Section 20 - Geotechnical Works

SECTION 20 – GEOTECHNICAL WORKS
20.1 REMOVAL AND REPLACEMENT OF UNSUITABLE MATERIAL ............................... S20-1

20.1.1 DEFINITION .......................................................................................................................... S20-1
20.1.2 DETERMINATION OF DEPTH FOR REMOVING UNSUITABLE MATERIAL
WITH JKR OR MACKINTOSH PROBES .................................................................................... S20-1
20.1.2.1 Description ...................................................................................................................S20-1
20.1.2.2 Equipment .....................................................................................................................S20-1
20.1.2.3 Procedures ....................................................................................................................S20-2
20.1.2.4 Criteria for Removal Unsuitable Material ...................................................................S20-2
20.1.3 MATERIALS FOR REPLACEMENT OF UNSUITABLE MATERIAL............................................... S20-2
20.2 GEOTEXTILE .......................................................................................................................... S20-2
20.2.1 GENERAL.............................................................................................................................. S20-2
20.2.1.1 Scope.............................................................................................................................S20-2
20.2.1.2 Types of geotextile ........................................................................................................S20-2
20.2.1.3 Contractor to Provide ...................................................................................................S20-3
20.2.1.4 Setting-Out ....................................................................................................................S20-3
20.2.1.5 Locally Produced Products ..........................................................................................S20-3
20.2.1.6 Construction Traffic......................................................................................................S20-3
20.2.2 PACKAGING AND STORAGE .................................................................................................. S20-3
20.2.2.1 Product Labelling .........................................................................................................S20-3
20.2.2.2 Product Packaging .......................................................................................................S20-3
20.2.2.3 Product Quality Assurance ...........................................................................................S20-3
20.2.2.4 Storage at Site ...............................................................................................................S20-3
20.2.3 TESTING OF GEOTEXTILE ..................................................................................................... S20-4
20.2.3.1 General .........................................................................................................................S20-4
20.2.3.2 Consignment Certificate ...............................................................................................S20-4
20.2.3.3 Routine Testing .............................................................................................................S20-4
20.2.4 JOINTING THE ADJACENT GEOTEXTILE................................................................................. S20-4
20.2.4.1 Methods of Jointing ......................................................................................................S20-4
20.2.4.2 Sewn Seams...................................................................................................................S20-5
20.2.5 NON-WOVEN GEOTEXTILE ................................................................................................... S20-5
20.2.5.1 Material Properties ......................................................................................................S20-5
20.2.5.2 Installation of Non-Woven Geotextile ...........................................................................S20-7
20.2.6 WOVEN GEOTEXTILE ..................................................................................................... S20-7
20.2.6.1 Material Properties ......................................................................................................S20-7
20.2.6.2 Installation of Woven Geotextile ...................................................................................S20-8
20.3 GEOGRID .................................................................................................................................. S20-9
20.3.1 GENERAL.............................................................................................................................. S20-9
20.3.1.1 Scope.............................................................................................................................S20-9
20.3.1.2 Contractor to Provide ...................................................................................................S20-9
20.3.1.3 Setting-Out ....................................................................................................................S20-9
20.3.1.4 Locally Produced Products ..........................................................................................S20-9
20.3.2 PACKAGING AND STORAGE ................................................................................................ S20-10
20.3.2.1 Product Labelling .......................................................................................................S20-10
20.3.2.2 Product Packaging .....................................................................................................S20-10
20.3.2.3 Product Quality Assurance .........................................................................................S20-10
20.3.2.4 Storage at Site .............................................................................................................S20-10
20.3.2.5 Durability of Geogrid .................................................................................................S20-10
20.3.3 TESTING ............................................................................................................................. S20-10
20.3.3.1 General .......................................................................................................................S20-10
20.3.3.2 Consignment Certificate .............................................................................................S20-11
20.3.4 MATERIAL PROPERTIES ...................................................................................................... S20-11
20.3.4.1 Products ......................................................................................................................S20-11
20.3.4.2 Technical Properties ...................................................................................................S20-12
S20 - i
20.3.5 INSTALLATION.................................................................................................................... S20-12
20.3.5.1 General .......................................................................................................................S20-12
20.3.5.2 Fill Material ...............................................................................................................S20-12
20.3.5.3 Installation of Geogrid for Reinforced Slope..............................................................S20-13
20.3.5.4 Protection of Completed Geogrid Reinforced Slopes from Erosion ...........................S20-13
20.4 PREFABRICATED VERTICAL DRAINS (PVD) ............................................................... S20-13
20.4.1 GENERAL............................................................................................................................ S20-13
20.4.2 MATERIALS ........................................................................................................................ S20-14
20.4.2.1 Prefabricated Vertical Drains ....................................................................................S20-14
20.4.2.2 Geotextile Separator ...................................................................................................S20-15
20.4.2.3 Drainage Blanket ........................................................................................................S20-15
20.4.3 INSTALLATION.................................................................................................................... S20-16
20.4.3.1 Prefabricated Vertical Drain (PVD) ..........................................................................S20-16
20.4.3.2 Geotextile Separator ...................................................................................................S20-18
20.4.3.3 Fill Surcharge .............................................................................................................S20-19
20.4.3.4 Instrumentation ...........................................................................................................S20-19
20.5 SURCHARGE / PRE-LOADING .......................................................................................... S20-20
20.6 STONE COLUMN .................................................................................................................. S20-21
20.6.1 GENERAL............................................................................................................................ S20-21
20.6.1.1 Design Requirements. .................................................................................................S20-21
20.6.2 STANDARDS AND DEFINITIONS ........................................................................................... S20-21
20.6.3 TOLERANCES ...................................................................................................................... S20-21
20.6.3.1 Setting Out ..................................................................................................................S20-21
20.6.3.2 Position .......................................................................................................................S20-21
20.6.4 PERSONNEL ........................................................................................................................ S20-21
20.6.5 DAMAGE TO STONE COLUMN ............................................................................................. S20-21
20.6.6 LOAD TESTS ON PRELIMINARY STONE COLUMNS .............................................................. S20-22
20.6.6.1 Plate Load Test on Preliminary Stone Column ..........................................................S20-22
20.6.6.2 S.O.’s Instruction to Commence Installation of Stone Columns .................................S20-22
20.6.7 DIAMETER AND LENGTH OF THE STONE COLUMNS ............................................................ S20-22
20.6.8 STONE CONSUMPTION ........................................................................................................ S20-22
20.6.9 VIBROFLOT......................................................................................................................... S20-22
20.6.10 OBSTRUCTIONS .............................................................................................................. S20-23
20.6.11 PROCEDURE FOR COMPACTION OF STONE COLUMNS ..................................................... S20-23
20.6.12 MATERIALS .................................................................................................................... S20-24
20.6.12.1 Stones ..........................................................................................................................S20-24
20.6.13 STONE COLUMN RECORDS ............................................................................................. S20-24
20.6.14 DISPOSAL OF ARISING .................................................................................................... S20-25
20.6.15 PLATE LOAD TESTS ON STONE COLUMNS ...................................................................... S20-25
20.6.15.1 General .......................................................................................................................S20-25
20.6.15.2 Safety Precautions Applicable to Plate Load Tests on Stone Columns ......................S20-25
20.6.15.3 Reaction System ..........................................................................................................S20-25
20.6.15.4 Equipment for Loading and Load Measurements .......................................................S20-26
20.6.15.5 Method of Measuring the Movement of the Bearing and the Surrounding
Ground Surface...........................................................................................................S20-26
20.6.15.6 Plate Dimensions ........................................................................................................S20-26
20.6.15.7 Locations ....................................................................................................................S20-26
20.6.15.8 Preparation of Top of Stone Column ..........................................................................S20-26
20.6.15.9 Protection of Testing Equipment and Supervision ......................................................S20-26
20.6.15.10 Test Procedure for Maintained Load Test ..............................................................S20-27
20.6.15.11 Plate Load Test Records .........................................................................................S20-27
20.6.15.12 Records Confidential ..............................................................................................S20-27
20.7 TERRAMESH WALL ............................................................................................................ S20-28
20.7.1 MATERIALS SPECIFICATION ............................................................................................... S20-28
20.7.1.1 Introduction ................................................................................................................S20-28
20.7.1.2 Definitions ..................................................................................................................S20-28
S20 - ii
20.7.1.3 General Description ...................................................................................................S20-28
20.7.1.4 Steel Wire ....................................................................................................................S20-28
20.7.1.5 Wire Mesh ...................................................................................................................S20-31
20.7.1.6 Selvedges ....................................................................................................................S20-31
20.7.1.7 Diaphragms and End Panels ......................................................................................S20-32
20.7.1.8 Lacing And Bracing Wire ...........................................................................................S20-32
20.7.1.9 Unit Sizes ....................................................................................................................S20-32
20.7.1.10 Stone Fill For Facing Box ..........................................................................................S20-32
20.7.1.11 Structural Embankment ..............................................................................................S20-32
20.7.2 ASSEMBLY AND ERECTION SPECIFICATION FOR TERRAMESH SYSTEM UNIT
REINFORCED WALLS .......................................................................................................... S20-33
20.7.2.1 Scope...........................................................................................................................S20-33
20.7.2.2 Preparation .................................................................................................................S20-33
20.7.2.3 Erection ......................................................................................................................S20-33
20.7.2.4 Geotextile ....................................................................................................................S20-34
20.7.2.5 Stretching ....................................................................................................................S20-34
20.7.2.6 Filling .........................................................................................................................S20-34
20.7.2.7 Structural Embankment Material ...............................................................................S20-34
20.7.2.8 Compaction of Backfill ...............................................................................................S20-34
20.8 GABION RETAINING WALL .............................................................................................. S20-35
20.9 REINFORCED SOIL WALL WITH CONCRETE FACING PANELS ............................ S20-35
20.9.1 GENERAL............................................................................................................................ S20-35
20.9.2 DEFINITIONS ....................................................................................................................... S20-35
20.9.3 DIMENSIONS ....................................................................................................................... S20-35
20.9.4 CODES OF PRACTICE AND TECHNICAL MEMORANDUM...................................................... S20-35
20.9.5 MATERIALS ........................................................................................................................ S20-36
20.9.5.1 Reinforcing Elements ..................................................................................................S20-36
20.9.5.2 Facings .......................................................................................................................S20-36
20.9.5.3 Fasteners ....................................................................................................................S20-36
20.9.5.4 Facing Unit Joint Filler Material ...............................................................................S20-37
20.9.5.5 Fill ..............................................................................................................................S20-37
20.9.5.6 Material Compatibility ...............................................................................................S20-37
20.9.6 DESIGN METHODOLOGY AND CRITERIA ............................................................................. S20-37
20.9.6.1 Design of Reinforcing Elements .................................................................................S20-37
20.9.6.2 Design of Facings and Fasteners ...............................................................................S20-38
20.9.7 REINFORCING ELEMENTS ................................................................................................... S20-39
20.9.7.1 Deadman Anchor Walls ..............................................................................................S20-39
20.9.7.2 Reinforced Earth Walls ...............................................................................................S20-40
20.9.8 FRICTIONAL FILL ................................................................................................................ S20-40
20.9.8.1 Selected Fill for Reinforced Soil Retaining Wall ........................................................S20-40
20.9.8.2 Grain Size Distribution ...............................................................................................S20-40
20.9.8.3 Angle of Friction .........................................................................................................S20-40
20.9.8.4 Chemical and Electrical Properties............................................................................S20-41
20.9.9 FIXINGS AND FASTENERS ................................................................................................... S20-41
20.9.9.1 Fasteners for Deadman Anchor and Reinforced Earth Walls ....................................S20-41
20.9.10 FACINGS ......................................................................................................................... S20-43
20.9.11 JOINT FILLERS ................................................................................................................ S20-43
20.9.12 GRANULAR FILL BEHIND REINFORCED SOIL RETAINING WALL ..................................... S20-43
20.9.13 CONSTRUCTION .............................................................................................................. S20-43
20.9.13.1 Fill ..............................................................................................................................S20-43
20.9.13.2 Wall Erection - Concrete Panels ................................................................................S20-44
20.9.13.3 Fabrication and Handling ..........................................................................................S20-44
20.9.13.4 Tolerances ..................................................................................................................S20-45
20.9.14 TESTING OF FILL MATERIAL .......................................................................................... S20-45
20.9.14.1 General .......................................................................................................................S20-45
20.9.14.2 Testing of Fill for Reinforced Soil ..............................................................................S20-45
20.9.14.3 Testing of Chloride Content (Reinforced Earth and Deadman Anchor Walls) ..........S20-46
20.9.14.4 Testing Of Resistivity (Reinforced Earth and Deadman Anchor Walls) .....................S20-46
20.9.14.5 Testing of Redox Potential (Reinforced Earth and Deadman Anchor Walls) .............S20-46
S20 - iii
20.9.15 GALVANIZATION TESTS FOR REINFORCING ELEMENTS (REINFORCED AND
DEADMAN ANCHOR WALLS) .......................................................................................... S20-48
20.9.16 PULL OUT TESTS FOR REINFORCING ELEMENTS ............................................................. S20-48
20.10 RUBBLE MASONRY WALL ................................................................................................ S20-48
20.10.1 DESCRIPTION .................................................................................................................. S20-48
20.10.2 MATERIALS .................................................................................................................... S20-48
20.10.3 CONSTRUCTION METHODS ............................................................................................. S20-48
20.11 HORIZONTAL DRAIN .......................................................................................................... S20-49
20.11.1 GENERAL........................................................................................................................ S20-49
20.11.2 SETTING OUT ................................................................................................................. S20-49
20.11.3 MATERIALS .................................................................................................................... S20-49
20.11.3.1 Polyvinyl Chloride (PVC) Pipes Technical Properties ...............................................S20-49
20.11.3.2 Perforations of PVC Pipe ...........................................................................................S20-49
20.11.3.3 Filter Cloth Technical Properties ...............................................................................S20-49
20.11.4 PRODUCT QUALITY ASSURANCE PVC PIPE AND FILTER CLOTH .................................... S20-50
20.11.5 HANDLING AND STORAGE .............................................................................................. S20-50
20.11.5.3 Storage at Site .............................................................................................................S20-51
20.11.6 INSTALLATION ................................................................................................................ S20-51
20.11.6.1 Drilling .......................................................................................................................S20-51
20.11.6.2 Pipe Installation .........................................................................................................S20-51
20.11.6.3 Horizontal Drain beside Soil Nail/Ground Anchor/Rock Bolt....................................S20-52
20.11.6.4 Concrete Lined Chutes ...............................................................................................S20-52
20.11.7 SUBMITTALS ................................................................................................................... S20-52
20.12 SOIL NAILING ....................................................................................................................... S20-52
20.12.1 SCOPE ............................................................................................................................. S20-52
20.12.2 REFERENCE STANDARD .................................................................................................. S20-52
20.12.3 METHOD OF CONSTRUCTION .......................................................................................... S20-53
20.12.4 MATERIAL CERTIFICATION............................................................................................. S20-53
20.12.5 WORKMANSHIP RESPONSIBILITY.................................................................................... S20-53
20.12.6 REINFORCEMENT ............................................................................................................ S20-53
20.12.7 SLOPE TRIMMING ........................................................................................................... S20-54
20.12.8 TEMPORARY STAGING .................................................................................................... S20-54
20.12.9 DRILLING ....................................................................................................................... S20-54
20.12.10 GROUTING ...................................................................................................................... S20-54
20.12.11 CONSTRUCTION OF GUNITE ............................................................................................ S20-54
20.12.12 CORROSION PROTECTION OF SOIL NAIL HEAD AND STEEL PLATE ................................. S20-54
20.12.13 FITTING OF SOIL NAIL HEAD .......................................................................................... S20-54
20.12.14 SOIL NAIL STRESSING .................................................................................................... S20-54
20.13 GUNITING .............................................................................................................................. S20-55
20.13.1 GENERAL........................................................................................................................ S20-55
20.13.2 MATERIALS .................................................................................................................... S20-55
20.13.3 PROPORTIONING ............................................................................................................. S20-55
20.13.4 EQUIPMENT AND WORKMANSHIP ................................................................................... S20-55
20.13.5 PREPARATION ................................................................................................................. S20-56
20.13.6 APPLICATION .................................................................................................................. S20-56
20.13.7 CURING .......................................................................................................................... S20-57
20.13.8 SAFETY OF WORKS ......................................................................................................... S20-57
20.13.9 TESTING AND REPAIRS ................................................................................................... S20-57
20.14 STONE PITCHING SLOPE .................................................................................................. S20-57
20.14.1 DESCRIPTION .................................................................................................................. S20-57
20.14.2 MATERIALS .................................................................................................................... S20-57
20.14.2.1 Stone ...........................................................................................................................S20-57
20.14.2.2 Cement Mortar ...........................................................................................................S20-57
S20 - iv
20.14.2.3 Draining Material behind Stone Pitching Slope .........................................................S20-58
20.14.3 CONSTRUCTION METHODS ............................................................................................. S20-58
20.15 GEOCELL ............................................................................................................................... S20-58
20.15.1 SCOPE ............................................................................................................................. S20-58
20.15.2 CONTRACTOR TO PROVIDE ............................................................................................. S20-58
20.15.3 SETTING-OUT ................................................................................................................. S20-58
20.15.4 LOCALLY PRODUCED PRODUCTS.................................................................................... S20-59
20.15.5 PACKAGING AND STORAGE ............................................................................................ S20-59
20.15.5.3 Storage at Site .............................................................................................................S20-59
20.15.6 TESTING ......................................................................................................................... S20-59
20.15.6.1 General .......................................................................................................................S20-59
20.15.6.2 Consignment Certificate .............................................................................................S20-59
20.15.7 MATERIAL PROPERTIES .................................................................................................. S20-60
20.15.7.1 Product and Applications ...........................................................................................S20-60
20.15.7.2 Technical Properties ...................................................................................................S20-60
20.15.8 INSTALLATION ................................................................................................................ S20-61
20.15.8.1 General .......................................................................................................................S20-61
20.15.8.2 Installation of Cellular Retention System ...................................................................S20-61
20.15.8.3 Infill Material Placement ............................................................................................S20-61
20.16 ROCK STABILIZATION WORKS ...................................................................................... S20-61
20.16.1 GENERAL........................................................................................................................ S20-61
20.16.2 ACCESS TO ROCK SLOPES............................................................................................... S20-62
20.16.3 REMOVAL OF UNSTABLE ROCK MASS ............................................................................ S20-62
20.16.4 PREPARATION OF ROCK SURFACES ................................................................................ S20-62
20.16.5 SPRAYED CONCRETE ...................................................................................................... S20-62
20.16.6 PROTECTIVE SCREEN/ ROCKFALL NETTING ................................................................... S20-64
20.16.7 PRE-STRESSED ROCK BOLTS ........................................................................................ S20-65
20.16.7.1 General ......................................................................................................................S20-65
20.16.7.2 Materials ................................................................................................................S20-65
20.16.7.3 Construction Requirements.........................................................................................S20-66
20.16.8 ROCK DOWEL (UNTENSIONED ROCK BOLTS) ................................................................. S20-70
20.16.8.1 General .......................................................................................................................S20-70
20.16.8.2 Materials .....................................................................................................................S20-70
20.16.8.3 Construction Requirements.........................................................................................S20-71
20.17 APPENDIX 20A....................................................................................................................... S20-73
S20 - v
SECTION 20 – GEOTECHNICAL WORKS
20.1 REMOVAL AND REPLACEMENT OF UNSUITABLE MATERIAL

