Tender T-56-Procurement of Base course ,Asphalt Aggregate and Concrete Aggregate

in the case of a bid submitted by a joint venture (JV), the Bidder has failed to submit the Form Data on Joint Ventures, the Agreement governing the formation of joint venture, or letter of intent to form JV, including a draft agreement, in accordance with ITB Clause 4.1

Bidder is found to have a conflict of interest as described in ITB Sub-Clause 4.3

Bidder's have nationality in accordance with ITB Sub-Clause 4.2.

If the bidder is participating in a joint venture or consortium, they MUST submit the legally binding agreement document.  

Bidder MUST submit the bid security in hardcopy to the designated address before the bid submission deadline, in the form of a CPO (Certified Payment Order), Bank Guarantee, or Bid Bond, made out to the Ethiopian Roads Administration. 

Comprehensive laboratory test reports for all aggregates (crushed stone), demonstrating compliance with BS 812, ASTM, and AASHTO requirements for cleanliness, particle shape, strength, abrasion, water absorption, and soundness.

(e) Soluble Salts

The percentage of soluble salts in the untreated material (< 6.7 mm fraction) shall be subject to the following requirements when tested to SANS 3001 AG32.

• Where the pH < 6, it shall be treated with lime until the pH ≥ 10 and then used.

• Where the pH ≥ 6, the material is used as it is.

(Note: The aggregate is normally treated at the crusher and if the pH exceeds 10 at the stage, the decrease at any later stage shall be ignored should the pH remain ≥ 8)

Bidder MUST submit signed and stamped copies of the entire Technical Specification Requirement document, including a clause-by-clause commentary to the entire specification requirement

Bidder MUST submit signed and stamped Anti-Bribery Pledge Forms, including an Anti-Bribery/Corruption Declaration confirming their commitment to ethical business practices

Bidder MUST submit a signed and dated Delivery and Completion Schedule presented as per the template in Section 6, Statement of Requirements

The Bidder is responsible for the provision and construction of any necessary ancillary structures for the plant (e.g., equipment foundations, retaining walls), including all materials required

All maintenance and major repairs must be carried out by the Bidder's personnel. The Client reserves the right to perform minor/urgent repairs if the Bidder fails, and deduct the cost from the payment.

The Bidder must provide copies of the registration (Libre/Title) for the crusher and all associated major machinery. Originals must be presented upon request.

The Bidder must specify the following for the crushing plant:

1. Configuration: Must be a 3-stage crushing system (Feeder, Primary/Jaw Crusher, Secondary, Screen, Conveyors, etc.).

2. Manufacturer, Country, Year of Manufacture.

3. Hourly Capacity: Minimum of 200 Tons/Hour.

Impact Crusher is preferred. If a Cone Crusher is utilized, the Bidder assumes full responsibility for ensuring the product meets the required Cubical Shape (low Flakiness Index). The Client will not pay for rejected/flaky aggregate.

All asphalt aggregates must strictly meet the attached ERA Standard Technical Specification Requirements (Division 6400).

All concrete aggregates must strictly meet the attached ERA Standard Technical Specification Requirements (Division 8400).

Nominal Size (mm) Percentage of total mass passing sieve

Sieve size (mm)

-----31.25--25--19--12.5--10--4.75--0.075

25--90 - 100 --- 0 – 20--0 - 2 -- 0 - 0.5

20--- -- 100---- 80–100---10 - 40---0. 4--0.0.5

10------100----90-100-40 - 70--0 - 15--0-0.5

(a)  Road base material shall be obtained from sources located by the Contractor and approved by the Engineer.

(b) Road Base Material Types

The materials used for the construction of road base layers shall be one of the following as described in the Contract:

• Crushed rock or stone;

• Naturally occurring granular materials and weathered rock, either unstabilised or chemically stabilised as specified in Division 4500;

(c) Plasticity Index

The fine fraction of a GB1 material shall be non-plastic when determined in accordance with AASHTO T-90.

