Soil & Earthworks
Compaction (Standard & Modified Proctor), Field Density (Sand Cone / Nuclear Gauge), California Bearing Ratio (CBR), Atterberg Limits, Sieve Analysis, Moisture Content.
Quality is a Procedure. Safety is a Culture.
How Al Zahraa specifies, controls, tests, and audits every road and bridge we deliver — and how we protect the people who deliver them.
Our Approach
Quality, health, safety and the environment — managed as one system.
On a road and bridge programme, quality and safety are not two conversations. A poorly-detailed method statement is a quality risk and a safety risk. A rushed inspection produces a schedule saving that gets erased by a rework on the wearing course three months later. Al Zahraa manages Quality, Health, Safety and Environment (QHSE) as one integrated system — one policy set, one audit cycle, one accountability line to the Chairman.
Written down, not improvised. Every construction activity we perform is governed by a written method statement, a written inspection & test plan, and a written risk assessment. The three documents are prepared together, reviewed together, and signed off together before a machine turns on site.
Owned by the project manager, audited by an independent function. Day-to-day QHSE performance is the accountability of the project manager. Audit and non-conformance authority sits with an independent QHSE function that reports directly to senior management — not through the project it audits.
Documented so a client can verify it. For public-sector projects, our QC and HSE records are prepared to the standard the client's supervising consultant expects to see: test certificates traceable to the source, inspection records dated and signed, incident logs closed out with corrective actions.
- Quality Assurance
- Quality Control
- Health & Safety
- Environmental Management
By the Numbers
QHSE performance, measured and reported.
We track a fixed set of quality and safety indicators across every active site. They are reviewed by management on a defined cycle, and they are the first thing we put in front of a client's HSE lead.
Lost-Time Injury Frequency Rate, rolling 12 months: 0.42
Lost-Time Injury Frequency Rate (LTIFR) — rolling 12 months
Total Recordable Incident Rate, rolling 12 months: 1.18
Total Recordable Incident Rate (TRIR) — rolling 12 months
Safe man-hours worked, cumulative: 4,850,000
Safe Man-Hours Worked — cumulative
Toolbox talks delivered, last 12 months: 3,640
Toolbox Talks Delivered — last 12 months
Materials tests performed, last 12 months: 12,400
Materials Tests Performed — last 12 months
Percentage of non-conformances closed at first inspection: 94 percent
Non-Conformances Closed at First Inspection — %
KPIs are reviewed monthly and reported to senior management quarterly. Detailed breakdowns available to prospective clients on request.
Quality Policy
Built once, built right — the standard we work to.
Our Quality Policy commits Al Zahraa, at every level of the organisation, to delivering road and bridge works that comply with the project specification, the applicable Egyptian standards, and — where the contract references them — international standards. What follows is a summary of the policy commitments; the controlled document is available on request.
The specification is the contract. If a proposed method or material differs from specification, it is raised in writing and formally approved before use.
Every construction decision on our sites is made with the intended service life of the asset in mind — subgrade tolerance, layer bond, drainage, material selection.
No layer is covered by the next until it has been inspected and signed off by our QC team and, where the contract requires it, the client's supervising consultant.
Every material we use — subgrade fill, subbase, base course, binder course, wearing course, concrete, steel — is tested to a written Inspection & Test Plan (ITP) prepared for the specific contract.
Aggregate, cement, bitumen, steel, admixtures — all sourced from approved suppliers with valid test certificates, logged against the batch delivered to site.
A raised Non-Conformance Report (NCR) stays open until the root cause is understood, the corrective action is documented, and preventive action is applied to the wider works.
Internal QA audits run on a fixed schedule. Findings are treated with the same discipline as an external audit.
Lessons learned from every project feed back into the next tender's method statements — not into a filing cabinet.
How We Control Quality
Five checkpoints. One asset that meets specification.
Every road or bridge we hand over passes through five sequential control gates. Each gate has a written inspection record, a client-visible sign-off, and — where the specification requires it — a laboratory result attached before the next stage begins.
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Design & Method Review
Before mobilisation, our engineering team reviews the design against constructability. Method statements, ITPs, and risk assessments are prepared for each activity and submitted to the client for approval.
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Materials & Supplier Approval
All materials — aggregates, cement, bitumen, steel, admixtures — are sourced from approved suppliers with valid test certificates. Samples are tested against specification before bulk delivery is authorised.
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Pre-Pour / Pre-Placement Inspection
For every concrete pour, every asphalt lift, and every structural element, a documented inspection precedes the work — formwork, reinforcement, subgrade, screed, temperature, weather window.
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In-Process Control & Testing
During the works, field density tests, compaction checks, slump tests, temperature monitoring, and geometric surveys run continuously against the ITP frequency.
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Post-Completion Verification
Cores, cubes, cylinders, and profilograph runs verify the finished asset. Non-conforming areas are marked, opened, and rectified before the section is handed over.
Each stage produces a controlled record that follows the works into the project handover file.
Testing & Laboratory
A test result is either a certificate or a red flag.
Al Zahraa performs materials and construction testing to the specification of each contract. Where the client's specification requires a nationally-accredited laboratory, samples are dispatched to an accredited third-party laboratory approved for that contract; site-level tests are performed in-house against the same procedures.
Aggregates
Grading & Sieve Analysis, Los Angeles Abrasion, Flakiness & Elongation Index, Water Absorption, Specific Gravity, Sand Equivalent, Aggregate Impact Value.
