SOCIETE AUTOROUTIERE DU GABON REPUBLIC OF GABON

Rehabilitation Upgradation of 2-lane National

Highway Road from PK 24+000 to PK 105+000 on
RN1 in the Republic of Gabon

QUALITY ASSURANCE PLAN

AFCONS-DDC-PAQ-REV-001 Dated July 26th, 2021

Contractor Contractor’s Independent Control Officer

Table of Contents
1 Introduction
1.1 Background.
 1.2 Objectives of the Quality Assurance Plan.
1.3 Importance of Quality Assurance plan.
1.4 Project Quality Policy.
1.5 Some Terminology.
1.5.1 Quality.
1.5.2 Quality Control.
1.5.3 Quality Assurance.
1.5.4 Acceptance.
1.5.5 Confirmatory Test.
1.5.6 Process Control Test.
1.6 Effective Quality Control.
1.6.1 Pre-Requisites of Effective Quality Control.
1.6.2 Quality of Work.
1.7 Need for Quality Control/Assurance.

2 Quality Management
2.1 The Management Frame Works.
2.2 Quality Cycle.
2.3 Contractors Responsibilities.

3 Contractors Construction Activities

3.1 Quality Control Aids and Instruction
3.1.1 Setting out.
3.1.2 Pre-construction Checks.
3.1.4 Construction Stage Checks.
3.1.4 Post Construction Stage Checks.

4 INDEPENDENT CONTROL OFFIER’S(ICO) Responsibilities

4.1 Team Leader.
4.2 Design Proof Checking Engineer.
4.3 Highway Engineer – Supervision.
4.4 Bridge / Hydraulic Engineer – Supervision.
4.5 Quality/Material Engineer.

5 Method of Statement
5.1 Method Statement- Clearing and Grubbing
5.1.1 Scope.
5.1.2 Reference Documents.
5.1.3 Inspection and Test Plan.
5.1.4 Bench Marks.
5.1.5 Equipment Details.

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 5.1.6 Safety and Protection of Environment.
5.1.7 Personal Employed for Supervision.
5.1.8 Tolerances.
5.2 Method of Statement sub formation(Embankment) and Capping Layer
5.2.1 Scope.
5.2.2 Reference Document.
5.2.3 Materials.
5.2.4 Preparation of Bed.
5.3 Unbound Material Earth work
5.3.1 Scope
5.3.2 Reference Document.
5.3.3 Materials.
5.3.4 Frequency of Test and Sampling.
5.4 Sub Base –Unbound Material
5.4.1 Scope.
5.4.2 Reference Documents.
5.4.3 Materials.
5.4.4 Frequency of Testing and Sampling.
5.5 Prime Coat/ Tack Coat
5.5.1 Scope.
5.5.2 Frequency of Testing and Sampling.
5.6 Sub Base-Base Course Asphalt Concrete
5.6.1 Scope.
5.6.2 Reference Documents.
5.6.3 Materials.
5.6.4 Frequency of Testing and Sampling.
5.7 Wearing course
5.7.1 Scope.
5.7.2 Reference Documents.
5.7.3 Materials
5.7.4 Frequency of Testing and Sampling.
5.8 Method of Statement of all Structures
5.8.1 Scope.
5.9 Ancillary Works
5.9.1 Scope of Work.
5.10 Management and Maintenance Performance Measures
5.10.1 Road Usability.
5.10.2 Road User Service Levels.
5.10.3 Road User Service Levels on the Existing Road before Completion of
Improvements.
5.10.4 Road User Service Levels after Completion of Improvements.

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 5.10.5 Road Durability.
5.10.6 Road Roughens.
5.10.7 Non- Compliance.
5.10.8 Management Services.
5.11 Inspection of Service Levels by the Team Leader
5.11.1 Formal Inspections of Service Levels.
5.11.2 Informal Inspections of Service Levels.
5.12 Design Proof Checking Engineer
5.12.1 Contract Review.
5.12.2 Pavement Design Works.
5.13 Project Control and Administration
5.13.1 Contract Review.
5.13.2 Pavement Design Works.

6 Acceptance Criteria
6.1 Request for Review.
6.1.1 Material and Construction Works.
6.1.2 Testing.
6.1.3 Surveyor.
6.1.4 Inspection.
6.1.5 Measurement.
6.2 Non-Conforming Reports (NCR).

7 Tests on completion.
7.1 Tests on Completion: Annexure -D

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8.1 Performance for Site Instruction, NCR, QC Tests and Checklist.
8.1.1 Quality Control Checklist.
8.1.2 Site Instruction.
8.1.3 Non-Compliance.
8.1.4 Survey Strip Layer chart.
8.1.5 Management and Maintenance Service Level.
8.1.6 Documentation.

9 Conclusion
9.1 LIST of Tables
9.2 Sub formation(Embankment)and Capping Layer
9.2.1 Materiel Specifications.
9.2.2 Test Frequency.

9.3 Unbound material for Earth work

9.3.1 Materiel Specifications.
9.3.2 Test Frequency.
9.3.3

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9.4 Sub Base Unbound Material
9.4.1 Materiel Specifications.
9.4.2 Test Frequency.

9.5 Base Course Asphalt Concrete

9.5.1 Materiel Specifications.
9.5.2 Test Frequency.
9.6 List of Figures
9.6.1 Quality of work.
9.6.2 Quality Assurance Management Frame work.
9.6.3 Quality Cycle.
9.7 Annexures
 Annexure 01: Inspection Test Plan.
 Annexure 02: Check List
 Annexure 03: Site Instruction
 Annexure 04: Non-Conformance Report.
 Annexure 05: Quality Test Formats.
 Annexure A: Certification of Milestones
 Annexure B: As Built Drawings
 Annexure C: Basis of Engineering & Execution studies (VISA Mission)
 Annexure D: Tests on Completion.

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 ABBREVATIONS

AASHTO : American Association of State Highway and Transportation Official.

ASTM : American Standard of Testing Material.
BS : British Standard.
EN : European Standards.
ERPS : Employer’s Requirements Part III-2 Performance Specifications.
CEG : Consulting Engineers Group Ltd.
MDD : Maximum Dry Density.
OMC : Optimum Moisture Content.
Pd OPN : Optimum Moisture Content Normal Proctor.
Pd OPM : Optimum Moisture Content Modified Proctor.
QAP : Quality assurance Plan.
QMP : Quality Management Plan.
QC : Quality Control.
CIC : Contractor's Independent Control Officer.
QAM : Quality Assurance Manual.

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1 INSTRUCTION
1.1 Background.
Project: EPC Contract for Permanent Anticipated Works between KP24 and KP105 of Transgabonaise
National Road from Libreville to Francevelli located in the Republic of Gabon.

The Société Autoroutière du Gabon (SAG) awarded Contract of the Project Road to Afcons
Infrastructure Limited for Design, Improvement Works and Management and Maintenance Services
(EPC) from PK 24+000 to PK 105+000.

As per the Contract Agreement the Contractor is required to appoint an Independent entity as
Contractor’s Independent Control Officer (ICO) whose roles and responsibilities are:
 Review Engineering studies and Execution studies (including VISA Mission).
 Implementing the contract Program and take into account the modifications occur during its
implementation.
 Certifying the completion of Milestones. ( Annexure - A) attached for detailed procedure
 Translating in terms of specifications the requirements up to a level of detail sufficient to
ensure the control of the execution of the works.
 Drafting and submitting to the contractor, which will further
 Communicate with the Employer the contents of as Built Documents and validating the
compliance of the elements collected by EPC. Attached ( Annexure- B)
 Carrying out, on a regular basis, as may be further described, in particular, in the
Employers Requirements, and in accordance with the progress of the works, external
controls of the construction in accordance with the quality assurance plan submitted by
EPC.
 Confirming satisfactory progress on the critical path items and/or hard points in support of
the ad hoc justifications and to report on a monthly basis to the Contractor for
Communication to the Employer and its advisers.
 Attending the tests during execution and on completion.

 Selection of Independent Control Officer

M/S Consulting Engineering Group is engaged as ICO by Contracting Agency M/S AFCONs
Internationals for performing the above objective. The Selected M/s Consulting Engineering Group
Limited (CEG), having experience in the area of design and supervision of the large-scale
Infrastructure Projects. M/s CEG has professionals having experience in international construction
industry and their brief description is enclosed as Annexure A7.

 Approach Methodology
M/s CEG’s approach and methodology has been based on experience in executing similar projects
around the globe and project requirement. M/s CEG has assisted various clients in the
implementation and providing Engineering and Management solutions to engineering planning,
designing, contract administration, design review, quality control & quality audit, cost control and
value engineering, variation orders, environmental management plan & HSE audit etc. and thus

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brings on board a rich experience in engineering excellence. M/s CEG has a pool of international
experts to cater to the services in different geographies of the globe.

1.2 Objectives of the Quality Assurance Plan.

The main aim of the Quality Assurance Plan is to ensure that the Contractor provide a data of known
and acceptable quality and in sufficient quantity to demonstrate compliance with the provision of
the Contract Agreement. In this regards the ICO established a project Team in respect of the
Consultancy Contract Agreement to fulfil the objectives based on applicable Specification of the
contract.

The basic concept of the process is that the Contractor performs adequate sampling, testing and
inspections to ensure a quality output and ICO team performs to ensure that the Contractors Quality
Control test results are accurate and conform within the acceptable limits. However, the system
requires that both the Contractor and the ICO representative have to work together, who are
competent in sampling, testing and inspection of all the specified works.

The contractors are fully responsible to mobilize the competent personnel, to establish comfortable
laboratory and to supply accurate apparatus/equipment’s to perform quality control as per
commitment and undersigned in the Contract.

To achieve this said objectives of assessing and ensuring quality, it is essential to have a Quality
Assurance Plan (QAP) for the job in the initial stage itself and followed by until the completion of the
Contract.

1.3 Importance of Quality Assurance plan.

The Employer’s Requirements Part III-2 Performance Specifications applicable to the project provide
for Quality Control and Quality Assurance of the work executed by making use of a Quality
Management System. The basic concept of this process is that the contractor performs adequate
testing and inspections to ensure a quality product and the Construction and ICO performs adequate
testing and inspection to ensure that the Contractor’s Quality Control as per Quality Assurance
manual (QAM) submitted by our Quality Assurance Expert along with the Team Leader.

During the operation of Contract if any deficiency and improvements, amendments is felt necessary,
this Document will be amended as per provision of Contract.

The system requires that both the Contractor and the ICO's Representative have Material Engineer
who are competent in testing and inspection of all road works. The general idea is that the
Contractor has to perform the necessary tests and inspection to ensure that all his works in road
construction meet the specification instead of "after the fact" testing to see if all works meet the
specifications. This approach enables the Contractor much more control over his operations. The
Contractor is responsible for the product from the beginning to the end, from the design changes to
the construction of works till the final acceptance of all the works. The Construction ICO monitors
the Contractors process of testing to make sure that what he is doing is adequate and accurate.
Ensuring quality and durability of the product and uniform performance of Construction Contractor

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is the most important aspect of the Construction Supervision assignment of the ICO's
Representative engaged by the Contractor.

The Contractor's part of this QMS process is referred as Quality Control (QC), while the Construction
Supervision ICO's part of the process is referred as Quality Assurance (QA). The Contractor is
responsible to mobilize competent personnel and laboratory equipment's to perform his quality
control as per his Construction Quality Assurance Management Plan, and the ICO is responsible to
provide competent personnel to perform and implement the Quality Assurance Plan. To achieve this
said objectives of assessing and ensuring quality, it is essential to have a Quality Assurance Plan
(QAP) for the job in the initial stage itself.

1.4 Project Quality Policy

The aim of Quality Assurance Plan (QAP) is to ensure that the Contractor provide a product, which
complies with the provisions of the Contract Agreement. In response of this aim, the ICO
representative is in the process establishing a Project Team, in accordance with the Consultancy
Contract Agreement to fulfil its obligation.

In respect of the project Quality Policy, the ICO Team carryout role on the project to produce
products as per Agreement and Specification. This can be achieved by dedicated, committed and
qualified team members and by following QAP systems established for the Project as documented in
this QA Manual.

This QAP Manual established for the Project Team conforms to the requirement of Quality policy
disseminated by the company at corporate level, which is restated here under.

