Surfacing Methodology
UPGRADING OF APPROXIMATELY 104KM OF ROAD D104/D791 CHIPATA TO MFUWE IN EASTERN PROVINCE SURFACING PLAN
1.0 INTRODUCTION This method statement covers materials, construction plant, construction method and other general requirements common to the construction of the double seal surface dressing specified in this contract. 2.0 MATERIALS
The following materials shall be made available and used on the project as specified. (i) (ii) 80/100 penetration grade bitumen Aggregates 13.2mm for first seal and 6.7mm for second seal
The aggregate shall be tested and approved for grading, hardness, shape, 10% FACT and flakiness. 3.0 3.1 PLANT AND EQUIPMENT General The following equipment shall be made available and in good working order:(i) (ii) (iii) (iv) (v) (vi) 1 No. 2 No. 2 No. 1 No. 2 No. Hand Bitumen distributer Chip Spreaders with spreading widths of 3.5m Pneumatic -tyred Rollers each of about 20 ton weight Rotary broom First Aid Kits for dealing with bitumen burns, etc brooms where mechanical brooms might not work
Prior to the surfacing operation, all the equipment shall be jointly inspected with the Engineers Representative to ensure that it is good working order. No equipment identified with oil and/fuel leaks shall be used in the operation until the defect is rectified. 4.0 WEATHER LIMITATIONS AND REQUIREMENTS (a) Weather limitations
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Surfacing Methodology
(a)
80/100 penetration grade bitumen will be sprayed at a minimum surface temperature of 25C. No bituminous work shall be done during foggy or rainy weather. No sealing works shall be done when strong winds are blowing which are likely to interfere with the proper execution of the work. All spraying shall be programmed to cease each working day at 15:00 hours during cold periods and 16:30 hours in hot times. The gun thermometer shall be available to check the surface and atmospheric temperatures Moisture content Since sealing is only supposed to be done when the moisture content of the upper 50mm of the base is 50% of the optimum moisture content, no surface dressing shall be done immediately after a rainy spell.
5.0
PREPARATION OF AREAS TO BE SEALED The areas to be sealed shall first be checked for compliance with the surface tolerances and all other requirements specified. Any portions that do not meet these requirements shall be corrected before they are sealed. The surface, having been checked or corrected for compliance, shall then be cleaned of all dust, dirt, dung, oil or any other foreign matter that may be deleterious. Prior to the surfacing operation, the Engineers Representative shall be invited to approve the prepared section.
5.1
Setting out and demarcation of working areas - The outer edge of the road shall be marked with white paint using a 3 mm thick sisal or hemp twine, secured by nails driven into the existing surface at 15 m intervals on straights and 5 m intervals on curves. On super-elevation a small soil windrow shall be applied on the inner side of the curve to stop spillage.
5.2
Tolerances and Finish Requirements Firstly before the surfacing operation it shall be ensured that all requirements relating to the primed base on which the seal is constructed are within specification in terms of level and grade, width, cross section and surface regularity. Secondly, it shall be ensured that the actual spray rates measured at spraying temperature of tack coat, does not deviate from the required spray rate as specified by more than 0.06 ltr/m 2. The application rates
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Surfacing Methodology
for tack (13.2mm) stones and seal (6.7mm) stones shall be maintained within the ranges of 11 to 15 Kg/ m 2 and 9 to 13 Kg/m2 respectively as advised by the Engineer. Lastly, the completed seal shall be free from corrugations or any other wave effect, and any areas which show signs of bleeding after the section has been opened to traffic shall be corrected as directed by the engineer. 6.0 HEATING AND STORAGE OF BITUMINOUS BINDERS The 80/100 penetration grade bitumen binder shall be heated to a temperature between 165C and 190C but kept within the average of 175C as per specifications. Every effort shall be made to maintain the binder temperature for spraying to within 5C of the recommended temperature of 185C. 7.0 7.1 STOCKPILING OF AGGREGATE General Sites for the stockpiling of aggregates shall be prepared in such a manner that no grass, mud, dirt or other deleterious material will be included when the aggregates are loaded for use. Where stockpile sites are not close to the paved or well watered road, the access roads shall be prepared and maintained in such a way that no dirt is conveyed by vehicle wheels onto the areas to be sealed whilst aggregate is being transported to or from the stockpiles. Stockpiles shall be so sited that they will not be exposed to excessive contamination with dust arising from traffic on the road or access roads. 7.2 Precautions Temporary diversions and access roads in the immediate proximity shall be watered. During the wet season when there is danger of soaking the aggregate, the stockpiles shall be covered with tarpaulins or similar protective coverings. 8.0 8.1 CONSTRUCTION OF SURFACE DRESSING Binder Application - Where the tank of the binder distributor could become empty during spraying against inclines, the spraying shall be done while the binder distributor is moving uphill. In the event that the spraying has to be carried out in adjacent strips, the spraying shall overlap by 100 mm. Chips may not be placed on the 100 mm overlap before the adjacent strip has been sprayed. The adjacent strip will not