20.1.1 Definition
Definition of unsuitable material (USM) as per Clause 2.2.1 (d) in Section 2: Earthworks.
20.1.2 Determination of Depth for Removing Unsuitable Material with JKR or Mackintosh
Probes
20.1.2.1 Description
The JKR or Mackintosh probes shall be carried out at locations shown in the Drawings or as
indicated by the S.O. and shall consist of driving a standard probe into the ground and
recording the resistance of penetration, to determine depth of unsuitable material.
20.1.2.2 Equipment
The apparatus used shall be the standard JKR probes or the normal Mackintosh probes. Details
of the JKR and Mackintosh probes are shown in Figure 20.1 and Figure 20.2
The probing rig shall consist of a stable frame for driving the extension rods and cone
vertically, with a guide to provide lateral support for the part of the extension rods protruding
above the soil or exposed in water, a means of handling and operating the driving device, and a
means of extracting the rods and cone. The guide shall be such that not more than 1.2 m of rod
is unsupported at any one time, and if the driving device is not separately provided with a
guide then not more than 0.6 m of rod shall be supported where the blow count is in excess of
15 blows per 300 mm.
Figure 20.1: General Arrangement of JKR Probe
Figure 20.2: Pointer Geometry of JKR and Mackintosh Probes
S20 - 1
Table 20.1: Compares the JKR and Mackintosh Probe
Type of Cone Dia. of Dia. of Weight Height Measured

Penetrometer Dia. Cross Angle Rod Coupling of of Fall Value
(mm) Section (Degree) (mm) (mm) Hammer (cm) (blows/n.mm)
(sq.cm) (kg)
JKR Probe 25 5 12 22 5 5 29 n = 300
Mackintosh
25 5 13 26 6.5 4.5 30 n = 300
Probe
20.1.2.3 Procedures
(a) The probing rig shall be erected so that the deviation from the vertical of the first
extension rod shall not be greater than 2 per cent. Maximum deviation from the vertical
of the extension rods during driving shall be 5 per cent.
(b) The driving shall be as continuous as possible but in no case shall interruptions longer
than 5 minutes be allowed. The hammer shall be raised in such a way as not to carry it
more or less as the defined height above the driving head. The cone shall be driven at a
rate of between 15 to 30 blows per minute, and the number of blows shall be recorded
for each 300 mm increment of penetration.
(c) The probing shall be stopped when the resistance has reached 400 blows/300 mm
penetrations or the depth has reached 15 metres, whichever is reached earlier, unless
otherwise directed by the S.O.
20.1.2.4 Criteria for Removal Unsuitable Material

The criteria to remove unsuitable material shall be as shown on the Drawings.
However, in the case of the criteria for the removal of unsuitable material not shown on the
Drawings, the unsuitable material shall be removed to a depth of 40 blows/300 mm probe
resistance OR up to a maximum depth of 3.0m, whichever is the earlier; all subject to the
S.O. approval.
20.1.3 Materials for Replacement of Unsuitable Material

Unless otherwise indicated in the Contract, materials for replacement of unsuitable material
shall consist of hard, clean crushed rock, gravel or sand having grading conforming to the
grading limits given in Table 2.1, Clause 2.2.3.5 in Section 2: Earthworks.
20.2 GEOTEXTILE
20.2.1 General
20.2.1.1 Scope
This specification covers the technical and general requirements for the supply and installation
of geotextile as described herein. All materials used shall meet the requirements of this
specification and all works shall be executed in accordance with the details shown on the
Drawings.
20.2.1.2 Types of geotextile

Generally, two types of geotextile are used for geotechnical works, i.e. non-woven geotextile
and woven geotextile. Non-woven geotextile shall be used as separators or wrappers in
drainage works. Meanwhile woven geotextile shall be used as stabilization applications during
constructing fill embankment on the soft ground.
S20 - 2
20.2.1.3 Contractor to Provide
The Contractor shall provide all necessary resources including materials, skilled workers, and
plants/equipment to execute and complete the works related to supply and laying of geotextile
as shown on the Drawings.
20.2.1.4 Setting-Out
The Contractor shall be responsible for the true and proper setting-out of the areas to which the
geotextile is to be placed and for the correctness of the lines, widths, levels and slopes.
20.2.1.5 Locally Produced Products

The geotextile to be used in this contract shall be fully of Malaysian origin. The geotextile
shall be produced by local factory with ISO certification and equipped with testing laboratory,
where sampling and testing can be readily carried out.
20.2.1.6 Construction Traffic
During installation of geotextile, make sure no traffic shall travel directly on the geotextile and
there shall be no sudden stops, starts or turns on the fill materials by the construction
equipment or other such actions that may cause damage to the geotextile.
20.2.2 Packaging and Storage

20.2.2.1 Product Labelling
The geotextile shall be supplied with, the manufacturer's label on each roll showing the
following identification: -
(a) Product brand name;
(b) Product type;
(c) Roll width and length; and
(d) Batch serial number
20.2.2.2 Product Packaging

The geotextile shall be supplied in rolls. Labelled and wrapped in packaging materials to
protect against water and photo degradation by ultraviolet light.
20.2.2.3 Product Quality Assurance

The Contractor must provide a Certificate of Approval from the manufacturer to confirm that
their local manufacturing factory's production and management systems are certified to be
operating under a Quality Management System consistent with at least the Quality Standards
BS EN ISO 9002: 2000 or equivalent.
20.2.2.4 Storage at Site

The Contractor shall ensure that the geotextile in properly stored in a covered area at the
worksite. If no covered area is available, the geotextile may be stored on raised platform and
covered with a waterproof canvas.
The Contractor is solely responsible for the good condition of the geotextile stored at the
worksite and in the event of damages or deteriorations of the geotextile due to improper
storage, he shall be liable to replace the affected materials at his own cost when directed to do
so by the S.O.
S20 - 3
20.2.3 Testing of Geotextile
20.2.3.1 General
Prior to the procurement of materials, the Contractor shall provide a sample and the
Manufacturer's Independent Test Report (ITR), showing full compliance of the proposed
geotextile to all the specified property values corresponding to their respective test methods,
for the approval of the S.O.
All tests shall be carried out in accordance with the codes of practices and standards as
provided within this specification, unless otherwise approved by the S.O. The independent test
report and tests shall be prepared and carried out at reputable institution or laboratory such as
SIRIM, IKRAM, UTM, UKM, UPM, UM or other accredited laboratories approved by the
S.O.
Routine sample testing, when requested and specified, shall be carried out at factory or at an
independent laboratory witnessed by the S.O's representative. The Contractor shall submit test
report showing compliance of the specification by independent testing authority or laboratory
such as listed above or an accredited laboratory approved by the S.O.
20.2.3.2 Consignment Certificate

For the purpose of ascertaining that each consignment of geotextile supplied to site is to the
approved type and quality and are fully from the same manufacturer and batch as indicated, the
Contractor must furnish with every consignment, an original consignment certificate from the
manufacturer giving the following information: -
(ii) Name and address of the manufacturer;
(iii) Contact telephone/fax/email address of the manufacturer;
(iv) Consignment certificate reference number and date;
(v) Title of the contract and name of project owner;
(vi) Name and address of the purchaser; and
(vii) Product types and quantities, corresponding to each consignment.
(viii) Product composition and information on the raw material used as type of fibre, their
proportions and the type of connection between the elements of the fabric.
20.2.3.3 Routine Testing

Prior to installation and at the discretion or the S.O samples of each 50,000m 2 of geotextile
shall be selected for routine test at the testing laboratory located in the factory or other
approved laboratories.
Where the individual samples fail to satisfy the requirements of this Specification on the
geotextile, the roll from which the sample is obtained shall be rejected. Two additional samples
shall then be selected from two other rolls of the same batch.
If either of these two additional samples fails to comply with the requirements, the entire batch
represented by the samples shall be rejected.
20.2.4 Jointing the Adjacent Geotextile

20.2.4.1 Methods of Jointing
There are two common methods to joint the geotextile, overlap or seam. The decision to use an
overlap or seam shall be based on the following:-
S20 - 4
(a) the weakness of the sub grade upon which the geotextile is directly placed with respect
to the potential for mud waving during the backfill operation;
(b) the material and labour costs of deploying individual geotextile panels with extra
material required for the overlap versus the material and labour costs of seaming and
installing large, fabricated panels; and
(c) the feasibility of deploying individual geotextile panels in poor access and/or climatic
conditions.
Table 20.2 is provided as a guide for determining overlap requirements for

separation/stabilization applications based on sub grade strength. When the sub grade soils
upon which the geotextile is directly placed provides shear strength less than CBR = 0.5, the
adjacent geotextile panels shall be seamed.
Table 20.2: Guidelines for Geotextile Overlap Requirements as a Function of Soil

Subgrade Strength (AASHTO M288-06)
Soil CBR Minimum Overlaps
>3 0.3 – 0.45 meters

1–3 0.6 – 1 meters
0.5 – 1 1 meter or sewn
< 0.5 sewn
20.2.4.2 Sewn Seams

The geotextile fabric may be jointed using an approved handheld sewing machine by sewing a
double thread „lock stitch‟ with 'prayer' or „J‟ or „butterfly‟ seam (minimum lap of 50mm).
Typically, Polypropylene thread is often used for seaming lower strength geotextiles and
Polyester thread is used for seaming higher strength geotextiles. Minimum required density of
stitches during sewing of the geotextile is 3 stitches per 25mm. The thread shall have a
breaking load of not less than 200N.
The expected seam strength shall be more than 70% of the original strength of the geotextile.
Samples of such sewn seam assembly shall be tested in accordance with ASTM D4884 as
deemed necessary by the S.O.
(i) (ii) (iii)
(i) Prayer Seam (ii) J Seam (iii) Butterfly Seam - with double thread ‘lock stitch’
20.2.5 Non-Woven Geotextile

