gauge.
13. A dial gauge, having a travel of 25 mm and reading to 0.01 mm to be fitted to the tripod
for measuring swell.
14. Soaking tank, large enough to allow the CBR mold with base plate to be submerged,
preferably supported with an open mesh platform.
15. Annular surcharge discs for soaking, each having mass known to +50g. Half circular
segments may be used. Combined weight 4.5 kg
16. Petroleum jelly
17. A cylindrical metal plunger/ piston with diameter 49.65 mm
18. A CBR compressor machine. The machine shall be capable of applying at least 45 kN at a
rate of penetration of the plunger of 1 mm/min to within ± 0.2 mm/min.
19. A loading ring
20. A dial gauge with 25 mm travel, reading to 0.01 mm for measuring the penetration of the
plunger into the specimen.
21. A stopwatch
22. Annular surcharge discs for penetration test. Combined weight 5.5 kg.
Sample preparation.
Test to be carried out on material passing the 20 mm sieve. The fraction retained is
weighed and if found to exceed 25% of the total mass, CBR test will be unreliable in
emulating site conditions.
A portion of about 25 kg is taken on passing the 20 mm sieve and brought to (OMC ±
0.3% according to BS heavy compaction test. On thorough mixing, it is sealed and stored
for at least 24 hours before compacting into molds.
Test procedure
Preparation of mold
1. Weight of the mold with its base plate is recorded as m1
2. The extension collar is attached the mold is placed on a solid base.
3. A quantity of moist soil is placed in the mold such that when compacted it occupies a
little over 1/3 of the height of the mold body.
4. The rammer is placed with guide on the material in the mold. The rammer handle is
lifted until it reaches the top of the guide and then released to drop freely resulting to a
blow.
5. The process is repeated to achieve 30 blows into each of the layers then the extension
collar is removed, edges straightened and a new mass is recorded as m2.
50
Compaction rammers
Test method Mass Height of Number of Blows per
of drop (mm) layers layer
rammer
(kg)
2.5 kg rammer method 2.5 300 3 62
Intermediate compaction 4.5 450 5 30
4.5 kg rammer method 4.5 450 5 62
Vibrating hammer method ** * 3
* Recommended procedure to obtain a specimen density between that achieved by