Consulting Engineers Group Ltd is committed to persistently meet the expectations and requirement
of its Employer by providing innovative, optimal, efficient, and effective and time bound better
engineering practices. This shall be achieved through proficient human resources and developing
harmonious environment at site.

1.5 Some Terminology

1.5.1 Quality
Quality is defined by ISO 9000:2014 as the degree to which a set of inherent  characteristics of
an object fulfils requirements, where an object is anything perceivable or conceivable. 

1.5.2 Quality Control

It is the process of inspecting products to ensure that they meet the quality standards, in other
words it is adopted control procedure exercised by Construction agency that ensure qualified
personnel achieve the defined objectives through appropriate tests, check, inspections and takes
defects out. Moreover, the objective evidence of all tests, checks and inspection carried out from
time to time are documented in prescribed formats for records and references.

1.5.3 Quality Assurance

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Quality Assurance of a job is defined as a process that to ensure build the quality of work right from
the beginning and inspect regularly during the production periods, adopted control procedure that
has been properly design and acceptance.

1.5.4 Acceptance
Acceptance is the operations, inspections, sampling and testing that are conducted to determine
whether the product or service will be qualified for use and payment Acceptance is determined
using a statistically based acceptance plan in construction with assurance that the Contractor has
fulfilled the quality control obligations. Acceptance is the responsibility of the ICO representative/
Team Leader.

1.5.5 Confirmatory Test

It is a prior sampling and testing independently that come to know defined quality can be achieved
or not for further process and use of material based on given parameters.

1.5.6 Process Control Test

It is a frequency of sampling and testing of materials that ensure acceptable quality of work is
producing during the construction periods and it helps to avoid the default and unacceptable quality
of works.

1.6 Effective Quality Control

The aim of Quality Control during production is to ensure that the product is constructed/ built in
accordance with the specifications prescribed. However, the quality control alone in itself does not
guarantee durability and uniform performance during its service life in case of design deficiency
unless and until it gets identified and rectified during construction. In case, it goes unnoticed, the
product does not perform as envisaged to perform for the project. The main responsibilities of
Construction & Quality Work lie on the Contractor in terms of the Contract Documents.

Process controlled specifications in combination with end product requirement are best suited to
Gabon conditions. In addition, control exercised by the Employer's Representative at each stage of
road construction or its elements for dimensional correctness and/or accuracy, meeting the laid
down acceptance criteria is ideal for a production of a quality work in practice.

ICO's Representative (Contractor Independent Control Officer) is not to accept a substandard input
or a substandard work at any stage. A substandard input or a work must be rejected and should not
be accepted. Acceptance of a substandard input or work at a reduced rate is no solution. A
substandard work must be either redone or rectified by the Contractor to the full satisfaction of the
Employer's Representative to conform to prescribed drawings and specifications. Availability of a
Quality Assurance Plan in the initial stages of work and its implementation at all relevant stages
including maintenance alone ensure a durable and functional product over its design life as
envisaged in the design document.

1.6.1 Pre – Requisites of effective Quality control

The pre-requisites for effective quality control on highway construction are:

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 (i) Setting up of field laboratory
(ii) Equipping the laboratory with adequate equipment and personnel
(iii) Specifications and estimates must be provided for quality control
(iv) Documentation and Periodic appraisal of data for improvement
As per the provision in the Contract, the Contractor is to construct a laboratory building and set-up
the laboratory for the sole use of the Project Team. The contractor has to conduct necessary
inspections and testing jointly with ICO.
The Contractor is to submit his design and drawings for the approval of ICO prior proceed with the
construction activities.
(i) Specifications
Specifications applicable to project works are in accordance with "Employers Requirements Part III-2
Performance Specifications. The EPC Contractor responsible for establishing fully equipped
laboratory in accordance with the EPC contract.

(ii) Documentation and Periodic Appraisal of Data for Improvement

It is absolutely necessary to keep a proper record of laboratory testing for each and every item
passed for payment. Proper filing system is to be maintained. It is also necessary that periodical
appraisal of data is done to identify corrective measures with a view to ensure improvement in
Quality Control and Assurance.

1.6.2 Quality of work

The basic concept for production of quality of work is illustrated in the model below

Quality Inputs
Process Control as per specificationPeriodic Check Quality Outcome

The main inputs are Men, Materials, Machines, Money and Time. The contract document specifies
Qualification and experiences of key personnel for the job. The documents specify the materials,
their qualities and acceptable dimension limits for their use. Process control as per specification are
incorporated in the contract documents. Further they specify the functional requirements of the
machinery and or equipment to be used in the Production process. The other inputs i.e. money and
time, are normally established by the Contractor.

The inspections during production process are carried out as laid down in the Contract documents
and the codes mentioned therein jointly by the EPC Contractor and the ICO. The application of
these activities would nearly assure a quality product at the end.

1.7 Need for Quality Control/Assurance

Quality Control is an essential part of the of any production process, Construction of any works.
Particularly for the Highway Construction Quality Control/ Assurance Plan shall be applied for
durability and betterment of works. All materials to be used, all methods adopted and all works
performed are strictly to be in accordance with the requirements of the Standard Specification.
Quality control besides leading to construction of improved quality and conformity and ensuring

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better utilization of materials, also affords a significant reduction in user assets in terms of lower
costs of vehicle operation, transportation and maintenance.

2. Quality Management
2.1 The Management Frame Works
The ICO’s Representative’s will ensure that high quality of construction is achieved and that all works
are undertaken as per approved Engineering Designs and Specification as specified in the Contract
Document.
This will be achieved by ensuring effective real time supervision and monitoring by the ICO Team.
The Team will carry out all routine construction supervision duties. The Quality Management
Framework is given in the following Figure.
Obviously, it is noted that effective coordination between team members will be ensured through
periodic review meetings, so that common problems and remedies are known to each member of
the team. The ICO team structure is shown in the following figure.

2.2 Quality Cycle

Quality Management job is a cyclic process. The following diagram for a roadwork illustrates a
quality cycle. The quality cycle starts with quality control measures prior to actual construction
activities. It runs during construction stage and quality audit of the results achieved and
identification of defects and establishment of their causes. It ends with suggestion of remedial
measures, their execution and ensures their implementation against recurrence of the defect.

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 Pre- Commencement Activities of Contractor Construction Activities by Contractor
Mobilization and management: Men, Machines, Applicable
Money, Materials: remedial and corrective measures
Setup quality control systemPre- Commencement Implementation by self-control
Activities of Contractor
Mobilization and management: Men, Machines,
Money, Materials:
Setup quality control system Analysis of Problem by the ICO
Study and plan the works Finding the defects
Obtain various approval Suggest remedial measures
Design and drawing approval
Start the works
Study and plan the works
Quality Assurance by Monitoring
Obtain various approval
and System Development,
Design and drawing approval
Carrying out periodical checks
Start the works

2.3 Contractor’s Responsibilities

The Road Project is designed as a Rehabilitation & Upgradation of 2 lane National Highway Road
from PK 24+000 to PK 105+000 on RN1 therefore the EPC Contractor is solely responsible to ensure
that all actions are taken to design, build and maintain in Quality Assurance in the planning and
execution of works in all stages. The Contractor is to furnish in advance his work program as per
General Condition of Contract (GCC) indicating items of work, methods and details of resources
mobilization (Man, Machine, Materials). Following are some points that the Contractor putting in
front responsible.

The contractor is responsible for developing, presenting, implementing and supplementing a quality
control procedure to ensure that all aspects of his work meet the standards set forth in the
specifications and is of acceptable quality. The Contractor is totally responsible for quality
throughout, and he is to take all necessary measures to ensure quality by adopting correct
construction practices to produce the end products of acceptance quality.

It is mandatory for the contractor to provide all facilities as stipulated in the Contract document such
as fully furnished Office, Power, Staff Quarters, Vehicles, and all Equipment’s and its running and
maintenances etc. QA/QC procedures to be adopted and he should be satisfying the ICO about
adequacy and safety of his program as per Contract.

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The details of construction methodology including the details of construction machineries proposed
and to be used by the Contractor. The sequence and series of the various activities and schedule got
to be approved by the ICO before commencement of work. The Contractor has to provide a trial run
of each major items as per the contract document in order to maintain the given specifications and
tolerances.

The Contractor has to establish the field laboratory to conduct all quality control/quality assurance
tests. He will ensure that the laboratory is managed by the adequately by qualified and trained
staffs. The Contractor has also responsible for calibration of laboratory equipment at periodical
interval during the tenure of the project.

The Contractor is to collect the samples of construction materials jointly with the ICO or Employer
for testing and receive approval from the ICO office prior to use in the field.

The Contractor is to take precautionary safety measures for environment and social issues. He shall
be keeping all the equipment in good working condition and get them periodically checked to
control the hazards and pollution, further Contractor shall address and settle the social issues as per
social and rehabilitation plan.

The Contractor shall prepare the traffic management plan to maintain the smooth traffic flow during
the construction stage. He must make all necessary arrangement for the safe traffic diversion and
shall install traffic signals in appropriate location.

The Contractor shall satisfy that the site data furnished by the ICO is in order, and in case of any
discrepancy, he should get it correct through the ICO.

The Contractor shall establish the survey control points in the construction field as required with
close accuracy. He must establish bench marks near by the major structures like as Bridge structure,
buildings, any permanent structure shall re-establish any disturbed Bench mark/ reference point and
apply periodical checks on it.

The Contractor shall stack out the centre line pegs as well as offset pegs in every 20 m interval in the
straight portion and every beginning midpoint and end of the curve in every stages of construction
with accuracy.

The Contractor shall write and rewrite the chainages in close interval, specially shall write the
chainages in permanent structures. The font of the letters shall be legible.

The Contractor shall firmly install traffic sign post, guard post and any informatorily post in every
hazardous and critical section of the road.

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3 Contractor’s Construction Activities
The Contractor is required to carry out the following major construction works. However, safety
measure is always considering at first.
 Survey Works: Establishing all ground control points, permanent bench marks and well
as temporary bench marks as required then stake centre pegs and offset pegs.
 Cleaning, grubbing top debris up to 10 cm depth and dismantle any structures within the
road corridor.
 Earth Works- Embankment filling /Cutting, and Capping layers.
 Sub-base Unbound materials
 Prime coat, Tack coat
 Base course Asphalt concrete
 Wearing course
 Construction of Structures (Side drains, Pipe culvers, RCC box culvert, Bridges)
 River training works
 Protective works line, side slope in cutting, backfill, selected back fill.
 Road furniture’s (Road marking, Sign post, Kerb stone, guard post, crash barriers)
 Any other work for smooth working such as coordinating with respective service
provider/ authorities, cutting trees, shifting of public utilities and removal of
encroachments.
 Environment and Social mitigation measure.

In General construction field there are three stages

Pre-construction Stage: Details preparations are necessary before undertaking any construction
activity. Their nature will vary from work to work, location to location, and project to project.
However, it can be broadly classified in to the following categories.

Mobilization of Resources: Mobilize of Construction equipment, its serviceability, recruiting

potential manpower, identification camp site and erection of camp, stores, compound and utilities.

Procurement of Materials, Storing and testing: This shall be done well in time to ensure that
quarries are identified and approved. Factory made procurement shall be done and get approval
from the Employer.

3.1 Quality Control Aids and Instruction

Quality Control laboratory equipment are checked for their serviceability. The aids like cube moulds,
soil testing apparatus (CBR, Atterberg Limits, Proctor & Granulometry) Los Angles, Micro Deval, AIV,
ACV and bitumen test kits), three Edge camber board with all accessories & Bankelman Beam with
all accessories are available in required numbers and in good working conditions before the work is
taken up.

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3.1.1 Setting out
This setting out of road centreline excavation plan for structures are to be carried out in advance and
as per the guidelines given in the Standard Specification and approved drawing. The setting out will
include establishment of Bench Mark, Ground Control points, centre line, reference line by using the
highly precise survey equipment.

3.1.2 Pre-construction Checks

Pre-construction checks like checking of construction equipment mixer machine, Vibrator, form
works, reinforcement, line level, layout pegs etc, pre-construction activities are absolutely vital for
achieving quality, dimensional control and should not be neglected.

