Soil R e i nf o r cem e n t

S o l ut i ons MacWall and Te r r a m e s h ™ s y s t e m s

African
Gabions
Environmental Solutions

Introduction to retaining wall
structures
Retaining wall structures built today comprise of:
• simple gravity walls;
• larger composite reinforced soil wall structures, or
• a combination of both.
Reinforcing structures contain or stabilise slopes, walls
and embankments and consist predominantly of two
components:
Front face: Primarily a retaining function, which
contributes to the aesthetics of the completed structure.
Internal reinforcing layers: The reinforcement layer
enhances the shear properties of the soil enabling large
composite reinforced soil structures to be constructed.
Through dedicated research and development and the
desire to ensure optimum performance from the finished
structure, Maccaferri has developed a range of soil
reinforcing solutions to meet your needs.
3. Mesh pullout resistance provided
by the soil interlock mechanism.
2
1 2
1-2. One of the first examples of reinforced soil walls using gabions with
“Soil Reinforced” system along the road from Sinsuran to Kota Kinabalu,
Sabah, Malaysia.
History
Maccaferri’s experience in Reinforced Soil using double
twisted wire mesh dates back to 1979 with the first
structure built in Sabah, Malaysia.
Through ongoing international research and development
with the cooperation of world renowned Research Institutes
and local construction companies, Maccaferri has
accumulated a wealth of knowledge. The experience
acquired and the desire to ensure optimum performance
while simplifying installation have led to the development
of state-of-the-art soil reinforcing systems.
Today Maccaferri is capable of offering the competitive
market, innovative, engineered solutions based on durable
high performance products, which are easy to construct
even in the most demanding conditions.
4. Schematic of Green Terramesh™
embankment with reinforcing
layers of mesh.
 5

5. Steel wire and geogrids have proper

coatings to optimise durability.

Research and Development
Maccaferri undertook detailed research into the behaviour
and interaction of double twisted wire mesh in compacted
granular and cohesive soils (Australian Defence Force
Academy, Canberra; Federal Highway Administration,
USA; ISMES, Bergamo, Italy; Transport Research
Laboratory, UK).
Further research with ISMES, Bergamo, Italy and R.J. Bathurst
i n C a n a d a o n t h e d e f o r m a t i o n s o f t h e d i ff e re n t
re i n f o rc e m e n t m a t e r i a l s , a l l o w e d M a c c a f e r r i t h e
opportunity to further develop their range of solutions to
include a combination of double twisted wire mesh
products with high resistance geogrids.
Full scale testing combined with laboratory analysis of the
materials used, enabled accurate determination of material
characteristics such as durability, tensile resistance and
anchoring capacity. In addition, correct design parameters,
limitations and safety factors, used in the engineering
design of the structure were determined.
Results show that Terramesh™ is able to provide its full
tensile resistance at only 2% strain.
The selection of materials with appropriate corrosion
protection make Maccaferri a leader in product quality
standards as required by the most demanding international
institutions. Terramesh™ has been certified by the British
Board of Agrement (BBA) for a 120 year design life.

6-7. Pull-out test and direct shear test on double twisted wire 8. Research into the behaviour of double
mesh. ENEL Hydro, Bergamo, Italy. twisted wire mesh as reinforcement.
6 Canberra University, New South Wales,
Direct shear box, testing interface soil/mesh Australia.
LOAD
700 PISTON DOUBLE TWISTED WIRE
MESH WELDED ON
STEEL PLATE

WELDING 8

STEEL
PLATE

200 200 331

C6 45
C5 C4
1

369 400
CLAY

1500

3
 9 10
9. Vegetated geosynthetic. (MacMat™) 10. Vegetative pocket insertion into gabion walls.