Table 5204/2: Aggregate Strength and Durability Requirements for Crushed Stone Road Base Materials (GB1)

RockType---Matrix------10%

FACT---------Dry (min kN)----Wet (min kN)---Wet/Dry ratio (min)

General requirement for most rock types ----------110-------------75

--------------Non-siliceous cementing Arenaceous---- material--140---------- - ---- 75

--------------Siliceous cementing

------------material---110---------- -- -----75

Diamictites (Tillites)------200-------- -- --------70

Argillaceous------------- 180-----125------------ --

Aggregate is the major component in HMA and the quality and physical properties of this material has a large influence on mix performance. The qualities required of aggregates are described in terms of shape, hardness, durability, cleanliness, bitumen affinity and porosity. In addition to these properties, the micro texture of the aggregate particles will also strongly influence the performance of a compacted HMA layer. Smooth-surfaced river gravel, even partly crushed, may not generate as much internal friction as a totally crushed aggregate from particles having a coarse micro texture.

Coarse and fine aggregate shall be clean and free from decomposed materials, vegetable matter and other deleterious substances.

The coarse aggregates used for making HMA should be produced by crushing sound, un weathered rock or natural gravel. Gravel should be crushed to produce at least two fractured faces on each particle.

Property--Rolled in chippings--Open graded surfacings---Stone mastic surfacings 

10% FACT (13.2mm and---Dry -->210-->210 -->210 

9.5mm fractions)--Wet/Dry ratio-->75%-->75%-->75%  

Flakiness Index (>13 mm)---<20----<30---<30 

• Angular and not excessively flaky, to provide good mechanical interlock;

• Clean and free of clay and organic material;

• Strong enough to resist crushing during mixing and laying as well as in service;

• Resistant to abrasion and polishing when exposed to traffic;

• Non-absorptive - highly absorptive aggregates are wasteful of bitumen and also give rise to problems in mix design; and

• Have good affinity with bitumen - hydrophilic aggregates may be acceptable only where protection from water can be guaranteed or a suitable adhesion agent is used.

In addition, for asphalt road bases, at least 50% by mass of the individual fractions retained on each of the standard sieves with a square mesh size of 4.75 mm and larger shall have at least one fractured face and for wearing courses at least 95% of all particles shall have at least three fractured faces.

Enhanced specifications for rolled-in chippings and for open graded surfacing  

Filler (material finer than 0.075 mm) can be crushed rock fines, Portland cement or hydrated lime. Portland cement or hydrated lime is often added to natural filler (1 - 2 per cent by mass of total mix) to improve the adhesion of the bitumen to the aggregate.

The required properties for aggregates are given in Table 6402/5.

The Polished Stone Value (PSV) of aggregates shall not be less than the values shown in

In addition, for asphalt road bases, at least 50% by mass of the individual fractions retained on each of the standard sieves with a square mesh size of 4.75 mm and larger shall have at least one fractured face and for wearing courses at least 95% of all particles shall have at least three fractured faces.

Enhanced specifications for rolled-in chippings and for open graded surfacing are shown in Table 

Graded crushed stone (GB1) (as defined in the prevailing ERA Flexible Pavement Design Manual) shall be produced by crushing fresh, quarried rock and may be an all-in product, usually termed a 'crusher-run', or alternatively the material may be separated by screening and recombining to produce a desired particle size distribution, as per the specifications.

The material shall be clean and free from organic matter, lumps of clay or other deleterious substances.

The material shall be of such a nature that it can be readily transported, spread and compacted without segregation.

(b) Particle Size Distribution and Shape

The combined grading of the material shall be a smooth continuous curve falling within the grading limits shown in Table 5204/1 when determined in accordance with the requirements of AASHTO T-27.

The mass of material passing the 0.075 mm sieve shall be determined in accordance with the requirements of AASHTO T-11.

The flakiness index determined in accordance with BS 812, Part 105 or ASTM D 3398 shall not exceed 30 per cent.

