Construction of Eleven (11No.

) Dams
ONB No: MWDS/PSU/W/06/2023
MINISTRY OF WATER DEVELOPMENT AND SANITATION
ZAMBIA

METHODOLOGY

By GALNET CONSTRUCTION LIMITED

1.0 MOBILISATION
1.1 GALNET CONSTRUCTION LIMITED’S CAMP
Before commencing any establishment on Site, the proposed layout of GALNET CONSTRUCTION
LIMITED’s offices, stores and services shall be submitted to the client for approval. The client will approve
the layout or otherwise request modifications within five working days after receipt of the proposal. GALNET
CONSTRUCTION LIMITED’s camp shall be kept clean at all times. GALNET CONSTRUCTION LIMITED
Limited's office for this contract will be established to enable us fulfil our obligations under the Contract. We
will be responsible to provide a suitable site for our camp and to provide accommodation for our personnel
and laborers.
The first step during mobilization will be establishing of the GALNET CONSTRUCTION LIMITED’s camp
which will comprise of the following
 Setting up of offices and furnishing them
 Setting up of Tools and Material Storage Shed
 Setting up Equipment/Vehicle service center
 Reinforcing steel Workshop
 Setting up of perimeter boundaries
 Constructing of site toilets
 Setting up project bill boards
 Obtaining permits from authorities
 Fuel Depot

The listed activities will be cardinal as they kick start the whole project. Both plant and personnel will be
brought to site at mobilization stage. List of plant/Equipment and key personnel and the organization
structure are shown below.
GALNET CONSTRUCTION LIMITED shall make own arrangements for accessing electric power, water and
all other services. We understand that no direct payment will be made for the provisional of electricity, water
and other services by the employer. The cost thereof is in the rates and amounts contained in our tender for
the various items of work for which these services are required.
Fuel
In order to ensure the continuity of construction, the storage capacity of the fuel depot will be designed by
GALNET CONSTRUCTION LIMITED. The depot will be located near the main camp.
Security
GALNET CONSTRUCTION LIMITED's shall provide 24hrs security on site for the project duration.

1.2 ENVIRONMENTAL, HEALTH AND SAFETY REQUIREMNETS

We understand that environmental, health and safety are a requirement of this project, that we must conduct
operations in a manner that protects the environment, safety and health of our employees and the general
public. We commit ourselves to ensure compliance with all relevant environment, health and safety
requirement, regulations, policies, practices and procedures. To this effect we shall conform to all the
stipulations as set out in this document an all statutory acts and regulations. Our environment, health and
safety plan shall encompass the following key points;
1. To take reasonable precautions to maintain the environment in the areas of operations
2. To take reasonable precautions to maintain the health and safety of all our employees
3. We shall appoint a qualified accident prevention officer at the Site responsible for maintaining safety
and protection against accidents. The accident prevention officer shall have the authority to issue
instructions and take protective measures to prevent accidents.
4. We shall conduct HIV-AIDS awareness programs via an approved service provider, to reduce the
risk of the transfer of the H I V virus between and among our Personnel and the local community. We
shall also endeavor to promote early diagnosis and to assist affected individuals.

1.3 PROJECT ORGANISATION

We shall constitute an experienced and qualified team to undertake the project. This team will be mandated
to ensure that the project is undertaken within the period in the stated schedule of works. The required quality
standard and workmanship shall be achieved by use of appropriate tools, materials and equipment and
workforce comprising of the following.

1. The Project Manager shall be responsible for overall execution, quality, and safety of the Project.
The PM will review and approve upon satisfaction, the Methodology of Execution for works, to the
required Quality in a safe manner acceptable to all stakeholders.

2. The Site Engineer will be responsible for the execution of the individual activity to the required
quality, in accordance to the Approved Method Statement, in a safe manner acceptable to all
concerned.

3. The Surveyor will be key in ground controls and ensuring the dam is built at the selected location and
to the correct dimensions and height according to the drawings and specifications.
4. The Construction Technician shall ensure that the workforce is aware of procedures of executing the
activity and that the activities are per approved method statement.

Below is the typical organization structure of the project. The project will comprise of several general, Skilled
and operators.

