2008

EXECUTIVE SUMMARY

KUNDAN SINGH CONSTRUCTION KENSETSU KAIHATSU CONSULTANTS

4/1/2008

EXECUTIVE SUMMARY

2008 KENSETSU KAIHATSU CONSULTANTS

CONFIDENTIALITY AND COPYRIGHT This document is for the sole use of the addressee (Kundan Singh Construction Ltd.) and Kensetsu Kaihatsu Consultants. The document contains proprietary and confidential information that shall not be reproduced in any manner or disclosed to or discussed with any other parties without the express written permission of Kensetsu Kaihatsu Consultants. Information in this document is to be considered the intellectual property of Kensetsu Kaihatsu Consultants. in accordance with Kenyan copyright law. This report was prepared by Kensetsu Kaihatsu Consultants. for the account of Kundan Singh Construction Ltd. The material in it reflects Kensetsu Kaihatsu Consultants.s best judgement, in the light of the information available to it, at the time of preparation. Any use which a third party makes of this report, or any reliance on or decisions to be made based on it, are the responsibility of such third parties. Kensetsu Kaihatsu Consultants. accepts no responsibility for damages, if any, suffered by any third party as a result of decisions made or actions based on this report. 2008 Kensetsu Kaihatsu Consultants

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EXECUTIVE SUMMARY
ES1 Introduction In 2004, the Government of Tanzania (GoT) through its agency TANROADS signed a contract with BCEOM France in association with MKonsult Tanzania for consulting services for Detailed Design for upgrading of MbeyaChunya-Makongolosi Road. With the intention to upgrade the road to tarmac grade through MoW and TANROADS, the GoT retained BCEOM/M-Konsult Ltd. To carry out both detailed design work including environmental and social impact assessment and preparation of Tender Dossier.

The Project road is about 115km long and lies between 0802500 0805336S and 3300048 3400712E. The altitude for the Project road ranges from 1200 to 2450 metres above sea level (m.a.s.l). The project road traverses the highest point of trunk roads in Tanzania, standing at 2457 m.a.m.s.l at Kawetele and about 18km away from Mbeya Municipality. The Works contract for the upgrading of Section I of the Project Road was signed in August 2007 between TANROADS and Kundan Singh Construction Ltd. Kenya (KSC). The Section runs from Mbeya town at km 0+000 to km 36+000 and rises from 1688 masl at Mbeya to 2456 masl at km 17+625 and then drops to 2008 masl at km 26+000. The alignment of the road undulates along a meandering horizontal path with some sharp hair pin bends and several sections lying on the edge of ridges or at times dangerously on slopes where severe hydrological hazards are bound to cause faults.

Fig. 1 Location Map

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Fig. 2a Some problematic sections of the Project Road

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Fig. 2b Some problematic sections of the Project Road Significant deficiencies in the Design leading to seriously impacted on the engineering feasibility leading to a decision by the Contractor to seek consultant an independent third opinion. One of the sections within the landslide zone identified during the visit ES2 Geotechnical Consultant Team The Contractor KSC having encountered major technical difficulties in terms of implementing the required sound engineering standards based on the original design, decided to engage the services of a highly qualified Geotechnical Engineering Consultant with comprehensive knowledge and specialization of the geotechnical and hydrogeological conditions of Africa, particularly the EA Region (including Sudan, Burundi) and on problematic soils. Kensetsu Kaihatsu Consultants (KKC) is a Kenyan firm of Consultants led by a worldwide recognized Geotechnical Engineer, Dr. JN Mukabi who is reputed to have offered many innovative solutions for major problematic areas and designs. He is a recognized and highly honored engineer/scientist with international awards and accolades having contributed immensely to top geotechnical, soil mechanics and civil engineering societies and forums. It was upon the site visit that the Consultant advised the Contractor that Kensetsu Kaihatsu Page 4

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Site visit by independent consultant

