Method Statement details the standard procedure for Roadwork execution

Method Statement for Roadwork Construction

1.0 Revision Status

Revision Number	Date	Originator	Reviewed	Approved	Description of Re-submittal

2.0 Scope & Objectives

• This Method Statement details the standard procedure for Roadwork execution[cite: 1].
• The contractor shall design and prepare structural/pavement drawings backed by detailed design calculations[cite: 1].

3.0 Reference Standards

• Project Technical Specifications[cite: 1]
• Civil Drawings[cite: 1]
• IRC 37:2001 – Guidelines for the Design of Flexible Pavements (incorporating bituminous surfacing, granular base, and sub-base as per MoRTH Specifications Sections 400 & 500)[cite: 1].
• IRC: SP-20:2002 – Rural Roads Manual (for road formation, culverts, and minor bridges on rural roads/ODRs with projected traffic < 450 CVPD)[cite: 1].
• IRC 81:1997 / 81:2001 – Guidelines for Strengthening Road Pavements using Benkelman Beam Deflection Technique[cite: 1].
• IRC 58:1974 – Guidelines for the Design of Rigid Pavements for Highways[cite: 1].
• IRC 15:1981 – Standard Specification and Code of Practice for Construction of Concrete Roads[cite: 1].
• IRC 86:1983 – Geometric Design Standards for Urban Roads in Plains[cite: 1].
• IRC 73:1980 – Geometric Design Standards for Rural (Non-Urban) Highways[cite: 1].
• IRC 64:1990 – Guidelines for Capacity of Roads in Rural Areas[cite: 1].

4.0 Definitions & Terminology

MS	Method Statement[cite: 1]
QCP	Quality Control Procedure[cite: 1]
ITP	Inspection & Test Plan[cite: 1]
NH	National Highways – Main arterial highways connecting ports, state capitals, and industrial centers[cite: 1].
SH	State Highways – Routes linking district headquarters and major cities to National Highways[cite: 1].
MDR	Major District Roads – Key roads connecting production areas and markets[cite: 1].
ODR	Other District Roads – Roads serving rural production areas and market outlets[cite: 1].
ROB / RUB	Road Over Bridge / Road Under Bridge[cite: 1]

Technical Terminology

• Consolidation: Process of making freshly placed concrete into a uniform, compact mass by eliminating voids around reinforcement[cite: 1].
• Clearing & Grubbing: Preparing the road right-of-way by removing surface trees, stumps, and organic debris[cite: 1].
• Staking: Transferring alignment and design elevation data from construction drawings to the ground[cite: 1].

5.0 Health and Safety Hazards

Specific safety measures must be strictly enforced on-site as covered in the Project Safety Plan and IRC: SP: 55 (Guidelines on Safety in Road Construction Zones)[cite: 1].

6.0 Roles & Responsibilities

6.1 Project Engineer

• Ensure roadwork execution aligns strictly with specifications and approved construction drawings[cite: 1].
• Verify that equipment is in good operational condition and activities follow the approved baseline schedule[cite: 1].
• Coordinate with Client/Consultant, Site Engineers, Safety Team, and Surveyors for seamless execution[cite: 1].
• Directly oversee quality control and health/safety plan enforcement[cite: 1].

6.2 Site Engineer

• Supervise field execution according to drawings and technical specifications[cite: 1].
• Distribute daily responsibilities to construction foremen and monitor daily progress outputs[cite: 1].
• Coordinate with Safety Engineers to maintain safe site practices and QA Engineers for required sampling/testing[cite: 1].
• Verify levels and alignment markers with the survey team[cite: 1].

6.3 QA/QC Engineer

• Enforce quality control procedures and conduct inspections prior to requesting Client approval[cite: 1].
• Maintain complete, auditable inspection and material test records[cite: 1].

6.4 Safety Engineer

• Implement site safety measures as per the HSE Plan, keeping the workforce trained and aware[cite: 1].
• Inspect active work zones, prevent unsafe conditions, and keep working areas clean and tidy[cite: 1].

6.5 Foreman

• Distribute daily manpower and machinery resources in coordination with the Site Engineer[cite: 1].
• Track daily outputs, oversee setting out execution, and report site incidents immediately[cite: 1].

6.6 Surveyor

• Establish control benchmarks and maintain final alignment centerline, formation levels, and survey files[cite: 1].
• Perform double-run leveling and angular measurements using high-precision instruments (e.g., Automatic Level, Theodolite, Distomat)[cite: 1].

