PMR - 30.12.14

Consulting Services for the Design and Supervision of construction works for Kangundo - Kenol (C99), Kenol - Koma
(E474),
Katumani - Mombasa Road Junction at Konza (D522) and Rehabilitation of Kenol - Machakos Town - Katumani (C99) Roads
December, 2014
Table of Contents
CHAPTER 1 INTRODUCTION.................................................................................1-4
1.1
1.2
1.3
1.4
1.5
1.6
1.7
GENERAL.................................................................................................................... 1-4
CONSULTANTS APPOINTMENT.................................................................................1-4
PROJECT ROADS DESCRIPTION.................................................................................1-4
TOPOGRAPHY............................................................................................................... 1-5
CURRENT ROAD CONDITION AND SURFACE TYPE.................................................1-5
CLIMATE AND RAINFALL.................................................................................................. 1-6
STRUCTURE OF THIS REPORT..........................................................................................1-6
CHAPTER 2 - MATERIALS INVESTIGATIONS AND PAVEMENT EVALUATION CARRIED OUT......2-1

2.1
MATERIALS INVESTIGATIONS FOR THE 4NO. ROAD SECTIONS......................................2-1
2.1.1
Alignment Soils.................................................................................................... 2-1
2.1.2
Base-course and Sub-base materials......................................................................2-1
2.2
PAVEMENT EVALUATION FOR ROAD SECTION IV.........................................................2-4
2.2.1
General.............................................................................................................. 2-4
2.2.2
Detailed Visual Inspection.....................................................................................2-5
2.2.3
Falling Weight Deflectometer (FWD) Survey............................................................2-5
2.2.4
Trial Pitting (Trenching)......................................................................................... 2-5
2.2.5
Dynamic Cone Penetrometer (DCP) Testing............................................................2-5
CHAPTER 3 - RESULTS OF MATERIAL TESTING AND PAVEMENT INVESTIGATIONS...............3-1
3.1
RESULTS OF MATERIAL TESTING...............................................................................3-1
3.1.1
Alignment Soils.................................................................................................... 3-1
3.1.2
Base-course and Sub-base materials......................................................................3-1
3.1.3
Soft stone for sub-base......................................................................................... 3-4
3.1.4
Hard-Stone......................................................................................................... 3-5
3.1.5
Fine Aggregates.................................................................................................. 3-6
3.2
RESULTS OF PAVEMENT INVESTIGATIONS.................................................................3-7
3.2.1
Pavement condition survey....................................................................................3-7
3.2.2
Trenched samples from existing sub-grade, sub-base and base-course layers..............3-8
3.2.3
Relative compactions and moisture contents for the existing pavement layers...............3-8
CHAPTER 4 - ANALYSIS OF MATERIALS TEST RESULTS AND PAVEMENT DESIGN................4-1
4.1
ANALYSIS OF ALIGNMENT CBR VALUES FOR ROAD SECTION I...............................................4-1
4.1.1
Proposed Embankment Construction Approach........................................................4-1
4.1.2
Adopted/New design sub-grade class.....................................................................4-1
4.2
ANALYSIS OF ALIGNMENT CBR VALUES FOR ROAD SECTION II...............................................4-1
4.2.1
4.2.2
4.3
ANALYSIS OF ALIGNMENT CBR VALUES FOR ROAD SECTION III..............................................4-3
4.3.1
4.3.2
4.4
ANALYSIS OF ALIGNMENT CBR VALUES FOR ROAD SECTION IV.............................................4-1
4.4.1
4.4.2
4.5
FACTUAL DESIGN DETAILS...............................................................................................4-1
4.6
ADOPTED DESIGN DETAILS..............................................................................................4-1
4.7
PROPOSED PAVEMENT STRUCTURES FOR ROAD SECTIONS I, II AND III.....................................4-1
4.8
DESIGN FOR KENOL - MACHAKOS TOWN - KATUMANI ROAD SECTION.........................4-1
4.8.1
General Approach................................................................................................ 4-1
4.8.2
Proposed pavement structures...............................................................................4-1
4.9
CHOICE OF PAVEMENTS.................................................................................................. 4-4
Preliminary Materials Report
Consulting Services for the Design and Supervision of construction works for Kangundo - Kenol (C99), Kenol - Koma (E474),
December, 2014
4.10
MATERIALS UTILIZATION.................................................................................................4-4
APPENDICES:
APPENDIX
MATERIALS TEST RESULTS
Appendix
A.1
Alignment soils
Appendix
A.2
Gravels for fill, sub-grade and pavement layers
Appendix
A.3
Construction water
PAVEMENT EVALUATION DATA
APPENDIX B
Appendix
B.1
Pavement Condition Details
Appendix
B.2
Field and laboratory test results for existing pavement layers
Appendix
B.3
DCP data
APPENDIX C
KEY PLAN FOR MATERIAL SITES
APPENDIX D
TRENCHING LOGS FOR ROAD SECTION IV
ABBREVIATIONS
AASHTO
American Association of State Highways and

Transportation Officials
AC
Asphalt Concrete
ACV
Aggregate Crushing Value
BS
British Standards
CBR
California Bearing Ratio
ESA
Equivalent Standard Axles
GCS
Graded Crushed Stone
LAA
Los Angeles Abrasion
MDD
Maximum Dry Density
MoLH&UD
Ministry of Lands, Housing and Urban Development
DoNMED
Directorate of Nairobi Metropolitan Development
NaMSIP
GS
Nairobi Metropolitan Services Improvement Project

Gravel Site
OMC
Optimum Moisture Content
ii
December, 2014
PI
Plasticity Index
RDM Part III
Road Design Manual Part III
SSS
Sodium Sulphate Soundness
ORN
Overseas Road Note
MTRD
Material Testing and Research Department
FDD
Field Dry Density
DCP
Dynamic Cone Penetrometer
FWD
Falling Weight Deflectometer
CSIR
Council for Scientific and Industrial Research
NITRR
National Institute for Transport and Road Research
CIG
Cement Improved Gravel
NG
Natural Gravel
iii
December, 2014
1.0
CHAPTER 1 INTRODUCTION
GENERAL
The Government of Kenya, through the Ministry of Lands, Housing and Urban
Development (MoLH&UD), Directorate of Nairobi Metropolitan Development, (DoNMED)
is committed to providing the residents of the Nairobi Metropolitan Region (NMR) with
world-class services. Some of the service areas identified have been underperforming or
have no critical infrastructure. The Ministry is committed that the natural resources are
properly utilized for the benefit of the residents of NMR.
The Ministry has secured the assistance of the World Bank for a proposed Nairobi
Metropolitan Services Improvement Project (NaMSIP). The project is aimed at addressing
some of the challenges faced by the metropolitan region including the following:
Inadequate Solid Waste Collection and Environmentally hazardous dumping.

Inadequate water and Sanitation Services
Inadequate Storm Water Management Systems
Severe Transport Problems
Safety & Security.
The part of the assistance is directed towards development in Transport Sector and shall
be used for financing Consultancy Services for the Design and Supervision of
Construction works of the Kagundo - Kenol (C99), Kenol - Koma (E474) and Katumani Mombasa Road Junction at Konza (D522) and Rehabilitation of Kenol - MachakosTown Katumani (C99) Roads all in Machakos county.
CONSULTANTS APPOINTMENT
Ministry of Lands, Housing and Urban Development (MoLH&UD), Directorate of Nairobi
Metropolitan Development, (DoNMED), has appointed Intercontinental Consultants &
Technocrats (ICT) Pvt. Ltd, India in association with Geodev (K) Ltd Kenya (herein after
referred as Consultants) to provide
Consultancy Services for the Design and
Supervision of Construction works of Kagundo - Kenol (C99), Kenol - Koma (E474) and
Katumani - Mombasa Road Junction at Konza (D522) and Rehabilitation of Kenol MachakosTown - Katumani (C99) Road . The consultancy contract between MoLH&UD
and the Consultants was signed on 18th August 2014 and the commencement date was
set to 15th September 2014. The duration of the Phase A Detailed Engineering Design
of the consultancy services is 7 months.
PROJECT ROADS DESCRIPTION
The scope of the services involves preliminary and detailed design for the upgrading of:Section I:
Section II:
Section III:
Kagundo - Kenol (C99): 16.38km

Kenol - Koma (E474): 9.4km
Katumani - Mombasa Road Junction at Konza (D522): 9.0km
and rehabilitation of
Section IV:
Kenol - Machakos town - Katumani Road: 30.425km
All the four project roads are located in Machakos County.