Comprehensive Engineering Analysis and Review of Original (Current) Design

EXECUTIVE SUMMARY Consultants undertake a Comprehensive Geotechnical Engineering Analysis and Review of the Original Design to offer recommendations and possible designs/method of construction to benefit the Client by realizing a cost-effective Value Engineeering (VE) structure that would be durable, while being sensitive to the environment, as well as offering possible mitigation mesures for geohazards that are more than likely to happen. Kensetsu Kaihatsu Consultants therefore made and makes an undertaking to partake this assignment under the guidelines of geoprofessionals within the provisions of the International Society of Soil Mechanics and geotechnical Engineering (ISSMGE), and SubClause 2.6 of the Fourth Edition of The FIDIC Conditions of Contract presented in the Table below in ES4 and ES9. ES3 Analysis and Review Objective The Project Area has the following factors that contribute immensely to geohazards: high rainfall prone to landslides seismic activity hydrology/hydrogeological assessment/design and environment/ppp (locals involvement). The overall objective of the Study is to establish the actual existing geotechnical problems including slope stability, the hydrogeological conditions and engineering impediments that could culminate in failure of the road and longterm cost in-effectiveness rendering the Contract non-viable. The specific objectives of the Study are: (1) To undertake a Comprehensive geotechnical soil and materials study of the Mbeya~Lwanjilo Trunk Road. (2) To comprehensively review the original design in relation to the soils, materials and geotechnical engineering aspects. (3) To determine the ground stability vide comparative analysis of cut and fill areas along the Project Road. (4) To propose a cost-effective value engineering based approach that will realize a sound and durable road pavement structure. ES4 Brief Analysis of Relevant Contractual Clauses An analytical digest of the relevant contractual clauses is given under Sub-section 1.1.3 of the Main report (Comprehensive Geotechnical engineering Analysis and Review of the Original Design). KKC reviewed the Contract and has noted the various Clauses/Sub-Clauses pertaining to the process of construction and necessity to analyze and review the design. The implications in liability, costs and risks of both the Client and/or the Contractor have been analyzed and determined. The pragmatic approach to resolving the current situation will be both contractual and value engineering based. KKC noted Sub-Clause 8.1 of the FIDIC Conditions of Contract and noted that:

2008 KENSETSU KAIHATSU CONSULTANTS

Mbeya and a better part of Tanzania which lies in the Rift receives significant seismic activity as indicated in the above figure Some of the factors that must be seriously considered in design for the area include slope failure/slope stability, slope protection, cut versus fill, material stability,

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Contents Clause 8.1 Contractors General Responsibilities The Contractor shall, with due care and diligence, design(to the extent provided for by the Contract), execute and complete the Works and remedy any defects therein in accordance with the provisions of the Contract. The Contractor shall provide all superintendence, labour, materials, Plant, Contractors Equipment and all other things, whether of a temporary or permanent nature, required in and for such design, execution, completion and remedying of any defects, so far as the necessity for providing the same is specified in or is reasonably to be inferred from the Contract. The Contractor shall give prompt notice to the Engineer, with a copy to the Employer, of any error, omission, fault or other defect in the design of or Specification for the Works which he discovers when reviewing the Contract or executing the Works. Brief Analytical Remarks This Clause clearly indicates that it is the Contractor who is liable to the proper execution of and completion of the Works as provided for in the Contract. On the other hand in accordance with Sub-Clause 8.3 part a) i) on page No.11 of the conditions of Particular Application for this Contract, the Contractor is responsible for ensuring that sound Engineering practice is observed at all times and for all aspects of the project. Essentially therefore paragraph 1of this Sub-clause provides that the Contractor takes full responsibility of ensuring the proper and practical implementation of this project. The foregoing fact is emphasized by paragraph 2 of the same sub-clause, which requires that the Contractor should have the ability to detect any error, omission, fault or other defect in the design or specification for the works, upon which the Contractor has the obligation to notify the Engineer and Employer promptly. The main pragmatic interpretation and implication here is that: 1) The Contractor has the full responsibility of reviewing the design and all other associated, corresponding and/or otherwise relevant documents, in the post-bidding stage (Contract

