Progress Report No.

11On the Design, Supervision and Construction of selected Chalala roads

1

Contents

1.0 Project Summary ....................................................................................................................... 2
2.0 Introduction ............................................................................................................................... 3
3.0 Progress of Works ..................................................................................................................... 4
3.1 General State of Progress ...................................................................................................... 4
3.2 Drainage ................................................................................................................................ 6
3.3 Problems Encountered .......................................................................................................... 6
3.4 Program of Works ................................................................................................................. 7
3.5 Quality Assurance ................................................................................................................. 7
4.0 Project Resources ...................................................................................................................... 8
4.1 Labour Returns...................................................................................................................... 8
4.2 Plant Returns ......................................................................................................................... 9
5.0 Project Financial Assessment ............................................................................................... 100
6.0 Conclusion ............................................................................................................................ 111
7.0 Photographic Report ......................................................................................................... 112


















Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

2

1.0 Project Summary



Implementing Agency Road Development Agency
Contract No. TB/ORD/011/08
Client The Government of the Republic of Zambia
Paying Agency National Road Fund Agency
Beneficiary The Government of the Republic of Zambia
Contract location East of the Chilenje South suburb in the
City of Lusaka
Name of the Project Consulting services for the Design,
Supervision, and Construction/Upgrading
of selected Chalala Roads, Musi-O-Tunya
Road extension, Part of Shantumbu Road
and South of Chilenje South newly
constructed road parallel to ZESCO pylons
Length 15 .3 Km
Main Contractor BCHOD ICU
Supervising Engineers BCHOD and Partners
Negotiated Contract value ZMK 36,896,223,626.00
Total variations Approved ZMK 12,649,733,154.97
New Contract Sum ZMK 49,545,956,781.25
Total Amount Claimed To Date ZMK 39,816,716,981.52
Date of award of the Contract 29 September 2008
Contract Start Date 9 October 2008
Project Delay due to Financial Constraints 24 months
Payment Currency ZMK
Construction Period 8 Months
Contract Completion Date 15
th
July 2011
Reporting Period November 2011

Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

3

2.0 Introduction

The Government of the Republic of Zambia through the Road Development Agency
(RDA) intended to carry out the Design, Supervision and Construction/Upgrading of the
selected Chalala Roads (6.8 km), Musi-O-Tunya Road extension (2.7 km), part of
Shantumbu Road (3 km), and the newly constructed road parallel to Zesco pylons (2.7
km) south of Chilenje South, in Lusaka District to Bituminous Standard Class 1 based on
Integrated Construction Unit (ICU) method of works, using funds approved in the Annual
Work Plan (AWP) for 2008. Some of these funds would have to be carried over into the
subsequent years.

In January 2011 the ICU was given confirmation that funds were now available for the
project and that works should resume immediately. Work was initially slow to restart due
to the time of year (rainy season) and availability of Contractors equipment.

This report is the eleventh of scheduled progress reports produced by BCHOD
Consulting Engineers being the Supervision Engineers on this project, and covered the
period August to October 2011.













Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

4

3.0 Progress of Works

3.1 General State of Progress

Up to the reporting period all layer works had been completed. Additionally there had
been 9.1km of road surfaced, this partly consisted of approximately 1.9km of the
extension of Mosi-O-Tunya (entire length U1), the road running parallel to the ZESCO
pylons (U5) had been surfaced for approximately 1.0km, and part of Shantumbu road
from Pemba road (U4), approximately 900m. The table below outlines the major asphalt
surfacing work that had been carried out.

Table 1: Lengths of surfacing work carried out
Road Length of
surfacing
required (km)
Length
surfacing done
(km)
Per centum
done
U1 1.94 1.94 100%
U2 0.35 0.35 100%
U3 0.11 0.11 100%
U4 3.21 0.90 28.0%
U5 1.80 0.95 52.8%
U6 2.35 2.35 100%
U7 2.03 0.80 39.4%
U8 0.90 0.31 34.4%
U9 0.24 0.24 100%
U10 2.15 1.13 52.6%

The above tabulated work translated to an overall per centum length of 60% surfacing for
the Project.
Prime coat had also been applied on some of the remaining worked bases as follows:
On U4, 400m by half width
U5, 800m by full width
U7, 900m by half width
Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

5

The Revised Program of Works, Fig 1, shows the per centum achieved progress in
relation to the planned program for some major activities of the Project.


Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

6

3.2 Drainage

There had not been much progress made on the drainage works as at reporting time. The
Contractor had mainly focused on keeping the existing drains clear of obstructions and
debris, and continuing with the lining of the drains along Mosi-O-Tunya (U1). The
workmanship along this drain had not been of the required standard and the Contractor
was instructed to repair sections and rework them, as shown in the photographic report.
3.3 Problems Encountered

The issue of constant traffic on the roads during construction was ongoing. The traffic
was urged to use the deviations adjacent to the roads when available in order to try and
stay out of the way of any construction vehicles. When roads needed to be crossed certain
crossing points were established for vehicles to get from one side of the road to the other.