A map showing the project roads in relation to the existing road network is given in the
December, 2014
Figure 1.1 : Index Map.

Figure 1.1 : Index Map
December, 2014
TOPOGRAPHY
Kagundo - Kenol (C99): Section 1
From Km 0+000, the road traverses a generally flat terrain at an average altitude of 1,500
meters A.M.S.L (above mean sea level) as it runs through various market centres
including Syanthi, Muonyweni and Kenol (Km 16+300).
Kenol - Machakos Town Katumani (C99): Section IV
From Km 0+000 the terrain changes is hilly with the alignment becoming increasingly
circuitous as it climbs to its highest elevation of about 1,800 meters A.M.S.L at Ngeleni
market. From Ngelani Market, the alignment descends steeply in tight curves to Mutituni
at Km 12+200. From Mutituni the terrain is progressively flattish as it runs through
Machakos Town to its end at Katumani at Km 30+100.
1.1
CURRENT ROAD CONDITION AND SURFACE TYPE

The consultancy services covers 4no sections as follows:Part A - Upgrading Design
Section I
: Kangundo - Kenol (C99): 16.38km
Section II
: Kenol - Koma (E474): 9.4km
Section III
: Katumani - Mombasa Road Junction at Konza (D522): 9.0km
The total length under Part A is approximately 34.78km and the surfaces of all the road
sections are entirely gravel and/or earth which are fairly motorable during dry weather.
Sections II and III becomes imposable during rainy seasons due to the predominant
expansive in-situ alignment soils. Under this part the consultant is required to carry out
alignment soils investigations, sample and test natural construction materials before
embarking on upgrading pavement design.
Part B Rehabilitation Design
Section IV
: Kenol - Machakos Town - Katumani (C99)
This
section
is
approximately
30.425km,
is
paved
and
requires
rehabilitation/reconstruction pavement design solutions. In addition to alignment soil
sampling, prospecting, sampling and testing natural construction materials, detailed
pavement evaluation by visual and equipment is also required.
The section can be categorised as follows:Km 0+000 (Kenol) - km 11+000 :- This road segment is fairly intact with isolated surface
distress, varying carriageway widths of 6-7m, no shoulders and cuts through a relatively
hilly terrain (Mua hills). The surfacing is double seal, base and sub-base is improved
gravels from km 0+000 - 2+000 while on the rest of the section both base and sub-base is
made of hard fill material.
Km 11+000 - km 20+800 (Machakos Town):- This road segment is dilapidated with
several surface distress like potholes, cracks, edge breaks, patches etc. The carriageway
widths varies between 5-6m with completely worn out shoulders. The surfacing is double
seal while both base and sub-base is made of hard fill material.
December, 2014
Km 20+800 (Machaoks Town) - km 27+900 (Katumani Market):- This road segment was
recently overlaid with 50mm thick asphalt concrete, but the failed shoulders were not
reconstructed. Both base and sub-base is made of hard fill material
Km 27+900 (Katumani Market) - km 30+425 (D522 Jnc):- This road segment was recently
re-sealed using 6/10mm chippings and again the failed shoulders were not reconstructed.
The surfacing is double seal while both base and sub-base comprises improved gravel.
CLIMATE AND RAINFALL
The project area lies in a moderate rainfall zone with a mean annual average of between
700 and 900 mm. Rainfall is fairly uniform throughout the area except on the high plateau
of Mua hills where annual rainfalls are much higher.
STRUCTURE OF THIS REPORT
This Preliminary Materials Report is presented in four chapters and six appendices.
The contents and main aspects contained in the various chapters and appendices are
highlighted below:Chapter 1 gives the general introduction of the project, including the project background,
project locations and information on the, current road condition, soils and
geology, climate and rainfall patterns in the project area;
Chapter 2 describes the materials investigations and pavement evaluation carried out to
form the basis for the design of the project road;
Chapter 3
presents, analyses and discusses results of materials investigations and
pavement evaluation carried out;
Chapter 4 presents the designs of pavements proposed for the project roads.
The appendices contain tables of the results of materials investigations and pavement
evaluation and are complementary to the information presented in the main text of the
report.
December, 2014
2.0
CHAPTER 2 - MATERIALS INVESTIGATIONS AND PAVEMENT

EVALUATION CARRIED OUT
MATERIALS INVESTIGATIONS FOR THE 4NO. ROAD SECTIONS
2.1.1 Alignment Soils

Alignment soils samples were collected from trial pits dug alternately on both sides of the
project road to an average depth of 1m at intervals of 500m. On section IV of the project
road, trial pits were dug outside the existing road width and samples taken for purposes of
widening design
The samples are being tested at Ministry of Transport and Infrastructures Regional
Laboratory in Machakos. The tests being carried out are as follows:Atterberg Limits;
Linear Shrinkage;
Particle Size Distribution;
Standard Compaction Test (AASHTO T99);
Standard CBR Test (4 days soak).
o
o
o
o
o
Test results are contained in appendix A.1.

2.1.2 Base-course and Sub-base materials
2.1.2.1
Gravels
12No. potential gravel sources were identified, sampled and tested. The sampling was
done by digging trial pits spaced appropriately at 30m grids. The details of these gravel
sites are as given in the table below with their locations relative to the project road
detailed in appendix C
Kangundo - Kenol (C99): Section I
Gravel
Site No.
01
02
03
Name of GS
Syanthi
Marys Farm
Mama Musimi
Location
(Km + m)
3+200
9+400
13+300
Offset
(km)
0.2
0.2
Location
(Km + m)
Offset
(km)
Side
Remarks
LHS
LHS
RHS
Kenol - Koma (E474): Section II

Gravel
Site No.
Name of GS
04
Lukenya
1+000
0.3
05
Koma
9+400
0.4
Side
Remarks
LHS
Along Kenol - Lukenya

road
Along Koma - Tala
road
RHS
Katumani - Mombasa Road Junction at Konza (D522): Section III

Gravel
Site No.
06
Name of GS
Katumani
Junction
Location
(Km + m)
Offset
(km)
0+580
0.3
Side
Remarks
LHS
December, 2014
LHS
07
Mombasa Road
9+000
4.1
4.1km from Konza

along Mombasa road,
Mombasa direction
Kenol - Machakos Town - Katumani (C99): Section IV

Gravel
Site No.
Name of GS
Location
(Km + m)
Offset
(km)
08
Mama Musimi
0+000
3.1
08A
Lukenya
1+000
1.3
09
Kyanda
12+600
4.0
10
Mutukus Farm
22+000
4.0
11
12
Mwasia
Katumani
26+000
28+600
1.1
0.6
Side
Remarks
RHS
3.1km from Kenol, along

Kenol - Kangundo Road
Along Kenol - Lukenya
road
RHS
RHS
LHS
along Machakos - Kitui