using the 2.5 kg and 4.5 kg rammer methods.
** specification for vibrating hammer are different
6. The compacted soil is then removed and a sample is taken from which Natural
Moisture Content will be determined.
7. The remaining of the sample is the discarded.
8. Unless the sample is to be tested immediately, seal the sample (by screwing on the top
plate if appropriate) to prevent loss of moisture. With clay soils or soils in which the
air content is less than 5%, allow the sample to stand for at least 24 h before testing to
enable excess pore pressures set up during compression to dissipate.
Soaking
General. The test sample as prepared will normally represent the material shortly after compaction
in the road works. However, if the material is likely to be subjected to an increase in moisture
content, either from rainfall, ground-water or ingress through the surfacing it is probable that its
strength and, hence, CBR, will drop as the moisture content increases. In an attempt to estimate
these effects CBR samples can be soaked in water for 4 days prior to penetration testing.
CBR test machine
Procedure
a) The mold is placed with base-plate containing the sample, with the top face of the sample
exposed, centrally on the lower platen of the testing machine.
b) The appropriate annular surcharge discs on top of the sample is positioned.
c) The cylindrical plunger and force-measuring device assembly is fitted into place with the face
of the plunger resting on the surface of the sample. The proving ring dial gauge is properly
adjusted, i.e. that there is no daylight between the bottom of the stem and the proving ring anvil
d) A seating force is applied to the plunger, depending on the expected CBR value, as follows:
CBR VALUE (%) SITTING FORCE APPLIED, kN
5 10
5-30 50
> 30 250
e) The reading of the force-measuring device is taken as the initial zero reading (because the
seating force is not taken into account during the test.
51
f) The penetration dial gauge is set in position. Its initial zero reading is recorded, or reset to read
zero. All connections between plunger, crosshead, proving ring and penetration dial gauge
assembly should be tight.
g) The test is started so that the plunger penetrates the sample at the uniform rate of 1±0.2
mm/min, and at the same instant start the timer.
h) Readings are recorded for every 0.25 mm penetration up to a penetration not exceeding 7.5 mm
i) At the end, the moisture content of the sample is determined.
Calculation and plotting
1. Force applied from each reading of the load ring observed.
2. Each penetration value is plotted against force. Normal curve is convex upward (see table)
3. Internal volume of mold
Vm = Height (H)× /4
4. Density calculations
i. Bulk density of the compacted specimen, = × (kg/m3 )
Where;
m1= mass of the mold and base plate (g)
m1 = mass of the empty mold (g)
V = volume of the mold (cm3)
r
ii. Dry density d= (kg/m3 )
Where w is the moisture content of the soil (%)
iii. The graph of dry density against moisture content is plotted, at the maximum point of the
graph which gives the MDD, its corresponding value of moisture content gives the Optimum
Moisture Content (OMC).
iv. On the same plane, graphs corresponding to 0%, 5%, and 10% air voids calculated from the
equation;
d =
r r
Where;
d = dry density (kg/m3)
s = particle density (kg/m3)
w = density of water (kg/m3)
Va = volume of air voids in the soil
w = moisture content in the soil
52
CBR computations cont.
5. Swell calculation (%)
S= × 100
Where;
S = swell, expressed as a percentage of the height of the molded material
before soaking, i.e. 127 mm
k = dial gauge after 4 days’ soaking
L = dial gauge reading before soaking
6. CBR value = P × where P is the plunger force at 5 mm penetration
Figure 21: plotted graphs from data obtained from CBR tests
53
PROJECT: DESIGN AND BUILD FOR STANDARD GAUGE RAILWAY LINE FROM MWANZA TO ISAKA (341 KM)
California Bearing Ratio (CBR)
LOCATION KM 330+900-331+340 DATE SAMPLED 23-Jul-2022
SOURCE OF MATERIALS: B/PIT KM 335+000 DATE TESTED 29-Jul-2022
DEPTH: (m) TESTED BY
SAMPLE No.: S 3- CHECKED BY
219
LAYER 9th Layer
VISUAL SOIL DESCRIPTION:
TEST METHOD CML TEST 1.9, Ref: BS 1377: Part 4: 1990
Compaction Method: Three Point Method MDD 2144.8 Target Soaking days NMC
OMC
Proving Ring Factor 0.049 Target MDD 7.1 4 1.11
3
Test No. A B C Mass of water to be added
Container No. PA TVT NEW No. A B C
Weight of wet Soil +Container 323.1 314.4 322.9 Initial Mass of Sample 6000 6000 6000
Weight of dry Soil + Container 298.5 288.4 295.4 Difference in % of Moisture 6.0 6.0 6.0
Weight of Container 36.3 38.2 36.7 Water to be added for OMC (ml) 354 354 354
Weight of dry Soil 262.2 250.2 258.7
Weight of water 24.6 26.0 27.5 Penetration Testing
Moisture content, % 9.4 10.4 10.6 Penetra 3 layers, 2.5kg, 62 blows 5 layers, 4.5kg, 30 5 layers, 4.5kg, 62
tion, blows blows
mm
Force = 0.0493* Dial gauge reading
Test No. A B C
Mold No. 17 2 F9
Volume of Mold 2305 2305 2305
Weight of compacted soil + mold 9438 9668 9942 No. Reading kN Reading kN Readi kN
ng
Weight of mold 4941 4936 4912 0.0 00 0.000 00 0.000 00 0.000
Weight of compacted soil 4497 4732 5030 0.5 04 0.197 05 0.247 07 0.345
Wet Density 1.951 2.053 2.183 1.0 06 0.296 10 0.493 12 0.592
1.5 10 0.493 14 0.690 19 0.937
After soaking moisture content 2.0 14 0.690 15 0.740 21 1.035
Test No. A B C 2.5 16 0.789 17 0.838 24 1.183
Container No. AL NW NI 3.0 18 0.887 19 0.937 26 1.282
C
Weight of wet soil + container 308.3 329.8 328.0 3.5 20 0.986 21 1.035 28 1.380
Weight of dry soil + container 274.9 297.0 299.0 4.0 22 1.085 23 1.134 29 1.430
Weight of container 37.1 36.2 35.7 4.5 24 1.183 25 1.233 32 1.578
Moisture content, % 14.0 12.6 11.0 5.0 26 1.282 27 1.331 35 1.726
5.5 28 1.380 29 1.430 37 1.824
Test No. A B C 6.0 30 1.479 31 1.528 39 1.923
Dry Density kg/m^3 1711 1824 1966 6.5 32 1.578 33 1.627 40 1.972
Dry Density % 79.8 85 91.67 7.0 34 1.676 37 1.824 42 2.071
7.5 34 1.676 37 1.824 43 2.120
Swell A B C CBR=21*ln(PR)-91
Initial dial gauge reading 3.85 7.07 3.80
Final dial gauge reading 6.94 9.64 5.14
Swell percentage 2.43 2.02 1.06 CBR VALUE vs COMPACTION
CBR value at soaked Density in % MDD 95% of MDD 1996
Test No. A B C CBR value (%) 90 93 95 98 100
CBR at 2.5 mm 6 6 9 8 9 9 10 11
CBR at 5.0 mm 6 7 9 Swell
%
Table 3 of results on CBR test
54
Maintenance
3. The molds must be kept clean with smooth inside walls.
4. The rammer must be free of sticky materials
Man power required:
5. Material technicians for documentation and conducting experiments
6. Materials laborers for sample preparation
7. Materials engineer for data inspection and provision of conclusive results
Man power required:
formwork.
 Remote areas for sample sourcing
 Dusty and inconvenient site areas
 Adequate transport is provided to ensure timely retrieval of samples.
 Personal Protective Equipment (PPE) is ensured to have been worn at all times.
Health and safety measures to be considered during laboratory work
protective helmet and visible reflector need be worn at all times. Masks need to be worn
wherever there’s exposure to heavy dust.
 Care needs to be taken while operating the proctor hammer to avoid injury from impact.
Gloves need to be worn throughout operation to avoid severe abrasion.
 Resting when needed is also recommended since continuous working can result to fatigue,
dizziness, fainting and/or muscle failure.