Organization Structure
 Project
Manager

Site
Surveyor
Engineer

Construction
Technician

Artisans

List Plant/Equipment

No. Equipment Type and Characteristics Minimum Number required

1 Excavator 1
2 Water Bowser 1
3 Tipper Truck 3
4 Sheep-foot Roller 1
5 Bulldozer 1
6 Front end loader 1
7 Concrete Mixer 1
8 Surveying Equipment 1 Set
9 Grader 1
10 Field Testing Equipment (Compaction and 1 Set each
Soil Classification)
All the equipment will be mobilized to the project at the same time before the project commences.
2.0 SURVEYING METHODOLOGY
The GALNET CONSTRUCTION LIMITED will engage a specialized private company to carryout soil
investigations and testing.
A topographical survey of the area will also be conducted by surveyors and project levels will be established
that will allow for cuts and fills on the project.

2.1 INTRODUCTION

A clear and adequate survey methodology is important for any Project to attain its stated quality standards
and expectations within time and cost. The Surveyors carrying out various setting out task must be clear of
the procedures to follow to ensure the setting-out is done correctly the first time to avoid costly rectifications
of the works.
This method statement summarizes the method of surveying as will be carried out in the contract for
construction of the Mbaswa Dam.
. The summary includes notes on the process and equipment to be used.

2.2 METHOD

a) General: The following shall be the sequence of operations during the process of surveying on the
above mentioned project.

1. Setting out of works by Surveyor

2. Execution of works by Construction Technician
3. Level checks by Surveyor (advice to Construction Technician if there is need for rectification)
4. Remedial measures by Construction Technician
5. Conformance checks (lot size, finish levels, layer thickness, etc)
6. Submission of finish levels/report to Engineer for approval

b) Survey Instrument/Equipment Maintenance: The equipment used for all survey works i.e. Total
Station, Automatic levels, nylon and Steel Tapes, staff, plumb-bobs, verticality bubbles, etc shall be
checked and adjusted as may be necessary. The equipment shall be serviced by authorized
dealers. A record of instrument/equipment calibration certificates shall be furnished to the Engineer.

c) Carrying out OGL survey to verify existing Ground Levels: The stripped levels or ground levels are
now picked for use on quantity calculation.

d) Setting-out of Levels for earthworks is be done using modern precise automatic levels and staffs
which are in good adjustment. After concreting the bench marks and reference pegs we carry out a
three line leveling so as to have revised levels for use when controlling or checking. Independent
checks are also carried-out on all setting out to ensure that it is error free.

2.3 RECORD KEEPING

Every time a layer is completed, levels are taken and recorded on level check sheets. This is before dumping
for the next layer commences. This way a record is kept of the levels for all subsequent layers done during
construction and these are checked each time a layer level has been attained. These levels are controlled by
the use of boning rods. The levels taken and recorded are then submitted to the Engineers for their record
also. The Surveyor shall keep record of all original field sheets, checks and reduced levels.
3.0 CONSTRUCTION METHODOLOFY

3.1 SETTING OUT OF THE WORKS

The GALNET CONSTRUCTION LIMITED will carry out the transferring the data from the reference beacons
as indicated on the drawings to the Site of Works. The Works shall be set out in accordance with the co-
ordinates, dimensions and levels as shown on the Drawings. The co-ordinates on the drawings are based on
UTM 36S WGS 84 and levels to mean sea level.

GALNET CONSTRUCTION LIMITED shall check the condition and accuracy of all reference and level
beacons and satisfy himself that they have not been disturbed and are true with regard to position and level.
A beacon that has been disturbed shall not be used until its true position and level have been re-established
and the new values have been certified by the Engineer. The GALNET CONSTRUCTION LIMITED shall
thereafter be held entirely responsible for the protection of all reference and level beacons.

3.1.1 SITE CLEARANCE

The dam’s footprint, as well as the borrow areas, shall be cleared of all vegetation, which will be disposed at
a designated spoil site on site.

3.2 SCOPE
This method statement covers the construction, fill and compaction of various zones of the dam

3.3 MATERIALS
GALNET CONSTRUCTION LIMITED shall use the materials as specified in the contract and will conduct
testing to ensure the right materials are used. The material to be used for each zone are
3.3.1 Selected impervious core : Zone I
The selected impervious material in this zone shall consist of cohesive clay/ sandy clay/ clayey sand with a
Plasticity Index (P.I.) of between 8 and 15, with a mean greater than 10. The material shall contain no
pebbles greater than 50 mm. The mean clay content must be more than 15%.
The material shall be obtained from the clayey deposits in the dam basin, indicated as possible clay borrow
areas on the Drawings.