3.1.3 Construction Stage Checks

In general, these activities are varying in accordance of the types of works, therefore suitable
formats have been prepared, the format may be inspection requisition forms, check list, instruction
sheet, quantity measuring sheet laboratory materials test format.

3.1.4 Post Construction Stage Checks

These activities are carried out on completion of the construction activity. Some examples are curing
of concrete, barricading to prevent entry over the freshly laid concrete surface/crushed stone base,
bituminous surfaces to prevent traffic damaging the freshly laid surfaces.
4. Role and functions of the Contractor’s Independent Control Officer

Design Phase / Period

During the Design Period, the Contractor’s Independent Control Officer will undertake a
review of the Drawings furnished by EPC/CE along with supporting data, characteristics of
materials from borrow areas and quarry sites, topographical surveys and traffic surveys. The
Contractor’s Independent Control Officer will communicate review / comments /
observations to the EPC. In particular, such comments shall specify the conformity or
otherwise of such Drawings with the Scope of the Project and Specifications & Standards.

 The Contractor’s Independent Control Officer will review the Safety Report and
furnish its comments thereon to CE/Afcons.

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  The Contractor’s Independent Control Officer will review the construction methodology and
the procurement, engineering and construction time schedule sent to it by the EPC and
furnish its comments.

 Quality Assurance Manual and Plan forms the basis of quality of the work. It is therefore
essential that the Quality Assurance Manual and Plan prepared by the EPC will be checked
and approved. Thus, the Contractor’s Independent Control Officer will check contents of
Quality Assurance Plan and Manual of EPC as per requirements of Quality Management
System (as per ISO 9001), standards &specifications. The Contractor’s Independent Control
Officer will also offer their comments for modifying/ improving the document. After
receiving the modified document, the Contractor’s Independent Control Officer will approve
the QAM and Quality Plan, send one copy to the SAG.

Construction Period
 The Contractor’s Independent Control Officer will review the monthly progress report
furnished by the EPC and send its comments thereon to the EPC and Employer SAG).

 On a daily basis, the concerned key personnel of Contractor’s Independent Control Officer
will inspect the Construction Works based on the Request for Inspection Note raised by the
EPC, ensure compliances to the following activities.
 Review of construction including progress, quality and safety of construction.
 Witnessing quality inspection tests at labs established by EPC. Review of
quality of work shall be done in reference to Quality Assurance Plan (QAP)/Manual
and ISO 9001:2008, Standards & specifications as set forth.
 On a monthly basis, the Contractor’s Independent Control Officer will prepare a
Monthly Inspection Report. The Contractor’s Independent Control Officer will submit
a copy of its Inspection Report to the Employer (SAG) and the EPC.
 In the event that the EPC fails to achieve planned / scheduled progress, the
Contractor’s Independent Control Officer will undertake a review of the progress of
construction and identify potential delays, if any. Upon receipt of a report from the
EPC, the Contractor’s Independent Control Officer will review the same and send its
comments to the Employer (SAG) and the EPC Contractor (Afcons) forthwith.
 The Contractor’s Independent Control Officer shall carry out all the Tests and
recommend for issuing a Completion Certificate or Provisional Certificate, as the
case may be.

Roles & Responsibilities of Key Personnel:

4.1 Contractor’s Independent Control Officer
 Reviewing the entire project preparation and implementation activities of the
AFCONS (EPC).
 Will continuously interact with the AFCONS and SAG for effective implementation of
the Contract.
 Will undertake Project site visits and guide, supervise and coordinate and monitor the
works.
 Ensure execution of works at Site is as per Standards and Specifications.

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  Review the Environmental Management Plan.
 Review the Quality Assurance and monitoring provisions during the design and
construction phases.
 Review matters relating to Traffic Management Plan, Temporary diversions and
public safety measures proposed by EPC Contractor.
 Regular monitoring of Progress of works and identify potential delays, if any, and
issue of instructions to take remedial measures to expedite the progress.
 Review of Monthly Progress report submitted by the EPC Contractor and gives his
comments / observations to Employer (SAG).
 Verify and Certify EPC contractors Interim Payment certificates.
 Supervise the compliance and verification of As-Built Drawings.
 Recommend for issuing of Provisional / Completion certificate.
 Ensure all communications, instructions, drawings etc. are kept in safe custody and
hand over to Employer (SAG).
 The Annexure –C is attached for detailed reference of review procedures as per Cl 1.4
of EMPLOYERS REQUIREMENTS PART-III.2: PERFORMANCE SECIFICATIONS.

4.2 Design Proof Check Engineer

Contractor’s Independent Control Officer shall approve the design and drawings and issue
“Good for Construction” Drawings only after getting clearance from the Proof Check
Designer.
 Review of Topographic Survey.
 Review of Geotechnical and subsoil investigations.
 Review of Hydrological and Hydraulic studies.
 Review of traffic Survey and analysis.
 Review of pavement condition survey, soil and material survey.
 Review of Geometric Design of the Project Highway Alignment including horizontal &
vertical profile.
 Review of Pavement Design.
 Review of Structures design.
Design Proof Checking Engineer will be assisted by a team of Engineers, as and when required, who
shall be working in back hand office support.

4.3 Highway Engineers – Supervision

The Highway Engineer shall be responsible for supervising the works of Highway to be constructed
by AFCONS. His prime responsibility being as given below are given under.
 Review of Technical Specifications, Implementation schedules of the Project, Project
Documents & Contract.
 Check and verify the Survey control Points, bench marks, reference points, setting out,
proposed centre line of the alignment, toe points etc.
 Review and advice on safety and traffic management during Construction.

18
  Will inspect the site as per ‘Request for Inspection” (RFI) raised by the EPC for each layer.
 Will check the Surface lines and levels of the layers constructed by EPC are as per approved
cross sections.
 Upon his Approval next layer shall be processed.

4.4 Bridge / Hydraulic Engineer – Supervision

Bridge / Hydraulics Engineer will be responsible for ensuring the construction is as per the approved
design and drawings and in compliance to the standards and specifications as defined under the
contract document. His prime responsibility is given below.
 Review of Technical Specifications, Implementation schedules of the Project, Project
Documents & Contract.
 Organize survey team and verify the Survey Control Points, bench marks, reference
points, setting out, proposed centre line of the alignment, toe points etc.
 Review and advice on safety and traffic management during Construction.
 Will inspect the site as per ‘Request for Inspection” (RFI) raised by the Contractor for
each activity.
 Will review and approve the Formwork / shuttering arrangements made by the EPC.
 Will review and approve the Bar Bending schedule prepared by the EPC.
 Will inspect the site to verify reinforcement is as per approved Bar bending schedule.
 Will check the mix design of the concrete and ensure that concrete mix is as per QA/QC
plan and confirming to required standards and specifications.

4.5 Quality/Material Engineer

Material Engineer shall be responsible for the following tasks has been given below.
 Review of Geotechnical and sub soil investigations.
 Review of Material Sources and material test reports.
 Review of Mix Designs
 Review of Inspection Test Plans as proposed by the Contractors TQM Plan
 For supervising all the tests to be done in different stages of the construction, besides
ensuring the specified tests are done as per the Codal stipulations and as per specifications
laid down in the contract agreement for all different stages of the construction.
 Inspection of Layers as per RFI and witness tests for compliance to Optimum Moisture
Content and density / compaction results in line with the specifications.
 Upon his satisfactory evaluation of having achieved the desire results as per specifications
approval for next layer shall be granted.
 Inspection & testing of concrete Slump, workability, cube strength etc. and approval up on
achieving satisfactory results.

5.0 Method Statement

Method of statement for each section of the works has been prepared based on the resources
required, technical specifications and best engineering practice. The method of statement describes
the steps to be followed and the sequences of activities to complete the works and document as per
the contract. It includes the scope of work, reference documents, pre-requisites like approval of
borrow area, quarry, source of manufactured materials, working drawings, setting out, process
control, plant, men and machinery deployed, acceptance criteria, test frequencies and tolerance

19
limits for end products. The method of statements for the following main items of work is detailed
in these Chapters and the format/check lists are attached as Annexures to this report.
 Clearing and Grubbing
 Method of Statement sub formation(Embankment) and Capping Layer
 Sub Base –Unbound Material (GNT2 Granularity 0/31.5)
 Prime coat / Tack coat
 Base Course-Asphalt Concrete (0/20 Class 2 High modulus asphalt concrete)
 Wearing course (0/14 Class 3 High modulus asphalt concrete)
 Method of Statement for All structures
 Method of Statement for Ancillary works
5.1 Method statement Clearing Curbing
5.1.1 Scope.
The scope of work covers all the operations required to be executed as per Employers Requirements
Part III-2 Performance Specifications clause 4.0.

5.1.2 Reference Document

Employers Requirements Part III-2 Performance Specifications clause 4.0.
 Setting out of Works & Protection of Survey Monuments.
 Clearing and grubbing Drawings.
 Bench Mark List Summary.
 Horizontal and Vertical Curves List Summary. Plan Profiles.
 Approved Cross Sections.

5.1.3 Inspection and Test Plan

These Documents has to be submitted by the Contractor one day (24hrs) advance with detailed
inspection summary for the following activity.
 Obtain & Check construction drawings.
 The centreline of the proposed road shall be marked accurately using total station and got
checked by the ICO’s Representative. The field data in digital form prepared and submitted
to the ICO.
 The benchmarks shall be established after connecting with the GTS benchmarks in the
region at least@ 4 nos. per Km both sides of the road.
 Trees and other utilities are enumerated and concerned authorities are approached and the
same shall be cleared as required.
 Area where striping of soil is required shall be marked and area for stock piling of the top
soil to be identified.

5.1.4 Bench Marks

Concrete temporary bench marks to be fixed and toe line to be marked.

5.1.5 Equipment Details

1. Survey equipment: Total Station, Auto Level, Staffs etc.

20
 2. Stripping and loading: Dozer, Excavator, Mortar Grader, and Trucks.

5.1.6 Safety and Protection of Environment

All effective and requisite measures shall be implemented to ensure full safety to all the
concerned work force, machinery, traffic and general public.
Effective and sufficient care shall be taken to minimize damage to the environment and
cleanliness in all works is given the utmost importance. As far as possible, trees and vegetation
shall be retained unless it is essentially required to be removed. By way of penalty for damage
inflicted on designated trees the Contractor shall plant ten new trees for each designated tree
damaged. The new trees shall be of species approved by Employer's Environmental and Safety
Branch.

5.1.7 Personal Employed for supervision

In the leadership of Team Leader, highway of works, Surveyor and the Contractor technician will be
deploying for the site supervision. The following main activates have to be performed by the
supervision team.
 The vegetation is completely cleared and trees stumps are extricated along with roots.
 The pits formed due to stumps removal is made good with filling and compaction as per
specifications.
 The useful materials shall be stockpiled and all other objectionable materials are disposed
as per directions of Team Leader in the designated waste area.
 Topsoil shall be stripped and useful material is stockpiled, if so directed by the ICO.
 Levels shall be taken before and after stripping/clearing & grubbing/bed compaction.
 The measurements are recorded and submitted for verification/documentation.
5.1.8 Tolerance
For topographic survey and fixing the TBMs, following tolerance limit will be followed as per
applicable specifications for survey work.

Every benchmark is to be checked levelled by a forward run and a subsequent backward run forming
a closed "loop."

The following standard of accuracy will be maintained.

C =±K
Where C = maximum permissible error of closure in centimetres, K = distance between bench marks
in kilometres.

5.2 Method Statement sub formation (Embankment) and capping layers

5.2.1 Scope

21
This item covers all the operations required to form earth work, embankment and sub-grade (also
called as capping layer) to the required lines and levels as per the requirements of widening of
existing road as well as construction of new road.

5.2.2 Reference Documents

1. Employer’s Requirements Part III-2 Performance Specifications
2. NF P 11-300.
3. NF P 94-068.
4. NF P 94-078.
5. NF P 97-117-1.
6. NF P 97-117-2.
7. SETRA Technical Guide LCPC July-2000.