20.2.5.1 Material Properties
20.2.5.1.1 Products
All non-woven geotextile shall be from an approved manufacturer and shall be manufactured
from polypropylene or polyester as shown in the Drawings. Non-woven geotextile shall be
S20 - 5
durable and resistant to naturally occurring chemical, fungi and bacteria when installed in
contact with the materials to be separated. Non-woven geotextile shall be free of any flaws that
may have an adverse effect on the physical and mechanical properties of the non-woven
geotextile.
Unless otherwise approved by the S.O, non-woven geotextile shall be needle punched staple
fibre geotextile in accordance with the Specification and shall be used as shown and described
on the Drawings or as directed by the S.O.
Non-woven geotextile shall be stabilized against ultra-violet radiation to the degree that one
month's exposure of the geotextile to sunlight shall not reduce its strength to less than 90% of
the specified strength rating in the specification.
The width of each roll of non-woven geotextile shall be 4m.
20.2.5.1.2 Technical Properties

The type of non-woven geotextile fabrics as shown or as described on the Drawings shall
comply with the following properties as listed in Tables 20.3 below or as shown on the
Drawings:
Table 20.3: Properties of Non-woven Geotextile.
No. Description Test Standard Unit Limit NW 15 NW 9 NW 22
1. Tensile Strength ISO 10319 kN/m > 15 9 22

2. Tensile Elongation ISO 10319 % > 40 40 50
3. CBR Puncture Resistance ISO 12236 N > 2350 1500 3300
4. Cone Drop BS 6906/6 mm < 21 27 14
5. Apparent Pore Size (O95) ASTM D 4751 mm < 0.21 0.26 0.18
2
Vertical Water Flow l/m /s
6. ISO 11058 > 75 110 58
50mm Head (mm/s)
7. Grab Strength ASTM D 4632 N > 900 550 1250
8. Permittivity ASTM D 4491 s-1 < 1.9 2.9 1.7
9. Nominal Mass ISO 9864 g/m2 > 200 125 285
10. Thickness (2kPa ) ISO 9863 mm > 1.9 1.2 2.5
11. UV Resistance
- Tensile Strength ISO 10319 > 70% Strength retention after 3 months outdoor weathering
- Puncture Strength ISO 12236 > 70% Strength retention after 3 months outdoor weathering
12. Chemical Resistance No influence at pH range 2 - 13
(a) Details of Test Certificates

The test certificate of non-woven geotextile shall include the following: -
(i) Tensile strength;
(ii) Elongation (longitudinal/transverse);
(iii) CBR Puncture Resistance.
(iv) Cone Drop
S20 - 6
(v) Effective opening size (095);
(vi) Vertical Water Flow / Permeability;
(vii) Mass per unit area;
(viii) Thickness (under 2 kPa pressure);
20.2.5.2 Installation of Non-Woven Geotextile

(a) General
Installation of non-woven geotextile shall be carried out by qualified and experienced workers
under the supervision of a qualified engineer The installation of non-woven geotextile shall be
executed in accordance with the manufacturer's instructions utilizing approved
plants/equipment.
(b) Non-woven Geotextile Exposure Following Placement

Exposure of non-woven geotextile to natural elements between placement and cover shall be
an aggregated period to a maximum of seven (7) days to minimize damage.
(c) Site Preparation

Prior to the installation of the non-woven geotextile fabric, site clearance shall be carried out in
accordance with the Specification and Drawings or as directed by the S.O. All voids shall be
filled with suitable material and the area cleared of large stones and exposed tree root systems
or other such like protrusions.
(d) Installation of Non-woven Geotextile

Non-woven geotextile shall be installed to the shape and requirements as specified herein or as
shown and described on the Drawings. The non-woven geotextile shall be unrolled smoothly
on the prepared ground and generally in a direction perpendicular to the edge of the platform,
embankment or area of fill. Adjacent non-woven geotextile rolls shall be overlapped or sewn in
accordance with this Specification. Overlapping of non-woven geotextile without sewn
connections shall only be allowed with the approval of the S.O.
(e) Seaming
The seaming of non-woven geotextile has been described above in Clause 20.2.4.2. The
sewing thread used shall be of polyester or polypropylene with a minimum of 3 stitches per
25mm and a breaking load of not less than 200N.
(f) Backfill Placement

The specified overlying fill material on the non-woven geotextile fabric shall be placed in
accordance with the requirements shown and described on the Drawings or as directed by the
S.O. These fill materials shall be deposited in layers not exceeding 500mm loose depth or at a
thickness controlled by the compaction effort requirement and shall be spread simultaneously
with the dumping in a manner to prevent any localized distress or failure of the ground.
20.2.6 WOVEN GEOTEXTILE

20.2.6.1 Material Properties
20.2.6.1.1 Products
The woven geotextile required for this contract shall comprise of high modulus polyester fibres
that can meet the required properties in aspects as described herein. Knitted geotextile shall not
be accepted as equivalent directly without considering other practical technical information.
S20 - 7
The width of each roll of woven geotextile shall be 5.40m.
20.2.6.1.2 Technical Properties

The properties of the woven geotextile shall meet or exceed the minimum or maximum values
corresponding to the respective test methods, as shown in Tables 20.4 below:-
Table 20.4: Properties of Woven Geotextile
Test
No. Description Unit Limit Properties
Standard
HS HS HS HS HS HS HS
1. Type (or equivalent)
100/50 150/50 200/50 300/50 400/50 600/50 800/50
2. Mechanical Properties
Ultimate Tensile Strength ASTM kN/
a. > 100 150 200 300 400 600 800
– Warp (MD) D4595 m
Elongation at Tensile ASTM
b. % < 10.0
Strength – Warp (MD) D4595
Ultimate Tensile Strength ASTM kN/
c. > 50.0
– Weft (CD) D4595 m
Elongation at Tensile ASTM
d. % < 12.0
Strength – Weft (CD) D4595
Tearing Strength – ASTM 800/ 1200/ 1000/ 2500/ 2500/ 4600/ 4900/
e. N >
MD/CD min D4533 400 400 400 500 700 700 700
ASTM
f. Puncture Strength N > 500 1000 1000 1800 2200 2800 3200
D4833
Creep at 50% of Ultimate ASTM
g. % < 1.0
Load After 2 Years D5262
3. Physical Properties
ASTM
a. Mass Per Unit Area g/m2 > 330 330 430 540 700 100 1300
D5261-92
ASTM
b. Nominal Thickness mm > 0.65 0.75 0.85 1.1 1.6 2.1 3.1
D5199
ASTM
c. Apparent Pore Size (O95) mm < 0.212 0.212 0.15 0.3 0.425 0.425 0.425
D4751
d. Minimum Unsewn Width m 5.0
20.2.6.2 Installation of Woven Geotextile

(a) General
Installation of woven geotextile shall be carried out by qualified and experienced workers
under the supervision of a qualified engineer.
(b) Earthwork
The surface upon which the woven geotextile is to be laid shall be prepared or excavated/cut
and trimmed to the required level as shown in the contract Drawings.
The surface shall be smooth firm, unyielding and free of large vegetation, protruding sticks,
sharp rocks, void spaces, etc., that can damage the Geotextile during installation.
(c) Woven Geotextile Placement

The Woven geotextile shall be placed transversely, across the direction of the road, unless
otherwise directed by the S.O. All woven geotextile shall be laid flat on the underlying surface,
pull taut with no wrinkles or fold, and shall extend far enough over the edges of the
embankment for a wrap-around as shown in the contract Drawings.
(d) Seaming
The seaming of woven geotextile has been described above in Clause 20.2.4.2. The sewing
thread used shall be of high tenacity polyester with a minimum of 3 stitches per 25mm and a
breaking load of not less than 200N.
S20 - 8
(e) Damage Repair
If the woven geotextile is damaged (torn, punctured, perforated, etc.) during installation it snail
be repaired by laying an additional layer of woven geotextile extending at least lm beyond the
damaged area, subject to the approval of the S.O.
(f) Backfill Placement

Fill materials in contact with the woven geotextile shall be free of angular stones or other sharp
objects that could damage it.
To ensure the proper tensioning to the woven geotextile during the filling process, backfilling
shall start at the embankment edges forming bunds, which serve to anchor the woven
geotextile. The protruding ends of the woven geotextile shall then be wrapped around these
bunds and further weighed down with more fill materials before the central region of the
embankment is being backfilled.
The backfilling process is a continuous one with filling works on the embankment edges
leading the filling works to the centre of the embankment. At no one time shall the filling
exceed 500mm thick at this stage.
However a minimum thickness of 300mm of cover shall be maintained between the

construction equipment tires tracks and the woven geotextile at all times during the backfilling
process. There shall be no sudden stops, starts or turns of the construction equipment on the fill
materials.
The height of the embankment shall be raised to the required level by not more than 500mm at
a time following the backfilling procedures described above and compacted in
accordance to the Specifications.
20.3 GEOGRID
20.3.1 General
20.3.1.1 Scope
This specification covers the general and technical requirements for the supply and
installation of Geogrid as described herein. All materials used shall meet the
requirements of this specification and all works shall be executed in accordance with the
details as shown on the drawings and the procedures described herein.
20.3.1.2 Contractor to Provide

The Contractor shall provide all necessary resources including materials, skilled workers,
and plants/equipment to execute and complete the works related to supply and laying of
geogrid as shown on the drawings.
20.3.1.3 Setting-Out
The Contractor shall be responsible for the true and proper setting -out of the areas to
which the Geogrid is to be placed and for the correctness of the lines, widths, levels and
slopes.
20.3.1.4 Locally Produced Products

The geogrid to be used in this contract shall be fully of Malaysian origin unless otherwise
approved by the designer. The geogrid shall be produced by local factory with ISO
certification and equipped with testing laboratory, where sampling and testing can be
readily carried out.
S20 - 9
The geogrid shall be supplied with the Manufacturer's Label/Logo on each roll showing
the following identifications:-
(a) Product Brand Name
(b) Product Type
(c) Roll Width and Length
(d) Batch Serial Number

The geogrid shall be supplied in rolls, labelled and wrapped in packaging materials to
protect against water and photo-degradation by ultraviolet light.
20.3.2.3 Product Quality Assurance

The contractor must provide a Certificate of Approval from the Manufacturer to confirm
that their Local Manufacturing Factory's production and management system are certified
to be operating under a Quality Management System consistent with at least the Quality
Standards BS EN ISO 9002: 2000 or equivalent.

The Contractor shall ensure that the geogrid is properly stored in a covered area at the
worksite. If no covered area is available, the geogrid may be stored on raised platform
and covered with a waterproof canvas.
The Contractor is solely responsible for the good condition of the geogrid stored at the
worksite and in the event of damages or deteriorations of the geogrid due to improper
storage, he shall be liable to replace the affected materials at his own cost when directed
to do so by the S.O.
20.3.2.5 Durability of Geogrid

The geogrid shall not deteriorate from exposure to sunlight for a design life of 120 years;
Durability of the geogrid shall be such as to ensure a design life of 120 years; The
geogrid shall not deteriorate due to chemical action or biodegradation when buried in wet
soil;
Information relating to the durability of the geogrid shall be submitted as required by the
S.O. for his approval. The decision of the S.O. on the adequacy of the geogrid against
durability shall be final.
20.3.3 Testing
20.3.3.1 General
Prior to the procurement of materials, the contractor shall provide a sample and the
geogrid to all the above-specified property values corresponding to their respective test
methods, for the approval of the S.O..
All tests shall be carried out in accordance with the codes of Practices and Standards as
provided within this specification, unless otherwise approved by the S.O. The
S20 - 10
independent test report and tests shall be prepared and carried out at reputable institution
or laboratory such as SIRIM, IKRAM, UTM, UKM, UPM, UM or other accredited
independent laboratories approved by the S.O.
Routine sample testing, when required and specified, shall be carried out at factory or at
independent laboratory witnessed by the S.O.'s representative. The Contractor shall
submit test report showing compliance of the specification by independent testing
authority or laboratory such as listed above or an accredited independent laboratory
approved by the S.O.

For the purpose of ascertaining that each consignment of geogrid supplied to site is to the
approved type and quality and are fully from the same Manufacturer and batch as
indicated, the contractor must furnish with every consignment, an original Consignment
Certificate from the Manufacturer giving the following information: -
(a) Name and Address of the Manufacturer
(b) Contact telephone/fax/email address of the Manufacturer
(c) Consignment Certificate Reference Number and Date
(d) Title of the Contract and Name of Project Owner
(e) Name and Address of the Purchaser
(f) Product Types and Quantities, corresponding to each consignment
20.3.4 Material Properties

20.3.4.1 Products
The geogrid shall be manufactured from high tenacity polyester encased within
polyolefin sheaths. The bond between the sheath and the high tenacity polyester shall be
adequate to transfer the required loads to the elements. The geogrid shall be formed from
cross-laid strips (geo-linear elements) bonded at the cross-over points. The geo-linear
elements shall consist of continuous high tenacity polyester fibre s encased within a
polyolefine sheath. The geo-linear elements shall be formed by drawing continuous fibres
through an extrusion die.
Bonding at the cross-over points shall be such that the properties as required by the
Contract are not affected. The strength of the bond shall be such as to ensure the function
of the geogrid;
The polyester fibres shall be:
(a) completely encased within a protective polyolefine sheath to completely prevent

ingress of moisture;
(b) all free ends shall be sealed to completely prevent ingress of moisture;
(c) the minimum thickness of the protective cover shall be 1mm.
The weft elements shall be the same quality material as the warp elements.
S20 - 11
20.3.4.2 Technical Properties
The properties of the Geogrid shall meet or exceed the minimum or maximum values
corresponding to the respectively test methods as shown in Tables 20.5a and 20.5b
below:
Table 20.5a: Properties of Geogrid
Test GD GD GD GD GD
No. Description Unit
Standard 30/30 50/30 55/30 80/30 100/30
Ultimate Warp Tensile ASTM D4595
1. kN/m 30 50 55 55 100
Strength ISO 10319
Ultimate Weft Tensile ASTM D4595
2. kN/m 30 30 30 30 30
Strength ISO 10319
Ultimate Warp & ASTM D4595
3. % 11 11 11 11 11
Weft Elongation ISO 10319
Creep limited strength
4. ASTM D5262 kN/m 18 30 33 48 60
(LTDS) 120 years
Creep at 50% Ultimate
5. ASTM D5262 % 2 2 2 2 2
Load After 2 years
6. Mass per Unit Area ASTM D5261 g/m2 200 250 270 350 415
7. Mesh Size (± 5.0mm) - mm 25 x 25 25 x 25 25 x 25 25 x 25 25 x 25
8. Width (± 0.1m) - m 5 5 5 5 5
9. Length (Standard) - m 50 or 100
Table 20.5b: Properties of Geogrid
Test GD GD GD GD GD GD
No. Description Unit
Standard 120/30 150/30 160/30 200/30 200/50 400/200
Ultimate Warp Tensile ASTM D4595
1. kN/m 120 150 160 200 200 400
Strength ISO 10319
Ultimate Weft Tensile ASTM D4595
2. kN/m 30 30 30 30 50 200
Strength ISO 10319
Ultimate Warp & ASTM D4595
3. % 12 12 12 12 12 12
Weft Elongation ISO 10319
Creep limited strength
4. ASTM D5262 kN/m 72 90 96 120 120 240
(LTDS) 120 years
Creep at 50% Ultimate
5. ASTM D5262 % 2 2 2 2 2 2
Load After 2 years
6. Mass per Unit Area ASTM D5261 g/m2 450 540 570 700 750 1865
7. Mesh Size (± 5.0mm) - mm 25 x 25 25 x 25 25 x 25 25 x 25 25 x 25 25 x 25
8. Width (± 0.1m) - m 5 5 5 5 5 5
9. Length (Standard) - m 50 or 100 50
20.3.5 Installation
20.3.5.1 General
Installation of geogrid shall be carried out by qualified and experienced workers under
the supervision of a qualified engineer. The geogrid shall be installed in compliance to
Manufacturer's instructions utilizing approved plants/equipment.
20.3.5.2 Fill Material