rolling hilly land, slopes and environment, the original (current) design fails to properly address the most appropriate, suitable and optimum engineering solutions for a sound design of the Project Road. Furthermore, there is no evidence that a detailed and comprehensive study was undertaken, as is depicted in Figure 6.1 in Chapter 6 of the pavement Design Manual-1999 (ref. to Sub-section 4.4.4 of the Main Design Review Report). The overview of the review presented in Chapter 4 of the Main Design Analysis and Review Report. While the recently developed State-of-the-Art methods of investigation, study, survey, analysis and design are extensively discussed in Chapters 5, 6, 7 and 9 of the Main Review Report. On the other hand, the Consultant who undertook the design states, on page 4-10 of the Detailed design Final report and page 10 of the Bidding Documents Volume 3 under the sub-topic Improved Subgrade Layers and Areas of Low Strength (Expansive/Dispersible) Soils, that:(1) It was established that the first 45 kilometres of the Project road contain low strength in-situ subgrade soils (2) The remaining portion of the road has relatively good subgrade soils, which do not require improvement. This section also is mainly located on cut areas. (3) The first 45 kilometres of the Project Road Contains Soils, which exhibit high plasticity and low strength characteristics. This soils are termed as problem soils since they have high shrinkage and swelling properties which usually affects the overall performance of the pavement structure.

ES5 Contractors Concern and need for Independent Professional Consultation The Contractor on various occasions raised the issues of the problems encountered and deficiencies in both the Documentation and design. In minutes of various Site Meetings and that held on Thursday, 13th March 2008, in particular, this is noted. It was due to the Contractors concern and the decision to engage an independent expert was reached. The copy of minutes attached as Appendix to the Main report refers. ES6 Strategic Direction The decision to have a comprehensive analysis and review has led to the compilation of the Main Report, of which this is the Executive Summary. A presentation is also to be made on the scheduled date. The innovative solutions and recommendations will lead to a costeffective and highly viable and beneficial project if all parties concerned appreciate the problems and deficiencies encountered while agreeing mutually to accept and expedite the implementation of the recommended approach. ES7 Current Design of Mbeya and Method of Construction (Analysis) The Original design stipulates the extensive use of fills and gabions in construction of the road for Section 1 (km1~km36). Considering the topography of the existing Project Road, the

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EXECUTIVE SUMMARY 10metres of fill! should show that this is highly unstable and a time consuming construction method as demonstrated in figures below.

Furthermore, the possibility of dangerous slope failures seems to have been completely omitted in the engineering analysis of the detailed design. The time needed to compact some of the high fill areas was not properly computed. ES8 Analysis of the Effect of Moisture, Slope failure /Landslides and Seismicity Geohazards Monitoring Rainfall: Mbeya region has high rainfall that can reach a maximum of 2700mm.

2008 KENSETSU KAIHATSU CONSULTANTS

The use of gabions as slope protection in fill areas without considering the hydrology, seepage that must occur and instability of the fill material is considered an engineering oversight. The eventual collapse of the gabions and slope from the slip that will eventually form in the fill will prove catastrophic. Designing over

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Creep

Effect of rainfall on Landslides: Perhaps the most common trigger of a landslide, water reduces the friction between the bedrock and the overlying sediment, and gravity sends the debris sliding downhill. In sand and clay soils, a small amount of water may increase stability. You've likely seen this when building a sand castle or working with clay. However, too much water causes the sediment to flow, which is why many landslides occur after rainstorms.

A Rotational Slide or Slump

Gravity is the primary factor in a landslide. Soil on a flat surface does not move. On a slope, gravity alone also may not trigger a landslide. But when another disrupting factor -- like rain -- comes into play, gravity will pull sediment downhill.