Test sieve (mm) Percentage by mass of total Aggregate passing test sieve

Nominal maximum particle size

----------37.5 mm------ 28 mm-----20 mm

50------100 ------------- - ---------- -

37.5----95-100 --------100----------- -

28 ----- - ------------ - --------------100

20-------60 – 80--------70 - 85-----90 – 100

10------40 – 60---------50 - 65----- 60 – 75

5--------25 - 40-------- 35 - 55----- 40 – 60

2.36----15 – 30-------25 - 40--------30 – 45

0.425----- 7 – 19-----12 - 24------- 13 – 27

0.075(1)------ 5 – 12--- 5 - 12------ 5 – 12

(d) Density, Strength and Durability

The in-situ dry density of the placed material should be a minimum of 98% of the maximum dry density obtained from AASHTO T-180 method D (hereinafter also referred to as modified AASHTO density); or as indicated on the Drawing; or as indicated in the Particular Specifications; or on instruction of the Engineer. The compacted thickness of each layer should not exceed 200 mm.

Crushed stone road base constructed with proper care with GB1 materials should have CBR values in excess of 100 per cent.

The strength and durability requirements of crushed stone shall be assessed using the 10% Fines Aggregate Crushing Test (10% FACT) (SANS 3001-AG10) in terms of the dry and wet strength, and the wet/dry ratio related to rock type as specified in Table 5204/2.

The sum of the percentage of all deleterious substances in the aggregate delivered to the mixer, shall

not exceed 3% for fine Aggregate and 2% for coarse aggregate. If there is a potential danger of alkali aggregate reaction the Engineers decision as to the suitability of the aggregate shall be final and binding.

• Fine Aggregate for Portland Cement Concrete.

Fine aggregate shall consist of natural sand, manufactured sand, or a combination of natural and manufactured sand conforming to AASHTO M-6 Class B including the reactive aggregate supplementary requirement, except as amended or supplemented by the following:

Sieve size (mm)--- Percentage of total mass passing sieve

10-----------------------100

4.76--------------------95-100

2.38--------------------68 - 86

1.19--------------------47-65

0.59-------------------27 - 42

0.30--------------------9 - 20

0.15--------------------0 - 7

0.075------------------0 - 2.5(4.0)

Item----------Maximum Percentage by

-------------------Mass

------------------Fine--------Coarse-

--------------Aggregate---- Aggregate

Material Passing----2.0-------1.0

0.075 mm sieve

Lightweight---------2.0----------2.0

materiai

Organic matter-------0------------0

Clay lumps------------1.0---------0.5

Other deleterious--- 2.0---------1.0

substances

Property Test Wearing course Properties Test Method

Cleanliness Sand equivalent: for < 4.75mm fraction >1.5 x 106 ESA > 40 AASHTO T176-86 

Material passing 0.425mm sieve Plasticity Index < 4 AASHTO T-90 

Linear shrinkage % < 2

Particle shape Flakiness Index < 35 BS 812, Part 105 (1990) 

Strength 10% FACT (dry) kN > 160 BS 812, Part 3 (1985) 

10% FACT – wet/dry ratio > 75% BS 812, Part 3 (1985) 

Los Angeles Abrasion (LAA) < 30 ASTM C131 and C535 

Abrasion Aggregate Abrasion Value (AAV) < 250 cv/lane/day < 16 BS 812, Part 3 (1985) 

> 3250 cv/lane/day < 12

Polishing Polished Stone Value (see Table 6303/13) BS 812, Part 3 (1985) 

Water absorption Water absorption 6 <2 BS 812, Part 2 (1975) 

Soundness  

(5 cycles, % loss) Sodium Sulphate Test: Coarse < 10 AASHTO T104-99 

Fine < 16

Magnesium Sulphate Test: Coarse < 15

Fine < 20

Bitumen affinity Immersion Mechanical Test: Index of retained Marshall stability > 75 D Whiteoak (1990) 

AASHTO T283 

Bidder has to submit Written statement by a power of attorney (or notary statement, etc.) proving that the person, who signed the bid on behalf of the company partnership /joint venture/consortium, is duly authorized to do so.

Bidder has to submit dated Technical Specification + Technical Offer+ Compliance Sheet Form

The Bidder shall be fully responsible for the entire crushing process, including rock blasting, quarrying, transportation of raw material to the crusher, crushing/processing to required specifications, and final delivery (loading onto the Client’s vehicle at the stockpile site). The Bidder shall provide all necessary machinery, vehicles, and full manpower

The crushing plant must be located within the Client's designated area on the Shasha-Gera Project site.