Concrete
Slump, Compressive Strength (7-day & 28-day cubes/cylinders), Air Content, Density, Water-Cement Ratio verification, Core Testing where in-place strength is required.
Asphalt (Hot Mix)
Marshall Stability & Flow, Bulk Density, Voids Analysis, Bitumen Content Extraction, Aggregate Gradation post-extraction, Field Density on Cores, Temperature Monitoring.
Full test menus and reporting formats align with the specification of each project. Certified copies of test reports are provided in the project handover file.
HSE Policy
No production target overrides a safety judgement.
Al Zahraa's HSE Policy commits the firm to protecting the health and safety of every person on our sites — employees, sub-contractors, client representatives, and members of the public — and to minimising the environmental impact of the works we perform. The policy is signed by the Chairman and is displayed at every active site.
Every operator is trained, certified, and authorised.
No person operates a machine, works at height, or performs a hot-work activity on our sites without documented competence.
PPE is a hiring standard, not a suggestion.
Hard hat, hi-vis, safety footwear, eye protection, gloves — issued, replaced, and enforced. Where the task requires it (welding, confined space, work at height), task-specific PPE is added and inspected before use.
Pre-task risk assessment before every activity.
Toolbox talks are delivered daily, in the language of the workforce. The talk covers the specific hazards of that day's task, not a generic reminder.
Traffic management on active carriageways.
Roadworks on live traffic corridors are the highest-risk work we do. Signage, coning, speed control, and flagging are laid out to a written traffic management plan for every phase.
Report everything — including near-misses.
A near-miss reported today is an incident that didn't happen tomorrow. Our reporting culture rewards raising a concern, never punishes it.
Environmental care alongside safety.
Dust suppression, spill control, waste segregation, and noise management are treated as HSE line items — not afterthoughts.
Training & Culture
A safe site is a habit, not a poster.
Al Zahraa treats safety training as a continuous programme, not an induction check-box. What follows is what that programme actually looks like on our sites.
Induction before site access. No person accesses an Al Zahraa site until they have completed a documented induction covering the site's specific hazards, the emergency arrangements, the PPE requirements, and the escalation chain for raising a safety concern.
Daily toolbox talks. Before every shift, the site supervisor delivers a short toolbox talk tied to that day's activity. Attendance is recorded, and the topic is logged in the site's HSE register.
Task-specific training. Work at height, confined-space entry, hot works, lifting operations, and traffic management on live roads each require task-specific certification refreshed on a defined cycle.
Behavioural safety observations. Site management performs recorded safety observations on a rolling schedule — coaching rather than policing, so that unsafe habits are corrected before they cause an incident.
- Toolbox talks per week 68
- Task-specific certifications tracked 312
- Induction pass-rate 98%
- Behavioural safety observations per month 240
Environment & Sustainability
A road is a permanent installation. So is its environmental footprint.
Environmental performance is a specification item on modern public-sector infrastructure. Al Zahraa's environmental management addresses the impacts of construction — dust, noise, spillage, waste — and the longer-term impacts of the asset we hand over. What follows is the framework, not a marketing claim.
Dust and air-quality control.
Water bowsers on active earthworks and haul roads, covered aggregate stockpiles, and speed limits on unpaved site roads — all standard, all logged.
Spill prevention and containment.
Bunded fuel and oil storage, spill kits at every plant location, defined procedures for hydraulic-line failures, and separate collection for used oils and filters routed to licensed disposal contractors.
Waste segregation and disposal.
Site waste is segregated at source — inert construction waste, recyclables, hazardous — and disposed of through authorised routes with documentation retained in the project file.
Noise and community impact.
Working hours on populated corridors are managed against local requirements. Community notifications precede noisy activities where the works run near residential areas.
Framework aligns with the principles of ISO 14001:2015 environmental management. Client-specific environmental management plans are prepared for each project.
Certifications & Frameworks
Aligned to the standards our clients expect.
Al Zahraa's Quality, HSE and Environmental management systems are structured around the principles of the ISO management-system standards, and the contractor classifications required by the public-sector authorities we work with. Verified certification documents are available to prospective clients on request.
ISO 9001:2015
Quality Management Systems
Certified — valid to March 2028
ISO 14001:2015
Environmental Management Systems
Certified — valid to March 2028
ISO 45001:2018
Occupational Health & Safety Management Systems
Certified — valid to August 2028
Egyptian Federation for Construction & Building Contractors
Contractor Classification, Class 1 — Roads & Bridges
Registered — renewed annually
Ministry of Housing — Approved Contractor Register
Public-sector contractor registration
Registered — valid to December 2027
Additional accreditations and audit reports available on request.
Learning & Improving
Every incident, every non-conformance — a chance to be better on the next project.
Al Zahraa treats reporting as the input to a learning process, not as an administrative burden. What follows is how a raised issue becomes a permanent improvement.
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Report.
Any person on site can raise a Non-Conformance Report (NCR), a Safety Observation, or a Near-Miss Report. The reporter is protected; the report is logged the same day.
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Investigate.
The QHSE function investigates root cause — not just the immediate cause. Findings are recorded against the incident.
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Correct and prevent.
Corrective action addresses the specific issue; preventive action changes the method, the training, or the procedure so the root cause cannot recur.
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Close and share.
The report is closed only when the preventive action is verified. The lesson is distributed across active sites and folded into the next project's method statements.
Auditing us before you award a contract?
We'll send a full QHSE pack — policies, ITPs, HSE records, and certification documents — matched to your project scope and specification.