Road
RHS
LHS
Tests on neat gravel site samples

Samples from each positive trial pit were subjected to the following tests:
o
Atterberg Limits and;
o
Samples from trial pits were combined to form large samples for CBR testing in such a
manner as to obtain at least one sample for every 5,000m3 of material proposed for use.
Each large sample was subjected to the following tests:o
Atterberg Limits;
o
Linear Shrinkage;
o
o
Compaction Test (AASHTO T 180);
o
3-point CBR Test (4 days soak).
Results of these tests are presented in Appendix A.2
Tests on treated gravel site samples
In addition, treatment tests are being carried out on each of the large samples using
Portland Cement CEM II 42.5N (POWER MAX) as improvement agent conforming to KS
EAS 18-1:2001 - Part I manufacturing standards.
The general criteria summarized in the table 1 below were used to assess the gravels
suitability for treatment with either lime or cement.
% passing 0.075 mm sieve
Less than 25%
More than 25%
PI (%)
PI is less than 6% or
PI x (% pass. 0.075 mm)
Is less than 60
6 - 10
More than 10
Less than 10
10 - 20
Best suited stabiliser

Cement only
Cement preferred
Cement or lime
Cement preferred
Cement or lime
Table 7.2 in the overseas road note 31
December, 2014
More than 20
In the following table, results of the evaluation is presented:GS No.
01
02
03
04
05
06
07
08
8A
09
10
11
12
% passing 0.075 mm
sieve
21
36
29
23
34
22
20
28
23
39
34
34
24
PI
(%)
10
12
12
9
17
8
6
8
9
11
14
14
8
Lime preferred
% passing 0.075
mm x PI
210
432
348
207
578
176
120
224
207
429
476
476
192
Best suited
stabiliser
Cement preferred
Cement or lime
Cement or lime
Cement preferred
Cement or lime
Cement preferred
Cement preferred
Cement preferred
Cement preferred
Cement or lime
Cement or lime
Cement or lime
Cement preferred
Each large sample is being tested as follows:o Compaction test (Heavy Compaction) on the large samples mixed at 2%, 3% and
4% cement content;
o CBR at 7 days cure + 7 days soak on specimens moulded dynamically at OMC
and 95% MDD at the above improvement contents;
o Atterberg limits after CBR testing.
2.1.2.2
Soft Stone
Soft stone is available between km 3+750 and 8+500 along Kangundo - Kenol road
section. Samples were taken from Syanthi area (km 6+100) for testing with the intension
here being to check if the properties satisfies the requirements for soft stone sub-base as
contained in RDM III
The sample was subjected to the following tests:o Los Angeles Abrasion (LAA);
o Plasticity Index (PI) on LAA fines;
o Aggregate Crushing Value (ACV);
o 10% Fines Aggregate Crushing Test (10% FACT);
o Sodium Sulphate Soundness (SSS);
o Specific Gravity and Water Absorption
2.1.2.3
Hard-Stone Quarry
Hardstone
Quarry No.
1No. possible hard-stone quarry detailed below was identified for Graded Crushed Stone,
surfacing and concrete works. Surface samples were picked from HSQ 01 and subjected
to the following tests:-
HSQ 01
Name of
HardStone
Quarry
Location
(Km)
Kinyau
11+750
Side
Distance
to the
project
road (km)
Remarks
LHS
Next to
Unexploited quarry along
December, 2014
Road
Kangundo - Kenol (C99) Road
o Los Angeles Abrasion (LAA);
o Plasticity Index (PI) on LAA fines;
o Aggregate Crushing Value (ACV);
o Aggregate Impact Value (AIV);
o 10% Fines Aggregate Crushing Test (10% FACT);
o Content;
o Specific Gravity and Water Absorption;
o Bitumen Affinity (static immersion test - AASHTO T182) using 80/100 and 60/70
penetration grade bitumen and K1-70 emulsions.
Results obtained are reported in section 3.1.4 of this report
2.1.2.4
Fine aggregates
2no. samples of fine aggregates were collected and tested. 1no sample of crushed rock
sand from the hard-stone source detailed in section 2.1.2.3 above and 1no. sample of
river sand from Kathiani river at km 16+100, 16.7km off, LHS along road section I
The samples were subjected to the following tests:o Grading to 0.075mm sieve;
o Clay, Silt and dust Content;
o Sulphate Content as SO3 (%m/m);
o Chloride Content as cl- (%m/m);
o Organic Content;
o Sand Equivalent Value.
Results obtained are reported in section 3.1.5 of this report
2.1.2.5
Water for Construction
Water is scarce within the project area and the contractor would be expected to include
the cost of providing acceptable water for the works in his rates as this may involve either
sinking boreholes or hauling water. Only river Mwania which crosses road section IV at
km 26+700 is available for construction works within the whole project area.
Water from this river is potable and hence considered as suitable for use in concrete as
per the guidelines contained in BS EN 1008:2002, Mixing water for concrete Specification for sampling, testing and assessing the suitability of water, including water
recovered from processes in the concrete industry as mixing water for concrete
Nevertheless, a sample was taken for testing to confirm its suitability for road construction
at the University of Nairobis Water and Waste Water laboratory and the test results are
contained in appendix A.3 of this report.
PAVEMENT EVALUATION FOR ROAD SECTION IV
2.1.3 General
The following investigations into the functional and structural condition of the road
pavement were carried out:(a) Pavement surface condition survey comprising detailed visual inspection and rut
measurement and
December, 2014
(b) Deflection measurement using FWD;

2.1.4 Detailed Visual Inspection
Detailed visual inspections of the road was conducted in order to classify visually
discernible pavement distress features and their level of severity, in accordance with
guidelines contained in RDM Part V (May, 1988). The features are as follows:
Cracking;
Longitudinal deformation e.g., corrugations and undulations;
Surface disintegration e.g., potholes, patching, peeling;
Edge spalling (edge breaks);
Bleeding;
Depressions and upheavals;
Drainage problems.
A summary of the findings are contained in appendix B.1 of this report

2.1.5 Falling Weight Deflectometer (FWD) Survey
The consultant contracted, MTRD to carry out and analyse deflection measurements
using Falling Weight Deflectometer (FWD). The measurements were done on the outer
wheel paths of both lanes at 100m spacing.
2.1.6 Trial Pitting (Trenching)
Trial trenches were excavated on both lanes at approximately 5km intervals along the
road, alternating from one lane to the other. Actual trench locations were the product of
considerations of safety and pavement type. The trenches were excavated across the
edge of the carriageway in such a manner as to expose both the carriageway and
shoulder construction. In-situ densities of granular layers were measured by the sand
replacement method as trenching progressed up to the native sub-grade. Detailed logging
of each trench was done by the Materials Engineer and samples of material taken for
testing at Highways laboratory, University of Nairobi.
Granular materials including sub-grade were subjected the following tests: Atterberg limits;
Sieve analysis;
Compaction: AASHTO T 99 for sub-grade and T 180 for sub-base and base;
CBR, 4 days soak, on samples compacted to the density and moisture content
specified in the Standard Specifications for the subject layer.
A summary of the laboratory and field test results are contained in sections 3.2.2 and
3.2.3 respectively of this report with the detailed test results in appendix B.2 and trenching
logs in appendix D.
2.1.7 Dynamic Cone Penetrometer (DCP) Testing
The in-situ strength (CBR) of unbound pavement layers and sub-grade was measured
using the Dynamic Cone Penetrometer (DCP) developed by the Transport Research
Laboratory (TRL). The DCP is an instrument designed for the rapid in-situ measurement
of the structural properties of existing road pavements with unbound materials. It consists
of a penetration rod 20mm in diameter with a 60-degree cone screwed to its tip. The
penetration rod is driven through the pavement layers by hammering with an 8kg weight,
falling through a height of 575mm. The DCP operates on the principle that the rate of
penetration of the cone is inversely related to the strength of the material as measured by
December, 2014
CBR. Conversion of the rate of penetration to CBR was done using the correlation
developed by Klyne and Van Heerden.
DCP testing was done right from the pavement surface and testing was performed on
alternate lanes on the outer wheel paths, at intervals of approximately 1km.
A summary of results of this investigation is contained in appendix B.3.
December, 2014
3.0
CHAPTER 3 - RESULTS OF MATERIAL TESTING AND PAVEMENT