The fill to the lines and levels shown on the Drawings shall be well graded granular and
dry cohesive soils as defined in Specification – Section 2: Earthworks.
S20 - 12
When well graded granular and dry cohesive soils are used, the soil immediately behind
the facing shall consist of a 200mm thick layer of topsoil or as shown on the drawings.
Soiling, grassing and hydraulic mulch grass seeding shall be carried out to the
requirements of the Specifications.
20.3.5.3 Installation of Geogrid for Reinforced Slope

At each level of geogrid reinforcement, backfill shall be roughly levelled before placing
the geogrid. Compaction shall be carried out to the requirements of the Specifications.
During backfill placement, trucks and heavy vehicles shall be kept back at least 2m from
the face of the Geogrid Reinforced Slope.
The deposition, spreading, levelling and compaction of the fill shall be carried out
generally m a direction parallel to the facing and shall be executed in stapes to alternate
with the placing and fixing of the reinforcing elements and the facing.
Care shall be taken to ensure that the reinforcing elements and facing are not damaged or
displaced during deposition, spreading, levelling and compaction of the fill. The program
of filling shall be arranged so that no machines or vehicles r un on the reinforcing
elements.
The fill within 2m of the face of the Geogrid Reinforced Slope shall be compacted using
one of the following:-
(a) Vibro tamper
(b) Vibrating plate compacter having a mass not exceeding 1000kg
(c) Vibrating roller having a mass per metre width of not more than 1300k g and a total
mass of not more than 1000kg
The rear of the Geogrid Reinforcing Slope shall be adequately supported either by
temporary shoring or by phasing the work in order to ensure the contemporaneous
deposition of the retained fill material.
20.3.5.4 Protection of Completed Geogrid Reinforced Slopes from Erosion

The Contractor, where instructed by the S.O., shall carry out Hydraulic Mulch Grass
Seeding in the erodible area before Hydraulic Mulch Grass works commence in other
areas.
20.4 PREFABRICATED VERTICAL DRAINS (PVD)

20.4.1 General
This specification covers the technical and general requirements for the supply and installation
of Prefabricated Vertical Drains (PVD) as described herein. All materials used shall meet the
requirements of this specification and all works shall be executed in accordance with the
details shown on the drawings and the procedures described herein.
plants/equipment to execute and complete the works related to supply and laying of PVD as
shown on the drawings.
PVD is to be placed and for the correctness of the lines, widths and levels.
S20 - 13
20.4.2 Materials
20.4.2.1 Prefabricated Vertical Drains
20.4.2.1.1 General Requirements
Prefabricated vertical drains shall be from an approved manufacturer and consist of a polymer
core enclosed within an external non-woven filter jacket, and shall comply with the
requirements as indicated in the Table 20.6. The PVD shall be fully of Malaysian origin. The
PVD shall be produced by local factory with ISO certification and equipped with testing
laboratory, where sampling and testing can be readily carried out.
The filter jacket shall be capable of resisting all bending, puncturing and tensioning subjected
during installation and design life of the drain.
The core shall be made of continuous plastic material fabricated to facilitate drainage along the
axis of the vertical drain.
The prefabricated vertical drain shall be resistant against rotting, mildew, bacterial action,
insect, salts, acids, alkalis, solvent and other constituents in ground water.
20.4.2.1.2 Transportation and Storage

The vertical drain materials shall be labelled or tagged for sample identification and other
quality control purposes. Each roll shall be identified by the manufacturer by lot number,
individual roll number, roll length, date of manufacture, manufacturer and product
identification of the jacket and core.
During transportation and storage, the drain shall be wrapped in heavy paper, burlap or similar
heavy duty protection covering. The drain shall be protected from sunlight, mud, dirt, dust,
debris and other detrimental substances during transport and on site storage.
The Contractor shall ensure that the PVD is properly stored in a covered area at the worksite.
If no covered area is available, the PVD may be stored on raised platform and covered with a
waterproof canvas.
The Contractor is solely responsible for the good condition of the PVD stored at the worksite
and in the event of damages or deteriorations of the PVD due to improper storage, he shall be
liable to replace the affected materials at his own cost when directed to do so by the S.O.
All materials which are damaged during transportation, handling or storage and do not meet
the minimum requirements of the vertical drain specifications shall be rejected by the S.O. No
payment of any kind shall be made on the rejected product.
20.4.2.1.3 Quality Control and Testing

Manufacturer's Independent Test Report (ITR), showing full compliance of the proposed PVD
to all the above-specified property values corresponding to their respective test methods, for
the approval of the S.O.
SIRIM, IKRAM, UTM, UKM, UPM, UM or other accredited independent laboratories
Routine sample testing, when requested and specified, shall be carried out at factory or at an
independent laboratory witnessed by the S.O's representative. The Contractor shall submit test
such as listed above or an accredited independent laboratory approved by the S.O.
S20 - 14
The actual vertical drain to be used shall be tested at the option of the contractor subject to the
approval of the S.O.
The Contractor shall indicate the proposed source of the materials prior to delivery to site. The
contractor shall also submit samples and Manufacturer's certificates to verify the physical,
mechanical and hydraulic properties of the drain to be used for S.O.'s approval.
Prior to installation and at the discretion of the S.O, individual test sample shall be cut from at
least one roll selected at random to represent each batch or every 100,000 metres, whichever is
lesser. Individual sample shall be no less than 3 metres in length and shall be full width.
Samples submitted for tests shall indicate the linear metres of drain and manufacturer's
identifications represented by the sample.
Table 20.6: Properties of Prefabricated Vertical Drains
Description of Properties Test Standard Unit Specified Requirement

Width mm 100 ± 3
Dimension of Drain
Thickness mm 4 to 5
Coefficient of Permeability of Drain
ASTM D4491 m/s 5 x 10-5
Filter
Discharge Capacity at 240 kPa and
ASTM D4716 m3/s 25 x 10-6
Hydraulic Gradient of 1
Apparent Opening Size ASTM D4751 μm < 150
Tensile Strength of Entire Drain ASTM D4595 N > 2000
Tensile Strength of Filter ASTM D4595 N/m > 3000
Trapezoidal Tear Strength of Drain Filter ASTM D4533 kN ≥ 0.10
Elongation at Break of Entire Drain ASTM D4595 % > 20
Elongation of Filter ASTM D4595 % > 30
20.4.2.2 Geotextile Separator

- Specification for non-woven geotextile separator, please refer to Clause 20.2: Geotextile.
20.4.2.3 Drainage Blanket

The sand drainage layer shall consist of hard, clean, crushed rock or gravel having a
grading with the limits specified below:
Table 20.7: Properties of Drainage Blanket
B.S Sieve Size % Passing By Weight

63.00mm 100
37.50mm 85 to 100
20.00mm 0 to 20
10.00mm 0 to 5
The sand drainage material for depositing in water shall be deposited without the associated
use of compaction plant.
The sand drainage layer shall be built up evenly in horizontal layers each of not more than
300mm thick. Filling shall commence from the lowest level, and each layer shall cover the full
area of the intended total fill area at that level before deposition of the subsequent layer
commences.
S20 - 15
20.4.3 Installation
20.4.3.1 Prefabricated Vertical Drain (PVD)
20.4.3.1.1 Equipment
Prefabricated Vertical Drain (PVD) shall be installed with approved modern equipment of a
type which will cause a minimum of disturbance of the sub-soil during the installation
operation and maintain the mandrel in a vertical position.
PVD shall be installed using a mandrel or sleeve and shall be inserted (i.e. pushed or vibrated)
into the soil. The mandrel or sleeve shall protect the drain material from tears, cuts, and
abrasion during installation, and shall be retracted after each drain is installed.
The size and shape of the mandrel or sleeve shall be as close as possible to the size and shape
of the drains in order to minimize disturbance to the soil. The length of the mandrel shall be
not less than the maximum length of the drain. The mandrel shall be capable of making a clean
puncture through any geotextile if necessary.
The mandrel or sleeve shall be provided with an anchor plate or similar arrangement at the
bottom to prevent the soil from entering the bottom of the mandrel during the installation of
the drain and to anchor the drain tip at the required depth at the time of mandrel withdrawal.
The dimension of the anchor shall conform as closely as possible to the dimensions of the
mandrel so as to minimize soil disturbance. The Engineer shall determine the acceptability of
the anchorage system and procedure.
20.4.3.1.2 Approval
4 weeks prior to the beginning of trial of PVD installation, the Contractor shall submit full
details of the materials, equipment, sequence and method proposed for PVD installation to the
Engineer for review and approval. Approval by the Engineer of installation sequence and
methods shall not relieve the Contractor of his responsibility to install drains in accordance
with the plans and specifications.
Prior to the installation of PVD, the Contractor shall demonstrate that the equipment, method,
and materials produce a satisfactory installation in accordance with these specifications. For
this purpose, the Contractor will be required to install 2 trial drains totalling approximately 16
linear metres at locations designated by the S.O.
Approval by the S.O. of the method or equipment used to install the trial drains shall not
constitute, necessarily, acceptance of the method for the remainder of the project. If, at any
lime, the S.O. considers that the method of installation does not produce satisfactory PVD, the
Contractor shall alter his method and/or equipment as necessary to comply with these
specifications.
20.4.3.1.3 Installation Procedure

PVD shall be located, numbered and pegged out by the Contractor using a baseline and
benchmark indicated by the S.O. The Contractor shall take all reasonable precautions to
preserve the pegs and is responsible for any necessary re-pegging. The as-installed location of
the PVD shall not vary by more than 150mm from the plan locations designated on the
drawings.
PVD that are more than 150mm from design plan location or are damaged or improperly
install, it will be rejected and abandoned in place.
PVD shall be installed from the working surface to the depth shown on the drawings, or to
such depth as directed by the S.O. who may vary the depths, spacing, or the number of drains
to be installed, and may revise the plan limits for this work as necessary.
S20 - 16
During PVD installation, the Contractor shall provide the S.O. with suitable means of
determining the depth of the advancing drain at any given time and the length of drain installed
at each location.
The Contractor shall supply to the S.O. at the end of each working day a summary of the PVD
installed that day. The summary shall include drain type, locations and length (to nearest
50mm) of PVD installed at each location.
Equipment for installing PVD shall be plumbed prior to installing each drain and shall not
deviate from the vertical more than 1 in 50 during installing of any drain.
PVD shall be installed using a continuous push using static weight or vibration to the specified
depth approved by the S.O.
Installation techniques using driving will not be permitted. Jetting techniques will be permitted
only after receiving written approval from the S.O.
The installation shall be performed, without any damage to the drain during advancement or
retraction of the mandrel. In no case will alternate raising or lowering of the mandrel during
advancement be permitted. Raising of the mandrel will only be permitted after completion of
an installation.
The mandrel penetration rate should be between 150mm and 600mm per second.
The completed PVD shall be cut off neatly 300mm above the working grade, or as otherwise
specified on the contract drawings.
The Contractor shall observe precautions necessary for protection of any field instrumentation
devices.
The Contractor shall replace, at his own expense, any instrumentation equipment that has been
damaged or become unreliable as a result of his operations prior to continuing with drain
installation or other construction activities.
20.4.3.1.4 Pre-augering/Obstructions
The Contractor shall be responsible for penetrating any overlying material as necessary to
install the drains.
Where obstructions are encountered below the working surface which cannot be penetrated by
the installation equipment, the Contractor shall complete the drain from the elevation of the
working surface to the obstruction and notify the S.O. prior to installing any more drains.
At the direction of the S.O. and under his review, the Contractor shall attempt to install a new
drain within 600mm horizontally from the obstructed drain. A maximum of two attempts shall
be made as directed by the S.O. If the drain still cannot be installed to the design tip elevation,
the drain location shall be abandoned and the installation equipment shall be moved to the next
location, or other action shall be taken as directed by the S.O.
The Contractor shall be responsible for penetrating overlying fill material as necessary to
satisfactorily install the PVD. Satisfactory installation may require clearing obstructions
defined as any man-made or natural object or strata that prevent the proper insertion of the
mandrel and installation of the PVD.
The Contractor may use augering, spudding, or other approved methods to loosen the soil and
any obstruction material prior to the installation of PVD. The obstruction clearance procedure
is subjected to the approval of the S.O.; however, such, approval shall not relieve the
Contractor of his responsibility to clear obstructions in accordance with the specification.
If augering is the selected method, the augers shall have a minimum outside diameter equal to
the largest horizontal dimension of the mandrel, shoe or anchor, whichever is greater.
S20 - 17
20.4.3.1.5 Splicing
Splicing of PV drain material shall be done by stapling in a workmanlike manner and so as to
ensure structural and hydraulic continuity of the drain. At the splice, lower portion of the
jacket shall be external to the upper portion.
A maximum of 1 splice per drain installed will be permitted without specific permission from
the S.O.
The jacket and core shall be overlapped a minimum of 150 mm at any splice.
20.4.3.2 Geotextile Separator
Prior to the laying of the geotextile fabric, site clearance shall be carried out in accordance
with the Specification and Drawing or as directed by the S.O. All voids shall be filled with
suitable material and the area cleared of large stones and exposed tree root systems or other
such like protrusions.
Geotextile fabric shall be installed to the shape and requirements as specified herein or as
shown and described on the Drawings. The geotextile shall be unrolled smoothly on the
prepared ground as approved by the S.O. and generally in a direction perpendicular to the edge
of the platform, embankment or area of fill as approved by the S.O. Adjacent geotextile rolls
shall be overlapped and sewn in accordance with this Specification. On curves and corners
geotextile may be folded or cut to conform to the direction as approved by the S.O. Adjacent
geotextile rolls shall be overlapped and sewn in accordance with this Specification. On curves
and corners geotextile may be folded or cut or conform to the direction as approved by the
S.O. Overlapping of geotextiles without sewn connections shall only be allowed by the S.O.
Geotextile fabrics shall be placed just in advance of placement of the specified overlying fill
material. Geotextiles so placed shall be covered by the relevant fill within 7 days of being
placed. Installation proposals and trials as deemed required shall be carried out for approval by
the S.O. prior to the acceptance of the placement method for the main works. The installation
trials shall include the placement operations of the overlying fill materials, including
excavation of such materials thereafter for examination of the geotextile fabric installation and
fill materials placement method with respect to the prevailing ground conditions and
constraints.
The geotextile fabric shall be joined using an approved portable industrial sewing machine and
by sewing a double chain stitch with 'J' or 'prayer' seam (minimum lap of 50mm) with high
tenacity polyester thread and a minimum of 3 stitches per 25mm shall be required. The thread
shall have a breaking lead of not less than 160N.
Exposure of geotextile to natural elements between placement and cover shall be an

aggregated period to a maximum of seven (7) days to minimize damage. The counting for this
foresaid seven (7) days shall commence immediately upon the geotextile being exposed from
its protective wrapping.
The specified overlying fill material on the geotextile fabric shall be placed in accordance with
the requirements shown and described in the Drawings or as directed by the S.O. These fill
materials shall be deposited in layers not exceeding 300mm loose depth and shall be spread
simultaneously with the dumping in a manner to prevent any localized distress or failure of the
ground.
In water logged or swampy areas, the geotextiles shall be sunk after jointing by ballasting with
sufficient sandbags. To control the location of the mattress, buoys shall be fixed with ropes on
the edges of the geotextile. As soon as possible after positioning, the mattress shall be
ballasted.
S20 - 18
No traffic shall travel directly on the geotextile and there shall be no sudden stops, starts or
turns on the fill materials by the construction equipment or other such actions which may
cause damage to the geotextile.
20.4.3.3 Fill Surcharge