5.2.3 Materials

The material shall be conforming to Employer’s Requirements Part III-2 Performance Specifications
clause 5.1. It shall be free from logs, stumps, roots, rubbish or any other ingredient likely to
deteriorate or affect the stability of the embankment /Capping layers.
The maximum size of coarse material shall not exceed 300 mm and 80mm for rock fill and 2/3rd of
the layer thickness for other fill material after compaction.
The maximum compacted thickness of the layer shall not be exceeding 300 mm.
The following tests on material shall be done for acceptability criteria: -
 The materials obtained from roadway excavation will be tested for its suitability for use as
fill material. Only when it is not suitable, fill material shall be obtained from approved
borrow pits.
 Approved material from roadway excavation/borrow pits are excavated by
excavators and transported in dump trucks to the embankment site.
Acceptance Criteria for Embankment Fill Materials

5.2.3.1 Backfill Material

Backfill from excavated material (work site) or from borrow pit shall reach the following
specifications.

Tolerance: T
Characteristics Specifications Test Rate
Recommendation : R
Materials
< 300 mm
Dmax
% of Fine < 35 % 1/1500 m3

Plasticity index(PI) < 35 % 1/1500 m3

Swelling <1% 1/1500 m3

CBR 90% 4 days immersion >5% 1/1500 m3

Implementation Defined according

Max layer thickness after to the SETRA

22
 compaction in Technical guide
Compaction q4
95 % pd OPN 50%
1/Profile
92% pd OPN 100%

5.2.3.2 Sub – Formation (Embankment)

Tolerance: T
Characteristics Specifications Test Rate
Recommendation : R
Materials
< 300 mm
Dmax
Plasticity index(PI) < 30 % 1/1500 m3

Swelling <1% 1/1500 m3

CBR 90% 4days immersion >8% 1/1500 m3

Implementation 95 % pd OPN 50%

1/Profile
Compaction q4 92% pd OPN 100%
Performance: Test Bearing Capacity 20
(NF P94-17) EV2 ≥ 40 MPa 95% Measurem
ents
20
Additional acceptance Criteria: 95%
<300/100mm Measurem
Deflection D90
ents
Passage of 13 Tonne loaded truck No visual deflections
On Each
to the axle
lane

5.2.4 Preparation of Bed

The existing ground is cleared and grubbed as per Employer’s Requirements Part III-2 Performance
Specifications clause 4.2 Unsuitable material to be taken out and replaced with good material.

i. Stripping and storing topsoil: The top soil shall be stripped to a depth of 150 mm and
stored in stockpiles of height not exceeding 3m, if so directed by the ICO. The original
ground supporting the embankment shall be levelled to facilitate placement of first layer of
embankment, scarified, mixed with water and then compacted by rolling as per SETRA
Technical Guide LCPC July-2009.
ii. Shaping and Compaction of the Road bed on Suitable Material: In case where the existing
ground beneath embankment has a density below 95% of MDD, the layer shall be scarified
to a minimum depth of 150 mm, watered and re-compacted in accordance with the
requirements of SETRA Technical Guide LCPC July-2009.
iii. Capping Layer: However, these materials will be often required to produce sufficient cover
on weak Capping Layers. It is used in the lower pavement layers as a substitute for thick sub
base to reduce costs. The physical requirement of capping layer as per in the Table given
below Employer’s Requirements Part III-2 Performance Specifications.
Physical Requirement of Capping Layer: -

23
Capping layer materials of lateritic gravel and any crushed stone, must meet the following
specifications. This material can be used for lateritic gravel sidewalk base.

Tolerance: T
Characteristics Specifications Test Rate
Recommendation : R
Materials
Lateritic gravel or unbound MDE≤45
1/1500 m3
material
1/1000 m3
Dmax < 80 mm
Tolerance: T
Characteristics Specifications Test Rate
Recommendation : R
Plasticity index(PI) < 25 1/1000 m3
% of fine (80µm) <35% 1/1000 m3
Normal Proctor ≥2050kg/m3 1/2000 m3
Swelling <0.5% 1/5000 m3
CBR 90% 4days immersion >30% 1/2000 m3
Implementation Test Section
Compaction
water content OMC +2,-2 % 1/500 m3
20
Compaction q3-Inspection test lot 98.5 % pd OPN 50% Measurements
1000m 96% pd OPN 100%

Performance: Test Bearing Capacity

20
(NF P94-17) Inspection lot 1000m EV2 ≥ 70 MPa 95%
Measurements
Deflection D90-Inspection lot <150/100mm 20
95%
1000m Measurements

3
Additional acceptance Criteria: Measurements
100 %
Thickness ±2 ar 20ml

3
Topographic Measurements
Measurements
-Inspection lot 1000m 100 %
±2 ar 20ml

2
Irregularity Measurements – Longitudinal and Measurements
Straightedge test –(NP-98-218) Transverse < 2ar 100ml

Width carriageway Layer total width : 0 1

to +5crr Measurements

24
 50m
Process:
 The approved soils from roadway excavation/borrow areas shall be excavated and
transported to the site of embankment.
 The material shall be spread in layers of uniform thickness not exceeding 300 mm
compacted thickness over the entire width of embankment by mechanical means and
finished by motor grader.
 The moisture content shall be checked and if found to be out of limits, the same shall be
made good.
 If the moisture is high, it shall be dried, by aeration and exposure to the sun, till the
moisture content is brought down to the required level. Compaction shall be suspended in
inclement weather.
 If the moisture content is less, water shall be sprinkled by water tanker having sprinkler
attachment and mixed thoroughly in soil by mechanical means till uniform moisture
content is obtained.
 The moisture content of each layer shall be checked. It shall be in between 2%above OMC.
 Compaction shall be done as per SETRA Technical Guide LCPC July-2009. Vibratory or other
rollers shall be used for achieving the required results.
 The surface of the embankment shall be maintained at such a cross slope as will shed water
and prevent pounding.
 Compaction tests shall be conducted to confirm the field dry density by nuclear density
gauge or by sand replacement method and rapid moisture meter shall be used to measure
field moisture content.
 The next layer shall be placed only after achieving the required test result and due
approvals.
 Before commencement of the actual construction of Capping Layer, a trial section shall be
demonstrated so that the adequacy of equipment and processes are established.

Equipment Details:
 Excavation and Loading: Hydraulic Excavators
 Transport: Dump Truck.
 Spreading and grading: Dozers, graders and tractors.
 Watering: Water tankers fitted with sprinklers.
 Compaction: Vibratory rollers.
 Testing equipment's: As per required standards.

Social and Environment Safety Measures:

 All effective and requisite safety measures shall be implemented to ensure full safety to all
the concerned work force, machinery, traffic and general public.
 Effective and sufficient care shall be taken to minimize damage to the environment and
cleanliness in all works is given the utmost importance.
 PPE compulsion for the navies.
 Traffic diversion, sings, delineation, barricades are placing as per required.

Personnel Deployed for Supervision:

In leadership of Team Leader, Highway Engineer, Material Engineer shall be deployed from ICO side
for the supervision, identification of defects and issues the necessary site instruction, similarly the

25
Contractor technical staff shall be deployed to proceed the works, supervision and defects
rectification.

Activities:
 Obtain and check latest construction drawing.
 The centreline and batter lines shall be marked and got checked by the Engineer's
representative.
 The benchmarks shall be established after connecting with the GPS benchmarks in the
region.
 The grid levels shall be recorded and got verified by ICO.
 The cross sections are plotted and the required profile of the proposed road section is
superimposed and the batter lines shall be identified and submitted for approval of ICO.
 The layout is set-out and beacons are established and protected.
 Approvals of borrow material obtained.
 Establish OMC & MDD and CBR value for all soils.
 Check for clearing and grubbing.
 Check for stripping.
 Check for bed compaction.
 Check for approved borrow areas.
 Excavate, transport and dump in approved areas for dumping.
 Spread in uniform layer and grade to the required lines and levels.
 Check moisture content and rectify if needed.
 Compaction using adequate mechanism/ rollers verify field Density for layers.
 If the density up to requirement not achieved repeat rolling until the required density is
achieved.
 Record the test results and process the filing system.
 Proceed to next layer until the level for next course is reached
 Obtaining required compaction.
 The reach is ready for next process.

5.3.1.4 Frequency of Sampling and Testing:

In the leadership of material engineer the lab team shall be deployed for the required test of the
layer, frequency of sampling and testing will be conducted as per the prescribed specification in the
established laboratory. However, if third party test required will be sent accordingly.

5.3 Method Statement Unbound Material For earth works

5.3.1 Scope
This item covers all the operations required to form earth work, embankment and sub-grade (also
called as capping layer) to the required lines and levels as per the requirements of widening of
existing road as well as construction of new road.

5.3.2 Reference Documents

1. Employer’s Requirements Part III-2 Performance Specifications
2. NF P 11-300.
3. NF P 94-068.
4. NF P 94-078.
5. NF P 97-117-1.

26
 6. NF P 97-117-2.
7. SETRA Technical Guide LCPC July-2000.

5.3.3 Materials
The material shall be conforming to Employer’s Requirements Part III-2 Performance Specifications
clause 5.1. It shall be free from logs, stumps, roots, rubbish or any other ingredient likely to
deteriorate or affect the stability of the embankment layers.
The maximum size of coarse material shall not exceed 300 mm for rock fill and 2/3rd of the layer
thickness for other fill material after compaction.
The maximum compacted thickness of the layer shall not be exceeding 300 mm.
The following tests on material shall be done for acceptability criteria: -
 The materials obtained from roadway excavation will be tested for its suitability for use as
fill material. Only when it is not suitable, fill material shall be obtained from approved
borrow pits.
 Approved material from roadway excavation/borrow pits are excavated by
excavators and transported in dump trucks to the embankment site.

Acceptance Criteria for Unbound Materials for Earth Work

Characteristics Specifications Test Rate

Materials
unbound material MDE≤45, LA ≤45 1/1500 m3
Dmax < 80 mm
1/1000 m3
Plasticity index(PI) Not Measurable

% of fine (80µm) <10% 1/1000 m3

Quantity of Methylene Blue in soil VBS < 0.1 1/1000 m3

Normal Proctor ≥2050kg/m3 1/2000 m3

Swelling <0.5% 1/5000 m3

CBR 90% 4days immersion >30% 1/2000 m3

Implementation Test Section

Compaction
water content OMC 1/500 m3

Compaction q3-Inspection test lot 1000m 98.5 % pd OPN 20

96% pd OPN Measurements

5.3.4 Frequency of Sampling and Testing:

In the leadership of material engineer the lab team shall be deployed for the required test of the
layer, frequency of sampling and testing will be conducted as per the prescribed specification in the
established laboratory. However, if third party test required will be sent accordingly.

27
5.4 Sub Base (Unbound Material)
5.4.1 Scope
Sub base course (unbound) is placing just over the prepared Capping as per the approved drawing
and the technical specification of the Contract. The granular sub base either natural quarry material
or graded river bed material or crusher run. It covers all the operations required to form granular
sub base course to the required lines and levels as per the drawings and the technical specification
of the Contract.
5.4.2 Reference Documents
1. Employer’s Requirements Part III-2 Performance Specifications.
2. EN 13285 the unbound mixture will be a GNT2 granularity 0/31.5.
3. NF P 18-545 and NF EN 13242.
4. NF P 98-115.
5. NF P 98-218

5.4.3 Materials
The quarry for GSB material shall be identified.

The material shall be the consisting of natural gravel, crushed gravel, crushed rock, river bed or
combination of crushed rock & natural gravel, or any other material complying with the
requirements of the clause 5.2(5.2.1) as per the Employer’s Requirements Part III-2 Performance
Specifications and approved by the ICO.

The complete sub base shall contain no material having a maximum dimension exceeding two thirds
of the compacted layer thickness. The following tests on material shall be done.