7.0 Construction Procedure

7.1 Documentation & Site Mobilization

• Maintain key project documents on site: Survey reports, BOQ, Site Order Book, Work Diaries, Quality Control Record Books, up-to-date schedule, and cloth-mounted working drawings[cite: 1].
• Establish temporary traffic diversions per site conditions for works executed over partial roadway widths[cite: 1].
• Ensure environmental protection: Keep borrow pits out of the ROW, control soil erosion, locate asphalt/batching plants away from habitations, and suppress dust[cite: 1].

7.2 Setting Out & Surveying

• Reference the main centerline every 50 m in plain/rolling terrain, 20 m in hilly terrain, and at all curve points[cite: 1].
• Establish working benchmarks tied to reference points at a minimum frequency of 4 per kilometer[cite: 1].
• Set offset timber/steel level posts 1 meter beyond formation edges to verify finished layer elevations[cite: 1].

7.3 Clearing & Grubbing

• Demarcate limits and preserve protected roadside utilities, trees, and structures[cite: 1].
• Cut trees and stumps such that no organic material remains within 500 mm of the subgrade[cite: 1].
• Strip and stockpile topsoil for reapplication on slopes; do not burn organic matter in forested areas[cite: 1].

7.4 Earthwork & Subgrade Preparation

• Maintain specified cross-falls right from the subgrade level[cite: 1]. The finished subgrade must be at least 0.6 m above the High Flood Level (HFL) or natural ground[cite: 1].
• Compaction Standards: Compact subgrade to at least 97% Laboratory Maximum Dry Density (per IS: 2720 Part VIII)[cite: 1]. Embankment layers must achieve at least 95% compaction[cite: 1].
• Layer Limits: Spread embankment material in loose layers not exceeding 200 mm[cite: 1].
• Material Density Criteria: Minimum dry unit weight for embankments up to 3 m height is 15.2 kN/m³; for heights > 3 m or subject to flooding, minimum is 17.5 kN/m³[cite: 1]. Subgrade CBR must exceed 5%[cite: 1].

7.5 Special Earthwork Conditions

• Expansive Clays: Not allowed in the subgrade or the 500 mm zone directly beneath it[cite: 1]. Allowed in lower embankment sections if compacted to ≥ 90% density[cite: 1].
• Widening Existing Roads: Cut horizontal benches 0.3 m wide if existing side slopes are steeper than 4:1 to ensure structural bonding[cite: 1]. Scarify existing asphalt surfaces by 50 mm if within 1 m of the new subgrade level[cite: 1].
• Backfilling Structures: Suspend filling around structures until concrete/masonry has cured for 14 days[cite: 1]. Raise fill symmetrically on both sides using non-plastic material (PI ≤ 20, LL ≤ 40)[cite: 1].
• Rockfill Embankment: Prohibited within 500 mm below formation level[cite: 1]. Layer thickness must not exceed 500 mm with maximum rock size of 300 mm, compacted with 5 passes of an 8–10 ton vibratory roller[cite: 1].

7.6 Blasting & Pre-Splitting Operations

• Conduct blasting only during fixed, pre-announced hours under experienced supervision with red flag warnings[cite: 1]. Store explosives in an approved, lightning-protected magazine[cite: 1].
• Pre-Splitting: Drill parallel holes (≤ 900 mm spacing) along the desired slope[cite: 1]. Keep production holes at least 2.5 m away from the pre-split line, firing pre-split holes prior to main blasts[cite: 1].

7.7 Macadam Base Course Construction

• Subgrade Protection: On high-plasticity subgrades, lay a blanket course (3–4 inches of sand/screenings) or geotextile to prevent base infiltration[cite: 1].
• Spreading & Compacting: Spread coarse aggregates uniformly[cite: 1]. Roll from edges to center (or low-to-high side on superelevations) with steel-wheeled rollers until wave movement ceases[cite: 1].
• Applying Screenings: Spread fine screenings in thin lifts while rolling continuously to fill surface voids[cite: 1]. Sprinkle water to flush screenings into voids, rolling until a grout wave forms[cite: 1]. Allow section to dry completely[cite: 1].
• Surface Tolerances: Check surface with a 12-foot straightedge[cite: 1]. Maximum allowable deviation is 3/4 inch for standard roads/airfields and 1/8 inch for jet aircraft pavements[cite: 1].

7.8 Rigid Pavement (PCC) Procedures

7.8.1 Placement

• Placement: Place concrete directly via transit mixers/spreaders avoiding excessive relocation to prevent segregation[cite: 1].