55
2.4.3. INTRODUCTION TO PRE-STRESSED CONCRETE SLEEPERS PRODUCTION
On the visit to the sleepers factory located at Seke Camp section 2 (KM 230+000), an
introduction was done on the progression of the trial production of concrete sleepers that were
to be placed once the railway embankment has been set. The proposed design for the main
track sleepers can be reviewed in Annex 3
PARAMETERS UNIT
Permissible axle loads 25t
Maximum speed 160 km/h
Concrete grade C 50/60
Concrete volume 104 I
Weight (without fastening) 260 kg
Length (L) 2400 mm
Width (W) 300 mm
Sleeper Height (H) 234 mm
Height of center of rail base (h1) 214 mm
Height of sleeper center (h2) 175 mm
Support surface total 6237 cm3
Standard application Main track sleeper
Design/Performance criteria
Sleepers shall be designed to operate in the environment detailed in Table 1, which provides
design information relating to track and rail operations where the pre-stressed concrete sleepers
will be used.
56
Criteria Description
Sleeper types Mono-block, pre-stressed concrete sleeper of two types, for use with
resilient fastenings and insulators: “Heavy Duty” suitable for heavy freight
tonnages and axle loads ≤ 30 tons; “Medium Duty” suitable for general use
with axle loads ≤ 25 tons.
Track gauge 1435mm gauge with installation tolerance ±4 mm (See AREMA 2010,
chapter 30).
Rail AS 1085.1 - 60 kg/m rail, with the capacity to use 53 kg/m.
Locomotive Sanding is applied for improved traction on extensive lengths of sharp
standing curves and steep gradients. Concrete sleepers are to be designed to
minimize potential for soffit abrasion and rail seat erosion in the operating
environment.
Curve radius Minimum Radius 200m
Impact factor The combined quasi-static and dynamic load factor (j) for Medium Duty
Concrete sleepers only is 2.04. For Heavy duty concrete sleepers use the
impact factor in AS 1085.14.
Rail weight Use 60kg/m rail to calculate the wheel load distribution factor for Heavy
Duty sleepers. Use 53 kg/m rail to calculate the wheel load distribution
factor for Medium Duty sleepers.
Thermal Thermal expansion and contraction forces act on the continuously welded
expansion and rails with a rail temperature range from -10°C to 75°C about a neutral rail
contraction temperature of 35°C.
Nominal 1.8 meters 30 Ton axle load.
distances between 1.7 meters 25 Ton axle load.
axes 1.6 meters 23 Ton axle load.
57
CHAPTER 3: SPECIFIC REPORT
3.1. EARTHWORKS
Location: KM 173+900-KM 177+000
Earthwork is a generic term for all items of work, materials and operations required to construct
the excavated areas and the embankments of a project. The project entailed the construction of a
railway embankment in accordance to the specifications of AREMA 2000.
In general, earthwork on a highway project consists of;
1. Embankment: Compacted fill material needed to construct the roadway, excluding the
base and pavement portions of the roadway and shoulders.
2. Regular Excavation: Excavation necessary for the construction of the roadway,
ditches, ponds, channel changes, etc. it includes the process of re-channeling, sampling
and level control.
3. Subsoil Excavation: removal and disposal of any material that is unsuitable in its
original position and that is excavated below the finished grading template.
The most important roadway operation involving earthwork is constructing the roadbed. The
roadbed is constructed by excavating soil from cut sections and placing soil as embankments
in fill sections. In cut sections, the roadbed is built below the original ground - the original
ground is excavated to the elevation of the proposed roadbed. In fill sections, the roadbed is
built above the original ground - the earth fill is on an embankment.
3.1.1. Technical Preparation
 Approved geotechnical report.
 Approved surveying data (Primary control points, Secondary control point, Temporary
control points, bench marks and Topographic survey of the section).
 Approved construction drawing for all culverts. Present along the embankment path.
 Specifications.
3.1.2. Site Preparation