INVESTIGATIONS
RESULTS OF MATERIAL TESTING

3.1.1 Alignment Soils
Alignment soils on the project roads are as follows:Road Section
Type of alignment soils
Kangundo - Kenol (C99)

Kenol - Koma (E474)
Katumani - Mombasa Road
Junction at Konza (D522)
Kenol - Machakos Town Katumani (C99)
Predominantly Silty Gravels

Predominantly Clayey Soils
Predominantly Clayey Soils
Rating as Sub-grade
material
Excellent to Good
Fair to Poor
Fair to Poor
Predominantly Silty Gravels
Excellent to Good
3.1.2 Base-course and Sub-base materials

3.1.2.1
Gravels
The table below summarizes the Road Design Manual Part III and/or standard
specification for road and bridge construction specifications for lime and cement improved
sub-base and base-course gravels.
Parameter
Maximum size
(mm)
Passing 0.075
mm (%)
Passing 0.425
mm (%)
Plasticity Index
(%)
Plasticity
Modulus
Organic matter
(%)
CBR at 95%
MDD
(4 days soak)
(%)
CBR at 95%
MDD
(7 days cure +
7 days soak)
(%)
Pavement layer
Sub-base
Base-Course
Before
Before
Treatment
Treatment
After
After
Treatment
Treatment
With
With
With
With
Lime
Cement
Lime
Cement
10 - 15
10 - 15
10 - 50
10 - 50
40
max.
40 max.
5 -35
5 -35
15 min.
15 min.
10 - 30
30 max.
15 max
10 - 25
25 max.
6 max.
2500
max.
2%
max
2500
max.
250 max.
2000
max.
2000
max.
250 max.
1% max
1% max
20 min.
20 min.
2% max
60 min.
160
n.
December, 2014
Suitability of material before improvement

The tables below summarises suitability assessment of improved natural gravel for subbase and base-course.
Passing 0.075mm Sieve Criterion
GS
No.
Passing
0.075
mm (%)
01
02
03
04
05
06
07
08
08A
09
10
11
12
21
36
29
23
34
22
20
28
23
39
34
34
24
With
lime
Subbase
40
max
Specifications
With
With
Lime
Cement
Base
5 - 35
Sub-base
40 max
With
cement
Remarks
Base
5 - 35
Meets specification for

treatment with lime
and cement for both
sub-base and base
except GS No. 09
which fails to meet
neat requirements for
lime and cement
treated base-course
Passing 0.425 mm Sieve Criterion
GS
No.
Passing
0.425
mm (%)
01
02
03
04
05
06
07
08
08A
09
10
11
12
43
47
39
40
53
42
34
40
40
51
55
61
46
With
lime
Subbase
15 min.
Specifications
With
With
Lime
Cement
SubBase
base
15 min.
With
Cement
Remarks
Base

treatment with lime
and cement for both
sub-base and base
December, 2014
Plasticity Criterion
01
02
03
04
05
06
07
08
08A
09
10
11
12
13
14
15
11
18
10
6
10
11
18
18
17
10
13
14
16
14
22
10
7
13
14
18
22
18
12
6
8
7
6
15
6
6
6
6
6
8
11
5
10
12
12
9
17
8
6
8
9
11
14
14
8
10 25
CementWith
Remarks
Base
With Lime
Base
10 30
Sub-base CementWith
With lime
Sub-base
Specifications
Mean
Min.
Max.
GS No.
10th %-tile
Plasticity Index (%)
30
max

treatment with lime
and cement for both
sub-base and base
except GS No. 07
which fails to meet
neat requirements for
lime treated sub-base
and base-course
25
max
Plasticity Modulus Criterion
2500 2000
max max
2500
max
CementWith
Remarks
Base
Sub-base CementWith
438
559
467
352
910
307
142
328
352
569
756
884
391
With Lime
240
230
294
228
748
222
102
228
228
288
520
462
245
Base
598
812
672
560
1320
462
294
546
560
954
1188
1296
636
With lime
Mean
584
777
592
445
1129
378
202
415
445
900
1017
1088
551
Specifications
Sub-base
Min.
01
02
03
04
05
06
07
08
08A
09
10
11
12
Max.
GS No.
10th %-tile
Plasticity Modulus
2000
max
Meets specification
for treatment with
lime and cement
for both sub-base
and base
December, 2014
CBR Criterion
CBR at 95%
MDD (4 days
soak) (%)
20
min
CementWith
Remarks
Base
49
35
42
40
30
38
42
49
40
60
50
43
53
Sub-base CementWith
48
33
40
40
29
38
40
47
40
50
47
41
52
01
02
03
04
05
06
07
08
08A
09
10
11
12
With Lime
Mean
Base
90th %tile
Sub-base With lime
GS
No.
Specifications
20
min

treatment with lime and
cement for both sub-base
and base
Overall assessment
The overall assessment is summarised in the table below:Gravel Site No.
01
02
03
04
05
06
07
08
08A
09
10
11
12
Suitability for cement or lime improved natural gravel for

Base-Course
Sub-base
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable only with cement
Suitable only with cement
Suitable
Suitable
Suitable
Suitable
Unsuitable
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
Suitable
3.1.3 Soft stone for sub-base

The table below compares the results of the tests on soft stone and the specifications for
sub-base as outlined under section 7.2.5 of the Road Design Manual Part III
December, 2014
Parameter
Test Results
Los Angeles Abrasion (LAA)

Aggregate Crushing Value (ACV)
Aggregate Impact Value (AIV)
10% FACT (KN)
Sodium Sulphate Soundness (SSS)
Plasticity Index (PI) on LAA fines
Specific Gravity
Water Absorption
40
42
18
273
22
Non-Plastic
1.79
15.6
Specifications for
sub-base
70 max
N/A
N/A
N/A
N/A
Non-Plastic
N/A
N/A
3.1.4 Hard-Stone
The table below compares the results of the tests on hard-stone quarries and the
specifications for GCS, surface dressing, asphalt concrete and concrete works as
outlined in the standard specifications for road and bridge construction, Road Design
Manual Part III and ORN 19.
Parameter
Los Angeles
Abrasion (LAA)
Aggregate Crushing
Value (ACV)
Aggregate Impact
Value (AIV)
Chloride Content
(chloride ion)
10% FACT (KN)
Sodium Sulphate
Soundness (SSS)
Plasticity Index (PI)
on LAA fines
Specific Gravity
Water Absorption
80/100 pen. grade
bitumen
60/70 pen. grade
bitumen
K1-70 emulsion
Specifications for
Surface
GCS (Stone
Test
Dressing Spec. Asphalt
Class C Results
(Chippings
Concrete
0/40mm)
Class 2)
for base
Concrete
works
16
25 max
35% max
45 max
50 max
19
20 max
25% max
32 max
35 max
10
25% max
45 max
0.03 Max
1,014
160 min
2.4
12 max
10 max
12 max
12 max
NP
Non-Plastic
NP
NP
N/A
2.45
1.4
2.0% Max
2.5% Max
>95
>95
95% min
>95
The result shows compliance with the respective specifications

