Annexure 1 - Inspection & Test Plan (ITP)

P2W-4021-QMS-ITP-0014
CONSTRUCTION OF POLIHALE TRANSFER TUNNEL
Rev: 00
INSPECTION TEST PLAN (ITP) Date:

P2W-4021-CMS-0059-00 - Gate Shaft Excavations Support and

ITP No.: 0014 Applicable Method Statement: Contractor: KKM JV Project: 4021
Monitoring
Works to be executed: GATE SHAFT EXCAVATION SUPPORT AND MONITORING Work Area: Zone:

SIGNATORIES
SURNAME NAME FUNCTION COMPANY TRIGRAM SIGNATURE

Contractor - Execution Contractor – Quality Control Engineer

Works to be executed Specifications and/or reference Type Date + trigram + Type Date + trigram + Type Date + trigram +
(Stages of verification) documents intervention initials intervention initials intervention initials
(WP, HP, AC, R) for approval (WP, HP, AC, R) for approval (WP, HP, AC, R) for approval
Control prior to commencement
of activities AC HP HP
- SCH 10 UNDERGROUND EXCAVATIONS
Validity and approval of execution - P2W-4021-CMS-0059
10 documents, drawings, permits, material
certificates, method statements, etc.
Comment(s): All materials to be incorporated into the works to be tested and approved in accordance with the project specifications.

Setting out AC + R AC WP
Lines and levels as per IFC drawings. - P2W-4021-CMS-0059
- Relevant IFC drawings
20
Comment(s): All setting out data, levels and dimensions shall be provided in electronic format and verified on site prior to construction. All survey and setting out data shall be provided on (WGS 84) co-
ordinate system. Engineer to confirm setting out, or direct otherwise in terms of site conditions.

EXCAVATIONS
Classification of Excavation
Agreement to be reached of excavation - P2W-4021-CMS-0059 WP WP HP
classification (soft / hard and bulk / - P2W-4021-QMS-QCC-0028
30 confined) - Drawing W-4021-T-G-G-0007

Comment(s): The classification shall be agreed between the Engineer and the Contractor based on an inspection of the material to be excavated and tunnel portal geology face maps, where applicable,
before excavation has started.
Surface Excavation - P2W-4021-CMS-0011
Surface excavations in rock or soil shall be - P2W-4021-QMS-QCC-0002 AC WP WP
carried out in vertical stages of limited, - Drawings W-4021-X-G-U-03XX
stable, height and length. - Relevant IFC drawings
40 - SCH 09 SURFACE EXCAVATIONS
SUPPORT
- Code of Practice “Lateral Support”
Comment(s):

Underground Excavation
The excavation method for the gate shafts
entails using a raise borer and shaft
- P2W-4021-CMS-0059 AC AC WP
- P2W-4021-QMS-QCC-0028
slashing technique. This involves initially - Drawings W-4021-H-G-U-9144-A, W-
drilling a pilot hole, followed by reaming it 4021-H-G-U-9145-A
to achieve the desired diameter. Strict - Other Relevant IFC drawings
50 adherence to a deviation limit of 0.5% - SCH 10 UNDERGROUND EXCAVATIONS
from the pilot hole's drilling depth is
ensured.
Comment(s): The Contractor is required to adhere to legal requirements outlined in Lesotho and South African legislation, as well as any additional regulations set by the Lesotho Commissioner of Mines
and Geology, ensuring compliance with labour, environment, explosives, mine safety, and occupational health and safety laws, including relevant provisions from South African legislation if more stringent.
See also “10.3.1.1- Legal Requirements” in Chapter 10.
Inspection of foundations
Before any blinding concrete, bedding - P2W-4021-CMS-0059 AC HP HP
material or fill is placed, the Engineer will - P2W-4021-QMS-QCC-0028
60 be requested to inspect and approve. - Relevant IFC drawings

Comment(s): The Contractor shall also cooperate with the Engineer in allowing space and time for detailed geological mapping of the exposed excavation surface.

Survey
Survey control will be done by total AC + R WP WP
- P2W-4021-CMS-0059
station till the depth is within 10m, and
- P2W-4021-QMS-QCC-0028
four lasers will be installed at the top of
70 shaft to guide the excavation survey
- Relevant IFC drawings
control.
Comment(s): The records of such survey shall be made available to the Engineer after each excavation step within 48 hours.