3.3.2 General fill - downstream: Zone II

The material for this zone is generally the same material as that used for the clay core in Zone I. The material
requires no additional selection and the available deposits in the dam basin may be used. No specific grading
requirements are imposed.

3.3.3 Rip-rap : Zone III

The material for this zone shall consist of clayey gravel and rock which can be obtained from the basin of the
dam, the spillway excavation or the rock outcrops around the site or granite quarry. The average rock size
(D50) shall be 200 mm and the maximum rock size (D100) 300 mm.
3.3.4 Gravel capping : Zone IV
The material for this zone shall consist of clayey gravel which can be obtained from excavations in the dam
basin. Between 30 % and 40% of the material must be retained on the 13.2 mm sieve. The plasticity index
must be between 6 and 12.

3.3.5 Chimney and blanket drains : Zone V

The material for this zone shall consist of a clean cohesionless sand (SW/SP material in terms of the Unified
Soil Classification System), a source of which has been identified in the dam basin indicated on the
Drawings.

3.3.6 Topsoil : Zone VI

This zone shall consist of a 150 mm layer of topsoil material which will be excavated in the dam basin or
stripped from the dam footprint prior to construction of the dam wall.

3.3.7 Rock toe : Zone VII

The material for this zone shall consist of hard, durable, well-graded broken rock and gravel with sand,
obtained from the dam basin, the spillway excavation or from the rock outcrops close to the site. 80 % of the
material must be larger than 50 mm with the largest cobble size 150 mm.

3.3.8 Gravel Filter: Zone VIII

This zone shall consist of 19 mm gravel (clean, hard and cohesionless) to be placed at the rock toe to serve
as filter transition material. If this material is not present in the dam basin, this should be imported and
therefore a rate only item was included in the Bill of Quantities.

3.4 SPECIAL CONSIDERATIONS

3.4.1 Settlement allowance
The embankment dam shall be constructed 2% higher than the height above the general ground level to the
theoretical crest level as shown on the Drawings, in order to allow for long term settlement. This shall be
achieved by constructing the slopes 2% steeper than shown on the Drawings.

3.4.1 Preparation of surfaces

The surface on which material shall be placed shall be excavated so that the slopes are not steeper than
1V:1H as specified by specifications. This surface shall be prepared by ensuring that it is cleared of mud, silt
and standing water.
GALNET CONSTRUCTION LIMITED shall remove any unsuitable material that will be found at the founding
depth of the core or pipe trench, these shall be removed by further excavation.

3.4.2 Borrow areas

GALNET CONSTRUCTION LIMITED shall survey the nearby areas for burrow pits of suitable materials. The
burrow pits show be tested to establish suitable materials before being used on the project. The sides of all
borrow areas shall be excavated to a slope of 1V:3H or shallower. No additional payment shall be made for
this.
3.4.3 Compaction
The core zone (Zone I) of the embankment shall be compacted to at least 98% of Proctor density. The other
zones (excluding Zone VIII) to at least 95% of Proctor density. In this case the mean density as determined
from a number of tests shall be higher than or equal to the specified density (95% of Proctor density).
Additionally, no one density may be lower than 90%.
The compaction shall be tested in accordance with the sand replacement method (TMH1 Test Method
A10(a)). Testing with nuclear density testing apparatus may be permitted if it can be shown to be consistent
with regard to field densities and moisture contents when compared to the sand replacement method. This
does not exempt GALNET CONSTRUCTION LIMITED of his responsibilities in terms of Clause 7 of SANS
1200 DE.
The material at the base and sides of the dam basin excavation need not be compacted, but should be
trimmed neatly to the specified slope of 1V:3H or flatter.

