MST-06029 - 0D - Method Statement Cement Treated Base Mixture-Word

0D 25/01/23 Review following comments FLR FLR JRO
0C 18/12/23 Review following comments FLR FLR JRO
0B 03/11/23 Review following comments FLR FLR JRO
0A 09/10/23 Internal review FLR FLR JRO

Issued Checked Approved
Rev. Date
Purpose Description of revision Visa Visa Visa
nn dd/mm/yy (Originator) (Discipline) (Project)
Employer:
CONTRACTOR:
Project name:
Nectar Bulk Terminal Berth Extension

Freetown, Sierra Leone
Document number (CONTRACTOR's codification): Rev. Format
2 0 8 9 1 3 E G C MM A R C O N M S T 0 6 0 2 9 0 D A4
Document title:
METHOD STATEMENT – CEMENT TREATED BASE MIXTURE

Company’s or other entities documents No.: Sheet:
1 / 36
The disclosure of this document by EIFFAGE GENIE CIVIL MARINE confers no proprietary rights on the reader or use
Any information contained hereto is the property of EIFFAGE GENIE CIVIL MARINE and shall not be disclosed and/or communicated to third parties without EIFFAGE GENIE CIVIL MARINE express consent.
NECTAR BULK TERMINAL BERTH EXTENSION Date : 25/01/23
FREETOWN, SIERRA LEONE

Rev. : 0D
WORK METHOD STATEMENT CEMENT TREATED BASE
MIXTURE
208913 EGCM CIV CON MST 06029 Page : 2/28
Réf. Unit/Subunit Type of Sequent.
Job code Origin Discipline
code document Number
TABLE OF CONTENT
1. INTRODUCTION ................................................................................................................................................... 4
1.1 PROJECT OVERVIEW.................................................................................................................................................. 4
2. PURPOSE OF THE DOCUMENT ............................................................................................................................. 5
3. REFERENCE DOCUMENT ...................................................................................................................................... 6

3.1 CONTRACT DOCUEMENTS .......................................................................................................................................... 6
4. RESSOURCES ....................................................................................................................................................... 7
4.1 CIVIL WORKS EQUIPMENT ......................................................................................................................................... 7
4.2 SURVEY EQUIPMENT................................................................................................................................................. 7
5. WORKFORCE ....................................................................................................................................................... 8
5.1 ACCESS AND CIRCULATION ......................................................................................................................................... 8
5.2 PAVEMENT STRUCTURE ........................................................................................................................................... 10
5.3 PLATEFORM ORGANISATION ..................................................................................................................................... 11
6. WORK PHASES ...................................................................................................................................................11
6.1 SUBGRADE COMPACTED SAND (CBR>5%) .................................................................................................................. 12
6.2 GRADED CRUSHED ROCK.......................................................................................................................................... 12
6.3 SUBGRADE LAYER CONTROL...................................................................................................................................... 13
6.3.1 Altimetry control ....................................................................................................................................... 14
6.3.2 Bearing capacity ....................................................................................................................................... 16
6.4 FIRST LAYER OF CEMENT TREATED BASE MIXTURE.......................................................................................................... 17
6.4.1 Mixing in place .......................................................................................................................................... 17
6.4.2 Grading and compaction........................................................................................................................... 20
6.4.3 Curing ........................................................................................................................................................ 22
6.5 SECOND LAYER AND THE THIRD LAYER OF CEMENT TREATED BASE MIXTURE........................................................................ 22
7. APPENDIX ..........................................................................................................................................................22
7.1 APPENDIX N°1: RISK ASSESSMENT CEMENT TREATED BASE MIXTURE .............................................................................. 23
7.2 APPENDIX N°2: INSPECTION AND TEST PLAN ............................................................................................................... 24