 Land Acquisition of the section finalized.
 Personnel and equipment are available on the site.
 Required access road are prepared.
 Materials needed for construction are available and approved.
58
3.2. Main activities
Activity Description Tools & equipment
Material Dumping trucks obtain materials from the borrow pits and  Grader
dumping, are poured along the cut section.  Compactor
spreading, The amount of material required is calculated in terms of  Wheel loader
mixing to distance from peg to peg.  Bulldozer
uniform, Dumping trucks have capacity of 15m3 which is used to  Dumping trucks
moisture determine the amount of trucks required to fill a section.
content, and Water bowser was sprayed frequently to help mitigate the
compaction to high dust levels
the specified
density A single compacted layer has a thickness t= 0.25m and a
width equivalent to the sum of offset distance from either
side for 20cm peg-to-peg distance.
Thus volume, V per section is given as length(l) ×
thickness(t) × width(w)
( )
Thus, number of truck required, n= ( )
All the dumped material is layered-in using motor graders
and bulldozers and then proof rolled and compacted.
ADDITIONAL ACTIVITY: soft soils were identified
within the compaction of the 6th layer and thus, it had
to be extracted, thoroughly mixed to enable
redistribution of moisture, then further compaction.
Level control Mainly entails two processes; setting up of newer pegs and  Levelling staff
determination of the Reduced levels of the newly  Leveling
compacted layer. machine
New pegs are set using a GPS device aligned from the  Tripod stand
nearest bench mark (MIS 078). The new offsets(N0) can be  GPS base and
determined as; rover
N0= [(old elevation-new design elevation) ×(slope=1.75)]  Digging steel
+ (design offset) +(walking space=0.5m) rod
The answer obtained above is located along the layer using  Wooden pegs
the GPS rover by the surveyor.
 Tape measure
Then the center is identified by measurement followed by
levelling process that gives you all the reduced levels along
the layer, which will be compared to the design elevations
to verify if the required compaction level has been
achieved.
Allowable difference between design elevation and
achieved elevation is 0.005
Field density test This test is done to determine the achieved compaction of  Sand pouring
at site on a soil layer. Sand-cone method was employed. cylinder
A cylindrical section 20cm deep is dug along the center of  Sand of known
each peg-to-peg section and the cavity created is refilled density i.e.
with smooth sand of known mass on the test hole using a calibrated sand
base plate and the and was let to run by opening the control  Standard base
valve which is closed when it stops running. plate
59
The extracted soil sample is tested for its moisture content  Excavating steel
(w) at the soil lab from wet soil mass (m1) and dry soil mass rod
(m2);  Field soil
-
w= × 100% container
then, the volume of the hole, V given as, (bucket)
( )  Ruler
V= is used to determine the dry
( )  Two nails
density of the sample(d)  Digital balance
As, d= ( × 100%)( ). Hence the degree of
( )
compaction=
, ( )
Tools and equipment used in setting out of embankment
Figure 16: GPS base and rover
Tools and equipment used in level control
60
Figure 22 level machine and tripod stand
61
Tools and equipment used in field density test
Figure 23base plate, digging steel rod, spoon, brush, and calibrated sand as used in field density
test.
Tools and equipment used in the embankment construction and level control
Figure 17: a water bowser | Figure 18: a wheel loader
62
Figure 19: soft spot regions located in KM 164+200
Figure 20: roller/compactor machine | Figure 24: dumping trucks
63
Geotechnical analysis
A minor intrusive soil exploration was conducted on site along km 175+000 for further testing to
achieve info that was previously not obtained from the preliminary test. Borehole technique was
employed, a method of site investigation used to extract samples at depths greater than 3m which is
outside the typical depth range of trial pits.
Figure 24: borehole drilling by wash borehole drilling technique
3.3. Skills and manpower