3.5 TESTING
3.5.1 Taking and testing of samples
GALNET CONSTRUCTION LIMITED shall for the duration of the Contract conduct density control tests using
a nuclear density testing apparatus with a qualified technician to operate the device. GALNET
CONSTRUCTION LIMITED shall also provide a Calibration Certificate for the device.
GALNET CONSTRUCTION LIMITED may use this device to conduct his routine density control and moisture
content control tests. It does, however, not exempt him from his responsibility to achieve the specified density
and moisture content. GALNET CONSTRUCTION LIMITED shall conduct moisture content control tests in
his laboratory to check the results obtained from the nuclear device.
The frequency with which these routine density and moisture content control tests shall be conducted shall
be, on average, one set per main zone per four layers of placed material at roughly 50 m intervals along the
embankment.
GALNET CONSTRUCTION LIMITED shall make the device available to the Engineer for his control tests
whenever the engineer wants to conduct his own tests.
The costs of any control tests conducted by the Engineer which do not conform to the requirements shall be
for GALNET CONSTRUCTION LIMITED’s account
3.5 PROTECTION AND MAINTENANCE
It shall be ensured that the completed layers are protected against rain and flood water. Maintenance shall
include, the immediate repair of any damage or defects that may occur.

3.6 ROUTINE INSPECTION AND TESTS

The Engineer will do routine inspections and conduct routine tests to determine whether the quality of
material and workmanship provided comply with the requirements of this Section. The test results and
measurements shall be assessed in accordance with the provisions.

3.7 SAFETY, WORKERS AND PROTECTIVE CLOTHING

All works shall overall be supervised by a Site Engineer, who shall ensure that a safe working 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 the public 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 Safety Officer shall conduct regular on-site inspections of works, equipment, tools and personnel. He
shall also hold regular safety meetings with all work groups to discuss and instruct in safety, and shall
produce weekly reports to Management.
Good working and handling practices shall be ensured on site
All workers shall be provided with such protective clothing such as hand gloves, overall suits, boots, reflective
jackets and dust masks.
Only suitable hand tools and devices, free from any defect, shall be used.
Only experience operators shall be used to operate plant and equipment on site.
All detours shall be maintained in serviceable condition.
5.0 CONCRETING METODOLOGY

5.1 INTRODUCTION
This method statement covers the manufacture, transportation, placing and testing of concrete that will be
used on the contract for construction of Mbaswa Dam. The summary includes notes on materials to be used
and their storage, quality of concrete, measurement of materials, mixing, placing and compacting concrete,
falsework/formwork and surface finish, construction joints, curing and protecting concrete, weather
considerations, quality and workmanship, equipment requirements and, safety of workers and protective
clothing.
5.2 MATERIALS
a) Cement:

All cement used on Site shall comply with SANS 50197-1 for CEM I 42,5. From the Zambian market, this
shall either be Portland Limestone Cement from Lafarge or Zambezi Portland Cement.
Cement shall be used in the order in which it is received. GALNET CONSTRUCTION LIMITED shall
always have at its disposal on the Site a minimum stock of cementitious materials sufficient for 2 weeks
normal work and unless approved by the Engineer, cement kept in storage for longer than 8 weeks shall
not be used in the Works. The Contractor shall endeavour to obtain all cementitious materials supplies
from the same factory or source.
b) Aggregates:

Both the coarse (20mm crushed stones) and fine (sand) aggregates shall be of approved quality i.e.
grading and shape, complying with the requirements of SABS 1083 or equivalent and shall fall within set
limits for drying shrinkage in accordance with SABS 836, flakiness Index and Aggregate Crushing Value
as determined by TMH 1 Method B3, and the Fineness Modulus of the fine aggregate.
The aggregates shall be clean and free of dust, clay, organic matter and any other deleterious matter.
c) Water:

Water shall be clean portable fresh water, free from detrimental concentrations of chemicals and organic
impurities such as acids, alkalis, salts and sugar that could impair the durability and strength of concrete
or the imbedded steel.
d) Admixtures

No admixtures or curing agents shall be used in this project without the approval of the Project Manager.
e) Steel Reinforcements:

Mild steel shall be according to SANS 920 - Type A 250 MPa yield and high yield stress steel according
to SANS 920 - Type C, Class 2, Grade 1, 450 MPa yield.

Welded steel fabric for concrete reinforcement shall be according to SABS 1024.
 For each consignment of steel reinforcement delivered to site, the product certificate from a
recognized testing authority shall be submitted to the Client to confirm compliance with project
specifications.

f) Pre-cast Concrete Materials: The following specified pre-cast materials shall be nused in the
project; Standard kerb stones of various specified sizes.