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LIST OF FIGURES
Figure 1: Freetown Location ............................................................................................................................................... 4
Figure 2: Queen Elizabeth Quay - Site Location .................................................................................................................. 4
Figure 3: General Layout ..................................................................................................................................................... 5
Figure 4: Circulation Plan .................................................................................................................................................... 9
Figure 5: Pavement structure ........................................................................................................................................... 10
Figure 6: Results on CBMG ............................................................................................................................................... 10
Figure 7: Progression of works ......................................................................................................................................... 11
Figure 8: Example of layout point grid .............................................................................................................................. 12
Figure 9: Layer of 0-100m graded crushed rocks.............................................................................................................. 13
Figure 10: Extract from the design of concrete pavement and supplementary report.................................................... 13
Figure 11: Extract from the structural design of Heavy duty pavements for ports and other industries ........................ 14
Figure 12: 2D Laser ........................................................................................................................................................... 15
Figure 13: Example of layout paint grid ............................................................................................................................ 15
Figure 14: plate Test being performed ............................................................................................................................. 16
Figure 15: Additional compaction of subgrade layer ........................................................................................................ 17
Figure 16: Surveyors controlling of 0/40mm layer ........................................................................................................... 18
Figure 17 : Spreading of cement on site ........................................................................................................................... 18
Figure 18: Cement spread on top of the 0/40mm ............................................................................................................ 19
- Figure 19: Mixing with the grader ............................................................................................................................ 20
Figure 20: Grader .............................................................................................................................................................. 21
Figure 20: Drum compactor .............................................................................................................................................. 21

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1. INTRODUCTION
1.1 PROJECT OVERVIEW

The Nectar Bulk terminal Berth Extension project (hereafter the “PROJECT”) consists in the construction of a new berth
extension at Nectar bulk terminal, Nectar Sierra Leone Bulk Terminal (NSBT), at the Queen Elizabeth II (QE II) Quay,
located at Fourah Point, on the northern side of the Freetown peninsula (Sierra Leone) between Destruction Bay and
Cline Bay.
The facility currently has a main quay wall of 500m length spanning from east to west. The general site location can be
seen in Figure 2 (hereafter the “PROJECT’s SITE”.
Figure 1: Freetown Location
Figure 2: Queen Elizabeth Quay - Site Location

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The aim of the PROJECT is to provide greater berthing capacity with the construction of a new berthing structure. The
new structure will include:
 Main berth wall of approximate 230m, to accommodate a maximum size vessel of 225m (Panamax);
 Dredging of berth to a depth of -13mCD;
 Onshore mooring blocks, to moor the mentioned vessel;
 Land reclamation, to increase the landside area available for use by the Client; and
 Pavement and drainage to remove surface and subsurface water.
Figure 3: General Layout
2. PURPOSE OF THE DOCUMENT

This Method Statement aims to provide a description regarding the realisation of the cement treated base mixture,
setup of used equipment and possible methods on the Nectar Bulk Terminal Berth Extension of Freetown, in Sierra
Leone

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3. REFERENCE DOCUMENT
3.1 CONTRACT DOCUEMENTS

Ref. Number of document Rev Title
1 2023-BRL-05-PVM-DR-C-6000 P04 PAVEMENT PLAN
2 2023-BRL-05-PVM-DR-C-6001 P05 PAVEMENT SECTIONS AND DETAILS
3 2023-BRL-05-DRG-DR-C-7000 P05 DRAINAGE PLAN
4 2023-BRL-05-DRG-DR-C-7001 P05 DRAINAGE SECTIONS AND DETAILS– SHEET 1
5 2023-BRL-05-DRG-DR-C-7002 P05 DRAINAGE SECTIONS AND DETAILS– SHEET 2
6 2023-BRL-05-DRG-DR-C-7010 P05 DRAINAGE PRE-CAST SECTIONS AND DETAILS
7 2023-BRL-05-EL-DR-C-9000 P02 ELECTRICAL DISTRIBUTION PLAN
2023-BRL-05-EL-DR-C-9001 P01 ELECTRICAL MANHOLE GENERAL ARRANGEMENT
8 2023-BRL-05-XX-SP-C-1010 P01 Pavement

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4. RESSOURCES
4.1 CIVIL WORKS EQUIPMENT

The following table indicates the equipment that will be employed by EIFFAGE Genie Civil Marine SLE for installation
of the capping beam:
EquipmentE Pictures
Weigth : 12T
- Grader Length of grader blade
3.66m
Weigth : 22T
- Drum compactor Vibration Frequency :
29/35 hz
- Water Bowser
4.2 SURVEY EQUIPMENT

Equipment Pictures
- Total station

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- Automatic level
- Reflective survey target
5. WORKFORCE
The following table indicates the resources that will be employed by EIFFAGE Genie Civil Marine SL per shift
Team per shift