CONSTRUCTION MANAGER
To ensure all operations are in accordance with the relevant Project contract specifications and
check the accuracy of the works done by the site engineers. He is responsible and accountable for
all the construction works.
SITE ENGINEER/SUPERVISOR
Ensures that all works are carried out as per the approved drawings and specifications in a proper
manner. Coordinate with surveyors and lab technicians for accuracy of the work, as well as
coordinate with the Engineer’s inspectors for inspection and present at time & point construction
operation. They are responsible and accountable for all site activities.
QC/LABORATORY TECHNICIAN
Ensures the construction activities are as per approved ITP. Inspect the materials at sources and
carry out the testing as required. Ensure the use of approved materials. They are responsible for
quality of the earthworks.
HSE OFFICER:
64
Ensure that the works are carried out in compliance with the ESHS requirements of the Contract
and ER. Give necessary guidelines to the workforce and facilitate safe working condition. They
accountable for ESHS requirements.
SURVEYORS:
Ensure that the work is being carried out accurately as per the approved drawings in coordination
with Site Engineers and Foreman. Be accountable for all survey works.
FOREMAN:
Ensure to carry out the work with proper control over labor and equipment. Coordinate with
surveyor and lab technician for accuracy and quality of the work.
MASON
Responsible for carrying out concrete works, ensure all the concrete works are of good quality and
adhere to this method statement.
CARPENTER
Responsible for performing all wood works, ensure all the wood works are of good quality.
STEEL FIXER
Responsible for steel works, ensure all the steel works are done accurately as per approved
drawings
WORKERS
 Responsible to execute the work accordingly, risk assessment and permit
 conditions and excavation requirements.
 They notify the supervisor of any unmarked utilities found or if not inspected
 Follow basic guidelines as provided in this document.
 Not permitted in an equipment operation area.
 They report any unsafe condition to the supervisor immediately
OPERATORS
 Responsible to operate the equipment in safe manner, follow equipment safety operation
 rules
 They notify supervisor of any unmarked utilities found or if not inspected.
 Follow basic health, safety & environment guidelines as provided in this document.
 Report any unsafe condition to the supervisor immediately
 Excessive dust
 Remoteness of the site
 Inadequate transport
 Unsatisfactory network reception.
65
 The water bowsers were operated through the site frequently to help settle and
accommodate the dusty environment
 Early communication was made with the coordinator so early assistance can be offered
Health and safety measures to be considered during site work
 Observing all the protective attire (PPE) during work: safety boots, protective helmet and
visible reflector need be worn at all times. For the particular chainage km 174+000 to km
174+980, masks or protective clothing should be worn to avoid inhalation of heavy dust.
 Steering clear of heavy machinery under operation; bulldozers collapse heavy
embankments and do not advance corners under short range. Care should be taken to avoid
being run over. Furthermore, compactors can lead to excessive vibrations that may result
to silicosis.
 Resting when needed is also recommended since many working hours in the sun can result
to fatigue, dizziness, fainting and/or muscle failure.
66
Chapter 4: Miscellaneous
Challenges encountered on site
 Remoteness of the site areas. Movement was limited to arrival in the morning and
departure in the evening. Availability of transport for midday breaks was an encountered
setback. In areas as remote as KM 182+000 – KM 188+000, it was almost entirely
unavailable.
 Excessive dust on site: due to the nature of materials used in earthwork, there was a high
buildup of dust along KM 173+000 – KM 177+000 such that the continuous operation of
water bowsers for dust control was incapacitated
 Communication barriers were experienced in remote areas such as KM 180+000, where
mobile phone reception was hindered resulting to setbacks in convenient flow of
information.
Measures offered to mitigate the situation
 Dusty surroundings were treated with compaction with newer materials to lower the
dust levels in the area
 The setback with communication has been reported and is being addressed effectively
 Transportation setbacks are addressed by relay of movement schedules to aid in
convenience in movement.
ESHS guidelines
4.1. General ESHS Requirements
CCECC-CRCC JV ensures that all the earth works will be programmed and executed in a safe
manner complying with all the Tanzania relevant regulations, so as not to cause danger,
inconvenience or interference to the general public. The construction site is adequately provided
with welfare facilities such as drinking water point, washing facilities and toilets. The operations