Grading Requirement:
According EN 13285 the unbound sub base mixture will be a GNT2 granularity 0/31.5.
Physical Requirement of Sub base:
Tolerance: T
Characteristics Specifications Test Rate
Recommendation : R
Aggregates:

NF P18-545 and NF EN 13242

Intrinsic Characteristics: DNC code
1/10000T
Coefficient Los Angles(LA) LA ≤30

Coefficient Micro Deval(MDE) MDE≤25,

28
 Granularity T: GTc 25/15 or 20/15 or
Manufacturing characteristics of the GC 80/20 20/17.5 1/1000 T
gravel type III F2
FL 35
Granularity
Cleanliness
Flattening
Sand Manufacturing characteristics: GA 85
Type b
Granularity MB2.5 and SE45
MB-Methylene blue T : GTA10
Cleanliness of the elements < 2mm SE –Sand Equivalent 1/1000 T

Approved material at a selected location and care shall be taken to prevent contamination of
unbound sub base material.
Construction Process:
 The selected sub-grade layer shall be checked for density and bed preparation before
placing the sub base material for any damage or deficiency which shall be made good as
directed by the ICO.
 The approved granular material from stockpile shall be transported to the site.
 The material shall be spread in layers of uniform thickness not exceeding 300mm
compacted thickness over the entire width of capping layer by mechanical means and
finished by motor grader.
 The moisture content shall be checked and if found to be out of limits, the same shall be
made good.
 If the moisture is high, it shall be dried, by aeration and exposure to the sun, till the
moisture content is brought down to the required level. Compaction shall be suspended in
inclement weather.
 If the moisture content is less, water shall be sprinkled by water tanker having sprinkler
attachment and mixed thoroughly by mechanical means until uniform moisture content is
obtained.
 The moisture content of each layer shall be checked. It shall not be in more than +2% -1%
above OMC.
 The compaction shall be completed as soon as possible after the material has been spread.
Vibratory rollers shall be used for achieving the required results.
 The compaction shall be done to achieve minimum field density 95% of Modified Proctor
NF P98-115 for a single test. Around structures, compaction shall be done by using small
vibratory roller/plate vibrators.
 The surface of the sub base shall be maintained to the required cross fall.
 The tests shall be conducted to confirm the field dry density by Sand
Replacement Method.
 Before commencement of the actual construction of sub base course, a trial section shall
be demonstrated so that the adequacy of equipment and processes are established.
 Only when such a trial section has been satisfactorily laid and finished and complies with
the specified requirements, the actual sub base layer work shall commence.

29
Equipment Details:
 Excavation and Loading: Hydraulic Excavators
 Transport: Dump Truck
 Spreading and grading: Dozers, graders and tractors
 Watering: Water tankers fitted with sprinklers
 Compaction: Vibratory rollers
 Testing equipment's: As per required standards.

Social and Environment Safety Measures:

 All effective and requisite safety measures shall be implemented to ensure full safety to all
the concerned work force, machinery, traffic and general public.
 Effective and sufficient care shall be taken to minimize damage to the environment and
cleanliness in all works is given the utmost importance.
 PPE compulsion for the navies.
 Traffic diversion, sings, delineation, barricades are placing as per required.
Personnel Deployed for Supervision:
In leadership of Team Leader, Highway Engineers, Materials Engineer shall be deployed from ICO
side for the supervision, identification of defects and issues the necessary site instruction, similarly
the Contractor technical staff shall be deployed to proceed the works, supervision and defects
rectification.

Activities:
 Obtain and check latest construction drawing.
 The centreline and batter lines shall be marked and got checked by the Engineer's
representative.
 The benchmarks shall be established after connecting with the GPS benchmarks in the
region.
 The grid levels shall be recorded and got verified by ICO.
 The cross sections are plotted and the required profile of the proposed road section is
superimposed and the batter lines shall be identified and submitted for approval of ICO.
 The layout is set-out and beacons are established and protected.
 Approvals of borrow material obtained.
 Establish OMC & MOD and CBR value for all soils.
 Check for stripping.
 Check for bed compaction.
 Check for approved borrow areas.
 Spread in uniform layer and grade to the required lines and levels.
 Check moisture content and rectify if needed.
 Compaction using adequate mechanism/ rollers verify field Density for layers.
 If the density up to requirement not achieved repeat rolling until the required density is
achieved.
 Record the test results and process the filing system.
 Proceed to next layer until the level for next course is reached
 Obtaining required compaction.
 The reach is ready for next process.
Construction Tolerances:
Surface Level ± 2cm,

30
Layer Total Width,0 to + 5 cm and Theoretical edge layer + 3cm shown in the drawing.
Thickness, the mean layer thickness of the lot is not less than the specified thickness minus ± 2cm.
5.4.4 Frequency of Testing and sampling
In the leadership of material engineer the lab team shall be deployed for the required test of the
layer, frequency of sampling and test will be conducted as per the prescribed specification in the
established laboratory. However, if third party test required will be sent accordingly.
The following Table given the testing frequency for process control.
Tolerance: T
Characteristics Specifications Test Rate
Recommendation : R
Implementation (NF P98-115)
1/5000 T
Proctor Compaction
water content OMC +2,-1 % 1/500 m3
20
Measureme
Compaction q2-Inspection test lot 97 % pd OPN 50%
nts
1000m 95% pd OPN 100%

3
Thickness % Measurements at the Measureme
100 %
prescribed thickness. nts 20ml

3
Topographic Measurements
Measureme
-Inspection lot 1000m 100 %
±2 ar nts 20ml

2
Irregularity Measurements – Longitudinal ≤ 1.0cm Measureme
100 %
Straightedge test –(NP-98-218) Transverse < 1.5cm nts 100ml

5.5 Prime coat/Tack Coat

5.5.1 Scope
This item covers the procuring, furnishing, placing and constructing Bituminous materials and
surface dressing aggregates in accordance with these specifications in conformity with the lines,
grade, thickness and typical cross sections shown on the drawings and/or as directed by the ICO.
Reference Documents
1. Employer’s Requirements Part III-2 Performance Specifications.
2. NF EN 12272-1
3. NF EN 13808
Equipment Details:
 Boomer
 Water tanker.
 Bitumen distributor

Prime Coat:
 A prime coat is a thin layer of cutback bitumen such as C55B(F)5 sprayed on to the existing

31
 subbase surface. It assists in promoting and maintaining adhesion between Sub base layers
of the pavement. Application rate of prime is likely to lie within the range of 1.1kg/m2 of
residual bitumen and spraying temperature is in between 45 0c to 700c and surface
temperature shall be above 150c. The prime shall be penetrating completely under the
surface.
Process
 No longer than 24 hours before spraying, the layer to be primed shall be broom and
cleaned of all loose or deleterious material by means of a rotary broom and hand brooms.
A light spray of water, sufficient to dampen the surface, shall be uniformly applied to the
 layer immediately before the application of the primer. If the water is over applied the
layer shall be allowed to dry until a uniform damp surface is obtained.
 Before any prime material is sprayed the layer to be primed shall be checked for
compliance with the surface and other requirements specified. Any sections not complying
with the specified requirements shall be corrected as specified.
 Twine-reinforced paper or other suitable approved material shall be used at all joints at the
beginning and end of all sprays in order to obtain a neat start and cut-off. Curing period is
likely to minimum 24hrs-48hrs or as per ambient temperature.
 All prime materials stored in a heated condition shall be stored in a container with a
properly functioning circulation system and having a securely fitting lid. No heat shall be
added to materials delivered above storage temperature until the temperatures are below
those specified above unless the materials are intended for immediate use.
 The primer shall be applied in one or more lanes evenly over the full width of the road and
allowed to penetrate and cure until traffic can pass over the surface without the wheels
picking up the prime. All traffic shall be kept off the surface until this condition is obtained.
The total width of primed surface shall be 15cm outwards both sides of the edge of
granular base course. If primer is applied in more than one lane, allowance shall be made
for overlapping the lanes by 100 mm.
 Where it is not feasible for traffic to use bypasses, the primer shall be applied and allowed
to penetrate for as long as is practicable before a blinding layer of mineral aggregate is
applied.
 As soon as the primed surface has dried sufficiently to allow the traffic to pass over the
road without picking up or otherwise damaging the primed surface, the road shall, where
practicable, be opened to public traffic for a period of 3 days.
 Before commencing with the actual construction of any Prime Coat, laying a trial section
shall be demonstrated so that the equipment and processes that are proposed to be used
will enable to construct the Prime Coat in accordance with the specified requirements.
 The trail section(s) shall be laid where indicated by the ICO. Only when such a trial section
has been satisfactorily laid and finished, and complies with the specified requirements, the
actual permanent work shall commence.
Tack Coat
 Tack coat is a straight run bitumen. The primary function of a tack coat is to act as a glue to
assist bonding of a new surface layer to a previously bituminous surface. The application
rate of tack coat range in between 400gms/m 2 and temperature ranges 1450c to 1700c.
 Before application of tack coat the surface shall be broom and cleaned of all loose or
deleterious material by means of a rotary broom and hand brooms.

32
5.5.2 Frequency of Testing and sampling
In the leadership of material engineer the lab team shall be deployed for the required test of the
layer, frequency of sampling and test will be conducted as per the prescribed specification in the
established laboratory. However, if third party test required will be sent accordingly. The following
the testing frequency for process control test as per Employer’s Requirements Part III-2 Performance
Specifications Clause 5.2.4.

Prime Coat
 Rate of Fluidized bitumen per 1.1kg/m 2
 Rate of Spread of Binder Tolerance < ±10%

Tack coat
 Rate of Spread bitumen per 400gm/m2
 Rate of Spread of Binder Tolerance < ±10%
 Accuracy of Spread binder, Tolerance <15%
 Rate Test Implementation 1/1000m2

Social and Environment Safety Measures

 All effective and requisite safety measures shall be implemented to ensure full safety to all
the concerned work force, machinery, traffic and general public.
 Effective and sufficient care shall be taken to minimize damage to the environment and
cleanliness in all works is given the utmost importance.
 PPE compulsion for the navies.
 Traffic diversion, sings, delineation, barricades are placing as per required.
Personnel Deployed for Supervision
 In leadership of Team leader, Highway Engineer, Material Engineer are deployed from ICO
side for the supervision, identification of defects and issues the necessary site instruction,
similarly the Contractor technical staff shall be deployed to proceed the works, supervision
and defects rectification.

5.6 Asphalt concrete Base course

5.6.1 Scope
This item covers the procuring, furnishing, placing and constructing of aggregates and bituminous
binder for Asphaltic Base Course in accordance with these specifications in conformity with the lines,
grades, thickness and typical sections shown on the drawing and or as directed by the ICO.

5.6.2 Reference Documents

1. Employer’s Requirements Part III-2 Performance Specifications.
2. NF P 18-545 and NF EN 13043.
3. EN 1097-4.
4. EN 13179 -1.

33
 5. EN 933-9.
6. EN 12591 of EN 14023.
7. EN 1426.
8. EN 1427.
9. EN 12595 or12596.
10. EN 13108-1.
11. EN 13108-20.
12. EN 13108-21.
13. EN 13036-7.
14. NF P 98-150-1.

5.6.3 Materials
All materials shall be handled and stockpiled in a manner will prevent contamination of deleterious
substance, segregation or damage.

The Contractor shall as often as necessary test and control the materials produced directly, or the
materials received from suppliers, to ensure that the materials comply with the specified
requirements.

Mix Design
The contractor shall be designed the mix design of Asphalt Concrete for Base course based on the
recommendations given in the EN 13108-1 and 13108-20 carried out Test Procedure and get
approval from the ICO. Base course Asphalt material made of 0/20(EME2) class 2 high modulus
asphalt concrete, must meet the following requirements.
Material Requirement
Characteristics Specifications Test Rate
Aggregates:
NF P18-545 and NF EN 13043 1/5000T
Intrinsic Characteristics: DNC code
Coefficient Los Angles(LA) LA ≤30 1/5000T
Micro-Deval Coefficient (MDE) MDE≤25
Granularity
Manufacturing characteristics of the gravel type III
Granularity GC 85/20
Cleanliness F1 or F2 if MBF 10
1/1000 T
Flattening FL 25
Sand Manufacturing characteristics: Type a
Granularity GF 85
1/1000 T
Cleanliness of the elements < 2mm MB2

34
 Filler AggregateEN13043

Voids – Rig den(EN1097-4)

V28/45
Delta ring and ball(EN13179-1)
ΔR&B 8/25
Harmful fines(EN933-9) 1/500 T
MBF 10
BITUMEN (EN12591 or EN 14023)

Penetrability ar250c(EN1426) 1/day

See & material
softening Point (EN 1427) 1/day

Viscosity (EN 12595 or 12596) 1/truck

 Grading: Grading requirement for Asphalt Concrete Base course shall comply EN 13108-1
Table 1&2
 Bituminous Binder: The bituminous binder shall be 20/30 penetration grade shall be
complied with the requirement of EN 12591 and as per Employer’s Requirements Part-III-2
Performance specification clause 4.3.2.2 and bitumen sampling shall comply with the
relevant procedure as described in EN 12591.
 Elasticity Modulus Requirements: The Elasticity requirements for mixes designed for more
than 5 million esa traffic are as per specification table NF P 98-150-1.
 Core Cutting: The Contractor shall be provided suitable coring machines capable of cutting
100mm diameter cores from the completed Asphaltic layer as directed by the Engineer.