Maccaferri solutions for

soil reinforcement works
Reinforcing Systems
TERRAMESH™ SYSTEM
The Terramesh™ system developed by Maccaferri is made
of a series of pre-assembled units, which can be easily
joined to form a flexible, monolithic soil reinforcement
structure.
A Terramesh™ system unit comprises a front face and
reinforcement tail made from one continuous, heavily
galvanised and PVC coated double twisted wire mesh
panel.
Two different Terramesh™ structures are available,
depending on the type of front face:
Stone filled front face: A traditional box gabion
forms the front face. This is referred to as the Terramesh™
System.
Vegetated front face: The front face is inclined at a
70º angle, lined with an erosion control blanket and
strengthened with a welded steel panel. The unit is entirely
soil filled and referred to as the Green Terramesh™ System.
MACWALL SYSTEM
Manufactured under license from Keystone, the MacWall
system comprises split faced blocks, interlocking pins and
reinforcement layers. The unique patented interlocking,
fibreglass or steel pin system ensure a positive connection
between the structural wall unit and the soil reinforcement.
Reinforcement layers, which may range from geogrids
through double twisted mesh to steel ladders provide the
full range of suitable reinforcement materials, which allow
for construction of up to 15m high vertical walls.
Structural Embankment
The embankment forming the reinforced soil structure
should be of a selected granual fill, free draining with a
high angle of internal friction. The soil should not exhibit
any deterioration of these characteristics with time. The
foundation preparation, placing and compaction of the
fill should be in accordance with all relevant local
specifications for road construction.
Research and experience has shown that soil with a grading
varying from 0.02 mm up to 6 mm (100% passing) is ideal
for use as structural fill. Gradings with sizes up to 200mm
can be used but may need to be tested for construction
damage to the PVC coating.
S e l e c t i n g t h e f i l l i n a c c o rd a n c e w i t h t h e a b o v e
recommendations will ensure a material with consistent
anchorage capacity even if subjected to a variation in the
water level. A friction angle of at least 36º can be obtained
after compacting such material. Other materials, not
included in the above classification, may be used provided
they have the necessary resistance characteristics and do
not affect the durability of the reinforcement. In certain
cases it may be economic to use the in-situ soil, mixing it
with other materials (sand, gravel, chemical stabilisers,
etc.) to obtain an acceptable fill.
To prevent the loss of fines from the fill through the rock
filled front face, compact needle punched geotextile is
installed at the rock/soil interface.
12. Typical MacWall cross section.

Finished Grade Backslope or Surcharge

Total Wall
Height

11. MacWall bridge abutment - Australia. Low

MacWall Permeability
11 12
Compac Units Soil

Reinforced
Setback/ Soil Zone
Batter Backfill
Material

Specified
Reinforcement
Finished
Grade
Limit of
Excavation
(Rough cut)
4 Unit Drainage Fill
Embedded Levelling Pad Drainage Collection
Depth Pipe (if required)
 13

Compact needle
punched geotextile

TERRAMESH™ WITH A VERTICAL FACE

14

TERRAMESH™ WITH A BATTERED FACE

15

GR EE N T E R R A ME S H ™

13. 23 m high Terramesh™ retaining wall

structure in the mining industry.
Sumbawa, Indonesia.

14. Terramesh™ retaining wall structure

along a road.
Southern Highlands, Papua New Guinea.

15. Front face of Green Terramesh™.

Casalecchio di Reno, Bologna, Italy.

5
 1
Stages of Green Terramesh™ installation.
Benefits and Features
Structurally sound: C o m p u t e r s o f t w a r e a n d
technical support to assist in the design of structures
ensures a structurally sound engineered solution.
Excellent connection mechanisms eliminate the risk
o f f a i l u re b e t w e e n t h e re i n f o rc e m e n t a n d t h e f ro n t
face. Where hexagonal woven mesh is used, the
double twist does not unravel when one or more
w i re s a re d a m a g e d .
Durability: W h e t h e r i t s a s h o r t t o m e d i u m o r l o n g
term solution, our galvanised and PVC coated
products ensure high performance and durability
t h ro u g h o u t t h e l i f e o f t h e p ro j e c t .
Aesthetically pleasing: W h e t h e r y o u a re l o o k i n g
f o r a ro c k f i n i s h , a v e g e t a t e d f ro n t f a c e o r v a r i o u s
options for concrete colours, textures and patter ns,
o u r p ro d u c t s w i l l m e e t y o u r n e e d s .
Versatility: I n d i v i d u a l u n i t s a l l o w f o r e a s y d e s i g n
and construction of a site-specific solution.
Easy to install: A s t r a i g h t f o r w a r d s y s t e m o f
combining individual units to form a reinforced
structure. Unskilled staff are able to quickly and
efficiently install units on site, under the supervision
o f o u r s k i l l e d t r a i n e r s , i f re q u i re d .
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6
2
3
4
Cost effective: I n - s i t u m a t e r i a l s m i n i m i s e t h e c o s t
associated with using expensive imported materials.
F u r t h e r m o re , t h e m o d u l a r i t y o f t h e u n i t m a k e s t h e
construction time cost effective, whilst the durability
gives it an outstanding life cycle cost benefit.
Environmentally friendly: S t r u c t u r e s c a n b e
naturally integrated with the surrounding
environment by using in-situ materials combined
with various bioengineering techniques. The
f i l t e r i n g c a p a b i l i t y o f t h e ro c k f i l l , a l l o w s t h e s o i l ,
w a t e r, a i r a n d p l a n t l i f e t o i n t e r a c t n a t u r a l l y. P l a n t
life can be incorporated into the design to accelerate
vegetation.
Flexibility: W i t h t h e Te r r a m e s h ™ s y s t e m , t h e
structure’s flexibility allows its use even in poor
soils as it is able to adapt to foundation settlements
with moderate deformations.
Resistance to flame: T h e p r e s e n c e o f c o n c r e t e
blocks or PVC coated steel wire mesh, provide
e x c e l l e n t re s i s t a n c e t o f l a m e ; w h i c h i s n o t t h e c a s e
with exposed geosynthetics.
Protection against stray electrical currents: T h e
PVC coating on the metal wire isolates it electrically.
7
6
 Th e Te r r a m e s h ™ S y s t e m :
main phases of installation