will be carried out as per the recommendations contained in the latest version of the CCECC-
CRCC JV Health, Safety, environment and social management plan (MTI-CCJ-AS-GL00X-G-
PM-PRE-0002-02), Risk Management Procedure Page 22 of 25 (MTI-CCJ-AS-GL00X-G-PM-
PRE-0004-02) and Contractor's Contingency Plan for COVID-19 (MTI-CCJAS-GL00X-G-PM-
PRE-0003-02).
4.2. Personal Protective Equipment (PPE)
➢ Personal Protective Equipment (PPE) means all equipment which is intended to be worn or
held by a person at work and which protects them against one or more risks to their health and
safety, and any addition or accessory designed to meet that objective. Items such as reflective
jacket, safety belt, helmet, safety boots etc. are PPE as defined.
➢ Site supervisors ensure that all employees are provided maximum protection against the
inherent hazards of the work activity. The use of PPE is an effective barrier between a person and
potentially dangerous objects, substances, processes, etc. The following items of personal
protective equipment and dress are required on the Project. CCECC-CRCC JV/Sub-contractors
will furnish, helmet, gloves, boots, reflective jackets, safety belt, eye and masks, and any other
personal protective equipment as required for the specific activity.
67
4.4.Environment Controls
Any protected flora crossing with any of the work locations is also be reported to the
HSE/Environmental Manager in charge who should be notified before any re-alignment for any of
the works. Trees are not to be transplanted or pulled off their existing locations without getting
necessary approvals and notifying the JV HSE department. JV sub-contractor will always standby
and refer to the environmental aspects and impacts mentioned in the Construction Environmental
Management Plan (CEMP) for the project which covers the relevant environmental assessment for
any potential risks encountered during the site works;
Contractor/Sub-contractors confirms that all the environmental regulations and Laws covered in
Tanzania will be considered and covered in the Construction Environmental Management Plan
(CEMP).
Water trucks will be utilized to spray water on the construction access road to prevent the dust
arising during the construction operation.
4.2. Fencing/Signs/Site Security
➢ All construction sites are secure with proper signage/warnings for the dangers during the works
and prohibiting unauthorized access at all the times;
➢ Safety signage is inscribed in English and Swahili as a minimum around the perimeter. Fenced
storage areas, gantries, loading bays, skips and other temporary structures on the public highway
shall be provided and maintained to the conditions of a license issued by the Local Authority.
Suitable entry and exit signs shall be provided, at the points of access to and from the Site, for
vehicles and equipment engaged on the Works. As far as possible, vehicles and equipment shall
enter and exit the site in a forward’s direction.
4.3.Health, Safety & Environment Training
4.4.Induction Training
CCECC CRCC JV ensures that all the personnel involved in carrying out the works Will:
 be given project and site induction training prior to starting the site activities;
 be given prior knowledge of the activity;
 be given training on the equipment safety;
 be made aware of the environmental hazards related to the activity.
4.5. Pre-Task Briefings
Every work shift begins with a pre-task meeting. The health, safety & environment aspects of the
works of that particular day will be discussed. Any health, safety & environment issues which
have occurred on site, or need special attention will be discussed and evaluated. Appropriate
control measures will be taken prior to commencement of the works.
4.6.Tool Box Meeting
Weekly/Special tool box meeting will be held every week and to be conducted by
supervisor/foreman & safety officer. Safety and environment topics to be discussed & as an
68
opportunity for leadership to reinforce safety expectations and provide feedback including
previous incidents, it is also an opportunity to discuss any safety concerns workers may have by
any authority and change in standards, safety rules and regulations and other relevant guideline
will be a part of the tool box meeting.
Annexes
Annex 1: MAP SHOWING SGR RAILWAY ROUTE FOR PHASE 1 –LOT 5 .......................... 70
ANNEX 2: steel bar test results ...................................................................................................... 71
Annex 3: SLEEPERS DESIGN ...................................................................................................... 74
69
Annex 1: MAP SHOWING SGR RAILWAY ROUTE FOR PHASE 1 –LOT 5
70
ANNEX 2: steel bar test results
PROJECT: DESIGN AND BUILT FOR THE STANDARD GAUGE RAILWAY (SGR) LINE FROM MWANZA TO ISAKA (341 KM)
LOCATION: MALAMPAKA ENGINEER LAB DATE 18/07/2022
SUPPLIER: LODHIA TESTING OF REINFORCEMENT STEEL BARS ACCORDING TO BS 4449:2005 TECHNICIAN IMMA
GRADE B500 CHECKED BY: SIMCHIMBA
SAMPLE FROM SEKE CAMP
Steel bars Test results Report
SPECEMEN DIMENSION YIELD STRENGTH TENSILE ELONGATION STRENGTH BENDING