2008 KENSETSU KAIHATSU CONSULTANTS

Gravity has a very major role to play in ground/slope stability. Flat surfaces are usually stable while slopes have gravity force acting on the mass. Where there is much rainfall the tendency for the mass to creep or worse slump is high after rain effect.

Example of slope failure (landslide) on a similar environment to the Project Road

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Effect of Moisture as analyzed from Project road Permeability and Seepage

Slope failure and Gabions: The slopes at the fill areas protected by gabions are technically at a potential risk because of the dam effect that the gabions will cause if there is seepage into the fill. This has the effect of higher stress levels and seepage forces and will lead to the possibility of different stress-strain properties resulting in some zones being highly stressed than imagined.

Possible Slip failure along the Project road CASE STUDY: Slope failure on the Goha Tsion road in Addis Ababa.

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Dam effect of gabions on the Project road

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Normal fault

Click the play button to start the earthquake. When P and S waves reach the earth's surface, they form L waves. The most intense L waves radiate out from the epicenter.

It can be noted from the above computations that the Factor of Safety ( ) is extremely low implying that the gabions cannot provide the resistance required. Proof Rolling Results

2008 KENSETSU KAIHATSU CONSULTANTS

Seismicity: Mbeya Region lies within a highly seismic zone of the East African Rift system. The are is considered a goe-hazard prone area and combined with it being flood prone too and that the rainfall is very high, this could eventually lead to liquefaction.

Seismicity within and around Mbeya

ES9 Construction Problems and Contractors Liability / Clients Liability The Contractors/Clients liability in relation to the original (current) design problems are

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EXECUTIVE SUMMARY summarized in the Clause below and the following table. Clause 20.4 Employers risk The employers risk are g) Loss or damage to the extent that it is due to the design of works, other than any part of the design provided by the contractor or for which the contractor is responsible, and h) Any operation of the forces of nature against which an experienced contractor could not reasonably have been expected to take precautions. Relevant Clauses Based On Excepts From The Fourth Edition 1987 of The FIDIC Conditions Of Contractor-Part I General Conditions
Clause/Sub-Clause: Contents Clause 8.1 Contractors General Responsibilities The Contractor shall, with due care and diligence, design(to the extent provided for by the Contract), execute and complete the Works and remedy any defects therein in accordance with the provisions of the Contract. The Contractor shall provide all superintendence, labour, materials, Plant, Contractors Equipment and all other things, whether of a temporary or permanent nature, required in and for such design, execution, completion and remedying of any defects, so far as the necessity for providing the same is specified in or is reasonably to be inferred from the Contract. The Contractor shall give prompt notice to the Engineer, with a copy to the Employer, of any error, omission, fault or other defect in the design of or Specification for the Works which he discovers when reviewing the Contract or executing the Works. Brief Analytical Remarks This Clause clearly indicates that it is the Contractor who is liable to the proper execution of and completion of the Works as provided for in the Contract. On the other hand in accordance with Sub-Clause 8.3 part a) i) on page No.11 of the conditions of Particular Application for this Contract, the Contractor is responsible for ensuring that sound Engineering practice is observed at all times and for all aspects of the project. Essentially therefore paragraph 1of this Sub-clause provides that the Contractor takes full responsibility of ensuring the proper and practical implementation of this project. The foregoing fact is emphasized by paragraph 2 of the same sub-clause, which requires that the Contractor should have the ability to detect any error, omission, fault or other defect in the design or specification for the works, upon which the Contractor has the obligation to notify the Engineer and Employer promptly. The main pragmatic interpretation and implication here is that: 1) The Contractor has the full responsibility of reviewing the design and all other associated, corresponding and/or otherwise relevant documents, in the post-bidding stage (Contract

ES10 Typical Design for Mbeya Environment, Design Development, Implementation A design based on the Comprehensive Method of Design is recommended. An example is given under Chapter 9 of the main Report.