Due to the need to make GCS more cohesive and hence increase its capacity to
withstand horizontal stresses, in the event GCS from analysis of material tests results
December, 2014
emerges more viable then, the consultant proposes treatment of the GCS with a nominal
cement content of 2%.
3.1.5 Fine Aggregates
The test results for the 2no fine aggregate samples proposed for concrete works are
tabulated against specifications in the table below:Test Results/sand source
River sand
Crushed rock
from
sand from
River
Kinyua
Kathiani
Quarry
Passing 5mm and 75m sieves
(%)
Parameter
Grading to
0.075mm sieve
94 and 15
Sulphate content
as SO3 (%m/m)
Chloride Content
as cl- (%m/m)
Organic matter
content (%)
Sodium Sulphate
Soundness (%)
Sand Equivalent
(%)
Specification
Passing 5mm sieve: 100% Min

and Passing 0.075mm sieve: 3%
Max (uncrushed), 15% max
Not applicable as
(crushed) Grading shall be in
sample was hand
accordance with zones 1, 2 or 3 of
crushed
BS 882:1973
0.4% max
0.05% max
Trace
7.0
2.8
10% max
40min for asphalt concrete works
Particle size,
D(mm)
Grading of fine aggregates

River sand from
Crushed rock sand from
River Kathiani
Kinyua Quarry
10
5
2.36
1.18
0.6
0.3
0.15
0.075
97
94
89
73
45
29
18
15
Not applicable as sample

was hand crushed
Cumulative percentage finer than D
Testing is ongoing and complete results will be included in the next report
December, 2014
RESULTS OF PAVEMENT INVESTIGATIONS

3.1.6 Pavement condition survey
Below is a narrative description of the pavement condition for the Kenol - Machakos Town
- Katumani road section
Km 0+000 (Kenol) - km 11+000 :- This road segment is fairly intact with isolated surface
distress, varying carriageway widths of 6-7m, no shoulders and cuts through a relatively
hilly terrain (Mua hills). The surfacing is double seal, base-course and sub-base are
improved gravels from km 0+000 - 2+000 while on the rest of the section both base and
sub-base is made of hard fill material.
Km 11+000 - km 20+800 (Machakos Town):- This road segment is dilapidated with
several surface distress like potholes, cracks, edge breaks, patches etc. The carriageway
widths varies between 5-6m with completely worn out shoulders. The surfacing is double
seal while both base and sub-base is made of natural gravel.
December, 2014
Km 20+800 (Machaoks Town) - km 27+900 (Katumani Market):- This road segment was
recently overlaid with 50mm thick asphalt concrete, but the failed shoulders were not
reconstructed. Both base and sub-base is made of natural gravel
Km 27+900 (Katumani Market) - km 30+100 (D522 Jnc):- This road segment was recently
re-sealed using 6/10mm chippings and again the failed shoulders were not reconstructed.
The surfacing is double seal while both base and sub-base comprises improved gravel
3.1.7 Trenched samples from existing sub-grade, sub-base and base-course layers
Laboratory soaked CBRs (T99/T180) at 100% and 95% MDD and OMC and PIs for
existing sub-grade, sub-base and bas-course derived from trenched samples are as
summarised in the table below:Chainage
(km+m)
0+000 R
5+000 L
10+000 L
15+000 R
20+000 L
25+000 R
31+000 L
Sub-grade
Sub-base
Base-course
CBR
PI
CBR
PI
CBR
PI
7
10
7
11
20
23
9
21
25
20
23
29
23
21
14
N/A
N/A
11
28
32
58
22
N/A
N/A
20
26
19
NP
45
N/A
N/A
32
38
12
54
16
N/A
N/A
18
17
34
NP
Av. for the 3no. layers

Sub-grade
CBR
PI
class
22
20
S5
10
25
S2
7
20
S2
18
20
S4
29
24
S5
22
25
S5
40
11
S6
3.1.8 Relative compactions and moisture contents for the existing pavement layers
Relative compactions and moisture contents on existing sub-grade, sub-base and basecourse layers are tabulated in the table below:Chainage
(km+m)
0+000 R
5+000 L
10+000 L
15+000 R
20+000 L
25+000 R
31+000 L
Sub-grade
FDD
Moisture
(%)
(%)
91
89
73
77
86
86
92
84
84
67
85
78
88
66
Sub-base
FDD
Moisture
(%)
(%)
80
69
N/A
N/A
N/A
N/A
73
82
84
51
74
93
88
61
Base-course
FDD
Moisture
(%)
(%)
81
112
N/A
N/A
N/A
N/A
78
91
83
91
86
54
92
56
December, 2014
4.0
CHAPTER 4 - ANALYSIS OF MATERIALS TEST RESULTS AND PAVEMENT

DESIGN
ANALYSIS OF ALIGNMENT CBR VALUES FOR ROAD SECTION I
From the alignment CBRs, the road was delineated into sections by statistical analysis
(cumulative sum method) as shown in the respective charts below. Tables 4.1 shows the
different sections with the corresponding design CBRs and sub-grade classes
Table 4.1 - Alignment CBR Values
Chainage (Km)
Design
Sub-grade
CBR (%)
Class
From
To
0+000
0+500
28
S5
0+500
1+000
20
S5
1+000
3+750
29
S5
3+750
8+500 Rocky Section (Not Sampled)
8+500 10+000
20
S5
10+000 10+500
28
S5
10+500 11+000
15
S4
11+000 11+500
37
S6
11+500 12+000
16
S4
12+000 13+500
30
S5
13+500 15+500
11
S3
15+500 16+500
30
S5
Summary
S3 : 2.0km (12%)
S4 : 1.0km (6%)
Distance
(km)
0.5
0.5
2.75
4.75
1.5
0.5
0.5
0.5
0.5
1.5
2.0
1.0
S5 : 8.25km (50%)
Cumulative
distance (km)
0.5
1.0
3.75
8.5
10.0
10.5
11.0
11.5
12.0
13.5
15.5
16.5
S6 : 0.5km (3%)
Rocky Section : 4.75km (29%)
December, 2014
ROCKY SECTION
- NOT SAMPLED
December, 2014
ROCKY SECTION NOT SAMPLED
4.1.1 Proposed Embankment Construction Approach

Material for fill including sub-grade shall be soil class S4 (minimum CBR of 14% and a
swell of less than 1% measured after 4 day soak) quality. The top 300mm shall form the
sub-grade layer and be compacted to 100% MDD (AASHTO T99) while the layers below
the sub-grade shall be compacted to 95% MDD (AASHTO T99).
4.1.2 Adopted/New design sub-grade class
The resultant sub-grade class becomes S4
ANALYSIS OF ALIGNMENT CBR VALUES FOR ROAD SECTION II
December, 2014
Chainage (Km)
From
To
0+000
0+500
0+500
1+000
1+000
2+000
2+000
4+000
4+000
4+500
4+500
8+500
8+500
9+500
Summary
S1 : 6.0km (63%)
Design
CBR (%)
27
9
31
4
26
3
31
Sub-grade
Class
S5
S2
S6
S1
S5
S1
S6
S2 : 0.5km (5%)
Distance
(km)
0.5
0.5
1.0
2.0
0.5
4.0
1.0
S5 : 1.0km (11%)
Cumulative distance
(km)
0.5
1.0
2.0
4.0
4.5
8.5
9.5
S6 : 1.0km (22%)
December, 2014

Km 0+000 - 2+000, 4+000 - 4+500 and km 8+500 - 9+500: 3.5km (37%)
Km 2+000 - 4+000 and Km 4+500 - 8+500: 6.0km (63%)
Cut to spoil to 1m below formation level and backfill or fill 1m above the expansive
clays/weak soils to formation level with S4 quality material. The top 300mm shall form the
4.1.4
Adopted/New design sub-grade class

December, 2014
ANALYSIS OF ALIGNMENT CBR VALUES FOR ROAD SECTION III

Chainage (Km)
From
To
0+000
1+500
1+500
6+500
6+500
7+000
7+000
8+000
8+000
8+500
8+500
9+000
Summary
S1 : 6.0km (67%)
Design CBR
(%)
13
3
9
4
21
7
Sub-grade
Class
S3
S1
S2
S1
S5
S2
S2 : 1.0km (11%)
Distance
(km)
1.5
5.0
0.5
1.0
0.5
0.5
S3 : 1.5km (17%)
Cumulative
distance (km)
1.5
6.5
7.0
8.0
8.5
9.0
S5 : 0.5km (6%)
December, 2014
December, 2014