The crushing plant(s) must demonstrate a minimum daily production capacity of 400 cubic meters (m³) to meet project demand.

The Bidder is primarily responsible for providing all fuel, explosives, oils, and lubricants. If supplied by the Client (due to Bidder's inability), the cost will be deducted from payments based on the prices effective at the contract signing date.

The quarry site (raw material source) and the final crusher installation area (clearing and leveling) will be provided and prepared by the Client (EMA).

All Base Course (GB1) materials must strictly meet the attached ERA Standard Technical Specification Requirements (Division 5200).

Price Stability: No request for unit price adjustment will be entertained until the overall project aggregate demand (the full contract volume) is fulfilled.

Handover occurs at the stockpile area onto Client-provided vehicles, measured in cubic meters (m³). The Bidder must prepare the official handover/measurement form.

The Bidder must submit a Disbursement Schedule to access the 15% advance payment (50% released on crusher transport completion; 50% released upon accounting for the first 50% usage).

Impact Crusher is preferred. If a Cone Crusher is utilized, the Bidder assumes full responsibility for ensuring the product meets the required Cubical Shape (low Flakiness Index). The Client will not pay for rejected/flaky aggregate.

The sum of the percentage of all deleterious substances in the aggregate delivered to the mixer, shall

not exceed 3% for fine Aggregate and 2% for coarse aggregate. If there is a potential danger of alkali aggregate reaction the Engineers decision as to the suitability of the aggregate shall be final and binding.

• Fine Aggregate for Portland Cement Concrete.

Fine aggregate shall consist of natural sand, manufactured sand, or a combination of natural and manufactured sand conforming to AASHTO M-6 Class B including the reactive aggregate supplementary requirement, except as amended or supplemented by the following:

• Material passing a 0.075 mm sieve shall not exceed 3.0% when tested in accordance with AASHTO T-11.

• The Sand Equivalent value in accordance with AASHTO T-176 shall not be more than 75.

• Lightweight fine aggregate shall conform to AASHTO M-195

Coarse aggregate shall conform to AASHTO M-80 Class A, except as amended or supplemented by the following:

• The Los Angeles abrasion value shall not exceed 40% when determined in accordance with the requirements of AASHTO T-96.

• The adherent coating value shall not exceed 1.0% when determined in accordance with the requirements of FLH T-512.

• For bridge decks or surface courses, aggregates known to polish, or carbonate aggregates containing less than 25% by mass of insoluble residue as determined by ASTM D 3042, shall not be used.

• Lightweight coarse Aggregate shall conform to AASHTO M-195. The coarse aggregate grading shall comply with Table 8402/3

Filler (material finer than 0.075 mm) can be crushed rock fines, Portland cement or hydrated lime. Portland cement or hydrated lime is often added to natural filler (1 - 2 per cent by mass of total mix) to improve the adhesion of the bitumen to the aggregate.

The required properties for aggregates are given in Table 6402/5.

The Polished Stone Value (PSV) of aggregates shall not be less than the values shown in

(c) Aggregates

Aggregates, which are to be used in the Works, shall have negligible alkaline reactivity. When tested in accordance with ASTM C 227, the mean mortar bar expansion values at 3 and 6 months shall be less than +0.5% and +0.10% respectively.

When tested in accordance with ASTM 289, the aggregate shall be proven to be non-reactive.

Aggregate for structures shall be considered not susceptible to alkali aggregate reaction if all of the significant rock components meet the requirements of this sub-clause.

A significant rock component is defined as one, which forms, more than 4% by weight of the coarse or fine aggregate.

The Contractor shall provide the Engineer with petrographic details of the significant rock components contained in the aggregates.

Any aggregate containing the mineral opal shall be considered susceptible to alkali aggregate reaction. A qualified Geologist shall carry out the identification of rock and its placing in the appropriate group.

Aggregates shall not contain deleterious amounts of organic materials such as grass, timber or similar materials as shown in Table 8402/1.

External Audit ReportsCertified by an independent auditor for the last Three (3) Years.

The minimum average annual turnover required from the Bidder is ETB 300,000,000 (Two Hundred Million Birr), calculated as total certified payments received for contracts in progress or completed over the last three (3) years.