- 1 surveyor
Subgrade layer control
- 2 laboratory assistant
- 1 Foreman
Sand laying - 5 labourers
- 2 operators
- 1 Foreman
0/40 mm laying - 5 labourers
- 2 operators
- 1 Foreman
- 2 laboratory assistant
Realization of the gride and cement
- 1 surveyor
spreading
- 10 labourers
- 2 operators
- 1 Foreman
Premixing - 5 labourers
- 2 operators
- 1 Foreman
Cement spreading - 5 labourers
- 2 operators
- 1 Foreman
Mixing - 5 labourers
- 2 operators
- 1 Topographic engineer
Topographic survey team
- 4 assistants
- 1 QHSE engineer
QHSE team - 1 HSE officer
- 1 Quality officer
5.1 ACCESS AND CIRCULATION
The access on the cofferdam will be done from the final access of the project (trucks, front loader, mobil crane, exca-
vator, pick-up...). and also from the access on the Eat bund,

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The following figure indicates the circulation plan that will be respected.
Hinterland
Figure 4: Circulation Plan
All the platform will be cover of crushed rocks (0-100mm) on top of the reclamation sand in order to guarantee circu-
lation of tire equipment (trucks, trailer, crane…).

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5.2 PAVEMENT STRUCTURE
The following pavement structure for the whole platform had been choose :
Figure 5: Pavement structure
This method statement only focuses on road base layer completion activities.
Road base layer is a cement treated material for which EIFFAGE Génie Civil has selected the following materials:
- Crushed rocks 0/40 mm

- Cement
You will found below the results at seven days of the test done on the CBMG with 6%
Figure 6: Results on CBMG
Water is added to the crush rocks material, water content is done before on the crush rock 0/40mm before the spread
of cement. Following these results, we add water to the mix, and an other water content is done on the mix.
On site the cement content will be increase in order to compensate the loose on the bag and external elements.
A water curing is done after to avoid any problem of shrinkage.
The sampling of CBGM is taken only after final mixing.
Additional test will be done on site to demonstrate that our methods on site give good results also.

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5.3 PLATEFORM ORGANISATION
Cement treated base mixture will start after soil improvement activities completion and by plot. Progression of works
is shown on the following figure:
Zone 1
Zone 2
Figure 7: Progression of works

Two main zones are shown on this figure:
- Zone 1: West part, the work will be completed from the West to the East side,
In the same time, in the zone 2, the vibrocompaction can continue in box C the extrem part of the Zone 2
- Zone 2: East part, the work will be completed from the West to the East side
In the same time, the installation of paving blocks can start in the zone 1
The grader can work using forward and reverse.

On the return wall the grader will work in the transversal way.
Along the electrical manhole and in the corner, the mix will be prepared with the grader and send by hand in those
places.
The mixing is done in function of the gride, the length of the grader blade is not taken in account in the calculation
6. WORK PHASES
As stated before cement treated material will be completed in three layers (18 cm thick each). Several work phases are
required to complete this structure:
1. Control of subgrade layer (land reclamation)
For the following steps there will there two methods :
For the first methods we will do the mixing in place

2. 1st layer of cement mixture :
a. Laying of material
b. Cement spreading
c. Mixing with the grader
d. Compaction and grading
e. Curing
3. 2nd layer of soil cement mixture :


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b. Cement spreading
e. Curing
4. 3rd layer of soil cement mixture :

b. Cement spreading
e. Curing
6.1 SUBGRADE COMPACTED SAND (CBR>5%)
After the completion of the vibro compaction, the plateform will be clean from any soft peat on top of the sand.
A first passing is done on the top of this sand,
Then the reclamation sand will be spread on the top of the platform until the final level by layer of 20cm, using exca-
vator
The sand will be compacted by the simple drum compactor.
After completion of the layer, plate test will be done to verify if the CBR is higher than 5%.
Plate test will be done following a grid of 7m x 7m.
To verify the level of the platform, the altimetry will be check following the grid bellow:
Figure 8: Example of layout point grid
6.2 GRADED CRUSHED ROCK

For the crushed rock layer, rock of 0 to 100mm will be spread on the platform in one layer of 150mm, with the grader.
After completion of the layer, plate test will be done to verify if the CBR is higher than 80%.
Plate test will be done following a grid of 7m x 7m.