HP – Hold Point: A Hold Point is a mandatory inspection and/or validation point after which work cannot proceed without formal approval from the affected party.
WP – Witness Point: The party is invited to the inspection/test performed by others but is not required to attend. If the party attends and the results are acceptable, the party must sign the inspection/test report/ QC form.
S – Surveillance Informal surveillance during construction / erection / manufacturing by either party. Observations to be recorded.
AC – Auto Control: Internal KKM-JV visual inspection/control. Visual inspections with inspection points must be traceable and documented.
R – Report : An inspection report is provided so that the Contractor and the Employer can validate the phase in question.
TRIGRAM Three letter initials – First letter of first name + first two letters of surname

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 P2W-4021-QMS-ITP-0014
CONSTRUCTION OF POLIHALE TRANSFER TUNNEL
Rev: 00

INSPECTION TEST PLAN (ITP) Date:

Contractor - Execution Contractor – Quality Control Engineer

Works to be executed Specifications and/or reference Type Date + trigram + Type Date + trigram + Type Date + trigram +
(Stages of verification) documents intervention initials intervention initials intervention initials
(WP, HP, AC, R) for approval (WP, HP, AC, R) for approval (WP, HP, AC, R) for approval
UNDERGROUND EXCAVATIONS AND ROCK SUPPORT
Materials - P2W-4021-CMS-0059
Prior to installing or applying rock support, - P2W-4021-QMS-QCC-0028 AC + R AC HP
the Contractor shall submit to the - SCH 13 ROCK SUPPORT
Engineer for approval the type, number - SCH 14 DRILLING AND GROUTING
80 and dimensions of proposed supporting - Specifications as per SANS
items - Test certificates
Comment(s): The Contractor shall record and maintain the results of all tests performed on the dowels prior to and after the installation.

Drainage - P2W-4021-CMS-0059
Possible underground water from the pilot AC WP WP
- P2W-4021-QMS-QCC-0028
hole and shaft excavation will be collected
- Relevant IFC drawings
90 in the transfer tunnel through the pilot
- Typical detail drawings
hole.
Comment(s): The holes shall be drilled to the diameter and in the direction, inclination and location as indicated on the Drawings or directed by the Engineer.

Weldmesh Reinforcement - P2W-4021-CMS-0059

Only weldmesh provided in sheets shall be AC WP WP
- P2W-4021-QMS-QCC-0028
used.
- SCH 24 REINFORCEMENT
100 - SCH 13 ROCK SUPPORT

Comment(s): Weldmesh used as rock support shall be with 150 mm x 150 mm aperture and 6.0 mm diameter wire and minimum characteristic yield strength of 450 N/mm².

Sprayed Concrete - P2W-4021-CMS-0059

Sprayed concrete placed in the Permanent - P2W-4021-QMS-QCC-0028
Works shall be applied by the wet mix - SCH 13 ROCK SUPPORT AC + R AC HP
process. - Sprayed Concrete Guideline, Austrian
The mix for shotcrete shall be designed by Society for Concrete- and Construction
laboratory tests and field trials to meet Technology, 2006, Austria
the requirements for strength - BS EN 14487
110 development and final strength. - European Specification for Sprayed
For Quality Control Testing refer to the Concrete EFNARC
Quality Control Checklist - Specification for Tunnelling-British
Tunnelling Society
- Relevant ASTM standards
Comment(s): Plant and equipment used for mixing and delivery of shotcrete, and for application of shotcrete in surface excavations, shall comply with all the requirements of Chapter 13 – Rock Support

Permanent Rockbolt
(Installation, Grouting,
Tensioning) AC HP HP
- P2W-4021-CMS-0059
Thread bar anchors are made from - P2W-4021-QMS-QCC-0028
Dywidag-DSI Y1050H prestressing steel or - Relevant IFC drawings
an approved equivalent. Nominal
120 - Typical detail drawings
diameter of 47mm and a total length of - SCH 13 ROCK SUPPORT
10m. The anchors are double corrosion
protected and include steel bars, an
anchor plate, nuts, and washers.
Comment(s):

REQUIRED INSTRUMENTATION MONITORING AND TESTING

Pull out tests of permanent
dowels and rockbolts
The Contractor shall perform a number of AC + R HP HP
approved pull out tests.
A dial gauge shall be used to measure the - P2W-4021-CMS-0059
displacement of the rockbolt head during - P2W-4021-QMS-QCC-0028
the testing of the rockbolt. - BS 8081
130 The thread bar anchors have an ultimate - SCH 13 ROCK SUPPORT
tensile load of 1820 kN tensioned to 75%
of the ultimate load. The anchors have a
bound length of 6m and a free length of
4m.
Comment(s):

Required Instrumentation
Monitoring and Testing - P2W-4021-CMS-0059 AC + R HP HP
3D displacement monitoring Crack/joint - P2W-4021-QMS-QCC-0028
meter, Point load test, Water pressure - SCH 13 ROCK SUPPORT
testing, Water inflows measurement or - SCH 15 GEOTECHNICAL
140 other according to the project INSTRUMENTATION, MONITORING AND
requirement and as directed by the TESTING
Engineer
Comment(s):

HP – Hold Point: A Hold Point is a mandatory inspection and/or validation point after which work cannot proceed without formal approval from the affected party.
WP – Witness Point: The party is invited to the inspection/test performed by others but is not required to attend. If the party attends and the results are acceptable, the party must sign the inspection/test report/ QC form.
S – Surveillance Informal surveillance during construction / erection / manufacturing by either party. Observations to be recorded.
AC – Auto Control: Internal KKM-JV visual inspection/control. Visual inspections with inspection points must be traceable and documented.
R – Report : An inspection report is provided so that the Contractor and the Employer can validate the phase in question.
TRIGRAM Three letter initials – First letter of first name + first two letters of surname

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