Fill shall be placed and properly compacted according to the rate of filling indicated in the
Drawings.
Extra fill shall be placed to thickness specified in the Drawings as surcharge to speed up rate of
embankment settlement.
Surcharging fill shall be maintained for a period of time indicated in the Drawing and shall be
removed only with the approval of or when instructed by the S.O.
The fill be capable of being compacted to the requirements as indicated on the drawing and
shall not comprise of:-
(a) material from swamps, marshes and bogs
(b) peat, logs, stumps, perishable and toxic material
(c) material susceptible to spontaneous combustion
(d) clay of liquid limit exceeding 80% and/or plasticity index exceeding 55%
(e) organic content greater than 2.5% by weight on ignition
20.4.3.4 Instrumentation
20.4.3.4.1 General
The Contractor shall install instruments to enable measurements (monitoring) of vertical
movements and pore water pressure and carry out measurements (monitoring) of the
movements and water pressures and water levels during the currency of the works.
The depths and locations of all instruments shall be determined by the S.O. on site.
Provisional quantities shall be provided in the Bills of Quantities.
The Contractor shall be responsible for and shall follow the instructions of the manufacturer in
the installation, calibration and testing of all measuring instruments and equipment, which shall
be carried out under the direct supervision of the S.O. The Contractor shall inform the S.O. at
least 2 days prior to undertaking installation of the equipment or taking measurements. The
Contractor shall make due allowances in his construction programme for delays which may
arise on account of the installation of the instruments and their maintenance.
20.4.3.4.2 Settlement Gauges

Settlement gauges shall be provided and installed vertically by the Contractor in the positions
directed by the S.O. for the purpose of measuring settlement taking place under the
embankments. Settlement gauges shall be located at position as indicated by the S.O. and the
Contractor shall be responsible for installation of all gauges as work proceed.
The Contractor shall take all necessary measures to protect settlement gauges from damage by
the plant and vehicles and shall repair any such damage to the satisfaction of the S.O. at his
own expense. He shall erect substantial and readily visible barriers at a distance of 750mm
around each gauge;
S20 - 19
The Contractor shall replace any damaged settlement gauges within five days; at his own
expense should any settlement gauge be damaged in such a way as to make it useless for its
purpose.
20.4.3.4.3 Permanent Settlement Reference Stations

The Contractor shall be responsible for establishing permanent settlement reference station in
locations in selected by the S.O. The permanent settlement reference stations shall be located
on stable ground.
20.4.3.4.4 Method of Monitoring

Monitoring of vertical movements of settlement gauges shall be by precise levelling, with
respect to the permanent settlement reference stations. Measurement of settlement shall be by
the use of a precise level with an accuracy of 0.1mm (Refer Appendix 20A).
20.4.3.4.5 Installation
The method of installation shall be the most advantageous method recommended by the
manufacturer and shall be subjected to the approval of the S.O.
The Contractor shall install settlement gauges and reference settlement stations before
commencement of earthworks.
20.4.3.4.6 Frequency of Measurement

Settlement gauges/plates – please refer to Appendix 20A
20.4.3.4.7 Protection of Instruments

All instruments shall be protected against damage during the Works and the Period of
Maintenance. Instruments damaged during the above shall be immediately replaced by the
Contractor at his own cost.
20.4.3.4.8 Instruments Not Functioning

All instruments shall be designed to ensure proper functioning over the required period of
monitoring. Instruments not functioning during the period of monitoring shall be immediately
replaced by the Contractor at his own cost. The final decision whether an instrument is
functioning or not shall be decided by the S.O.
20.5 SURCHARGE / PRE-LOADING

In the areas shown on the Drawings where soil treatment shall be by surcharging, and in other
area that may be instructed by the S.O, the Contractor shall:-
(a) Construction the embankment to the surcharge levels and to the extent as shown on the
Drawings or as directed by the S.O.
(b) Permit the embankment to undergo settlement over the rest period given in the
Drawings or as directed by the S.O.
The date of commencement of the rest period in any one shall be the date at which the
Contractor completes the embankment to the prescribed surcharge level in that area.
Material used for constructing the embankment up to the specified surcharge level shall
comply with the requirements of Clause 2.2.1(e) "Suitable Material". Forming the
embankment shall comply with Clause 2.2.4 "Earth Embankment".
S20 - 20
On completion of the surcharge period the Contractor shall excavate the remainder surcharge
to the final formation level for subgrade preparation.
If the CBR of the material for the top 300mm of subgrade does not comply with the
requirements of Paragraph 1 of Clause 2.2.7, the material to a depth of 300mm below the
formation level shall be removed and replaced with compacted suitable material complying
with the requirements of Clause 2.2.7.
If the CBR of material for the top 300mm of the subgrade complies with the requirements of
Paragraph 1 of Clause 2.2.7, the top 300mm shall be sacrificed and compacted to 95% the
maximum dry density (MDD) as determined in the B.S 1377 Compaction Test (4.5kg rammer)
under 4 days soaked conditions all in accordance with the requirements of Clause 2.2.7.
20.6 STONE COLUMN

20.6.1 General
20.6.1.1 Design Requirements.
The stone column works must be executed by a Specialist Contractor. The drawings provided
in the Tender document shall only be used as a guide as to the extent of work, in so far as the
length and number of column required. The Specialist Contractor must submit design
calculations, drawings showing sections and elevation details, all executed and certified by a
Professional Engineer registered with the Board of Engineer, Malaysia, before the work can
commence. The Specialist Contractor shall guarantee that the performance of the wall in terms
of performance, stability and settlement must conform to good engineering practice.
20.6.2 Standards and Definitions

All materials and workmanship shall be in accordance with the appropriate current Malaysia
and British Standards except that where the requirements of Standards are in conflict with this
Specification, the latter shall take precedence.
20.6.3 Tolerances
20.6.3.1 Setting Out
Setting out shall be carried out by the Contractor from reference lines and points shown on the
Drawings. Immediately before installation of the Stone Column, the Stone Column positions
shall be marked with suitable identifiable pins or markers.
20.6.3.2 Position
The maximum permitted deviation of the stone column centre from the centre point shown on
the setting out drawings shall be 75mm in any direction.
20.6.4 Personnel
The Contractor shall employ only personnel experienced in the construction of Stone Columns
for this part of the Works.
20.6.5 Damage to Stone Column

The Contractor shall ensure that damage does not occur to the completed Stone Columns.
The Contractor shall submit to the S.O. for his approval the Contractor's proposed sequence
and timing for constructing Stone Columns having regard to the avoidance of damage to
adjacent Stone Columns.
S20 - 21
20.6.6 Load Tests on Preliminary Stone Columns
20.6.6.1 Plate Load Test on Preliminary Stone Column
Before installation of the stone columns as a whole commences, the Contractor will be directed
to install one or more preliminary stone columns at positions to be determined by the S.O. He
shall install these stone columns as soon as practicable to the depth as required. Loading of a
stone column shall not commence until seven (7) days have elapsed after completion of its
installation.
20.6.6.2 S.O.’s Instruction to Commence Installation of Stone Columns

The Contractor shall not install any stone column other than the preliminary stone column until
he has received instructions from the S.O. on the length of the stone column. Such instructions
shall be given not later than seven (7) days after complete results of the plate load tests on the
preliminary stone column have been submitted to the S.O. The Contractor shall allow in his
rates for stone columns for such delay.
20.6.7 Diameter and Length of The Stone Columns

The lengths of the stone columns shall be as shown on the Drawings -are indicative only. The
actual lengths of the stone columns shall be determined on site subject to the approval of the
S.O.
20.6.8 Stone Consumption

The consumption of stone for the stone column shall not be less than 0.78cu.m. per linear m.
The rate of consumption shall be assessed by averaging the material used in 10 adjacent stone
columns.
20.6.9 Vibroflot
The vibroflot (poker vibrator) shall be sufficiently powerful to ensure:
(a) The depth indicated in the Drawings can be reached;

(b) Verticality of the stone columns;
(c) Adequate treatment of the areas surrounding the treatment point to a minimum distance
of 1m from the centre of the stone column;
(d) Adequate compaction of stones.
The vibroflot shall possess the following minimum characteristics:
(a) Diameter = 420mm;

(b) Length = 3.0m;
(c) Frequency: 1800 oscillations per minute;
(d) Horizontal Thrust : 0.22MN;
(e) Output power: 120kW.
The vibroflot shall be equipped with automatic systems for continuous record of power output
and depth of penetration.
S20 - 22
20.6.10 Obstructions
In the event of obstructions preventing the penetration of the vibroflot lot the Contractor shall
inform the S.O. for his instructions.
The S.O. may instruct either or all of the following:

(a) Reposition the stone column a short distance from the original position;
(b) Additional stone columns around the obstruction;
(c) Requirements of the relevant sections of the Earthworks Specifications;
The S.O. may also instruct the carrying out of boreholes.
20.6.11 Procedure for Compaction of Stone Columns

The procedure for forming and compacting stone columns shall generally be as described
hereunder to be confirmed by the S.O. on site after the carrying out of field trials.
Power consumption shall form a basis for determining the adequacy of compaction of stone
columns.
The minimum power consumption at each level shall not be less than that approved by the S.O.
from the preliminary stone column installation. The Contractor shall install additional stone
columns at his own cost in the event that the required power consumption has not been
achieved throughout the length of the stone columns.
(a) Unless otherwise specified, penetration of the vibroflot to the required depth shall be
with air and/or vibrations. On reaching the required depth, the vibroflot shall be lifted
and lowered at least once over the full depth from commencement level to the required
depth;
(b) Compaction at any depth shall be as follows :
(i) Compaction with the vibroflot kept at that depth for not less than 3 minutes
while stones are fed in. Any arching of the stones between the vibroflot and the
sides of the hole shall be overcome by raising and lowering of the vibroflot over
a distance of approximately 0.5m;
(ii) Without further input of stone, the vibroflot lot shall be raised in steps of not
more than 25cm over a time interval of not less than l min/step or over such time
intervals as may be necessary to achieve the required power consumption
determined by the S.O. from installation of the preliminary stone column;
(iii) Input of stones shall be resumed and the procedures given in sub- clauses (a) and
(b) above shall be repeated.
(c) At a depth of approximately 1.0m below the final level, compaction shall be carried out
by repeated vertical movements of the vibroflot lot until the -required power
consumption determined by the S.O. from installation of the preliminary stone column
is achieved;
(d) Where shown on the Drawings, "Bottom-Feed Vibrators" shall be used where stones are
fed into that depth at which compaction is being carried out by means of gravel supply
tube with air pressure to prevent ingress of water or soil into the gravel supply tube.
Penetration of the vibrator shall be by jacking with air flushing.
S20 - 23
20.6.12 Materials
20.6.12.1 Stones
Stones used for forming stone columns shall consist of hard, durable inert material with
particle size distribution falling within the grading envelope given in Table 20.8. The stones
shall also be free of unsuitable material defined in the relevant clauses of the Earthworks
Specifications. When the stones are subjected to five (5) cycles of the sodium sulphate
soundness test (ASTM C88- 76, "Soundness of Aggregates by use of sodium sulphate or
magnesium sulphate" 1976) the weighted average loss shall not exceed 10 per cent.
Table 20.8: Grading of Stones
% Passing by Weight
BS 410 Test Sieve (mm)
Nominal Size of Singled-sized stone – 37.5mm
75.0 -
63.0 100
37.5 85 - 100
20.0 0 - 20
14.0 -
10.0 0-5
5.0 -
2.36 -
Prior to the commencement of the Works, the Contractor shall submit for approval samples of
the stone backfill aggregate from each proposed source of supply.
Throughout the period of the Works, when directed by the S.O., the Contractor shall be
required to substantiate that the output from the approved sources of stone consistently
conforms to the requirements of the Specifications and any conditions stipulated during the
initial approval.
20.6.13 Stone Column Records

Comprehensive records shall be kept. At the end of each day, 2 copies of the completed
records for each stone column shall be submitted to the S.O. The record shall include the
following information:
(a) Contract section;

(b) Reduced level of the stone column position;
(c) Stone column reference number;
(d) Nominal diameter of the stone column;
(e) Length of the stone column;
(f) Volume and weight of stone backfill in the stone column;
(g) Vibroflot power consumption during penetration and compaction;-
(h) Time for penetration, flushing, compaction and overcoming obstructions;
(i) Details of obstructions, delays and unusual ground;
(j) Weather report; and
(k) Any other information as may be required by the S.O.
On completion of the stone columns, the Contractor shall deliver to the S.O. a drawing
recording the final depths of all Stone Columns relative to Ordinance of Datum.
S20 - 24
20.6.14 Disposal of Arising
The Contractor shall ensure that the arising from the stone column installation cause minimum
contamination of the working surface. The Contractor shall remove the arising.
Surface depressions and/or contamination shall be made good by the Contractor with the
specified material before he commence the Works over the treated area.
20.6.15 Plate Load Tests on Stone Columns

20.6.15.1 General
Plate load tests shall be carried out directly on stone columns as required by the S.O. The
Contractor shall submit details to the S.D. for approval.
20.6.15.2 Safety Precautions Applicable to Plate Load Tests on Stone Columns