Km 0+000 - 1+500, 6+500 - 7+000 and km 8+000 - 9+000: 3.0km (33%)
Km 1+500 - 6+500 and Km 7+000 - 8+000: 6.0km (67%)
Cut to spoil to 1m below formation level and backfill or fill 1m above the expansive
clays/weak soils to formation level with S4 quality material. The top 300mm shall form the
December, 2014
ANALYSIS OF ALIGNMENT CBR VALUES FOR ROAD SECTION IV

Chainage (Km)
From
To
0+000
2+000
2+000
3+000
3+000
6+000
6+000
6+500
6+500
7+000
7+000
8+000
8+000
8+500
8+500
9+000
9+000 10+500
10+500 12+000
12+000 12+500
12+500 13+000
13+000 14+500
14+500 17+500
17+500 18+500
18+500 19+000
19+000 19+500
19+500 21+500
21+500 23+000
23+000 27+000
27+000 27+500
27+500 28+500
28+500 29+000
29+000 31+000
Design CBR
Sub-grade
(%)
Class
27
S5
11
S3
20
S4
18
S4
19
S5
16
S4
29
S5
12
S3
20
S5
7
S2
29
S5
14
S4
28
S5
14
S4
22
S5
14
S4
11
S3
22
S5
Machakos Town (Not Sampled)
13
S3
36
S6
10
S2
27
S5
11
S3
Summary
S2 : 2.5km (8%)
S3 : 8.0km (26%)
S6 : 0.5km (2%)
Not Sampled : 1.5km (5%)
Distance
(km)
2.0
1.0
3.0
0.5
0.5
1.0
0.5
0.5
1.5
1.5
0.5
0.5
1.5
3.0
1.0
0.5
0.5
2.0
1.5
4.0
0.5
1.0
0.5
2.0
S4 : 8.5km (27%)
Cumulative
distance (km)
2.0
3.0
6.0
6.5
7.0
8.0
8.5
9.0
10.5
12.0
12.5
13.0
14.5
17.5
18.5
19.0
19.5
21.5
23.0
27.0
27.5
28.5
29.0
31.0
S5 : 10.0km (32%)
December, 2014
10
December, 2014

Material for fill both on the widening benches and on the existing road width including
sub-grade shall be soil class S4 (minimum CBR of 14% and a swell of less than 1%
measured after 4 day soak) quality. The top 300mm shall form the sub-grade layer and be
compacted to 100% MDD (AASHTO T99) while the layers below the sub-grade shall be
compacted to 95% MDD (AASHTO T99).
FACTUAL DESIGN DETAILS
Road Name / Section

Kenol - Koma / II
Kangudo - Kenol / I
Kenol - Machakos / IV
Machakos - Katumani / IV
Katumani - Konza / III
AADT
in year
10
(PCU)
4,261
2,504
18,930
8,658
2,331
Design
CrossSection
Type
II
II or III
II
II
II or III
Width of
Shoulder Design
Traffic
Carriageway
Width
Class
(m)
(m)
7.0
7.0
7.0
7.0
7.0
1.5
1.5
1.5
1.5
1.5
T3
T3
T3
T3
T3
ADOPTED DESIGN DETAILS

From the traffic data based on medium growth rate, the pavement has been designed
based on traffic class T3 while the cross section adopted is type II (carriageway width of
7.0m and shoulder width of 1.5m) for all the project roads.
PROPOSED PAVEMENT STRUCTURES FOR ROAD SECTIONS I, II AND III
In view of the material test results presented under section 3 of this report, the analysis
thereof, the consultant proposes the following pavement options as detailed in the table
below for the road sections I, II and III.
11
Consulting Services for the Design and Supervision of construction works for Kangundo - Kenol (C99), Kenol - Koma (E474), Katumani - Mombasa Road Junction at Konza (D522) and Rehabilitation of
Kenol - Machakos Town - Katumani (C99) Roads
December, 2014
Design Parameters
Design traffic class
Design sub-grade class
Design life
Design Period
Procurement for works
contract
Scheduled start of
construction
Scheduled end of
construction
Road cross section
Fill including sub-grade

in embankments and
cuttings
Design Details
Kangundo
Kenol Kenol - Koma (E474) - Section II
Katumani - Mombasa Road Junction at
(C99) Road - Section I
Konza (D522) - Section III
T3
S4
20 Years
September 2014 - April 2015
May 2015 - July 2015
August 2015
January 2018
7.0m carriageway and 1.5m shoulders on each side. The shoulders
guardrails are required
Material for fill including Km 0+000 - 2+000, 4+000 - 4+500 and km
sub-grade shall be soil 8+500 - 9+500: 3.5km (37%)
class S4 (minimum Material for fill including sub-grade shall be
CBR of 14% and a soil class S4 (minimum CBR of 14% and a
swell of less than 1% swell of less than 1% measured after 4 day
measured after 4 day soak) quality. The top 300mm shall form the
soak) quality. The top sub-grade layer and be compacted to 100%
300mm shall form the MDD (AASHTO T99) while the layers below
sub-grade layer and be the sub-grade shall be compacted to 95%
compacted to 100% MDD (AASHTO T99).
MDD (AASHTO T99) Km 2+000 - 4+000 and Km 4+500 while the layers below 8+500: 6.0km (63%)
the sub-grade shall be Cut to spoil to 1m below formation level and
compacted to 95% backfill or fill 1m above the expansive
MDD (AASHTO T99).
clays/weak soils to formation level with S4
quality material. The top 300mm shall form
the sub-grade layer and be compacted to
100% MDD (AASHTO T99) while the layers
below the sub-grade shall be compacted to
95% MDD (AASHTO T99).
shall be widened by 0.5m on high fills where

Km 0+000 - 1+500, 6+500 - 7+000 and km
8+000 - 9+000: 3.0km (33%)
Material for fill including sub-grade shall be
soil class S4 (minimum CBR of 14% and a
swell of less than 1% measured after 4 day
soak) quality. The top 300mm shall form the
sub-grade layer and be compacted to 100%
MDD (AASHTO T99) while the layers below
the sub-grade shall be compacted to 95%
MDD (AASHTO T99).
Km 1+500 - 6+500 and Km 7+000 - 8+000:
6.0km (67%)
Cut to spoil to 1m below formation level and
backfill or fill 1m above the expansive
clays/weak soils to formation level with S4
quality material. The top 300mm shall form
the sub-grade layer and be compacted to
100% MDD (AASHTO T99) while the layers
below the sub-grade shall be compacted to
95% MDD (AASHTO T99).
12
Consulting Services for the Design and Supervision of construction works for Kangundo - Kenol (C99), Kenol - Koma (E474), Katumani - Mombasa Road Junction at Konza (D522) and Rehabilitation of
Kenol - Machakos Town - Katumani (C99) Roads
December, 2014
Sub-base
Base-course
Prime coat
Standard
Pavement Surfacing, 1A
Structure
Type 3 Pavement
option 1
Surfacing, 1B
Standard Sub-base
Pavement Base-course
Structure Prime coat
Type 7 Pavement Surfacing
option 2
Binder for Surface dressing
Binder for AC
Tack coat
175mm thick 2% cement improved gravel (Type of cement is CEM II, 42.5N)
MC 30 (base-course surface is close textured and hence requires less viscous primer)
50mm (0/20mm) thick binder course asphalt concrete (SUPERPAVE) to cover the carriageway only covered with
10/14mm single seal surface dressing. Shoulders shall be covered with double seal surface dressing (14/20mm +
6/10mm chippings). Chippings for surface dressing shall be class 2 (vehicles per day on the 2 lanes in year of
application of chippings is 2,000 - 6,000). The coarse aggregate for the asphalt concrete shall satisfy the
requirements contained in table 4.1 of ORN 19.
0/20mm, 50mm and 0/14mm, 35mm thick asphalt concrete designed to SUPERPAVE requirements following ORN
19 and asphalt institute, MS-2, 1994 to cover the carriageway and shoulders respectively. The asphalt concrete on
both the carriageway and shoulders shall be covered with 10/14mm single seal surface dressing. Chippings for
surface dressing shall be class 2 (vehicles per day on the 2 lanes in year of application of chippings is 2,000 6,000). The coarse aggregate for the asphalt concrete shall satisfy the requirements contained in table 4.1 of ORN
19.
150mm thick 2% Cement Treated Graded Crushed Stone (Type of cement is CEM I, 42.5N)
MC 70 (base-course surface is open textured and hence requires more viscous primer)
Same as for option 1B
80/100 cut back (Contractor to propose for approval by the Engineer the cuttings details during construction)
60/70 penetration grade bitumen (harder bitumen is required particularly due to the hot weather around the project
location)
K1-70 cationic emulsion
13
December, 2014
DESIGN FOR KENOL - MACHAKOS TOWN - KATUMANI ROAD SECTION