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be sprayed before the preceding strip (excluding the 100 mm overlap) has been covered satisfactorily with chips. 8.2 Application of Aggregates - Immediately after the binder has been sprayed, it shall be covered with clean, dry 13.2mm aggregate for the first seal and 6.7mm aggregate for the second seal. The aggregate so applied shall be free of dust or within minimum specified dust content of 0.5%. The aggregate shall be applied uniformly by means of mechanical chip spreaders. The chip spreaders shall be so operated that the binder shall be covered with aggregate before the wheels of the chip spreader or truck pass over the uncovered binder. To ensure optimum application of both binder and aggregate, minimum dry runs of 15m and 5m for the Binder Distributor and Chip Spreader respectively, shall be maintained as advised by the Engineer. The chip-spreader shall be thoroughly checked and cleaned of any settled fines every after 5 km of single surfacing operation to ensure consistency in the spreading rates of aggregate. 8.3 Initial rolling of aggregate - Immediately after the aggregate has been applied, rolling shall be commenced using two (2) No. selfpropelled 20 tonnes pneumatic (rubber tyred) rollers. Rollers shall operate parallel to the centre line of the road, from the shoulders inwards towards the crown of the road, until the entire surface has been covered at least three times with the wheels of the roller. Broom drag and final rolling of aggregate - After the bituminous binder has set-up sufficiently to prevent any aggregate from being dislodged, the surface shall be slowly broomed with a drag broom to ensure even distribution of the aggregate. If there are areas which are deficient in stone chips, additional material shall be added by hand so as to leave a single layer of chips lying shoulder to shoulder. If there are areas with an excess of stone chips, such excess shall be removed by hand so as to leave a single layer of chips lying shoulder to shoulder. There shall always be a follow-up team of at least 5 general workers to ensure that the surface is free from foreign particles and that the aggregate is well distributed in a single layer. After completing the spreading of the aggregate, the surface shall be rolled with a 20 ton pneumatic roller for a minimum three to four passes. All aggregate contaminated by fuel, oil or grease shall be removed and replaced with clean aggregate. 8.5 Joints between binder sprays - In order to prevent overlapping at junctions of separate binder applications the previous work along the
8.4
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Surfacing Methodology
joint shall be covered with appropriate material for a sufficient distance back from the joint to ensure that the sprayer is operating at the required rate before the untreated surface is reached, and also to prevent additional binder application onto the previously treated section. The same method shall be used to ensure a neat joint at the end of the run. 8.6 Protection of kerbs, channels, etc - Kerbs, channels, guttering, manholes, guard rails, bridge railings and any other structures which may be soiled by the binder during spraying operations shall be protected during spraying operations. DUST CONTROL Any temporary diversions and construction roads shall be kept watered and damp during surface dressing operations and all dust shall be removed from surfaces before any binder, aggregate or slurry is applied. 10.0 OPENING TO TRAFFIC The road shall not be opened to traffic until the binder has set sufficiently to retain the aggregate. No construction equipment which is likely to cause damage to the surface dressing shall be allowed access to the completed sections. Speed restriction signs shall be placed in accordance with the specifications in order to limit traffic speed on newly surfaced sections. Prior to opening the surfaced section, a formal request for final inspection and approval shall be made to the Engineer. 11.0 CONSTRUCTION 11.1 Second application of bituminous binder and Aggregate The second application of binder and aggregate shall preferably take place within 48 hours of the application of the first seal at the rate specified in the contract specifications. 11.2 Rolling - the initial rolling, brooming/ dragging and final rolling of second layer of aggregate shall be carried out as stated above. In favourable conditions, since adhesion is expected to be well established within 30 minutes of rolling, slow moving traffic, particularly heavy Lorries, will be allowed to traverse the dressing at traffic speeds of 20 to 30 km/hr. 12.0 PLANNING
9.0
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Surfacing Methodology
The following shall be the sequence of events for the surface dressing operation: o o o o o o o o A length of road requiring surface dressing shall be selected and indicated on the weekly program or communicated verbally where there is a sudden change of programme. Where there is need, we shall carry out patching, shoulder and edge repairs, drainage works, reinstatement of service trenches etc. Signage will also be prepared and the heating of the bitumen will commence a night before. All quality control measures i.e. tests on aggregates, binders etc will be confirmed We shall ensure chippings are stockpiled at convenient points along the road to be surface dressed to minimise haul distances during construction. All plant and equipment shall be inspected to ensure that the unit is in good working order. The Construction team shall be instructed of the details of the work programme through copies of weekly programs. Inform the Materials Laboratory and arrange for the testing of aggregates and binder and rate of spread checks during spraying.