Terramesh™ Green Terramesh™

Single factory-made unit, folded and ready to be Single factory-made unit, folded and ready to place
placed in position. in position, including the revegetation matrix, an
additional steel mesh panel, triangular reinforcing
steel brackets.

Unit in position, opened out along the folded corner. Unit in position, opened out along the folded corner.

Partition panels (diaphragms) attached by lacing at Opening and pivoting of the triangular supporting
edges. brackets.

Gabion portion filled with stone, and lid laced down. Backfilling up to desired level.
Geotextile positioned and backfilling commenced.

Placing next unit on top. Folding of the face upper side. Placement of the
next unit and attaching by stainless steel rings or
PVC coated binding wire to the unit below. 7
 Through promoting research and development, laboratory testing and on-site investigation, Maccaferri and its associates
have developed a suite of dedicated software to provide the engineer with design assistance. The software programs
are flexible tools that are updated and improved continuously.
Dating back from the last century to the present day, our philisophy is one of continual improvement through innovative
developments. Our presence and willingness to assist the design engineer and not only to be a product supplier, has
led us to become the leader in providing environmental solutions.

M A C S TA R S 2 0 0 0
M a c c a f e r r i S t a b i l i t y A n a l y s i s o f R e i n f o rc e d S o i l s
Maccaferri provides computer software and technical support to
assist in the design of Terramesh™ system structures. The MacStars
program performs a series of stability checks of the reinforced
structure and provides a detailed calculation report, cross sections
and safety factors for the final design.

Continual software development has allowed the design engineer

to verify all the design aspects taking into consideration the
various materials used for reinforcement, the different national
s t a n d a rd s , a l l t h e p o s s i b l e e x t e r n a l re q u i re m e n t s , t h e v a r i o u s
geometries, the different soil types and the possible hydraulic
s t re s s e s .

Analyses are carried out taking into account the true profile
of the reinforced soil structures. In the case of complex
slopes (e.g. due to the presence of several isolated works),
it is possible to describe the whole slope, taking into
account the mutual interaction of the works.

Available checks
(using Janbu or Bishop methods) are:

• Surface stability
• Internal stability
• Global stability Report
A report can be generated that
• Sliding summarises all the project data and results.
• Wall checks The Report is saved in MS Word format.

• Settlement

8
M A C WA L L a n d K E Y WA L L
M a c c a f e r r i S t a b i l i t y A n a l y s i s o f S e g m e n t a l R e t a i n i n g B l o c k Wa l l s
M a c c a f e r r i p ro v i d e s c o m p u t e r s o f t w a re a n d t e c h n i c a l s u p p o r t t o a s s i s t i n t h e d e s i g n o f M a c Wa l l
Segmental Retaining structures. T h e M a c Wa l l a n d K e y Wa l l s o f t w a r e p r o g r a m s a r e a v a i l a b l e
where steel ladders and polymer geogrids are respectively used for reinforcement.
T h e s e p ro g r a m s a l l o w f o r t h e e x t e r n a l a n d i n t e r n a l s t a b i l i t y c h e c k s o f t h e re i n f o rc e d s t r u c t u re
a c c o rd i n g t o a n u m b e r o f i n t e r n a t i o n a l s t a n d a rd s .

The external stability items checked during the design include:

• Sliding of the gravity wall;
• Sliding at the base of the reinforced zone or along the lower layers of geogrid reinforcement;
• Overturning about the toe;
• A p p l i e d b e a r i n g p re s s u re .