7.8.2 Screeding (Strikeoff)

• The screeding or strikeoff process cuts off excess roughly placed concrete to achieve target slab design elevations[cite: 1].
• This is typically performed by dragging a calibrated straightedge across the concrete surface at required grade levels[cite: 1].

7.8.3 Consolidation

• Consolidation is achieved using internal slender needle vibrators[cite: 1].
• Proper consolidation through controlled vibration is vital to structural performance and concrete durability[cite: 1].

CRITICAL VIBRATION NOTES:

• Over-Vibration Hazards: Prolonged vibration in one area or excessively high vibration rates can cause non-uniform aggregate distribution, loss of entrained air, and surface bleeding (water accumulation), leading to severe durability reduction[cite: 1].
• Under-Vibration Hazards: Insufficient vibration time or low vibration rates can result in poor coarse aggregate distribution and large entrained air voids, compromising compressive strength and slab integrity[cite: 1].
• Vibrator Static Head: The depth of fresh PCC above the vibrator head assists in driving coarse aggregate particles together as the vibrator advances[cite: 1].

7.8.4 Finishing Operations

Finishing encompasses all processes required to achieve final surface levels, smoothness, and non-skid texturing[cite: 1]:

• Floating: A flat float is passed over fresh concrete to eliminate high/low spots, embed coarse aggregate below the surface, clear minor imperfections, and consolidate top mortar in preparation for texturing[cite: 1].
• Texturing: Imparts a non-skid texture to the smooth floated concrete surface[cite: 1]:
  • Microtexture: Produced by dragging burlap or artificial turf behind the paver to enhance tire friction and safe low-speed vehicular control[cite: 1].
  • Macrotexture: Achieved via transverse tining to facilitate surface water drainage and prevent high-speed hydroplaning[cite: 1]. Standard tining dimensions require grooves 3–5 mm deep, 3 mm wide, and spaced 12–20 mm apart to obtain an average texture depth around 0.7 mm[cite: 1]. Untextured margins may be left over joint lines to ensure clean joint sawing and sealing[cite: 1].

8.0 Material Requirements

• Concrete: Plain Cement Concrete (PCC) and Reinforced Cement Concrete (RCC) mixes prepared strictly as per design specifications[cite: 1].
• Bitumen: Bituminous binders, tack coats, or prime coats as specified for flexible layers or expansion joint fillings[cite: 1].
• Aggregates: Clean, well-graded Fine Aggregates (sand) and Coarse Aggregates (crushed stone)[cite: 1].
• Soil: Suitable selected soil for subgrade or embankment construction (if required)[cite: 1].

9.0 Equipment Requirements

Auto Level Instrument & Staff[cite: 1]

Excavators & JCBs[cite: 1]

Rollers (Steel & Vibratory)[cite: 1]

Dozers & Earthmoving Machinery[cite: 1]

Bitumen Laying Machines / Pavers[cite: 1]

Bitumen Heating Drums & Boilers[cite: 1]

Concrete Pumps & Hose Pipes[cite: 1]

10.0 Health and Safety Provisions

• High priority is given to jobsite safety to maintain safe construction practices during all roadwork operations[cite: 1].
• Install safety barriers, warning signboards, advance traffic notices, and warning tape surrounding active construction zones[cite: 1].
• Enforce extra precautions during topsoil stripping and deep earthwork excavation operations[cite: 1].

11.0 Quality Control Approvals

All mandatory Quality Control documents must be formally approved prior to executing roadwork[cite: 1]:

• Quality Control Procedure (QCP) for Roadwork[cite: 1]
• Inspection & Test Plan (ITP) for Roadwork[cite: 1]
• Project Field Quality Plan[cite: 1]
• Execution & Testing Check Sheets for Roadwork[cite: 1]

12.0 Supporting Documentation

This Method Statement must be implemented in conjunction with[cite: 1]:

• Contract Specifications and Approved Construction Drawings[cite: 1]
• Quality Control Procedure (QCP) for Roadwork[cite: 1]
• Inspection & Test Plan (ITP) for Roadwork[cite: 1]
• Method Statement (MS) for General Roadwork[cite: 1]
• Project Quality Plan[cite: 1]
• Project HSE Plan[cite: 1]

13.0 Distribution List

Issued for implementation, field verification, and records[cite: 1]:

• Management Representative[cite: 1]
• Project Manager[cite: 1]
• Project Engineer[cite: 1]
• Site Engineer[cite: 1]
• HSE Engineer[cite: 1]
• QA/QC Engineer[cite: 1]