When preparing for and conducting a plate load test on stone columns, the Contractor shall
carry out the requirements of the various Acts, orders, regulations and other statutory
instruments that are applicable to the Works for the provision and maintenance of safe working
conditions, and shall in addition make such other provision as may be necessary to safeguard
against any hazards that are involved in the testing or preparations for testing.
The Contractor shall construct the foundation for the kentledge and any crib-work, beams or
other supporting structure in such a manner that there shall not be differential settlement,
bending or deflection of an amount that constitutes a safety hazard or impairs the efficiency of
the operation. The kentledge shall be adequately bonded, tied, or otherwise held together to
prevent it falling apart, or becoming unstable through deflection of the supports. The weight of
kentledge shall be greater than the maximum test load and if the weight is estimated from the
density and volume of the constituent materials, an adequate factor of safety against error shall
be allowed. The maximum test load or test pressure as read on the gauge in use shall be
displayed and all operators shall be made aware of this limit.
In all cases the Contractor shall ensure that when the hydraulic jack and load measuring device
are mounted on the bearing plate the whole system will be stable up to the maximum load to be
applied.
The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be operated under
hydraulic pressure shall be capable of withstanding a test pressure of 1.5 times the maximum
working pressure without leakage.
20.6.15.3 Reaction System

(a) Kentledge
The testing shall be carried out by use of kentledge as a reaction system. The kentledge
shall be supported on crib-work disposed around the bearing plate. The distance
between the centre of the bearing plate and the nearest edge of the supporting crib shall
be not less than three times the width of the bearing plate.
The bearing pressure under supporting cribs shall be such as to ensure stability of the
kentledge stack. This Specification does not cover the use of kentledge carried directly
on the bearing plate, and this method of loading shall not be used except at the
expressed direction of the S.O.
(b) Details of Loading Arrangement

The loading arrangement used shall be designed to transfer safely to the stone column
the maximum load required in testing. Full details shall be submitted to the S.O. prior to
any work related to the testing process being carried out on the Site.
S20 - 25
20.6.15.4 Equipment for Loading and Load Measurements
(a) Equipment for Applying Load
The equipment used for applying load shall consist of a hydraulic ram or jack having a
capacity at least equal to the required maximum load, and a hand or power driven pump
with a pressure gauge included in the hydraulic system. The ram shall be placed on the
bearing plate so as to transfer an axial load to the bearing plate. The complete system
shall be capable of transferring the maximum load required for the purpose of the tests.
The load from the reaction system shall be transferred axially to the hydraulic ram or
jack.
(b) Measurement of Load

The load shall be measured by a calibrated load cell and also by means of a calibrated
pressure gauge included in the hydraulic system of the jack. The load as shown on the
load measuring device shall be recorded. The calibrated pressure gauge is required to
check for gross error and shall also be recorded. The load measuring device shall be
calibrated immediately before the test. The pressure gauge and hydraulic jack shall be
calibrated together. Certificates of calibration shall be produced for the S.O.'s
inspection. The S.O.'s agreement shall be obtained in writing before any modification of
this procedure shall be used.
(c) Adjustability of Equipment

The equipment shall be capable of adjustment throughout the test to obtain a smooth
increase of load or to maintain each load constant at the required stages of maintained
load test.
20.6.15.5 Method of Measuring the Movement of the Bearing and the Surrounding Ground
Surface
In the plate load tests on stone columns, movements of the bearing plate and the surrounding
ground surface shall be measured by at least four (4) dial gauges mounted directly onto the
bearing plate and four (4) dial gauges disposed outside the plate and on the ground surface at a
distance from the centre of the plate equal to 1.5 times the width of the plate.
The dial gauges shall be capable of measuring settlement to an accuracy of 0.05mm and must
be supported by a reference frame independent of the kentledge.
Levels shall be taken of the reference frame against external datum at the end of each load
increment to check movement of the reference frame.
20.6.15.6 Plate Dimensions

The dimensions of the bearing plate shall be 1.Om diameter and least 5Omm thick unless
otherwise instructed by the S.O.
20.6.15.7 Locations
The bearing plate shall be located directly over the stone columns.
20.6.15.8 Preparation of Top of Stone Column

The top of the stone column shall be formed to give a level surface to accommodate the load
applying apparatus and settlement measurement equipment.
20.6.15.9 Protection of Testing Equipment and Supervision

(a) Protection From the Weather
Throughout the test period all load or settlement measuring equipment shall be
S20 - 26
protected from the weather.
(b) Protection From Disturbance
Construction equipment and persons who are not involved in the testing process shall be
kept at a sufficient distance from the test site to avoid disturbance of the measurement
apparatus.
(c) Notice of Test
The S.O. shall be given not less than 24 hours‟ notice of intention to commence the test.
(d) Records
During the progress of the test, the testing equipment and all records of the test shall be
available as required for inspection by the S.O or his representative.
(e) Supervision
The Contractor shall provide an experienced Supervisor to be present full time during
the duration of the tests to ensure that the loading sequence and method of taking
settlement readings are strictly followed and that the true load is maintained at all times.
Tests shall be carried out only in the presence of the S.O. or his representative.
20.6.15.10 Test Procedure for Maintained Load Test

Loading shall be in increments of 25% of the given load up to the maximum test load as
determined by the S.O. For each stage, the load or increment of load shall be applied as
smoothly and expeditiously as possible and time-settlement readings taken before and after
each increment.
A minimum period of 2 hours shall intervene between the applications of each increment
except that no increment is added until a settlement of less than 0.lmm is observed for 20
minutes under the previously applied increment.
At a load level to be specified by the S.O., the applied load shall remain on the bearing plate
for a minimum period of 24 hours and time-settlement readings taken in regular intervals as for
the load increments.
Unloading shall be carried out in four (4) equal stages and time-settlement readings taken. At
least sixty (60) minutes intervals shall be allowed between the unloading decrements.
One unload-reload cycle shall be carried out at each load level to be specified by the S.O.
20.6.15.11 Plate Load Test Records

Within forty eight (48) hours of completion of any load test on a stone column, the Contractor
shall submit to the S.O. or his representative four (4) copies of completed records of time,
loads, settlement and any other relevant information together with graphs of load against time
and settlement against time.
20.6.15.12 Records Confidential

All plate load test records shall be considered confidential and shall not be disclosed by the
Contractor to any third party without the expressed permission in writing of the Employer.
S20 - 27
20.7 TERRAMESH WALL
20.7.1 Materials Specification
20.7.1.1 Introduction
The specification below applies to Terramesh units and to the materials from which these are
manufactured.
For simplicity the word “Terramesh” is used. This may be changed for or have the words
“Terramesh System” added singularly or in combination as appropriate. Unless specifically
stated otherwise.
20.7.1.2 Definitions
Terramesh is defined as PVC coated heavily galvanized steel wire mesh box-shaped basket
with a section of the mesh extending into the soil to act as soil reinforcement into the backfill
soil. The basket is filled on site with clean-hard stones.
The selvedges of the Terramesh are the thicker perimeter and edge wires to which the wire
mesh is securely tied to withstand sudden or gradual stress from any direction.
The diaphragms are the internal wire mesh partitions which divide the Terramesh box into
approximately equal sized cells.
Lacing and bracing wire is the wire used to assemble and join the Terramesh units.
Connecting wires are the internal wires used to prevent the Terramesh from bulging during
filling.
20.7.1.3 General Description

Terramesh shall be made from flexible woven wire Heavily Galvanized and PVC Coated mesh
8 type mesh boxes with integral panels of dimensions as specified in the Contract Drawings or
an approved equivalent. The wire mesh shall bear the marking of the manufacturer‟s name,
along the selvedge wire to enable visual inspection.
All material supplied must be accompanied by a manufacturing certificate from the factory for
quality control and quality management purposes. The supplier and material shall comply with
the following criteria in order to supply the material:-
(a) Factory shall have certification ISO 9001/2 for quality control and management.
(b) Past experience in supplying material for wall more than 9m height.
(c) Shall comply with BBA certificate for expectancy life of material up to 120 years.
(d) The front face box and the soil reinforcement tail shall be made from one continues
mesh panel.
(e) The mesh twists are oriented vertically on the gabion face and perpendicular to the front
face in the reinforcement panel.
20.7.1.4 Steel Wire

(a) General
All steel wire used in the fabrication of the Terramesh, and also in the wiring operations during
construction, shall be to BS 1052, having a tensile strength of not less than 380 N/mm2 and not
exceed 550 N/mm2.
S20 - 28
(b) Wire Diameter
Wire diameters and relevant tolerances shall be in accordance with the following table:
Table 20.9: Wire Diameter
Wire Diameter Wire use Tolerance

mm mm
2.20 Lacing Wire ± 0.06
2.70 Body Wire ± 0.08
3.40 Selvedge Wire ± 0.10
(c) Zinc Coating

All wire used in the fabrication of the Terramesh and in the wiring operations during
construction shall be heavily galvanized and exceed BS 443, the minimum mass of the zinc
coating shall be according to the figures shown in the table below:
Table 20.10: Zinc Coating
Diameter of Wire Weight of Coating

mm g/sq.m
2.20 240
2.70 260
3.40 275
The adhesion of the zinc coating to the wire shall be such that when the wire is wrapped six
times around a four wire diameter size mandrel it shall not flake or crack to such an extent that
any zinc can be removed.
(d) PVC Coating

All wire used in the fabrication of Terramesh and in the wiring operations during construction
shall have extruded onto it (after coating it with zinc in accordance with the foregoing
specification) a coating of Poly Vinyl Chloride, otherwise referred to as “PVC”, or other
plastic material having superior characteristics than PVC as otherwise approved.
The coating shall be 0.50mm average thickness with a tolerance of ± 0.05mm, and nowhere
shall be less than 0.40mm thickness.
The PVC shall be grey in colour.
It shall be capable of resisting deleterious effects of natural weather exposure, immersion in

salt water and not show any material difference in its initial characteristics which are:
(i) Specific Gravity

Shall be 1.30 to 1.35 in accordance with ASTM D 792-91
(ii) Durometer Hardness

Shall be 50 to 60 shore D, in accordance with ASTM D 2240-91 (ISO 868-1985)
(iii) Volatile Loss

At 105°C for 24 hours - Shall not be greater than 5%
In accordance with ASTM D 2287-92 E2.
Residual Ashes shall be less than 2% according to ASTM D2124-62T.
(iv) Tensile Strength

Shall not be less than 210 kg/sq.cm in accordance with ASTM D 412-92.
S20 - 29
(v) Elongation
Shall not be less than 200% and not greater than 280% in accordance with ASTM D
412-92.
(vi) Modulus of Elasticity at 100% of Elongation

Shall not be less than 190 kg/sq.cm in accordance with ASTM D 412-87.
(vii) Resistance of Abrasion

The loss in volume shall be less than 0.30cm3 in accordance with ASTM D 1242-56.
(viii) Creeping Corrosion

Maximum penetration of corrosion of the wire core from a square cut end shall not be
greater than 25mm when the specimen has been immersed for 2000 hours in a 50%
solution of HCL (Hydrochloric Acid 12 BE).
Testing for deterioration shall be as described below. Variation of the initial characteristics
may be allowed, as specified hereunder, when the specimen is submitted to the following tests:
(i) Salt Spray

According to ASTM B 117-90
Period of test = 1500 hours
(ii) Exposure to Ultraviolet Light

According to ASTM D 1499-92 and ASTM G 23(93) apparatus type E.
Period of test = 2000 hours at 63°C.
(iii) Exposure at High Temperature

According to ASTM D 1203-89, (ISO 176-1976) and ASTM D 2287-(92)E2.
Period of test = 240 hours at 105°C.
(iv) Brittleness temperature: cold bend less than -30°C test method BS2782-104A; cold flex
less than +15°C in accordance with BS2782-151A(84).
After the above tests have been performed, the PVC coating shall exhibit the following
properties:
(i) Appearance
The vinyl coating shall not crack, blister or split and shall not show any marked change
in colour.
(ii) Specific Gravity

Shall not show change higher than 6% of its initial value.
(iii) Durometer Hardness

(iv) Tensile Strength

(v) Elongation
(vi) Resistance to Abrasion

(vii) Brittleness Temperatures

Cold-bend not exceeding -20°C; cold-flex not exceeding +18°C.
S20 - 30
20.7.1.5 Wire Mesh
Wire mesh shall be mechanically pre-fabricated to become a uniform hexagonal woven mesh
wherein the joints are formed by twisting each pair of wires through three half-turns
(commonly known as double twist), in such a manner that unraveling is prevented.
Double-twist mesh is demonstrated in the sketch below:
The tightness of the twisted joints shall be such that a force of not less than 1.7 kN is required
when pulling on one wire to separate it from the other wire, provided each wire is prevented
from turning under the applied forces, and the wire is all in the same plane.
The mesh tensile strength, in soil, is to be equal to or greater than 47 kN/m. All wire used in
Terramesh units shall be PVC coated.
Certain other wire diameters may be utilized if specified by the S.O.
The wire mesh dimensional layout is as per the diagram below:
Table 20.11: Wire Mesh Dimensional
Mesh X ( mm ) Y ( mm ) Tolerance %
8 82 122 +5%
20.7.1.6 Selvedges
The cut edges of all mesh used in the construction of Terramesh System, except the bottom
edges of diaphragms and the end of the soil reinforcing tail shall be tightly selvedged with a
wire having a diameter of at least 3.40 mm.
S20 - 31
The side selvedge of all and any mesh panels shall be woven integrally with the main mesh as
described in the above clause 1.5 with a selvedge wire of at least 3.40 mm in diameter.
Where the selvedge is not woven integrally with the mesh but has to be fastened to the cut
ends of the mesh, it must be attached by mechanically binding the cut ends of the mesh two
and half turns around the selvedge wire or by other approved method, provided that the force
of not less than 8.5 kN applied in the same plane as the mesh, at a point on the selvedge of a
mesh sample one metre long, is required to separate it from the mesh.
20.7.1.7 Diaphragms and End Panels

The rear/side panels shall be selvedged on the top, bottom and vertical sides as described in
clause 1.6. The diaphragms shall be selvedged and on the top and vertical sides.
The rear and side panels of the box gabion section of the Terramesh unit shall be formed by a
continuous panel connected to the main panel, along the bottom of the rear panel, either by a
spiral wire through the mesh openings or by being mechanically placed with four connecting
rings.
20.7.1.8 Lacing And Bracing Wire

Sufficient lacing and bracing wire must be supplied with the gabion cages to perform all the
wiring operations to be carried out in the construction of the Terramesh work.
The lacing and bracing wire shall be made from Heavily Galvanized Wire, coated with PVC
and have a core diameter of 2.20 mm.
20.7.1.9 Unit Sizes