5.3 STORAGE OF MATERIALS

a) Cement: Cement will be stacked closely and neatly (to heights not exceeding 12 bags) in the
storage shed for a period not exceeding 8 weeks. Cement from Lafarge and Zambezi shall
be stacked separately in the order that they are delivered. It shall be ensured that cement
bags are not in contact with the ground or walls of the storage shed.
Cement on site shall be stored covered in strong waterproof fabric sheets or polythene
sheets.
b) Aggregates: The concrete stones (20 mm) shall be properly stored to avoid
contamination.
c) Storage Capacity: Adequate storage for cement, aggregates and water shall be made
available so as to avoid any interruptions to the progress of work occasioned by lack of
materials.
d) Unsuitable Material: Deteriorated, contaminated and damaged materials shall not be used in
any concrete works, but shall be removed from site immediately it is discovered that the
material is unsuitable.
5.4 CONCRETE QUALITY
a) Concrete Strength: The classes of concrete specified in the Contract and our mix
designs are as tabulated below;

Characteristi
Maximum c 28-Day
Clas WATER:CEMEN
Size of Cube
s of Design Application T RATIO
Coarse Crushing
concr Mix Strength
Aggregate
ete (Mpa)
(mm)

Blinding of culvert
10/19 1:4:8 19 10 0.50
bedding
Culvert surround &
15/19 1:3:6 19 15 bedding, Blinding of 048
foundation for bridge
Concrete backfill on
20/19 1:2:4 19 20 culverts, Guide Posts 0.48
and Marker Posts
Culvert toewalls &
keywalls ,Head &
wingwalls, Inlet &
outlet structures;
25/19 1:2:3 19 25 0.46
bridge abutments,
piers, lining for open
drains, backfill below
chutes, edge beams

If there are any changes in the material sources, type or sizes for any constituent material for
concrete, samples, product certificates and a statement of the proposed mixed proportions shall be
submitted for the approval of the Resident Engineer before starting any concrete works.
Product Certificates shall also be submitted for approval for each consignment of cement.
 QUANTITIES: ONE CEMENT BAG MIX

DESIGN QUANTIES/ M³ QUANTIES/ONE BAG MIX

STENGTH
MATERIAL BY WEIGHT BY VOLUME BY WEIGHT BY VOLUME
(Kg) (M³) (Kg) (M³)
SAND 831 0.308 194 0.144
10Mpa STONE 1662 0.615 389 0.288
CEMENT 106 0.077 50 0.036
SAND 405 0.30 146 0.108
15Mpa STONE 810 0.60 292 0.216
CEMENT 138 0.10 50 0.036

SAND 385 0.286 99 0.072

20Mpa STONE 771 0.571 199 0.144
CEMENT 197 0.143 50 0.036

SAND 450 0.333 97 0.072

25Mpa STONE 675 0.500 146 0.108
CEMENT 230 0.167 50 0.036

SAND 369 0.273 73 0.054

30Mpa STONE 737 0.546 146 0.108
CEMENT 250 0.181 50 0.036

SAND 338 0.25 47 0.036

35Mpa STONE 675 0.50 97 0.072
CEMENT 345 0.25 50 0.036

Assumed Densities; Cement 1380Kg/m³ Aggregate – 1350Kg/m³ w/c – 0.4 to o.5

For routine quality control, a minimum of four 150mm x 150mm x 150mm concrete test cubes shall
be sampled for testing for a full days work, as and when required by Resident Engineer. Samples of
 aggregates and concrete cubes shall be taken at random as directed by the Resident Engineer. A
minimum of six steel moulds shall be provided.

5.5 MEASURING OF MATERIALS

The cement and aggregates be used for the concrete works shall be measured by the batch using a batch
box of size 300mm x 300mm x 400mm. Water shall be measured by volume while the reinforcement will be
as per specifications. Cement will be supplied in standard bags, and each bag will be assumed to be 50kg
5.6 MIXING
Concrete shall be mixed by mechanical batch mix and this shall be done with the approval of the Engineer.
The amount of water shall be sufficient to give a good workable mix and produce the specified strength as
described above.
The mixing water for each batch shall be measured, either by mass or by volume accurate to 3% of the
required quantity.
Where damp aggregate is used, the quantity of water added to the mix shall be adjusted to make allowances
for the moisture already in the stones and/or sand.
Discharging of concrete from mixer
Discharge of concrete from mixer shall be carried out at a minimum slope of 1:3 and not exceeding 1:2 to
avoid segregation of materials in the mix. The mixer shall be washed thoroughly before any concrete is
mixed and whenever it is stopped running for more than 30 minutes, to get rid of any built-up material in the
drum, loader and blades. A standby mixer shall be provided whenever it is important for casting to continue
without interruption.