12.1 The surface dressing operation The following is a summary of the surface dressing operation: i. ii. The temperature in the depot tanks is raised starting early the day before chipping in readiness for loading the distributor with bitumen. The temperature will be just above 185C. On the day of chipping, it shall be ensured that a safe environment is always maintained, and that on-site safety procedures are followed at all times. The Site Engineer shall see to it that adequate measures are taken to warn and protect road users and construction workers. He shall instruct all supervisors and foremen in safety measures including traffic control and use of clean standard temporary road signs. The surfacing foreman shall ensure all workers are provided with adequate safety gear, and that there are good working and handling practices on site all the time. He will ensure there is traffic control equipment and will supervise the placing of warning signs, control barriers, traffic cones, etc. iii. The surface dressing unit will then arrive on site and the distributor is parked off the road, preferably on a level site
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iv. v. vi. vii. viii.
ix. x. xi. xii.
xiii. xiv. xv.
xvi. xvii.
where the tank can be 'dipped' before and after spraying. If the parking area is not level, an alternative site will be located. Whilst the binder temperature is adjusted using the burners; binder is circulated through the spray bar, and the jets are checked for correct operation. The calibrated 'dip-stick' supplied with the distributor is used to measure the volume of binder in the tank at the start of the day's work. The Foreman will instruct the distributor crew on the spray rate required, the corresponding road speed and the pump output, where this is necessary. The tipper Lorries with chippings line up ready to follow the distributor at the location specified by the supervisor. The rollers also prepare to follow the distributor after the chipping Lorries. The foreman will ensure the road is thoroughly swept and road furniture such as manhole covers, reflective studs etc, is masked so as to prevent contamination with binder. He shall also ensure that the number of tippers used, cycle time for front end loader, spray lead time for bitumen distributor and, chip spreader to tipper truck changing time, are all harmonized so as to avoid drop in temperatures of applied binder in excess of 10% resulting from extended exposure times. Cut-off sheets of paper or other material are placed at the beginning and end of the spray run. The foreman checks that laboratory staffs are present and ready to do tray tests. The burners on the distributor are extinguished and the distributor is positioned at the beginning of the spray run. The distributor then commences the spraying run, the cut-off sheets being removed immediately the distributor passes to avoid contamination of the wheels of the chip spreader. The chip spreader and the rollers will then follow closely behind the distributor. Spraying will be stopped if the chipping operation is delayed for any reason. A strip of binder 150mm wide will be left un-chipped at the edge of the lane to allow for the overlap of the adjacent run of the distributor. A tipper and crew will then move slowly over the new dressing, spreading chippings by hand shovels on areas where there is a deficiency of chippings. The operation is then repeated on the adjacent pass. The distributor will then return to the original level parking site and the volume of binder remaining in the tank checked with the 'dip-stick'. The foreman records the amount of binder used and, knowing the total area sprayed, calculates the average rate-ofspread. Speed control and other traffic warning signs are left in position along the length of the new surface dressing. At the completion of the day's work the distributor spray bar will be cleaned, all vehicles and plant refueled and lubricated and
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the foreman checks that the bitumen heaters are loaded ready to supply the binder required for the next day. xviii. The surfacing checklist shall jointly be checked by the Surfacing Foreman and engineers Representative, before, during and after all surfacing operations. 12.2 After-care After-care will consist of removing excess chippings within 24 to 48 hours of the construction of a dressing. The chippings will be removed by brooming and care taken with brooming to avoid damage to the new dressing. The brooming will preferably be done in the early morning when the surface dressing binder is still relatively stiff.
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