Terramesh shall be mechanically pre-fabricated in such a manner that the sides, ends and
diaphragms can be assembled at the construction site into rectangular baskets of the standard
sizes indicated below or as specified and shown in the contract Drawings.
Table 20.12: Unit Sizes of Terramesh
Mesh type 80mm

Width (W) 2m
Length (L1) 1m
Length (L2) To suit design
Depth (D) 0.5m and 1m
Diaphragm Every 1m
All Terramesh dimensions shall be within a tolerance limit of 5% of the required size.
20.7.1.10 Stone Fill For Facing Box

The material used for Terramesh facing box fill shall be clean, dense hard and durable stone,
rounded and angular shape.
No rock shall exceed 250mm and at least 85% by weight of the stone shall have a size equal to
or larger than 100mm. No rock shall pass through the mesh.
20.7.1.11 Structural Embankment

The embankment forming the reinforced soil structure should be constructed with material
having the soil properties as specified in the design and approved by the S.O.
Ideally, the backfill shall be granular, free draining and have the following specification,
unless otherwise approved by the S.O:
S20 - 32
(a) not more than 15% by mass of total material to be finer than 75 micron sieve opening
(b) at least 90% by mass of total material to be finer than the 100 mm sieve opening
(c) maximum particle size to be limited to 125 mm
Cohesive frictional fill as described in the Specification of Highway Works – Classes 7C and
7D, is permitted provided it is in accordance with the design and internal drainage system is
included.
The soil should not exhibit any deterioration in these characteristics with time.
20.7.2 Assembly and Erection Specification for Terramesh System Unit Reinforced Walls
20.7.2.1 Scope
This part of the specification details the requirements from the assembly stage through to the
final wiring of the completed Terramesh® units.
The contractor shall provide to the S.O, for his approval, full details and specifications of the
Terramesh he proposes to use in this contract. Only those products so approved by the S.O
shall be allowed to be incorporated in the works.
20.7.2.2 Preparation
The site shall be surveyed, cleared, trimmed level and the ground compacted accordingly.
Prior to assembly, the Terramesh units shall be opened out flat on the ground and stretched to
remove all kinks and bends.
The Terramesh units shall be assembled individually by raising the front panel (with lid), the
hinged rear panel, and the two ends vertical ensuring that all creases are in the correct position
and that tops of all four sides are even. The diaphragm panel should be located in a vertical
plane centrally within the facing box.
The four corner edges of the facing box shall be laced first followed by the edges of the
internal diaphragm to the sides.
In all cases, lacing shall commence by twisting the end of the lacing wire tightly around the
selvedge/s. It shall then pass round the two edges being joined using alternate single and
double loops at 100mm intervals and be securely tied off at the bottom. The ends of all lacing
wires shall be turned to the inside of the box on completion of each lacing operation. Each
loop shall be pulled tight to prevent the joint opening during filling.
20.7.2.3 Erection
Only assembled boxes, or groups of boxes, shall be positioned in the structure. The side, or
end, from which work is to proceed, shall be secured either to the completed work, or by rods
or stakes driven into the ground at the corner. These stakes must be secure and be high enough
to reach at least to the top of the gabion box.
Further gabion boxes shall be positioned in the structure as required, each being securely laced
to the preceding one along all common corners and diaphragms using the lacing technique
described above.
Adjacent panels shall be laced longitudinally to provide a homogeneous reinforcement layer.
All lacing wire shall be PVC coated.
S20 - 33
20.7.2.4 Geotextile
Non-woven geotextile, as specified in the contract Drawings and approved by the S.O, shall be
placed vertically at the back of each gabion box section of the Terramesh units, and extend
backwards into the fill at least 0.5m parallel to the mesh of homogenous lower panel and also
0.5m below the panel directly above the unit, to prevent migration of fines.
20.7.2.5 Stretching
Final stretching of the gabion boxes shall be carried out using a pull-lift of at least one tonne
capacity, firmly secured to the free end of the assembled gabion boxes.
Whilst under tension, the gabion box section of the Terramesh units shall be securely laced
along all edges (top, bottom and sides) and at diaphragm points, to all adjacent boxes.
20.7.2.6 Filling
Filling shall be carried out whilst gabion boxes are under tension.
The front face and all other faces which will be exposed in the completed structure shall be
“hand packed” with the stones placed so as to produce a neat face free from excessive bulges,
depressions and voids.
Internal bracing wires shall be provided on the exposed faces at the rate of 4/cu.m at 330mm
centres to prevent distortion of the units during filling and in the completed structure. These
bracing wires shall be wrapped around two of the mesh wires and extend from front to back.
Additional bracing wires shall be provided on exposed ends at a rate of 4/sq.m of face.
Mechanical filling equipment may be used with the approval of the S.O, providing adequate
precautions are taken to protect the PVC coating from abrasion during filling operations.
Tension on the gabion boxes shall be released only when fully laced and sufficiently full to
prevent the mesh from slackening.
All gabions shall be overfilled by 25mm using flat stone to allow for minor settlement and to
provide a level surface for subsequent layers.
20.7.2.7 Structural Embankment Material

Select backfill shall be placed between each subsequent mesh panel layer to the full extent of
the mesh reinforcement at each level as specified in Clause 1.11.
20.7.2.8 Compaction of Backfill
The select backfill shall be compacted in lifts not exceeding 250-300 mm to 90% of maximum
density as determined by Test 12 of BS1377, unless otherwise specified on the Drawings or
specified by the S.O.
Care shall be taken to ensure heavy compaction equipment does not come into contact with the
mesh panels or within 1.0 m of the front face. Tracked construction equipment shall not be
operated directly upon the mesh reinforcement. A minimum fill thickness of 150mm is
required prior to operation of tracked vehicles over the mesh.
During construction, the surface of fill should be kept horizontal. A slight sloping surface
shall be maintained to facilitate drainage of surface water run-off.
Compaction adjacent to the front edge should be done using hand operated rollers or plate
compactors.
S20 - 34
20.8 GABION RETAINING WALL
- Specification for Gabion Retaining Wall, please refer to Section 3: Drainage - Clause 3.6.
20.9 REINFORCED SOIL WALL WITH CONCRETE FACING PANELS

20.9.1 General
The Wall Works shall comprise the construction of walls shown in Drawings in accordance
with the Contract. The Contractor shall also design in accordance with the Specifications
certain Wall components to the loads shown on the Drawings and submit the design
calculations, detailed Drawings and the exhibited Bills of Quantities duly filled in together
with his tender.
The external stability of the reinforced soil retaining wall has been catered for.
The Contractor shall provide the type of facing specified in the Drawings and design the
reinforcing elements, the facings, fasteners and connections between adjacent facing units, and
between the facings and the reinforcing elements, and joint fillers all in accordance with the
requirements of the Specifications and in conformity with the lines, levels and details given in
the Drawings or as amended by the S.O.
In this Specification various required attributes, properties, design methods, materials and other
parameters are defined for the three systems defined below. Should the Contractor propose a
different system to those defined he must submit full details of the design methods, materials
specifications, construction methods and all other matters relevant to the system together with
copies of all applicable Codes of Practice, Design Manuals, Specifications and other relevant
documents at the time of tendering.
20.9.2 Definitions
"Reinforced Soil" means any part of the Permanent Works comprising a mass of bulky
material of fragmented form having tensile reinforcing elements embedded in the mass so that
the elements interact with the material to stabilise it and includes any facing which may be
necessary for such part of the Permanent Works.
"Deadman Anchor Wall" means a reinforced soil comprising the mass of fill which is
reinforced with galvanized steel bars tied to multiple deadman anchor blocks at the rear and
connected to concrete facings by means of some mechanical connection. The name Deadman
Anchor Wall is not a registered trademarks.
"Reinforced Earth Wall" means a reinforced soil comprising the mass of fill which is
reinforced with tensile elements which is galvanised metal strip which is attached to concrete
facing by means of some mechanical connection. The name itself is a registered trademark.
A `Wall' of reinforced soil comprises the mass of fill which is reinforced with tensile elements
and the facing which is attached to the elements.
20.9.3 Dimensions
The lengths, heights and widths of the Reinforced Soil Retaining Wall shall be as shown in the
Drawings.
20.9.4 Codes of Practice And Technical Memorandum

The design and construction where relevant shall be carried out according to the following
Codes of Practice and Technical Memoranda:
(i) BS 5950 : British Standard 5950: Structural Use of Steelwork in Buildings;

(ii) BS 8110 : British Standard 8110: Structural Use of Concrete;
S20 - 35
(iii) BS8006: British Standard 8006: Code of Practice for Strengthened/Reinforced Soilsand
Other Fills;
(iv) AS 1204 : Australian Standard 1204 : Structural steels ordinary weldable grades -
Metric Unit;
(v) AS 1650 : Australian Standard 1650 : Galvanised Coatings on Ferrous Articles;
(vi) "Reinforced Earth Retaining Walls and Bridge Abutments of Embankments" Technical
Memorandum (Bridges) BE 3/78. Department of Transport, United Kingdom;
(vii) "Reinforced Earth Structures Recommendations - Rules of the Art" French Ministry of
Transport, August 1980 hereinafter referred to in its abbreviated form RESRRA. FMOT
(1980);
(viii) "Design and Construction Guidelines. Reinforced Soil Structures. U.S. Dept. of
Transportation. Federal Highway Administration". (Hereinafter referred to in its
abbreviated form as U.S. Dept. TFHA).
The recommendations of the Codes and memorandum shall be followed in so far as they are
applicable to the design and construction of the wall and its foundation. However, should there
be any discrepancies between the abovementioned Codes of Practice and this Specification,
then the latter shall take precedence.
All British or other Standards and Codes of Practice, etc. shall be deemed to be the editions
current at the time of Tender. Current editions may have the same numbering system as
previous editions or renumbered. Should the Contractor wish to propose compliance with
Standards or Codes of Practice different from those stipulated in the Specification then such
alternative standards of Codes of Practice shall only be considered by the S.O. if in the opinion
of the S.O. they are equivalent or superior to the Standards or Codes of Practice stipulated in
the Specification.
20.9.5 Materials
The following are criteria to be adopted with respect to materials in the Contractor's design of
components.
20.9.5.1 Reinforcing Elements

(a) Deadman Anchor Walls
Reinforcing elements shall be galvanised steel bars individually attached to deadman anchor
blocks.
(b) Reinforced Earth Walls
Reinforcing elements shall be galvanized carbon steel strips.
20.9.5.2 Facings
The facings shall consist of precast rigid concrete panels not less than 150mm thick.
20.9.5.3 Fasteners
(a) Deadman Anchor Walls and Reinforced Earth Walls
Fasteners for connections between adjacent facing units and between the facing and the
reinforcing elements shall take the form of dowels, rods, hexagon head screws or bolts of
galvanized steel alloys.
S20 - 36
20.9.5.4 Facing Unit Joint Filler Material
Fillers shall be durable, resistant to the effects of air pollution, insulation and water which may
be contaminated.
Bedding material shall consist of durable gasket material such as resin bonded cork strip. The
selection of the bedding material will depend upon the structural behaviour of the facing
assumed in the design of the wall.
Sealing material for filling joints other than bedding joints may consist of either polyethylene
foam or polyurethane foam strip.
20.9.5.5 Fill
Fill in the wall shall be wholly granular fill as specified in Clause 20.6.8.2
20.9.5.6 Material Compatibility

All metallic components buried in soil i.e. reinforcing elements, connections, facing lugs and
where applicable the facing units, shall be of electrolytically compatible materials.
20.9.6 Design Methodology and Criteria

20.9.6.1 Design of Reinforcing Elements
The lengths of the reinforcing elements shall be determined by the S.O. Provisional minimum
lengths of the reinforcing elements required for overall stability are given in the Drawings.
The Contractor shall design the reinforcing elements in accordance with the requirements of
the Specifications.
In the event that the S.O. alters the lengths of reinforcement and/or configurations of the
slopes, the Contractor shall redesign the reinforcing elements in accordance with the
requirements of the Specifications. The tendered rates shall allow for any change in quantities
as a result of redesign.
The lengths given are the minimum required for the design of the reinforcing elements. The
Contractor shall verify that the lengths given are satisfactory for the sound performance of his
wall system, and shall design for increased stresses and lengths if necessary.
(c) Particular Requirements for Deadman Anchor Walls

The design shall follow the recommendations set out in U.S. Dept. TFHA with the following
requirements:
(i) The lateral active soil pressure acting on the facing element shall be computed from the
vertical pressure assuming a Ko condition (Ko = 1-Sin);
(ii) The tension force in the tendon shall be computed from the active soil pressure in (i)
above acting over the tributary surface area of the facing for the tendon;
(iii) The deadman shall be located at a horizontal distance of not less than H/5 beyond the
Rankine failure plane inclined at (p/4 + f/2) to the horizontal emanating from the toes,
where H is the length of the wall as defined on the Drawings;
(iv) Pull out capacity of the deadman shall be estimated assuming the cohesion to be absent.
The friction angle shall correspond to the material over which the failure planes shall
develop. The Factor of Safety against pull out capacity shall be not less than 2.0.
S20 - 37
(d) Particular Requirements for Reinforced Earth Walls
The vertical spacing of the strips shall not be more than 750mm.
The Local Equilibrium Method described in Section 2.4.2 of the RESRRA.FMOT (1980) shall
be used in the design.
The design shall satisfy the requirements of Section 2.4.4.2.1 of the RESRRA.FMOT (1980).
For ribbed reinforcing strips (Highly Adherent (H.A.) reinforcements) the soil-reinforcement
friction coefficient (referred to as f* in RESRRA.FMOT (1980)) shall be as described in
Section 2.3.3.1 of RESRRA.FMOT (1980) with the exception that the coefficient fo* shall not
exceed 1.5;
For smooth reinforcing strips, the soil-reinforcement friction coefficient (f*) shall be equal to
0.40 as given in Section 2.3.3.2 of RESRRA.FMOT (1980).
20.9.6.2 Design of Facings and Fasteners