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And the same altimetry verification will be done on the top of the platform.
Figure 9: Layer of 0-100m graded crushed rocks
6.3 SUBGRADE LAYER CONTROL
Subgrade layer is controlled after completion of land reclamation improvement and before starting cement treated
base mixture operations. Two items are controlled:
- Altimetry of subgrade
- Bearing capacity: a bearing capacity of EV2 ≥ 80 MPa is required according to calculation note and K ≤ 2.
For a Sand, with a CBR > 5%, is equivalent to an EV2 > 50 Mpa
Figure 10: Extract from the design of concrete pavement and supplementary report
For the sub-base material, regarding the structure we have, we are in the case of classe 2 sub-base material.

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Following the extract bellow of the Heavy duty pavements for ports and other industries, we should have a test at 100
Mpa.
Figure 11: Extract from the structural design of Heavy duty pavements for ports and other industries
6.3.1 Altimetry control
Altimetry control is performed by a team of surveyors. Two different methods can be employed in order to control:

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- 2D laser
- Layout points grid
Tolerance suitable for subgrade grading is ± 3cm.
Figure 12: 2D Laser

Required altimetry is based on
Figure 13: Example of layout paint grid
The granulometric curve of the crush rock layer is as below :

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Granulometric Curve of the Crush rock layer

100%
90%
80%
Cumulative Percentage by Mass Passing
70%
60% S
éri
50% e2
40%
30%
20%
10%
0%
100 10 1 0,1 0,01
Size of Sieve in mm
6.3.2 Bearing capacity
A plate test is performed in order to check bearing capacity of subgrade layer. A team of laboratory technicians is re-
sponsible of performing this test.
Requirements regarding bearing capacity are:

- EV2 ≥ 80 MPa (test according to NF 94-117-1)
- K ≤ 2 (test according to NF 94-117-3)
Figure 14: plate Test being performed


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Following corrective actions can be undertaken in case of lack bearing capacity:

- Adjustment of moisture content of material using a water bowser
- Additional compaction using drum roller or tire roller
- Removal of material (in case of EV2 < 30 MPa)
Figure 15: Additional compaction of subgrade layer
A test is being performed after completion of corrective actions.
6.4 FIRST LAYER OF CEMENT TREATED BASE MIXTURE
Two methods will potentially done on site,
6.4.1 Mixing in place
6.4.1.1 Materials laying and grading
The first layer of cement treated base mixture is made of a layer 0/40 mm material that will be laid on top of graded
crushed rock. Required thickness of 0/40mm layer will around 180 mm. Stockpile will be located on EIFFAGE Site instal-
lations and transported using front loader and grader.

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Figure 16: Surveyors controlling of 0/40mm layer
Thickness of this layer is controlled by surveyors.

Water is add during the installation of the 0/40mm.
Before the installation of the cement bags, the water content of the 0/40mm will be taken
6.4.1.2 Cement spreading and mixing
The cement will be in bag, and open following a number of bag per square meters.
The grid will be a 2m x 1.42m, This can be adapted following the results on the crushing test.
On this grid two bags of 50kg will be spread.
The cement bag will be open on top of the previous 0/40mm graded.
After the spread of the cement, the mixing of material (with optional water spreading, depending of moisture content
of material) using the grader is done.
Figure 17 : Spreading of cement on site
To spread the cement, we will create a gride on top of the 0-40mm, this grid will be calculate following the formula-
tion we have.

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Figure 18: Cement spread on top of the 0/40mm
The joint will be prepared with the grader
For the vertical joint, two vertical joints, from two different layers cannot be aligned.
The drum roller will pass on top the joint without vibration.
Cover between two passes of cement spreader will respect SETRA GTS prescriptions as shown hereinafter:
Mixing of materials is performed using the grader. Mixing process is controlled:

- Visually
- Mixing depth is controlled as described before.
The mixing with the grader depends on the way you give the orientation of the grader blade.
The grader doesn’t only push the material, he is putting the material and the cement on the side of the grader,

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The mixture is made by the passage of the cement and 0/40 in the blade.
After some passage the mix came homogeneous.
The remaining water will be added following the results of the water content on the 0/40mm.
Water content will taken during the mixing process to confirm the correct water content in the mix.
-
- Figure 19: Mixing with the grader
The mixing is done on the full heigh of the 0/40mm layer, 18cm.
The grader blade has to be oriented with an angle and in the way to remove the mix on the side of the grader.
6.4.2 Grading and compaction
A grader is employed to complete le level of the layer. When the grader have achieve le final level of the platform, the
compaction can start.
Compaction then starts using drum roller, EIFFAGE expects to need 8 passes in order to meet compaction requirements.
This will be confirmed during trial length.