The Contractor used sign and flagmen to divert traffic from construction zones. The
location of the current work areas however, did not allow for deviations due to land
restraints, this also slowed the rate of construction down a great deal as the roads had to
be worked in half widths so as to accommodate traffic.

Another issue that came up in the months leading up to the reporting period was the lack
of a reliable supply of cement and bitumen from suppliers. Cement is required for the
stabilisation of road base while bitumen functions as the adhesive between wearing
course and base layer and also as the binding medium in the surfacing. This unfortunately
caused the Contractor to fall behind schedule as the processing of base and application of
asphalt wearing course could not be carried out.




Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

7

3.4 Program of Works

The hitherto administered Program of Works was as submitted at the end of January 2011
when the instruction to recommence was issued. However there were stoppages
experienced in project activities due to unreliability of supply and uncertainties in
availability of cement, diesel and bitumen. Variation to the Work had also been proposed
in form of additional bellmouths. Hence the current Revised Program of Works, Fig 1. As
at report time a total of 9.1 kilometres of roads had been surfaced out of a total of
15.3km, this representing approximately 60% of total project road length. The remainder
of the Project roads had been constructed with pavement layers in readiness for priming
and eventual surfacing. Project completion was set for December 2011.
3.5 Quality Assurance

All works are carried out under the supervision of the contractors Site Agent on site. The
Engineer from BCHOD takes regular visits to site to ensure the contractor is working to
the standards specified. The construction materials and road layer densities are being
carried out by the contractors own laboratory. Every now and again tests are carried out
by an independent laboratory in order to confirm the results submitted by the contractors
laboratory as an additional form of quality assurance.

The Contractor has submitted compaction results that he has carried out on the Sub-base,
and the stabilised base on some surfaced sections of project roads. In addition he has
submitted the asphalt mix design used for the surfacing.
Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

8

4.0 Project Resources

4.1 Labour Returns

The Contractor mobilised a single earthworks team to site in late January 2011. This
team started working on the roads preparing the roads for various pavement layers. A
drainage team joined them on site during the middle of March 2011. And the surfacing
team arrived in June 2011. The Contractor had the following staff on site for the reporting
period.

Table 2: Labour
Item Description Number of
1 Site Agent 1
2 Foreman 1
3 Site Clerk 1
4 Operators 4
5 Drivers (These are hired so vary from day to day) 3
6 Bricklayers 6
7 General Workers 7
8 Guards 4


Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

9

4.2 Plant Returns

The Contractors plant that was mobilized to site is summarised in the table below.

Table 3: Plant On Site
Item Description Make/Model Number of
1 Grader CAT 140G 1
2 Grader Komatsu 1
3 Pneumatic Roller Sakai 1
4 15,000 litre Water Bowser Benz 1
5 10,000 litre Water Bowser Leyland 1
6 Tractor Ford 1
7 2 ton truck Toyota 1
8 Water Pump - 2
9 Mechanical Broom - 1
10 Bitumen Distributor - 1

















Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

10

5.0 Project Financial Assessment

The current Financial Status of the Project has changed from the previous report. There
have been additional claims by the ICU team or payments made by the Client. The total
claim for the works comes to ZMK 39,816,716,981.52 out of the total project sum of
ZmK 49,545,956,781.25.







Chart showing expected expenditure versus actual.

The Table shows the amounts claimed to date on this project. Due to the erratic funding
available for this project and consequent reduced project activity there were insignicant
claims between April 2009 and January 2011. Subsequent Interim Payment Certificates
were substantial as they included major surfacing works and all the earthworks that were
done eventually.


0
10
20
30
40
50
60
1 2 3 4 5 6 7 8 24 25 26 27 28 29 30 31 32
Zmk
Billions
Month
expected
actual
Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

11

6.0 Conclusion

The Contractor re-mobilised to site during the months of January and February 2011. All
earthworks and layer works were completed as per specification.

In total 9.1km of road were surfaced out of the sanctioned 15.3km this representing
approximately 60% of the project. The Project deadline of 15
th
July 2011 had not been
met due to factors outlined herein. The ICU Team was however endeavouring to seek and
utilize all available possibilities of completing the Project at the earliest time and to the
desired quality. The Contractor expected to complete the remaining works by December
2011, as per Revised Program Works, assuming a consistent supply of the key road
construction materials: bitumen and cement.

All work carried out up to the reporting period had been done according to specification.


















Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

12

7.0 Photographic Report


Material processing for base stabilisation Testing of stabilised road base


Road base with applied prime coat Application of asphaltic concrete surface


Asphalt being controlled by workmen and rolled into thickness

Progress Report No.11On the Design, Supervision and Construction of selected Chalala roads

13



A mechanical broom removing Primed half width on U7
deleterious material on U7 road base


Asphalt being rolled to thickness A surfaced half width



A section on U1 with completed A spot on U8 with electric poles requiring
surfacing but poorly done drainage barriers