STRENGTH
RATIO
GRADE Size Mass L SO Mass per Fe Re Mpa FM Rm Mpa LO Lf Qs
mm gm mm mm2 metre (kg) kN N/mm2 kN N/mm2 mm mm % RM/RE
B500 10 595.0 1000 78.5 0.595 43.1 549.0 56.2 715.9 90 105 16.7 1.30
No fracture
B500 10 597.0 1000 78.5 0.597 46 586.0 55.1 701.9 90 110 22.2 1.20
B500 10 596.0 1000 78.5 0.596 47.6 606.4 54.7 696.8 90 110 22.2 1.15
AVERAGE RESULT 596.0 1000 78.5 0.596 45.6 580.5 55.3 704.9 90.0 108.3 20.4 1.22
SPEC 78.5 ± 0.617 ± 4.5 min 500 - max 650 min 540 min 14 min 1.08 To show no fracture
4.5

STRENGTH
RATIO
GRADE Size Mass L SO Mass per Fe Re Mpa FM Rm Mpa LO Lf Qs
B500 12 863.0 1000 113.0 0.863 64 566.2 84 743.1 80 94 17.5 1.31
No fracture
B500 12 863.0 1000 113.0 0.863 67 592.7 78 690.0 80 96 20.0 1.16
B500 12 860.0 1000 113.0 0.860 62 548.5 75 663.5 60 70 16.7 1.21
AVERAGE RESULT 862.0 1000 113.0 0.862 64.3 569.1 79.0 698.9 73.3 86.7 18.1 1.23
SPEC 113 ± 0.888 ± 4.5 min 500 - max 650 min 540 min 14 min 1.08 To show no fracture
4.5
Prepared by Checked by Verified by:
………………………………………. ………………………………………. ………………………………..
Assistant Materials Technician Consultant's Materials Technician Consultant's Materials Engineer
71
Steel bar test results cont.
TENSILE ELONGATIO
SPECEMEN DIMENSION YIELD STRENGTH STRENGTH BENDING
STRENGTH N
Rm RATIO
GRADE dnom Mass L SO Mass per Fe Re Mpa FM Mpa LO Lf Qs
B500 16 1509.0 1000 201.0 1.51 114.8 571.3 130.8 650.9 80 98 22.5 1.14
No fracture
B500 16 1602.0 1000 201.0 1.60 117.2 583.2 133.5 664.3 80 97.1 21.4 1.14
B500 16 1608.0 1000 201.0 1.61 113.8 566.3 135.7 675.3 80 96.6 20.8 1.19
AVERAGE RESULT 1573.0 1000 201.0 1.57 115.3 573.6 133.3 663.5 80.0 97.2 21.5 1.16
4.5
………………………………………. ………………………………………. ………………………………..
SPECEMEN DIMENSION YIELD STRENGTH TENSILE ELONGATIO STRENGTH BENDING

STRENGTH N
Rm RATIO
GRADE dnom Mass L SO Mass per Fe Re Mpa FM Mpa LO Lf Qs Test
B500 20 2369.0 1000 314 2.37 177.8 566.2 211.1 672.3 100 118.7 18.7 1.19
B500 20 2399.0 1000 314 2.40 168.4 536.3 208.7 664.6 100 120.3 20.3 1.24
No fracture
B500 20 2411.0 1000 314 2.41 173 551.0 212.5 676.8 100 119.2 19.2 1.23
AVERAGE RESULT 2393.0 1000 314 2.39 173.1 551.2 210.8 671.2 100.0 119.4 19.4 1.22
4.5
………………………………………. ………………………………………. ………………………………..
72
Steel bar test results cont.
STRENGTH R
Rm RATIO
B500 25 3980.0 1000 491 3.98 280.4 571.5 326.4 665.3 90 104.5 16.1 1.16
B500 25 3958.0 1000 491 3.96 271.2 552.8 334.2 681.2 90 109.2 21.3 1.23
No fracture
B500 25 4011.0 1000 491 4.01 268.9 548.1 341.2 695.4 90 107.2 19.1 1.27
AVERAGE RESULT 3983.0 1000 490.6 3.98 273.5 557.5 333.9 680.6 90.0 107.0 18.9 1.22
SPEC 491 ± 3.85± 4.5 min 500 - max 650 min 540 min 14 min 1.08 To show no fracture
4.5

STRENGTH R
Rm RATIO
B500 32 6011.0 1000 804 6.01 456.2 567.5 548 681.7 80 97.2 21.5 1.20
B500 32 6015.0 1000 804 6.02 450.1 559.9 541.5 673.6 80 93.2 16.5 1.20
No fracture
B500 32 6016.0 1000 804 6.02 452.1 562.4 537.1 668.2 80 97.4 21.8 1.19
AVERAGE RESULT 6014.0 1000 803.8 6.01 452.8 563.3 542.2 674.5 80.0 95.9 19.9 1.20
SPEC 804 ± 6.31± 4.5 min 500 - max 650 min 540 min 14 min 1.08 To show no fracture
4.5
Remarks…...............................................................................................................................................................................................................................................................................................