Equipment Requirements
 Hot Mix Asphalt Mixing Plant:
 Water tanker fitted with sprinklers
 Air Compressor: Tractor mounted I Truck mounted or self-wheeled
 Bitumen Distributor
 Drag Broom: Power operated capable to distribute chips evenly.
 Compaction: 2 nos. PTR capable of creating a tire pressure of 275 Kpa or as directed
by the ICO.
 Front End Loader: To load aggregate on tippers at stockpile
 Tippers: Adequate nos. to transport aggregate from stockpile to site.
 Paver with automatic electronic screed controls.
 Testing equipment's: As per required standards.

Construction Process

35
  Before commencing with the actual construction of any asphaltic course and surfacing
layers, lying of a trial section shall be demonstrated, so that the equipment and processes
that are proposed to be used will enable to construct the asphaltic layers in accordance with
the specified requirements. The trial section(s) shall be laid where indicated by the Team
Leader.
 Obtain and check the approved construction drawing.
 The centreline and batter line shall be marked and get checked by the supervision
consultant.
 Surface shall be clean and if needed rectification, rectify.
 The cut edge of the existing layer shall be painted with a thin coat of bitumen that is tack
coat.
 The mixture shall be delivered to the paver in such a manner that the paver will never be
forced to stop for lack of asphalt. Only minimal hand-working of asphalt shall be permitted
after discharge from the paver and before rolling and shall only be carried out with wooden
spreaders. Operatives shall not be permitted to walk on un-compacted asphalt. Paving shall
cease when rain starts falling or when, in opinion of the Team Leader, the surfaces to be
paved are visible wet.
 The mix shall be rolled as soon as possible after it has been laid by combination of vibratory
and non-vibratory steel-tired flat rollers and pneumatic-tired rollers in sequence. Rolling
shall commence with a self-propelled pneumatic-tired roller working parallel to the centre
line of the road from the shoulders towards the crown of the road until the whole surface
has been covered at least three times with the wheels of the roller initially.
 All joints between adjacent sections of the work shall be made by cutting back the layer
against which material is to be placed and cutting wheel shall be used for cutting joints.
Before a new layer is placed next to an existing layer the cut edge shall be painted with coat
bituminous of the same type used for tack coat. The outside edges of completed asphalt
layer shall be trimmed along the shoulders and parallel to the centre line to give the finished
width shown on the drawings, with tolerances specified.
 Only when such a trial section has been satisfactorily laid and finished, and complies with
the specified requirements, the actual permanent work shall commence.
 Falling Weight Deflector Meter and International Roughness Index (IRI)/ Roughness Profile-
meter Tests shall be carried out on completion of the road section or before its handover.

Social and Environment Safety Measures:

 All effective and requisite safety measures shall be implemented to ensure full safety to all
the concerned work force, machinery, traffic and general public.
 Effective and sufficient care shall be taken to minimize damage to the environment and
cleanliness in all works is given the utmost importance.
 PPE compulsion for the navvies.
 Traffic diversion, sings, delineation, barricades are placing as per required.

Personnel Deployed for Supervision:

 In leadership of Team Leader, Highway Engineer, Material Engineer shall be deployed from
ICO side for the supervision, identification of defects and issues the necessary site
instruction, similarly the Contractor technical staff shall be deployed to proceed the works,

36
 supervision and defects rectification. The ICO team shall have approved working drawing in
hand.
5.6.4 Frequency of Testing and sampling
In the leadership of Material Engineer, the lab team shall be deployed for the required test of the
layer, frequency of sampling and test will be conducted as per the prescribed specification in the
established laboratory. The minimum testing frequency that will be required from the Contractor in
terms of Clause 5.2(5.2.1) as per Employer’s requirements Part III-2 Performance Specifications for
the purpose of process control shall be given in the Table. However, if third party test required will
be sent accordingly.
Characteristics Specifications Test Rate
Composition in relation to the reference
formulation (absolute value) for the average
of 4 samples (EN 13108-21)

Bitumen content %
Formula±0.3 2 extractions
Aggregates (passing 0.063mm) Formula ± 2 minimum per
Formula ± 3 day
Aggregates (2mm passageways) (EN 12697-1)
Formula ± 4
Aggregates (6-10-and 14mm passageways)
Formula ± 5
Aggregates (20mm passageways)

Implementation (NF P98-150-1)

Compaction Test Board
Absolute compactness % -inspection lot 20
1000ml(interval method according XP P98- 94≤c≤100 Measurements
151) Vi≤c≤100 +1 test
core/500ml to
check
Thickness % Measurements at the prescribed thickness and
thickness. compactness
by hydrostatic
weighing
2
Topographic Measurements -Inspection lot
Measurements
1000m
±2 ar 100ml

2
Irregularity Measurements –Straightedge test Longitudinal ≤ 1.0cm Measurements
–(EN13036-7) Transverse < 1.5cm 100ml

Inter layer Bonding No deboning 2

Measurements
500ml

37
 1
Layer total width: 0 to +5cm. Measurements
Width carriageway
Theoretical edge layer ±3cm 50ml

5.7 Asphalt concrete Wearing course

5.7.1 Scope
This item covers the procuring, furnishing, placing and constructing of aggregates and bituminous
binder for Asphaltic Base Course in accordance with these specifications in conformity with the lines,
grades, thickness and typical sections shown on the drawing and or as directed by the ICO.
5.7.2 Reference Documents
1. Employer’s Requirements Part III-2 Performance Specifications.
2. NF P 18-545 and NF EN 13043.
3. EN 1097-4.
4. EN 13179 -1.
5. EN 933-9.
6. EN 12591 of EN 14023.
7. EN 1426.
8. EN 1427.
9. EN 12595 or12596.
10. EN 13108-1.
11. EN 13108-20.
12. EN 13108-21.
13. EN 13036-7.
14. NF P 98-150-1.
5.7.3 Materials
All materials shall be handled and stockpiled in a manner will prevent contamination of deleterious
substance, segregation or damage.
The Contractor shall as often as necessary test and control the materials produced directly, or the
materials received from suppliers, to ensure that the materials comply with the specified
requirements.
Mix Design
The contractor shall be designed the mix design of Asphalt Concrete for Base course based on the
recommendations given in the EN 13108-1 and 13108-20 carried out Test Procedure and get
approval from the ICO. Wearing course Asphalt material made of (BBM3)0/14 class 3 high modulus
asphalt concrete, must meet the following requirements.
Material Requirement
Characteristics Specifications Test Rate
Aggregates:

NF P18-545 and NF EN 13043

Intrinsic Characteristics: B code
1/5000T
Coefficient Los Angles(LA) LA ≤25

38
 1/5000T
Micro-Deval Coefficient (MDE) MDE≤15
1/20 000T
Polished stone Value(PSV) <50

Granularity
Manufacturing characteristics of the gravel type III GC 85/20

Granularity F1 or F2 if MBF 10

Cleanliness FL 25
1/1000 T
Flattening

Sand Manufacturing characteristics: Type a GF 85 1/1000 T

Granularity
MB2
Cleanliness of the elements < 2mm
Filler AggregateEN13043

Voids – Rigden(EN1097-4)
V28/45
Delta ring and ball(EN13179-1)
ΔR&B 8/25
Harmful fines(EN933-9) 1/500 T
MBF 10

BITUMEN (EN12591 or EN 14023)

1/day
Penetrability ar250c(EN1426)
See & material 1/day
softening Point (EN 1427)
1/truck
Viscosity (EN 12595 or 12596)

 Grading: Grading requirement for Asphalt Concrete Base course shall comply EN 13108-1
Table 1&2
 Bituminous Binder: The bituminous binder shall be 20/30 penetration grade shall be
complied with the requirement of EN 12591 and as per Employer’s Requirements Part-III-2
Performance specification clause 4.3.2.2 and bitumen sampling shall comply with the
relevant procedure as described in EN 12591.
 Elasticity Modulus Requirements: The Elasticity requirements for mixes designed for more
than 5 million Mesa traffic are as per specification table NF P 98-150-1.
 Core Cutting: The Contractor shall be provided suitable coring machines capable of cutting
100mm diameter cores from the completed Asphaltic layer as directed by the Engineer.

Equipment Requirements

39
  Hot Mix Asphalt Mixing Plant:
 Water tanker fitted with sprinklers
 Air Compressor: Tractor mounted I Truck mounted or self-wheeled
 Bitumen Distributor
 Drag Broom: Power operated capable to distribute chips evenly.
 Compaction: 2 nos. PTR capable of creating a tire pressure of 275 Kpa or as directed
by the ICO.
 Front End Loader: To load aggregate on tippers at stockpile
 Tippers: Adequate nos. to transport aggregate from stockpile to site.
 Paver with automatic electronic screed controls.
 Testing equipment's: As per required standards.

Construction Process
 Before commencing with the actual construction of any asphaltic course and surfacing
layers, lying of a trial section shall be demonstrated, so that the equipment and processes
that are proposed to be used will enable to construct the asphaltic layers in accordance with
the specified requirements. The trial section(s) shall be laid where indicated by the Team
Leader.
 Obtain and check the approved construction drawing.
 The centreline and batter line shall be marked and get checked by the supervision
consultant.
 Surface shall be clean and if needed rectification, rectify.
 The cut edge of the existing layer shall be painted with a thin coat of bitumen that is tack
coat.
 The mixture shall be delivered to the paver in such a manner that the paver will never be
forced to stop for lack of asphalt. Only minimal hand-working of asphalt shall be permitted
after discharge from the paver and before rolling and shall only be carried out with wooden
spreaders. Operatives shall not be permitted to walk on un-compacted asphalt. Paving shall
cease when rain starts falling or when, in opinion of the Team Leader, the surfaces to be
paved are visible wet.
 The mix shall be rolled as soon as possible after it has been laid by combination of vibratory
and non-vibratory steel-tired flat rollers and pneumatic-tired rollers in sequence. Rolling
shall commence with a self-propelled pneumatic-tired roller working parallel to the centre
line of the road from the shoulders towards the crown of the road until the whole surface
has been covered at least three times with the wheels of the roller initially.
 All joints between adjacent sections of the work shall be made by cutting back the layer
against which material is to be placed and cutting wheel shall be used for cutting joints.
Before a new layer is placed next to an existing layer the cut edge shall be painted with coat
bituminous of the same type used for tack coat. The outside edges of completed asphalt
layer shall be trimmed along the shoulders and parallel to the centre line to give the finished
width shown on the drawings, with tolerances specified.
 Only when such a trial section has been satisfactorily laid and finished, and complies with
the specified requirements, the actual permanent work shall commence.
 Falling Weight Deflector Meter and International Roughness Index (IRI)/ Roughness Profile-
meter Tests shall be carried out on completion of the road section or before its handover.

40
Social and Environment Safety Measures:
 All effective and requisite safety measures shall be implemented to ensure full safety to all
the concerned work force, machinery, traffic and general public.
 Effective and sufficient care shall be taken to minimize damage to the environment and
cleanliness in all works is given the utmost importance.
 PPE compulsion for the navvies.
 Traffic diversion, sings, delineation, barricades are placing as per required.

Personnel Deployed for Supervision:

 In leadership of Team Leader, Highway Engineer, Material Engineer shall be deployed from
ICO side for the supervision, identification of defects and issues the necessary site
instruction, similarly the Contractor technical staff shall be deployed to proceed the works,
supervision and defects rectification. The ICO team shall have approved working drawing in
hand.