5.7 PLACING AND COMPACTING

a) Placing:Concrete shall be cast in-situ, and deposited vertically whenever possible. Efforts will be
made to place entire thicknesses of slabs and decks in one pass, and whenever necessary,
construction joints shall be formed before placing fresh concrete against the old one.
Steel reinforcements shall be cut and bent to the dimensions specified in accordance with SABS 82.
b) Compaction: Concrete shall be compacted thoroughly, to form a solid mass free from voids,
honeycombing and planes of weakness, by means of a poker vibrator or tamping rods for small
volumes of concrete immediately after placing.

5.8 CONSTRUCTION JOINTS

a) Preparing the surfaces: When the concrete has set, the surface will be roughened and washed with
clean water to remove all dirt and loose material before placing fresh concrete.
b) Placing:The fresh concrete shall be cast directly against the construction joint.

FALSEWORK, FORMWORK AND CONCRETE FINISH

MATERIALS: Generally, the materials used in the construction of falsework and formwork shall be suitable
for the purpose for which they are required, and shall be of such quality as to produce the specified standard
of work.
The timber shall be free from any defects that may prejudice the stability of the falsework.
The boarding for the formwork shall be of suitably dried timber which will not warp, distort or cause
discoloration of the concrete.
Jacks, devices, clamps and fittings shall all be in good working condition, and of adequate design and
strength to ensure safety.
CONSTRUCTION: The falsework and formwork shall be constructed sufficiently rigid and tight and in correct
position, shape and profile in order to avoid undue losses or leakages of the mortar component of the
concrete, and to ensure that the specified dimensional tolerances are achieved when concrete is placed and
compacted.
Prior to placing reinforcing steel and/or concrete, dimensions shall be checked and unevenness of surface
shall be corrected. Special attention shall be paid to adequacy and tightness of all bolts, ties and bracings as
well as to the soundness of foundation.

Notice will be issued to the Resident Engineer 24hrs before placing of concrete for approval.
REMOVING THE FALSEWORK AND FORMWORK: Falsework and formwork shall not be removed before
concrete has attained sufficient strength to support its own weight and any other loads which may be
imposed on it.
Tab 6206/1 to 6203/3 SATCC shall provide a general guidance on the minimum periods of time for specific
situations.
SURFACE FINISHES: It shall be ensured that surface finishes comply with the specified classes. All surface
defects noted after removal of formwork shall be remedied as directed by the Resident Engineer.

5.9 CURING AND PROTECTING

After being placed and compacted in its final position the concrete shall be left undisturbed whilst setting, and
it shall be protected from vibration, loading, traffic or running water for a period of not less than 72 hours after
placing.
The concrete shall be thoroughly cured by being continuously maintained in a moist condition after setting by
means of wet sacking, spraying or other approved means for a minimum period of 7 days. Whenever
necessary, formwork shall be kept in place for a full curing period.

5.10 ADVERSE WEATHER CONDITIONS

a) Cold weather: Concrete shall not be placed during falling and rising temperatures when the
ambient air temperatures are below 7ºC and 3ºC respectively.
b) Hot Weather: Concrete shall not be paced when the ambient air temperature exceeds 30ºC.
5.11 QUALITY OF WORKMANSHIP AND MATERIALS
Routine inspections and quality control shall be done in accordance with the provisions relevant clauses of
section 7200 of SATCC.
5.12 EQUIPMENT
The following equipment shall be made available in good working order;
ITEM DESCRIPTION QUANTITY
1 Excavator 01
2 Tipper 02
3 Poker Vibrator 02
4 Plate Compactor 02
5 Concrete Mixer 02
6 Batch Boxes 06
7 150mmx150mmx150mm Moulds 20
8 Shovels 20
9 Picks 20
10 Wheel Barrows 10
11 20 ltr Container 04
12 Builders Line 02
13 Square 02
14 Spirit Level 02
15 Dumpy Level 02
16 Staff 02
17 Steel Cutter 02
18 Rammers 04
19 Tamping Rods 07