………………………………………. ………………………………………. ………………………………..
73
Annex 3: SLEEPERS DESIGN
Figure 25: DESIGN DRAWINGS FOR THE TRIAL PRODUCTION OF CONCRETE SLEEPERS
AT SEKE CAMP KM 230+000
74
REFERENCES/ BIBLIOGRAPHY
CML (2009), Laboratory Testing Manual, test no 1.9 p45-48; Dry density and moisture
content relationship
CML (2009), Laboratory Testing Manual, test no 1.10 p55-64; CBR tests
AREMA (2010), vol. 2 chapter 30; Design of Pre-Stressed Concrete Sleepers
Ministry of works (2000) Standard Specifications for Road Works, series 2000, p2000-8;
prefabricated culverts
Ministry of works (2000) Standard Specifications for Road Works, series 3602, p3000-16;
prefabricated culverts
75

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UNIVERSITY OF DAR ES SALAAM

COLLEGE OF ENGINEERING AND TECHNOLOGY

Figure 3: the slump achieved for the casting of bridge decks......................................................... 14

Additional gratitude to the University-assigned external supervisor(s);

1.2 ORGANIZATION CHART

1.3 PROJECT INFORMATION

PROJECT STAKE HOLDERS

Visit of MGR port link site 3

Concrete on site mixing and determination of slump, temperature and 4

Training relocated to lot 5. Received instructions to report at the head -

Sequence of operations for main job: concrete casting and formwork

Signature Training Officer Date

Figure 1: sequence of operations in the batching plant

DATE DRAWN NAME CHECKED DATE NAME

Figure 3: the slump achieved for the casting of bridge decks

Aggregate grading and PSD at materials lab for determination of MDD 5

Signature: Training Officer Date

Drawn Date Name Checked Date Name

Figure 5: Proctor machine, conducting all compaction for the mold

1. Bulk density of the compacted specimen, = × (kg/m3 )

Dry Density - Moisture Content Relationship

SOURCE OF MATERIALS: B/PIT KM 335+000 DATE TESTED 29-Jul-2022

DEPTH: (m) TESTED BY Maliyat HK

SAMPLE No.: S 3-219 CHECKED BY Eng. Nassoro

LAYER 9th Layer

VISUAL SOIL DESCRIPTION:

TEST METHOD CML TEST 1.9, Ref: BS 1377: Part 4: 1990

Bulk Density Determination

Weight of sample g 3000 3000 3000 3000 3000

Water Added g 2% 4% 6% 8% 10%

Weight of mold + sample g 5044 5166 5257 5252 5198

Weight of mold g 3080 3080 3080 3080 3080

Weight of sample g 1964 2086 2177 2172 2118

Volume of mold cm^3 949 949 949 949 949

Wet density kg/m^3 2070 2198 2294 2289 2232

Moisture Content Determination

Container No. FR GED RM KA BL

Weight of wet soil + Container g 316.2 331.2 330.2 339.2 345.2

Weight of dry soil + Container g 307.1 317.1 311.1 314.1 314.1

Weight of moisture g 9.1 14.1 19.1 25.1 31.1

Weight of Container g 35.1 36.2 37.1 38.5 38.6

Weight of dry soil g 272 280.9 274 275.6 275.5

Review and writing of daily and weekly reports 4

Cutting and bending of reinforcement bars of type BR035 and BR022 5

Formwork fixing at km133+00 5

Sequence of operations for main job

Signature Training Officer Date

DRAWN DATE NAME CHECKED DATE NAME

Arrival of structures at box culvert km157+00 2

Sequence of operations for main job: culvert inspection

5 The obtained data was compared to the bar bending

6 The process is done for main bars, distribution bars, wing

7 The observed setbacks were rectified as per the

Signature Training Officer Date

DRAWN DATE NAME CHECKED DATE NAME

M.H. Kassim 13/08/2022 Maliyat HK 13/08/2022

Preparation of reinforcement bars

< 1000mm +5, -5

> 1000mm to < 2000mm +5, -10

Table 2: allowable tolerances in the cutting and bending of reinforcement bars

1. Straight bars: A Stock bars are supplied in 12 m notional lengths in diameters of 12 mm

Figure 10: steel bar cutting machine

Figure 11: steel bar bending machine