4.1.9
General Approach
The approach to the design of rehabilitation/reconstruction proposals made herein
considers the technical feasibility of various improvement strategies based on the
assessed functional and structural status of the road and is intended to provide for further
design life of 20 years. The proposals for rehabilitation/reconstruction have also been
designed to realise, as far as practicable, the immense economic and environmental
benefits of the recycling of existing pavement materials.
For the following reasons, the consultant proposes 3no reconstruction options:1. materials forming the existing sub-base and base courses exhibits high PI and low
CBR values;
2. relative compaction densities and relative moisture contents for sub-grade, subbase and base layers do not comply with the specifications - see section 3.2.5 and
appendix B.4 of this report;
3. Part of the road section (km 2+000 - 11+000) comprises non-standard sub-base
and base-course made of hard fill material;
4. widening of the cross section is required to accommodate 7.0m wide carriageway
and 1.5m wide shoulders on either side;
4.1.10 Proposed pavement structures
Pavement Option 1 : Type 3 pavement on class S4 sub-grade and T3 Traffic

class
1.
Widen the road through benching to the bottom of the existing sub-grade layer to
accommodate 7.0m wide carriageway and 1.5m wide shoulders on either side.
Material for fill including sub-grade on the widening benches and on the existing
road width shall be soil class S4 (minimum CBR of 14% and a swell of less than
1% measured after 4 day soak) quality. The top 300mm shall form the sub-grade
layer and be compacted to 100% MDD (AASHTO T99) while the layers below the
sub-grade shall be compacted to 95% MDD (AASHTO T99).
2.
Km 2+000 - 11+00: scarify the surfacing, base-course and sub-base and stockpile
for re-use as directed by the engineer;
Scarify the existing sub-grade layer, add additional S4 quality material (minimum
CBR of 14% and a swell of less than 1% measured after 4 day soak) as
necessary, lay, process and compact to 100% of MDD (AASHTO T99) to form
150mm thick compacted layer of lower sub-grade spread across the carriageway
and the shoulders. This yields S4 sub-grade class;
3.
Km 0+000 - 2+000, km 11+000 - 20+800 and km 27+900 - 30+425:- Scarify the

existing surfacing, base-course, sub-base and sub-grade layers, add additional S4
quality material (minimum CBR of 14% and a swell of less than 1% measured
after 4 day soak) as necessary, lay, process and compact to 100% of MDD
(AASHTO T99) to form 150mm thick compacted layer of lower sub-grade spread
across the carriageway and the shoulders. This yields S4 sub-grade class;
4.
Km 20+800 - 27+900:-
14
December, 2014
(a) Mill the existing asphalt concrete surfacing and use the milled
material for surfacing deviations;
(b) Scarify the existing base-course, sub-base and sub-grade layers,
add additional S4 quality material (minimum CBR of 14% and a
swell of less than 1% measured after 4 day soak) as necessary, lay,
process and compact to 100% of MDD (AASHTO T99) to form
150mm thick compacted layer of lower sub-grade spread across
the carriageway and the shoulders. This yields S4 sub-grade class;
5.
Provide S4 quality material (minimum CBR of 14% and a swell of less than 1%
measured after 4 day soak), lay, process and compact to 100% of MDD (AASHTO
T99) to form 150mm thick compacted natural gravel upper sub-grade spread
across the carriageway and the shoulders;
6.
Provide, lay, process and compact to 95% of MDD (AASHTO T180) 175mm thick,
2% cement improved gravel for new sub-base layer;
7.
4% cement improved gravel for new base layer;
8.
Surfacing
i.
1A: 50mm (0/20mm) thick binder course asphalt concrete (SUPERPAVE)
to cover the carriageway only covered with 10/14mm single seal surface
dressing. Shoulders shall be covered with double seal surface dressing
(14/20mm + 6/10mm chippings). Chippings for surface dressing shall be
class 2 (vehicles per day on the 2 lanes in year of application of chippings
is 2,000 - 6,000). The coarse aggregate for the asphalt concrete shall
satisfy the requirements contained in table 4.1 of ORN 19;
ii.
9.
10.
11.
12.
1B: 0/20mm, 50mm and 0/14mm, 35mm thick asphalt concrete designed
to SUPERPAVE requirements following ORN 19 and asphalt institute, MS2, 1994 to cover the carriageway and shoulders respectively. The asphalt
concrete on both the carriageway and shoulders shall be covered with
10/14mm single seal surface dressing. Chippings for surface dressing shall
be class 2 (vehicles per day on the 2 lanes in year of application of
chippings is 2,000 - 6,000). The coarse aggregate for the asphalt concrete
shall satisfy the requirements contained in table 4.1 of ORN 19.
Prime Coat: MC-30;

Tack-coat:K1-70;
Binder for surface dressing: 80/100 cut back bitumen
Binder for asphalt concrete: 60/70 pen grade bitumen
Pavement Option 2 : Type 7 pavement on class S4 sub-grade and T4 traffic

class
1.
Widen the road through benching to the bottom of the existing sub-grade layer to
accommodate 7.0m wide carriageway and 1.5m wide shoulders on either side.
Material for fill including sub-grade on the widening benches and on the existing
road width shall be soil class S4 (minimum CBR of 14% and a swell of less than
1% measured after 4 day soak) quality. The top 300mm shall form the sub-grade
layer and be compacted to 100% MDD (AASHTO T99) while the layers below the
sub-grade shall be compacted to 95% MDD (AASHTO T99).
15
December, 2014
2.
Km 2+000 - 11+00: scarify the surfacing, base-course and sub-base and stockpile
for re-use as directed by the engineer;
Scarify the existing sub-grade layer, add additional S4 quality material (minimum
CBR of 14% and a swell of less than 1% measured after 4 day soak) as
necessary, lay, process and compact to 100% of MDD (AASHTO T99) to form
150mm thick compacted layer of lower sub-grade spread across the carriageway
and the shoulders. This yields S4 sub-grade class;
3.
Km 0+000 - 2+000, km 11+000 - 20+800 and km 27+900 - 30+425:- Scarify the