E11 Cost Benefit Analysis 11.1 Benefits from Structural Durability As was demonstrated in chapters 6, 7, as well as in sections 9.9 of chapter 9 and chapter 10, the Employer is certainly bound to benefit immensely if the road is constructed to withstand the prevailing external forces and environmental factors to a reasonably sustainable standard, the structural durability factor will then contribute greatly to the sustenance of the socio economic activities with the regions through which the road traverses due to the longevity of its design life. 11.2 Enhanced Road Safety The current geometric design with section 1 of the Project Road posses enormous dangers due to the acute blind curves, ridges, and frequent meandering. The re-design would have to consider cost-effective realignments that ensure the enhancement of road safety. 11.3 Extended Performance of the Contractor Contractual Clauses pertaining to these issues and the repercussions that are likely to prevail as a result of the failure of the pavement structure and/or slopes have been analytically discussed under Sub-section 1.1.3 of this Report. 11.4 Direct Cost Savings Direct cost savings will mainly be realized through commercial activities and social institutions such as schools, hospitals, community centres etc, in terms of the drastic reduction in travel time, trade etc. Page 11

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Clause/Sub-Clause: Contents 8.2 Site operations and methods of construction The contractor shall take full responsibility for the adequacy, stability and safety of all site operations and methods of construction .provided that the contractor shall not be responsible (except as stated here under or as may be otherwise agreed) for the design or specification of permanent works, or for the design or specification of any temporary works not prepared by the contractor. Where the contract expressly provides that part of the permanent works shall be designed by the contractor, ha shall be fully responsible for that part of such works, notwithstanding any approval by the engineer.

Brief Analytical Remarks This sub-clause basically qualifies the first paragraph of sub-clause 8.1 above and the corresponding brief analytical Remarks It is therefore interpreted that it is imperative for the Contractor to take the initiative, which is commensurate with his responsibilities, liabilities and obligations, to review any documents related to the execution successful completion of the Works where adequacy, stability and safety factors are upheld in the design and the construction Works, failure to which the Contractor is obligated to notify the Engineer and the Employer (client).

Comprehensive Engineering Analysis and Review of Original (Current) Design

EXECUTIVE SUMMARY (1) It is imperative that the pavement structural design is reconsidered in order to alleviate the potential Clients Liability problems. (2) It would be advisable that the redesign is based on the Comprehensive Method of design for purposes of achieving a cost-effective Value Engineering based Structure that fosters sound engineering practice. (3) Based on the analysis of the relevant contractual clauses during this Study, it is highly advisable that the employer takes expeditious action in resolving the current design problem, contrary to which the Project is likely to suffer enormous losses and socio-economic benefits or otherwise disastrous failure of the pavement structure.

11.5 Indirect Cost Savings Indirect cost savings would mainly be as a result of external trade and tourism activities within the vicinity of the Project Road.

E12 Conclusions Detailed investigations, survey, in-situ and laboratory testing were undertaken during this Study. Subsequently, the results were comprehensively analysed by adopting powerful state-of-the-art analytical tools that have been developed and tailored for most tropical soils that exist within this region. Based on the findings of this Study, the following conclusions are made: (1) The original (current) design was not based on detailed and comprehensive studies. This culminated in some serious flaws within the Fundamental design Concept. (2) Contrary to the normal engineering practice, the original (current) design specifies the construction of high fills and purging in problematic soil areas instead of cutting into the hilly sides. This indeed is not only an expensive method of construction but also renders the pavement structure susceptible to slope failure. The adoption of this design would be costly and disastrous. (3) From the evaluation made during this Study (Comprehensive Geotechnical and Engineering Analysis and Review of the Original (Current) Design for Mbeya-Lwanjilo-Chunya-Makogolosi Road Upgrading), it is apparent that comprehensive Environmental and Impact Assessment (EIA) was not made. E13 Recommendations The following recommendations are made on the basis of the results obtained in this Study.

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