The internal stability items checked during the design include:

• Te n s i l e o v e r s t re s s o f re i n f o rc i n g ;
• M a c Wa l l u n i t re i n f o rc e m e n t c o n n e c t i o n ;
• Pullout capacity of the reinforcing beyond the theoretical failure plane;
• Local stability of the facing - shear and bending.

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 General reinforcement solutions
G r e e n Te r r a m e s h ™ S y s t e m
3.79 6.30

2.40
2.40
10.80

2.40
2.40
1.20

7.00
16 17

FRONT VIEW (EXTENDED)

18 19

16-19. Retaining work along

the Imola Race Track carried out
by using soil type reinforced
Green Terramesh™.
Imola, Italy.

10
 Geogrids

8.80
8.80

20

20-21. Slope stabilisation

using Geogrids.
Passignano, Perugia, Italy.

21

Te r r a m e s h ™ s y s t e m + G e o g r i d s

Terramesh™
tail
15.50

Grid reinforcement 22
23

22-23. Road embankment

using Terramesh™ and
Geogrids.
Aliano, Matera, Italy.

11
 Mining solutions

50 kN/m2

24-25. A 15 m high Terramesh™ wall.

Potgietersrust Platinum Mine,
N. Province, South Africa. Compacted
Rock
Backfill
Face

15000
24 AG200
25 Geotextile

26

26. A vertical 10 m high Geogrid and

Terramesh™ structure combined with
a temporary, soil filled gabion wall.
Yetweni Mine, Angola.
(Courtesy of Diamond Works)

27. MacWall vertical headwall. 28. Retaining wall structure with Terramesh™ in a mining industry.
Quarry in Australia. Sumbawa, Indonesia.
27 28

12
 Ve g e t a t e d s o l u t i o n s

29 30
12 kN/m2 UDL
Vegetative
Topsoil

Green Terramesh™ Selected

units compacted

7800
backfill

Mixture of soil
and rock on
first 3 layers
29-31. Green Terramesh™. Gateway Shopping Centre,
600

AG200 Geotextile
La Lucia, KZN, South Africa.
5000
31

32. Bio-engineered bank reinforcement.

Thesen Islands, Knysna, W. Cape, South Africa.
32

2
1
33

Vegetative Topsoil

100mm set back

Green Terramesh™
units

4800
Selected
compacted
backfill
Terramesh™ System
units AG200
Geotextile
1000

4000

35. Green Terramesh™ retaining structure. 33-34. Construction of a Green Terramesh™ retaining wall.
Amanzimtoti, S. Coast, KZN, South Africa. Port Zimbali, N. Coast, KZN, South Africa.
35 34

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 Vertical and battered face solutions

36

36-37. Terramesh™ System used Existing

75mm Topsoil
for embankment stabilisation. and grass Embankment
N3, Hilton, KZN, South Africa. sodding
1000

37
1000

Rockfill

2500mm
5000

Side
Drain
AG400
Geotextile

39

100
38

Terramesh™
Units
3000

38-39. A near vertical

Terramesh™ System.
Gabion Culvert Durban, KZN, South
Protection 2000 4000 Africa.

3x1x0,3 Reno
Mattresses

3000 AG200 Geotextile

40 40-41. A Terramesh™ System

retaining wall along the Old
Howick Road, Pietermaritzburg,
KZN, South Africa.

41

Selected
Backfill
6000

Compacted
Soil Layers

14
AG200
Geotextile
 42
42. Terramesh™ System. Hex River Valley, Cape, South Africa.

43 43-44. A vertical Terramesh™ system.

N3 Expansion, Cato Ridge, KZN,
South Africa.

44

500
Gabion Front
Face Terramesh™ Tail

1000
AG200 Geotextile

3000

45-46. Combination Terramesh™ System and mass gravity wall supporting

a pipeline. Cato Manor, KZN, South Africa.
ROADWAY 45 46

500 Terramesh™
2000

Units

Phreatic
5000

Gabion
Units

AG200
Geotextile
300mm Thick
Reno Mattress

47. Combination of Terramesh™ System and Green Terramesh™.

Gateway Shopping Centre, La Lucia, KZN, South Africa. 48. 9m High vertical Terramesh™ wall. South Australia.
47 48

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P O Box 15777, Westmead, 3608 Tel: +27-31-700 8456 Fax: +27-31-700 8469 E-mail: sales@africangabions.co.za
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Environmental Solutions MALAWI:
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