5.6.4 Frequency of Testing and sampling

In the leadership of Material Engineer, the lab team shall be deployed for the required test of the
layer, frequency of sampling and test will be conducted as per the prescribed specification in the
established laboratory. The minimum testing frequency that will be required from the Contractor in
terms of Clause 5.2(5.2.1) as per Employer’s requirements Part III-2 Performance Specifications for
the purpose of process control shall be given in the Table. However, if third party test required will
be sent accordingly.

Characteristics Specifications Test Rate

Composition in relation to the reference 2 extractions

formulation (absolute value) for the minimum per day
average of 4 samples (EN 13108-21) (EN 12697-1)

Bitumen content %
Formula±0.3
Aggregates (passing 0.063mm)
Formula ± 2
Aggregates (2mm passageways)
Formula ± 3
Aggregates (6-10 mm passageways)
Formula ± 4
Aggregates (14mm passageways)

41
 Formula ± 4
Implementation (NF P98-150-1)
Compaction Test Board
Absolute compactness % -inspection lot 20 Measurements
1000ml (interval method according XP P98- 92 ≤ c ≤ 100 +1 test core/500ml
151) Vi ≤ c ≤ Vs to check thickness
and compactness
Thickness % Measurements at the by hydrostatic
prescribed thickness. weighing
2 Measurements
Topographic Measurements -Inspection lot ±1ar 100ml
1000ml
Irregularity Measurements –Straightedge Longitudinal ≤ 0.3cm 2 Measurements
test –(EN13036-7) Transverse < 0.5cm 100ml

Inter layer Bonding No debonding 2 Measurements

500ml

Width carriageway Layer total width: 0 to 1

+5cm. Measurements
Theoretical edge layer 50ml
±3cm

Evenness test according to the test method Short wave bond Psw≥6
LPC n046-2 July 2009 or EN 13036-5 Medium wave bond
inspection lot 1000ml Pnw≥6,Long wave bond
Plw≥5

5.8 Method of Statement of all Structures

5.8.1 Scope
The scope covers the work in connection with the construction of all kind of structures such as RCC
structures, pre-fabricated pipe, cross drainage, drain, stone masonry, RRC drain, pre-cast concrete
structures as per the line and levels of the approved drawings and specifications.

5.8.2 Reference Documents

1. Employer’s Requirements Part III-2 Performance Specifications
2. EN 12620
3. EN 206
4. NF EN 16-345
5. NF EN 14844

Materials

42
All general requirements of materials (Cement, Coarse aggregate, Fine aggregate and Steel, Gabion
wire) shall conform to the applicable Specifications.
Both coarse and fine aggregates shall be free from the deleterious contamination. Steel shall be used
free from the rust and tested.

Equipment Details
 Back hoe excavator for excavation of trench, foundation.
 Tripper trucks for transportation of fabricated and fabricated materials.
 Concrete mixture with weight batcher having water measuring system shall be used.
Ordinary motorized concrete mixture may be used if the permission given by the Engineer.
 Vibrator both needles and plat shall be used for effective compaction of concrete.
 Water pump if required in the drain out the ground water.
 Crane for lifting and placing of Hume pipe.
 Nails, hooks and props as per required for erection of form works.
 Personnel Employed for Execution and Supervision
 In leadership of Team Leader, Bridge Engineer, Material Engineer shall be deployed from ICO
side for the supervision, identification of defects and issues the necessary site instruction,
similarly the Contractor technical staff shall be deployed to proceed the works, supervision
and defects rectification. The ICO team shall have approved working drawing in hand.
 Sampling and Testing
 The sampling of all materials as per the ERPS Specification shall be collected and tested in
the laboratory established in the site for this project work and filling system of tested
reports shall be updated accordingly.

5.9 Ancillary Works

5.9.1 Scope of Work

It encompasses the Employer’s Requirements Part-III-2 Performance Specification’s clause 4.6 in

general, this section has mainly discussed the outsourcing construction materials that have been
procured through vendors or suppliers. In this regards the Contractor shall be submitted the
credentials are listed below.
 Credentials of Manufacture/ suppliers.
 Manufacturing test credentials of the materials.
 Quality Control test certificates of Sine Boards (Aluminium Alloy sign plate and Retro
Reflective sheeting) as stipulated ASTM D4956 and ASTM B209.
 Technical Specification of Guard Rails and
 Testing arrangement of the outsourcing materials

Referring documents
 Employer’s Requirements Part III-2 Performance Specifications
 French and European Standards to be respected.

Equipment Details
 Back hoe excavator for excavation of trench, foundation.

43
  Tripper trucks for transportation of fabricated and fabricated materials.
 Concrete mixture with weight batcher having water measuring system shall be used.
Ordinary motorized concrete mixture may be used if the permission given by the Engineer.
 Vibrator both needles and plat shall be used for effective compaction of concrete.
 Water pump if required in the drain out the ground water.
 Crane for lifting and placing of Hume pipe.
 Nails, hooks and props as per required for erection of form works.

Personnel Employed for Execution and Supervision

In leadership of Team Leader, Bridge Engineer, Material Engineer shall be deployed from ICO side for
the supervision, identification of defects and issues the necessary site instruction, similarly the
Contractor technical staff shall be deployed to proceed the works, supervision and defects
rectification. The supervision team shall have approved working drawing in hand.

Sampling and Testing

The sampling of all materials as stipulated the applicable Specification shall be collected and tested
in the laboratory established in the site for this project work and filling system of tested reports shall
be updated accordingly.

5.10 Management and Maintenance Performance Measures

The Management and Maintenance Service Levels required by the Project are divided into four
parts:
1. Road Usability
2. Road User Service
3. Road Durability
4. Management Service.

5.10.1 Road Usability

The usability of the road at all times during the Contract, including before the start of construction of
Improvement Works, during the construction period and after completion of improvements has to
be ensured by the Contractor and inspected by the Construction Supervision Consultant. This
entails that the road must be open to traffic and free of interruptions at all times. Road closures are
only permitted for a maximum of 6 hours in the following cases:
 An accident or breakdown which renders the road impassable to other road users;
 Localized flooding at a bridge or culvert location during the flood event itself (the hours start
from the moment the flood water level recedes below the level of the road);
 A rock falls or landslide which renders the road impassable to road users.
 The inspection for the road usability may be carried by the Team Leader out at any time in
case an obstruction of the road causes non-compliance with the road usability for a period
of greater than 6 hours, a deduction of 20% will be applied to the full monthly payment for
the entire road section under contract This deduction will be repeated for every 24-hour
period in which the obstruction is not removed and road usability is restored.

44
5.10.2 Road User Service Levels
The Contractor is required to maintain the Contract road in compliance with the Service Levels
defined in the Specifications. The road is divided into the following principle elements:
 Carriageway
 Shoulders
 Drainage
 Bridges
 Slopes and Right-of-Way
 Traffic Safety
 For each road element, one or more Performance Indicators are identified. For each
Performance Indicator, one or more Service Levels are specified w h i c h must be complied
w i t h . If a road element develops a defect which brings its condition below t h e Service
L e v e l , then the Contractor h a s to take action t o correct the defect and restore the
Service Level within the time period permitted which forms part of the Service Level.
The tables provided in Annexure 3 define the Services Levels, time permitted for
correction in days and method of measurement. Failure to maintain any specified Service
Level within the time. Permitted is defined as a Non-Compliance f o r which a deduction
will be made from payments t o the Contractor f o r Management a n d Maintenance
S e r v i c e s until the defect is corrected.

5.10.3 Road User Service Levels on the Existing Road before Completion of Improvements
The Cont ract or i s required t o maintain t h e existi ng g r a v e l r o a d i n c l u d i n g t h e r o a d
sections under construction and diversion routes at a reasonable Service Level for road users
until the construction of improvements is completed. The Performance Indicators and Service
Levels follow the same rationale as those specified for the improved road, including deductions
from payments for non-compliance but the number of Performance Indicators is smaller and the
Service Levels are lower as shown in Annexure 5

5.10.4 Road User Service Levels after Completion of Improvements

The Contractor is required to maintain the road after completion of construction to standard
which ensures that road users (motorized vehicles, non- motorized vehicles and pedestrians)
o b t a i n the full benefits of the improvements i n terms of increased safety. Increased comfort,
reduced travel times and reduced vehicle operating cost. These objectives shall be achieved
through maintenance of the road elements as specified in Annexure 5.

5.10.5 Road Durability

The following Road Durability Performance Measures apply to the project:
 Road roughness
 Road deflection
Rutting and pavement width are also Durability performance indicators but these are included in
Road User Service.

5.10.6 Road Roughens

The Contractor is responsible for ensuring that the road roughness is within the Service Levels
described below.

45
a) Measurement
The Team Leader will measure the road roughness in terms of the International Roughness Index
(IRI). The Contractor will be informed in advance and invited to attend all measurements. The
Contractor shall provide a Class 1 precision Roughness Profilometer according to the specifications
as defined by EN 13036-5, and calibrate/validate and maintain it as per the manufacturer's
requirements. The Evenness shall be calculated, in 50 m intervals in each direction and on average
calculated for each 1 km section of the road.

b) Service Levels
The average roughness over 1 km section of road in both directions based on the roughness of100 m
sections must be less than or equal to the IRI values shown in the table in Annexureure3. The
maximum roughness in any 100 m section must be less than or equal to the IRI values shown in table
in Annexure 5 otherwise the 1 km section is Non-Compliant and subject to a deduction for the
monthly lump payment until it is corrected. Measurements are made following completion of
construction and at the annual anniversary of completion of construction. The Service Level permits
a reasonable increase in roughness over the period of the contract as shown in the table in
Characteristics Specifications Test Rate
Evenness test according to the test method LPC Short wave bond Psw≥6
n046-2 July 2009 or EN 13036-5 inspection lot Medium wave bond Pnw≥6,Long
1000ml wave bond Plw≥5

5.10.7 Non- Compliance

Where the pavement deflection limits for new construction are exceeded and other site Specific
Quality Control or Assurance tests have identified construction related Non Compliances, then
the Employer may request the Contractor to reconstruct the non- complying pavement section.
Alternatively, the Employer may, at their sole discretion, calculate the expected reduction in
pavement service life and an adjust price to be paid to the Contractor that reflects the reduced
value of the new asset to the Employer. The Contractor is responsible for ensuring that the average
road deflection of any one road section is below the threshold values given in the table in Annexure
5,
5.10.8 Management Services
Performance Indicator Compliance
a) Initial Contract Area a) 28 days from start date – reduction for Non-
Condition r eport compliance 5%
b) Inception r e p o r t b) 42 days from start date – reduction for Non-
c) Performance Measures compliance 5%
Compliance report c) 7 days from each month end – reduction for Non-
d) Monthly report compliance 5%
e) Final Design report d) 14 days from each month end – reduction for Non-
f) Pre-Construction report compliance 5%
g) Post-Construction report e) 30 days after completion of design of last road section
h) Inventory Report —reduction for Non-compliance 10%
i) End of contract handover f) 30 days before programmed start of construction –
report reduction of Non-compliance 5%
j) Final contract report g) 60 days from substantial completion-reduction for

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 k) Program of performance Non-compliance 20% and withhold 50% from
and initial annual report payments for Improvement Work against non-
l) Agreed additional works submission and non-finalization of “as built drawings”
program h) 365 days before fro start date- reduction for non-
m) Project management compliance 5%
facilities i) 30 days before scheduled completion date –
n) Design quantity reduction for Non-compliance 20%
management plan and j) 90 days after completion date – reduction for Non-
construction quality compliance 20%
management plan k) Initial programme 28 days from start date, annual
o) Contract Quality update three year rolling programme in monthly
Assurance management report corresponding to year end–reduction to Non-
plan including: compliance 10%
 Traffic management l) 7 days from Employers notice to proceed – reduction
plan for Non-compliance 5%
 Environment and m) Temporary facilities 28 days from start date.
social management Permanent facilities to be handed over in 120 days for
plan start of work (refer item 8 of addendum 1)
 Health and safety Establishment of laboratory 120 days from start date
management plan – reduction for Non-compliance 205
 Emergency n) With inception and partial design report –reduction
procedures plan for Non-compliance 5%
p) Traffic management o) With inception report – reduction for Non-compliance
plan, health and safety 5%
management plan, and p) Full implementation of the plan – reduction for Non-
emergency procedure compliance 5%
plan q) Full implementation of the plan including restorations
q) Environment and social of barrow areas and quarries – reduction for Non-
management plan compliance 20%

5.11 Inspection of Service Levels by the Team Leader

5.11.1 Formal Inspections of Service Levels
Formal inspections will be scheduled in advance by the Team Leader, and will be carried out by
the Contractor (through his Self-control Unit) under the supervision of the Team Leader. The
main purpose of the formal inspections is to enable the Team Leader to verify the information
presented in the Contractor's Monthly Statement and to certify payment. The Team Leader
would inform the Contractor of his intention to carry out a formal inspection at least 48 hours
in advance, indicating the exact date hour and location where the formal inspection is to
begin. The Contractor is obliged to be present at the date, hour and location specified by the
Team Leader, providing the physical means needed for the inspection as indicated further below.