5.13 SAFETY, WORKERS AND PROTECTIVE CLOTHING

Generally all works will be supervised by a Site Engineer, who shall ensure that 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 Safety Officer shall conduct regular on-site inspections of works, equipment, tools and personnel. He
shall also hold regular safety meetings with all work groups to discuss and instruct in safety, and shall
produce weekly reports to Management.
Good working and handling practices shall be ensured on site
All workers shall be provided with such protective clothing such as hand gloves, overall suits, boots, reflective
jackets and dust masks. Where necessary, workers will also be provided with helmets.
Only suitable hand tools and devices, free from any defect, shall be used.
Only experience operators shall be used to operate such equipment, as concrete mixer, compressor, etc.
Falsework, formworks and scaffolding shall sufficiently and rigidly be secured in position before placing of
concrete as described in 8) above.

5.14 PERSONNEL

Working Force
1 Concreting Construction Technician
1 Overseer for each 10 Workmen
1 Concrete Mixer Operator
2 Bricklayers
1 to 2 Steel Fixers
10 to 20 General Workers
2 Traffic Controllers

Plant Operators and Drivers

1 Tipper Truck driver
1 Light Vehicle driver (for Construction Technician or overseer)
1 Water Bowser Driver
6.0 MEDIUM-PRESSURE PIPELINES (SANS 1200 L)

The dam’s outlet pipe shall be 355 mm OD High Density Polyethylene (HDPE) Class PE100 PN6
suitable for butt-welding manufactured complying with SANS 533:1982 and 1995 superseded in parts
by SABS ISO 4427:1996

6.1 Construction

6.1.1 Laying and concrete encasement of pipes underneath embankment.

The outlet pipe underneath the embankment shall be encased in concrete.
The section of the pipe platform below the encasement shall be prepared in accordance with Subclause
SDGA5-1, where after a blinding layer shall be placed true to line and level. The blinding layer shall be
treated as a construction joint and shall be prepared in accordance with SDGA5-7. The outlet pipe shall
be placed on precast Grade 30/19 pedestals or as alternative fixed with wires to fencing standards and
the reinforcement cage.
The pipes shall be anchored and filled with water to prevent the pipes from floating during concreting.
Concrete shall be placed from one side of the pipe only and shall be worked to the other side until the
bottom third of the pipe circumference is in contact with the concrete bed.
The concrete shall preferably be cast without interruption, but if this is not possible, a vertical
construction joint shall be made at a pipe joint.
The concrete shall have reached 80% of its specified strength and be covered with at least 300 mm of
soil before construction plant will be allowed to drive over the encasement.

6.1.2 Testing
6.1.2.1 General
All pipes shall be hydraulically tested after their installation but prior to their encasement. The pipes
under the dam wall shall be retested hydraulically 7 days after the pipe encasement has been
completed.

6.1.1.2 Test pressure and time of test

Except that the test pressure shall not be less than 6 bars, the Contractor shall carry out testing as
detailed in Clause 7 of SANS 1200 L.

GALNET CONSTRUCTION LIMITED shall:

  give the Engineer 48 hours notice before conducting a test;
 pressurize the pipeline and keep it at the required test pressure for 2 hours before the test;
 be present during the test;
 be responsible for providing temporary valves, end caps, blank flanges or other isolating
devices to complete the testing.

PROJECT COMPLETTION
GALNET CONSTRUCTION LIMITED shall upon completion conduct a comprehensive completion
survey of the Mbaswa Dam, its spillway, roads, outlet works and dam basin, which shall link into the
existing survey everywhere where construction activities have disturbed or changed something. This
survey shall be sufficiently detailed to provide a 0.5 m contour interval on the dam wall and a 1 m
contour interval in the dam basin. Details concerning all structures constructed as part of the Contract
shall be provided. The survey shall be submitted in *.xyz format with “break lines” to be utilised in Civil
3D, as well as a contour plan in *.dwg format (AutoCAD 14 or later version).