existing surfacing, base-course, sub-base and sub-grade layers, add additional S4
quality material (minimum CBR of 14% and a swell of less than 1% measured
after 4 day soak) as necessary, lay, process and compact to 100% of MDD
(AASHTO T99) to form 150mm thick compacted layer of lower sub-grade spread
across the carriageway and the shoulders. This yields S4 sub-grade class;
4.
Km 20+800 - 27+900:(a) Mill the existing asphalt concrete surfacing and use the milled
material for surfacing deviations;
(b) Scarify the existing base-course, sub-base and sub-grade layers,
add additional S4 quality material (minimum CBR of 14% and a
swell of less than 1% measured after 4 day soak) as necessary, lay,
process and compact to 100% of MDD (AASHTO T99) to form
150mm thick compacted layer of lower sub-grade spread across
the carriageway and the shoulders. This yields S4 sub-grade class;
5.
Provide S4 quality material (minimum CBR of 14% and a swell of less than 1%
measured after 4 day soak), lay, process and compact to 100% of MDD (AASHTO
T99) to form 150mm thick compacted natural gravel upper sub-grade spread
across the carriageway and the shoulders;
6.
2% cement improved gravel for new sub-base layer;
7.
Provide pant mixed 2% cement treated GCS, lay by paver and compact to 98% of
MDD (VH) 150mm thick for new base layer;
8.
Surfacing
0/20mm, 50mm and 0/14mm, 35mm thick asphalt concrete designed to
SUPERPAVE requirements following ORN 19 and asphalt institute, MS-2, 1994 to
cover the carriageway and shoulders respectively. The asphalt concrete on both
the carriageway and shoulders shall be covered with 10/14mm single seal surface
dressing. Chippings for surface dressing shall be class 2 (vehicles per day on the
2 lanes in year of application of chippings is 2,000 - 6,000). The coarse aggregate
for the asphalt concrete shall satisfy the requirements contained in table 4.1 of
ORN 19.
9.
10.
11.
12.
Prime Coat: MC-70;

Tack-coat:K1-70;
Binder for surface dressing: 80/100 cut back bitumen
Binder for asphalt concrete: 60/70 pen grade bitumen
16
December, 2014
CHOICE OF PAVEMENTS
From the economic evaluation of the proposed pavement options, it was found that option
1B for both the upgrading and rehabilitation sections, yields better results and hence
recommended for the project. Detailed information is contained in the projects Economic
Feasibility Study Report submitted separately.
MATERIALS UTILIZATION
The charts below shows the material utilization for gravel sites proposed for fill, subgrade, sub-base and base-course and hard-stone quarry proposed for surfacing and
concrete works for each of the road sections.
Road Section I
Road Section II
Road Section III
17
December, 2014
Road Section IV
Location
(km+m)
Material
Site
Usage
From
To
(Km)Haulage distance
The table below gives the haulage distances and approximate quantities of material
required from each of the material sites based on pavement option 1B for the 4no. road
sections viz-a-viz approximate available quantities.
Road Section I (HSQ 1 @ Km 11+750, RHS)

0+000
5+500
GS 01
2.95
Fill, sub-grade,
5+500 11+000 2.75
GS 02
sub-base and base
11+000 16+380 2.89
GS 03
HSQ 1 Surfacing and
0+000 16+380 8.19
Concrete works
Road Section II (HSQ 1 @ Km 0+000, 4.63Km off, RHS)
Fill, sub-grade,
0+000
5+000
GS 04
2.80
sub-base
and
base
GS 05
5+000
9+400
2.60
Surfacing and
HSQ 1
0+000
9+400
9.33
Concrete works
Road Section III (HSQ 1 @ Km 0+000, 35.06Km off, LHS)
Fill, sub-grade,
GS 06
0+000
7+000
3.51
sub-base
and
base
GS 07
7+000
9+000
5.10
Surfacing and
HSQ 1
0+000
9+000 39.56
Concrete works
Road Section IV (HSQ 1 @ Km 0+000, 4.63Km off, LHS)
Fill, sub-grade,
GS 08
0+000
3+000
4.60
sub-base
and
base
GS 08A
3+000
9+000
6.3
GS 09
9+000 12+600
5.8
GS 10
12+600 22+000
8.7
GS 11
22+000 26+000
3.1
Approx.
required
quantity (m3)
(excludes
fill)
Approx.
available
quantity
(m3)
46,500
46,500
45,500
17,280
25,920
33,480
13,500
Adequate
42,500
37,500
27,540
14,580
8,000
Adequate
59,500
17,000
126,000
20,520
7,500
Adequate
19,000
37,500
22,500
59,000
25,000
36,450
27,540
64,800
39,420
32,400
18
December, 2014
GS 12
HSQ 01
Surfacing and
Concrete works
26+000
30+425
2.8
28,000
48,600
0+000
30+425
19.8
24,500
Adequate
19
December, 2014
APPENDICES
Appendices
December, 2014
Appendix A
Material Test Results
Appendix A
December, 2014
Appendix A.1
Alignment Soils
Appendix A.1
December, 2014
Appendix A.2
Gravels for fill, sub-grade and pavement layers
Appendix A.2
December, 2014
Appendix A.3
Construction Water
Appendix A.3
December, 2014
Appendix B
Pavement Evaluation Data
Appendix B
December, 2014
Appendix B.1
Pavement Condition Details
Appendix B.1
December, 2014
Appendix B.2
Field and Laboratory test results for existing
pavement layers
Appendix B.2
December, 2014
Appendix B.3
DCP Data
Appendix B.3
December, 2014
Appendix C
Key plan for material sites
Appendix C
December, 2014
Appendix D
Trenching logs for Road Section IV
Appendix D

PMR - 30.12.14

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Consulting Services for the Design and Supervision of construction works for Kangundo - Kenol (C99), Kenol - Koma

CHAPTER 2 - MATERIALS INVESTIGATIONS AND PAVEMENT EVALUATION CARRIED OUT......2-1

Preliminary Materials Report

MATERIALS TEST RESULTS

Gravels for fill, sub-grade and pavement layers

PAVEMENT EVALUATION DATA

Pavement Condition Details

Field and laboratory test results for existing pavement layers

KEY PLAN FOR MATERIAL SITES

TRENCHING LOGS FOR ROAD SECTION IV

American Association of State Highways and

Aggregate Crushing Value

California Bearing Ratio

Equivalent Standard Axles

Graded Crushed Stone

Los Angeles Abrasion

Maximum Dry Density

Ministry of Lands, Housing and Urban Development

Directorate of Nairobi Metropolitan Development

Nairobi Metropolitan Services Improvement Project

Optimum Moisture Content

Preliminary Materials Report

RDM Part III

Road Design Manual Part III

Sodium Sulphate Soundness

Overseas Road Note

Material Testing and Research Department

Field Dry Density

Dynamic Cone Penetrometer

Falling Weight Deflectometer

Council for Scientific and Industrial Research

National Institute for Transport and Road Research

Cement Improved Gravel

Preliminary Materials Report

Inadequate Solid Waste Collection and Environmentally hazardous dumping.

Kagundo - Kenol (C99): 16.38km

Kenol - Machakos town - Katumani Road: 30.425km

All the four project roads are located in Machakos County.

Preliminary Materials Report

Figure 1.1 : Index Map.

Preliminary Materials Report

CURRENT ROAD CONDITION AND SURFACE TYPE

: Kenol - Machakos Town - Katumani (C99)

Preliminary Materials Report

Preliminary Materials Report

CHAPTER 2 - MATERIALS INVESTIGATIONS AND PAVEMENT

2.1.1 Alignment Soils

Test results are contained in appendix A.1.

Kenol - Koma (E474): Section II

Along Kenol - Lukenya

Katumani - Mombasa Road Junction at Konza (D522): Section III

Preliminary Materials Report

4.1km from Konza

Kenol - Machakos Town - Katumani (C99): Section IV

3.1km from Kenol, along

along Machakos - Kitui

Tests on neat gravel site samples

Best suited stabiliser

Table 7.2 in the overseas road note 31

Preliminary Materials Report

Preliminary Materials Report

Unexploited quarry along

Water for Construction

Preliminary Materials Report