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Figure 20: Grader
Figure 21: Drum compactor
Grading is controlled by a team surveyors. Tolerances regarding altimetry is ± 2 cm. for the two first layer.
The final layer will be graded +/- 5mm.
Density of material is controlled using sand-cone method (ASTM D1556 standard). Compaction requirement is q1 ac-
cording to GTR standard meaning 95% of controlled points must have 𝜌𝑑𝑚≥98%𝜌𝑑𝑂𝑃𝑀

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In case of lack of density additional passes of tire roller are applied until requirements are fulfilled.
6.4.3 Curing
After that the density tests have been performed.

Water is spread on this layer to maintain enough humidity for curing 12 hours after completion of the CBMG layer.
Water will be spread on the layer for 3 days using a water bowser. Frequency of water spreading will be adjusted ac-
cording to weather conditions.
The curing will be done until the CBMG achieved the 28 days strength.
A bituminous emulsion will be spread on top of the last layer of the CBMG.
6.5 SECOND LAYER AND THE THIRD LAYER OF CEMENT TREATED BASE MIXTURE
Second layer of cement treated is completed at least 3 days after completion of 1st layer to ensure curing. The same
operations described previously will be repeated.
Crushing test will be done to confirm that we have the results to continue the next steps.
From the test we have done, we see that at 7 days, we have the results expected.
7. APPENDIX

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0D 25/01/23 Review following comments FLR FLR JRO

0C 18/12/23 Review following comments FLR FLR JRO

0B 03/11/23 Review following comments FLR FLR JRO

0A 09/10/23 Internal review FLR FLR JRO

Nectar Bulk Terminal Berth Extension

Document number (CONTRACTOR's codification): Rev. Format

METHOD STATEMENT – CEMENT TREATED BASE MIXTURE

FREETOWN, SIERRA LEONE

3. REFERENCE DOCUMENT ...................................................................................................................................... 6

FREETOWN, SIERRA LEONE

FREETOWN, SIERRA LEONE

1.1 PROJECT OVERVIEW

Figure 1: Freetown Location

Figure 2: Queen Elizabeth Quay - Site Location

FREETOWN, SIERRA LEONE

Figure 3: General Layout

2. PURPOSE OF THE DOCUMENT

FREETOWN, SIERRA LEONE

3.1 CONTRACT DOCUEMENTS

FREETOWN, SIERRA LEONE

4.1 CIVIL WORKS EQUIPMENT

4.2 SURVEY EQUIPMENT

FREETOWN, SIERRA LEONE

- Reflective survey target

Team per shift

5.1 ACCESS AND CIRCULATION

FREETOWN, SIERRA LEONE

Figure 4: Circulation Plan

FREETOWN, SIERRA LEONE

5.2 PAVEMENT STRUCTURE

Figure 5: Pavement structure

- Crushed rocks 0/40 mm

Figure 6: Results on CBMG

The sampling of CBGM is taken only after final mixing.

FREETOWN, SIERRA LEONE

5.3 PLATEFORM ORGANISATION

Figure 7: Progression of works

The grader can work using forward and reverse.

For the first methods we will do the mixing in place

3. 2nd layer of soil cement mixture :

FREETOWN, SIERRA LEONE

4. 3rd layer of soil cement mixture :

6.1 SUBGRADE COMPACTED SAND (CBR>5%)

A first passing is done on the top of this sand,

Figure 8: Example of layout point grid

6.2 GRADED CRUSHED ROCK

FREETOWN, SIERRA LEONE

Figure 9: Layer of 0-100m graded crushed rocks

6.3 SUBGRADE LAYER CONTROL

FREETOWN, SIERRA LEONE

6.3.1 Altimetry control

FREETOWN, SIERRA LEONE

Tolerance suitable for subgrade grading is ± 3cm.

Figure 12: 2D Laser

Figure 13: Example of layout paint grid

The granulometric curve of the crush rock layer is as below :

FREETOWN, SIERRA LEONE

Granulometric Curve of the Crush rock layer