The formal inspections would allow the comparison of the information on compliance provided by
the Contractor in the standard tables which are part of his Monthly Statement, with actual
measurements taken in locations to be determined by the Team Leader.

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5.11.2 Informal Inspections of Service Levels
The Team Leader may carry out informal inspections of Service Levels as part of his general
mandate given to him by the Employer. He may do so on his own initiative, at anytime and
anywhere o n the roads included in the contract. He must use his own means for those
inspections. If he detects any road sections where the Service Level criteria are not met, he is
obliged to inform the Contractor within 24 hours in writing, in order to enable the Contractor to
take remedial action as soon as possible. The results of informal inspections may not be used by
the Team Leader for purposes of correcting the Contractor's monthly statements or applying
penalties or liquidated damages, except for cases in which the road has been completely
interrupted and the criteria of Road Usability has not been met.

5.12 Design Proof Checking Engineer

This project will be executed based on EPC basis & will be managed by the Contractor with following
procedure:

5.12.1 Contract Review

Contract review will be carried out at regular basis with the support of Design team and Site
execution team engaged by Contractor. The review will comprise the following:

5.12.2 Design Work

Contractor will provide the minimum specified pavement Thickness and depending on the sub
grade soil strength contractor will recommend and apply the necessary pavement layers to
adequately address the stated requirements. Contractor will design maintenance works which
provides the required outcome yet provides an advantage to the Employer, the Road User and
the Contractor in terms of enhanced performance (increased lifecycle), construction
timeframes, and/ or Environmental considerations. The Contractors Design will also provide
widening of the Road to Comply with Road types R60 in G a b o n Geometric Design Manual
and the Minimum design criteria's. In case of discrepancy between the various Design Criteria,
each particular case will be discussed and justified and presented to the ICO for approval.
The Contractor is solely responsible for completing the detailed Design for the Improvement
Works and Maintenance Works in accordance with the intent of the Contract and the scope of the
Conceptual Designs. This includes, Route selection, Topography Survey, geometrical Investigation,
geometrical Design, Geometric and Pavement Design Resettlement Action Plan, Bridge Design,
Assessments of existing Structures and Design of strengthening Works, Bridge Construction and
Rehabilitation, Culvert Design, retaining wall Design, Permanent Signing, Pavement Marking,
Routine maintenance, as require, period maintenance to comply with the required service life for
the pavement. Design Document and record drawings of as built plans.

5.13 Project Control and Administration

This project will be executed based on EPC basis & will be managed by the Contractor with following
procedure:

5.13.1 Contract Review

Contract review will be carried out at regular basis with the support of Design team and site
execution team engaged by Contractor. The review will comprise the following:

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5.13.2 Design Work
Contractor will provide the minimum specified pavement Thickness and depending on the sub
grade soil strength contractor will recommend and apply the necessary pavement layers to
adequately address the stated requirements. Contractor will design maintenance works which
provides the required outcome yet provides an advantage to the Employer, the Road User and
the Contractor in terms of enhanced performance (increased lifecycle), construction
timeframes, and/ or Environmental considerations. The Contractors Design will also provide
widening of the Road to Comply with Road types R60 in G a b o n Geometric Design Manual
and the Minimum design criteria's. In case of discrepancy between the various Design Criteria,
each particular case will be discussed and justified and presented to the Team Leader for approval.

The Contractor is solely responsible for completing the detailed Design for the Improvement
Works and Maintenance Works in accordance with the intent of the Contract and the scope of the
Conceptual Designs. This includes, Route selection, Topography Survey, geometrical Investigation,
geometrical Design, Geometric and Pavement Design Resettlement Action Plan, Bridge Design,
Assessments of existing Structures and Design of strengthening Works, Bridge Construction and
Rehabilitation, Culvert Design, retaining wall Design, Permanent Signing, Pavement Marking, Routine
maintenance, as require, period maintenance to comply with the required service life for the
pavement. Design Document and record drawings of as built plans.

6 Acceptance Criteria
6.1 Request for R eview
As mentioned in method statement the contractor, in the approved format, shall submit the
Inspection summary, 24 hours prior to execution of each and every activity or related activity
according to the Contract Document. The ICO will assign the Inspection summary to the
respective activity in charge/section head to attend the same. The section head will get the work
inspected and will forward to TL to close it. The Inspection summary will be pertaining to either.
6.1.1 Material and Construction Works
All material brought to site/ construction works executed at site shall conform to relevant codes/ as
per specifications (This has been brought in various method statements). Material and related
items of works shall be tested at regular frequencies as specified. Materials do not conform to
applicable specifications shall deemed to be rejected and shall be removed from the work site or
as instructed by TL.

6.1.2 Testing
The Tests on executed item of work I workmanship shall be conducted as per quality testing
plan. The testing result shall be duly combined and submitted to TL as per requirement. Only
those test results that are not accepted by TL, contractor shall be resubmitted after carryout
rectification as directed or remove unsuitable item of work from site to spoils and replace with
fresh material for further approval.

6.1.3 Surveyor
Survey works for checking layout, levels and benchmarks will be carried out and the works will
be accepted as per the specifications.

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6.1.4 Inspection
Inspection of completed works will be carried out to check if the produced is in conformity to the
specification. Inspection may also be required for the intermediate works before
commencement of the succeeding activity.
6.1.5 Measurement
Inspection summary will also be raised by the Contractor for measurement of works of the
completed works or before dismantling of existing structure/property for payments.

6.2 Non-Conforming Reports (NCR)

The purpose of NCR is to establish how to control nonconformity that does not conform to specific
requirements of design, drawing, or specification and to prevent them from unintended use or
installation, which occurs at the site during construction. The construction activities carried out by
contractor at site if not conforming based on QAIQC Manual as well as construction drawing, need
remedial measures and corrective action. Employer's Representative/PM shall raise NCR
immediately after finding/observed any defects/discrepancies on the work executed by the
Contractor. NCR (Explanatory Note)
Consultant by means of NCR shall report problems, defects or deficiencies identified during
construction.
NCR shall be raised in duplicate as per the form B of Annexure 3 indicating the,
 Description of Non conformity
 Reason for Non conformity
 Proposed remedial action
 Proposed corrective action to avoid recurrence
Contractor will receive the NCR with signature of Employer's Representative/PM with date on both
copies. The Contractor shall raise for the rectification of defective work and rectify the defective
work in the presence of the Team Leader/Inspector. On completion of remedial and corrective
action it will be signed by the Construction Supervision Consultant Inspector who has witness the
remedial and corrective action and attach any document like Inspection list that will be ticked in the
respective column and then forwarded to ARE/ME/Respective Engineer for review.
ARE/ME/Respective Engineer if find the remedial and corrective actions are in order, only then it will
be forwarded to PM for closure of NCR and the Original one will be return to Contractor and the
Duplicate NCR shall retain with the Consultant for their record.
In general, deficiencies occur in the following areas:
 Defective construction materials including rejected materials found at site I stock.
Substandard workmanship of construction works at any stage of construction.
 Failure of materials, finished works or structures to meet specified test requirements.
Deviation from approved methodology (method statement)
 Deviation from Drawing
 Use of unapproved machineries and equipment
 Safety issues Environment issues
 Traffic issues

The consultant shall verify the corrective action for its effectiveness before closing out. The
Contractor's Team Leader shall ensure that the NCR is closed out within the agreed time frame
for disposal.

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Defiance in addressing NCR (Preparation of proposed disposition I corrective action) or defiance in
implementation of approved disposition/corrective action within agreed time frame shall lead to
the rejection of non-conformity product.
7 Tests on Completion
7.1 The tests upon completion of the project works are carried out as per the Annexure – D
attached as per Employers requirements Part III.2: Performance Specifications.
(Attached - Annexure – D)

8 Quality Control Tests Performa

8.1 Performance for Site Instruction, NCR, QC Tests and Checklist
The Monitoring Consultant has prepared the Non-conformance format checklist and Site Instruction
delivered to the Contractor for the purpose of maintaining the quality, the individual personnel
those are responsible for specified works in daily inspection they shall be maintained it. However,
the various relevant quality control tests Performa for all related items of works as specified in the
ERA Standard Technical specification and the format of the test reports shall be produced as per the
requirement of test specific in the laboratory.

8.1.1 Quality Control Checklist

Each of the activities performed by the Contractor whether it is performing as per the approved
drawing, Specification shall be confirmed by the Consultant Engineer during the construction time by
filling the checklist as per the convenient of the work gravity by daily/weekly/fortnightly by the
Consultant site personnel. The checklist enclosed in the Annexure-1.
Under the leadership of TL, the special monitoring team has been formed in order to implement and
check the Occupational Health, Safety and Environmental Checklist. Schedule of inspection shall be
carried out every fortnightly. The team members are as follows.
ICO:
1. Team Leader
2. Design Proof Checking Engineer
3. Material Engineer.

Contractor:
1. Road Manager
2. Deputy Manager
3. Safety Expert
4. Quality Assurance Specialist

8.1.2 Site Instruction

The site instruction shall be issued by the Monitoring Consultant site personnel, whereas, they
observed the faulty works. In this regard the Contractor shall be taken initiation to improve the
faulty works and verify to Consultant immediately otherwise it will be non-compliances. The format
of the site instruction enclosed in the Annexure- 2.

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8.1.3 Non-Compliance
However, the Monitoring Consultant site personnel shall be issued the Non-Compliances whenever
they found the works are in substandard, the Contractor shall be rectified the substandard works
within the stipulated response time with satisfaction of Monitoring Consultant representatives. The
Non-compliance form enclosed in Annexure-3.

8.1.4 Survey Strip Layer chart

The form of Survey Strip Chart as attached in Annexure-4. These are extremely important when layer
number with respect to drawing issued is to be checked and vis-a- vis survey work needs to be done.

8.1.5 Management and Maintenance Service Level

The road performance indicator and format for Management and Maintenance Service level are
enclosed as Annexure-5. These are extremely important to check the compliance provided by the
Contractor in the standard tables.

8.1.6 Documentation
Any documentation preparing by Consultant and Contractor shall have the specific standard format,
it shall be included Table of Contents, Abstract/ Executive Summary/ Introduction, the font of the
documents shall be either Arial or Times New Roman and normal font size shall be 12, except some
exceptional condition.

Conclusion

This Quality Assurance Manual has been prepared in order to implement the activities as stated in the
Contract provision and delivering the quality of works. It has prepared based on the Contract Clauses,
and Employer’s Requirements Part III-2 Performance Specifications. It has precisely described the
procedure of major works. Simultaneously, some important checklist formats have been developed to
ensure the quality of works, role and responsibility of Consultant key personnel’s and Contractors also
described in brief.

The Project Road construction, on the basis of (EPC), whereas, the Contractor has the entire
responsibility to perform the quality. The Construction Supervision CICO the Contractor’s process of
executing to make sure that what they are doing adequate and accurate as per SAG Standard
Specification.

However, if any ambiguity or unclear for understanding the Contact Clauses and Specification that will
be made interpretation by the Employer, which will be unanimous.

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 Annexure-01
Inspection Test Plan

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Annexure - 02
Checklists

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 Annexure - 03
Site Instructions

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 Annexure - 04
Non Conformance Report

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 Annexure - 05
Quality Test Formats

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 Annexure - A
Certification of Milestones

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 Annexure - B
As Built Drawings

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 Annexure – C
Basis of Engineering & Execution studies
(VISA Mission)

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 Annexure - D
Tests on Completion

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