Design of facings and fasteners shall be in accordance with BS 8110 and BS 5950 where
applicable.
(a) Facing
Loads for which the facing shall be designed shall be as follows:
(i) The horizontal soil pressures and the corresponding reinforcing element tensile
reactions;
(ii) The loads arising from superimposed facing units;
(iii) Vertical shear forces derived from relative movement between the facing and the fill
and possible additional tensile reactions in the elements;
(iv) Longitudinal differential settlement.
Facings shall consist of rigid panels, each of area not exceeding 2.5 sq.m. and which are able
to move vertically relative to one another either by overlapping or by compressing a filler
placed in the horizontal joints between the units.
(b) Connections between Facing And The Reinforcing Elements for Deadman Anchor
and Reinforced Earth Walls
(i) Connections shall be designed to transfer the forces described in 20.8.6.2.1 and may be
either rigid or sliding. The latter type of connection may include the use of dowels, rods
or guide rods with tee-shaped bolts or strips. No bolt, screw, dowel or rod shall be less
than 12mm nominal diameter;
(ii) Stresses. Calculated values of stresses in bolts, screws, dowels and rods shall be based
on the cross sectional area derived from the nominal diameter of the component except
that the axial tensile stress in a bolt or a screw, and the shear stress in a screw shall be
based on the cross sectional area derived from the root diameter of the thread;
(iii) Combined stresses in bolts, screw, dowels and rods:-
a. Bolts and screws shall be so proportioned that the sum of calculated axial and
shear stresses to their respective permissible values does not exceed 1.4;
b. For combined bending, axial and shear stresses the design shall comply with the
requirements of BS 5950 Clause 14 except Clause 14d and Table 1. In no case
shall the equivalent stress exceed 0.7 times the yield or 0.2% proof stress of the
material.
S20 - 38
(iv) Holes for fasteners in metallic sheet and strip :-
a. Diameter
The design shall be based on the holes diameter being 2mm greater than the
nominal diameter of the fastener;
b. Pitch
The distance between centres of holes shall be not less than 2.5 times the
nominal diameter of the fastener;
c. Edge Distance
The distance from the centre of the hole to the edge of the sheet or strip shall be
not less than 1.5 times the nominal diameter of the fastener. Where edges are
sheared or hand flame cut the edge distance shall be increased by 5mm.
(c) Facing Joints and Connections

(i) General
Adequate provisions shall be made for angular movement and/or relative movement in
the plane of the facing at the joints to allow for the effects of longitudinal differential
settlement. An interlocking form of construction between parts of the facing shall be
used to limit relative out of plane movements except where connections in (ii) below
fulfill this purpose;
(ii) Connections between Adjacent Facing Units

Connections shall be provided to prevent leaching out of fill on to the face of the wall.
No bolt, screw, dowel or rod shall be less than 12mm nominal diameter.
20.9.7 Reinforcing Elements

20.9.7.1 Deadman Anchor Walls
(a) Galvanized Steel Rods
The reinforcing bars shall be made of steel bars generally in accordance with the composition
and property requirements of MS 146 and BS 4449 with minimum tensile strength of 250
MN/m2 and shall be hot dipped galvanised with zinc with a minimum thickness of 70 mm.
The bars shall be cut to length and threaded at both ends for the nuts to be screwed on. They
shall be inspected to ensure that they are free from defects that may impair their strength and
durability.
(b) Anchor Deadmen

Anchor deadmen shall be of mass or reinforced concrete complying with the following:
(i) Characteristic cube strength at 28 days : 30 MPa
(ii) Minimum cement content : 325 kg/m3
(iii) Maximum aggregate size : 20 mm
(iv) Maximum free water/cement ratio : 0.55
S20 - 39
20.9.7.2 Reinforced Earth Walls
(a) Galvanized Carbon Steel Strips
Steel reinforcement and tie strips shall comply generally with AS 1204 and shall be either:
(i) Plain flats cut from continuously hot dipped galvanised sheet of minimum yield stress
300 MPa; OR
(ii) Plain or ribbed flats in accordance with the composition and property requirements of
AS 1204 Grade 250.
Reinforcement shall be cut to length and holed in the specified locations. Reinforcement shall
be inspected to ensure that it is free from defects that may impair its strength or durability.
The non-structural sacrificial thickness to be allowed for on each surface exposed to corrosion
shall be 0.75mm.
20.9.8 Frictional Fill

20.9.8.1 Selected Fill for Reinforced Soil Retaining Wall
The Fill to the lines and levels shown in the Drawings shall be selected granular material, free
from organic or deleterious material, and shall conform to the limits specified in this Section.
20.9.8.2 Grain Size Distribution

The selected fill for reinforced soil retaining wall shall comply with the following:-
(a) It shall not contain chalk, unburnt colliery shale, pulverised fuel ash or unsuitable
material as defined in Section 2: Earthworks;
(b) The coefficient of uniformity shall be not less than 5 unless otherwise agreed by the
S.O.;
(c) The chemical and electrical properties of the fill shall be suitable for the reinforcing
elements. The requirements are given in Section 20.9.8.4;
(d) It shall comply with the following grading limits:
Table 20.13: Grain Size Distribution
Grading Limits
B.S. Sieve Size Percentage by Mass Passing
125 mm 100
90 mm 85 – 100
10 mm 25 – 100
600 microns 10 - 65
63 microns 0 - 10
20.9.8.3 Angle of Friction

(a) Fill for Deadman Anchor Walls
The angle of friction of the frictional fill corresponding to constant volume conditions from
shear box tests shall be not less than 30°.
S20 - 40
(b) Fill for Reinforced Earth Walls
(i) For ribbed reinforcing strip (Highly Adherent Reinforcement (H.A.)), the angle of
internal friction of a saturated specimen of the fill measured under conditions of rapid
shearing must be equal to or greater than 250;
(ii) For smooth reinforcing strip, the angle of friction earth/reinforcing strip measured under
the same conditions must be equal to or greater than 220;
20.9.8.4 Chemical and Electrical Properties

(a) pH Value
The pH of the material shall be in the range of 5 to 10.
(b) Solution Salts

Where the resistivity of the material is in the range of 1,000 ohm.cm to 5,000 ohm.cm or
where the material is of industrial origin, the concentration of chlorine (Cl -) and sulphate
(SO42-) shall be checked and shall not exceed the following limits :-
Table 20.14: Concentration of Chlorine (Cl-) and Sulphate (SO42-)
Description Outside Water In Soft Water

-
Cl (mg/kg) 200 100
SO42- (mg/kg) 1,000 500
(c) Sulphides
Where the origin of the material raises the possibilities of the presence of sulphides, the
concentration of the sulphide shall be checked and shall not exceed 300 mg/kg for structure
outside water and 100 mg/kg for structures in soft water.
(d) Electrochemical Resistivity

The resistivity of the fill material shall be determined on a saturated specimen after one hour of
soil-water contact at 20°C.
The resistivity of the material shall be greater than the following limits:
Table 20.15: Electrochemical Resistivity of Fill Material
Description Outside Water In Soft Water

Resistivity (ohm.cm) 1,000 3,000
(e) Minimum Redox Potential Volts

The minimum redox potential volts shall be 0.3.
20.9.9 Fixings And Fasteners

20.9.9.1 Fasteners for Deadman Anchor and Reinforced Earth Walls
(a) Precision hexagon bolts, screws and nuts shall comply with the dimensional
requirements of BS 3692 and shall be made from Steel Alloy Grade 8.8 complying with
BS 3692 hot dip galvanized in accordance with the requirements of BS 729;
S20 - 41
(b) Black hexagon bolts, screws and nuts shall comply with BS 4190 and shall be hot dip
galvanized in accordance with the requirements of BS 729. The strength grade
designation of bolts and screws shall be not less than 4.6 and of nuts not less than 4.0;
(c) Plain washers shall be of either Form A or Form E to BS 4320 and shall be made of
cold rolled carbon steel strip CS4 complying with BS 1449:Part 1 hot dip galvanized in
accordance with BS 729;
(d) Dowels and rods shall be made from one of the following :-
(i) Steel bar complying with BS 4449 hot dip galvanized in accordance with the
requirements of BS 729;
(ii) Steel of grade 50B complying with BS 4360 hot dip galvanized in accordance
with the requirements of BS 729;
(iii) Stainless steel complying with BS 970: Part 4 except that the 0.2% proof stress
of the bolt shall be not less than 450 N/mm2 and the tensile stress shall be not
less than 700 N/mm2.
Permissible stresses for bolts and screws up to 40mm stock size are given in Table 20.16.
Those for dowels and rods are given in Table 20.17.
Table 20.16: Properties of Bolts and Screw Up to Stock Size
Minimum Permissible Stresses

Yield or 0.2% Axial Tension Single Bearing
Material
Shear
N/mm² N/mm² N/mm² N/mm²
Carbon Steel (galvanized) BS
235 130 85 250
4190 : Grade 4.6
Alloy Steel (galvanized) BS
628 290 192 590
3692 : Grade 8.8
Table 20.17: Properties of Dowel and Rods up to 40mm Stock Size
Minimum Permissible Stresses

Yield or Axial Bending Single Bearing
Material
0.2% Tension Shear
N/mm² N/mm² N/mm² N/mm² N/mm²
Carbon Steel
250 150 165 90 265
(galvanized) BS4449
Carbon Steel
(galvanized) BS 4360: 355 195 215 117 367
Grade 50B
Stainless Steel BS970,

450 248 272 148 477
Pt 4:316S16, CR
S20 - 42
20.9.10 Facings
The concrete shall have a 28 days characteristic cube strength (fcu) of 30 MPa and cement
content of not less than 350 kg/m3 using Normal Portland Cement. Admixtures shall not be
used without the approval of the S.O.
Tie strips, connecting dowels, PVC tubes and lifting ferrules shall be cast in place to
dimensions which shall have been submitted by the Contractor to, and approved by the S.O.
Panels shall be cast on a flat area using the standard moulds properly assembled to form a
grout tight face at the joints. Concrete shall be placed and compacted to eliminate voids or
blemishes. Units shall be cured for a minimum of 28 days.
Panels shall be cast to the following tolerances:
(a) all dimensions within ± 5 mm
(b) the difference between the lengths of the diagonals shall not exceed 10 mm
Cover to reinforcements shall be to the requirements of BS 8110.
20.9.11 Joint Fillers

Horizontal joint fillers shall be expanded cork particles agglomerated with epoxy resins with
the following characteristics:
(a) Specific weight = 250 kg/cu.m
(b) 50% compressibility under applied pressures of 0.5 to 2MPa
(c) Recovery after 50% compression shall be greater than 90%
(d) Minimum thickness of 20mm
Vertical Joint fillers shall consist of polyurethane foam or polyethylene foam strips.
20.9.12 Granular Fill Behind Reinforced Soil Retaining Wall

The granular fill behind the reinforced soil retaining wall shall comply with the grading limits
given in Clauses 20.9.8.2.
20.9.13 Construction
20.9.13.1 Fill
Fill shall follow closely behind the wall facing erection. At each level of reinforcement,
backfill shall be roughly levelled before placing and/or bolting reinforcement elements. The
maximum thickness of each fill layer depending on reinforcement spacing shall be 0.3m or
lesser amount as required to meet the compacted density as specified below notwithstanding
the requirements of the Specifications for compaction (Earthwork Section of the
Specification).
The top 500mm of backfill of finished embankments shall be compacted to a density of not
less than 95% of the maximum dry density, as determined by the BS1377 Compaction Test
(4.5kg rammer method), over the full width of the embankment. Layers below this shall be
compacted to a density of not less than 90% of the maximum dry density.
During backfill placement trucks and heavy vehicles shall be kept back at least 2m from the
face of the wall.
S20 - 43
The deposition, spreading, levelling and compaction of the fill shall be carried out generally in
a direction parallel to the facing and shall be executed in stages to alternate with the placing
and fixing of the reinforcing elements and the facing.
Care shall be taken to ensure that the reinforcing elements and facing are not damaged or
displaced during deposition, spreading, levelling and compaction of the fill. The programme
of filling shall be arranged so that no machines or vehicles run on the reinforcing elements.
The fill within 2m of the face of the wall and anchor blocks shall be compacted using one of
the following:
(a) Vibro-tamper;
(b) Vibrating plate compactor having mass not exceeding 1,000kg;
(c) Vibrating roller having a mass per metre width of not more than 1,300kg and a total
mass of not more than 1,000kg.
Prior to the commencement of compaction the Contractor shall submit for the approval of the
S.O. the compaction plant proposed for use. The Contractor shall determine by site visits and
laboratory testing the density/moisture relationship of the material and the optimum field
moisture content to give the maximum dry density for the proposed compaction method.
The methods of compaction determined from the site trials giving results which satisfy the
Contract will be accepted by the S.O. and the Contractor shall follow the same methods for the
rest of the compaction works. The Contractor may not depart from the accepted method unless
further trials are carried out.
The rear of the wall shall be adequately supported either by temporary shoring or by phasing
the work in order to ensure that the facing of the reinforced soil and the granular fill behind the
wall can be raised together.
20.9.13.2 Wall Erection - Concrete Panels

Concrete panels shall be placed vertically with the aid of light cranes and lifting beams.
Panels shall be lifted using the erection inserts cast into the panels. Panels shall be placed in
successive horizontal lifts. As fill is placed, the panels shall be held vertically by temporary
timber wedges in the external joint at the junction of the two adjacent panels and by clamps at
the staggered joint between the panels. External bracing is required also for the initial row of
panels. During each stage of the erection, the panels shall be checked for alignment and level
by using the spacer bars and plumb bob for each panel.
20.9.13.3 Fabrication and Handling

Reinforcing elements shall be prefabricated and delivered to site ready for installation into the
Works. The elements shall be:
(a) Loaded, unloaded and handled in such a manner that:
(i) No permanent set is caused by bending;
(ii) Protective coating is not damaged.
(b) Stored flat and clearly marked to identify items having different lengths and cross
sectional dimensions;
The reinforcing elements shall be placed on compacted fill and looped between an outer fixing
bar and the panel connection. Reinforcing elements shall be pulled taut before commencement
of deposition and compaction of the subsequent layer of fill. All cut ends of the reinforcing
elements shall be sealed with approved sealant.
S20 - 44
20.9.13.4 Tolerances
The general tolerances applied to the finished wall shall be as follows:
(a) Local variations measured by a 4.5m straight edge shall not exceed 25 mm for
reinforced soil retaining wall
20.9.14 Testing Of Fill Material

20.9.14.1 General
For the purpose of carrying out tests on fill for reinforced soil retaining walls the Contractor
shall comply with all reasonable requests by the S.O.to afford him access to the site of any
borrow pit. He shall carry out such tests as may from time to time required by the S.O.
Method of test for fill material shall comply with the requirements for testing soils in BS 1377.
20.9.14.2 Testing of Fill for Reinforced Soil

(a) Procedures for testing the effective angle of internal friction shall be as follows:
(i) The undrained constant rate of strain shear box shall be 300mm square with a
depth not less than 150mm. The particle size shall be not greater than 0.125 of
the depth of the sample in the shear box.
(ii) Three samples shall be tested, each sample occupying the full depth of the shear
box and shall be compacted to (92% ± 2%) of the maximum dry density which
shall be determined in accordance with BS 1377 Compaction Test (4.5 kg
rammer method).
(iii) The normal stress shall be equal to the maximum vertical pressure in the fill,
obtained from the design calculations, and shall be applied to the sample which
shall be sheared within one hour of compaction. The rate of shearing shall be not
greater than l.2 mm/minute.
(iv) The peak shear stress, corresponding with a particular normal stress, shall be
obtained from the measurement of the maximum shear value.
(v) The residual shear stress, corresponding to a particular normal stress shall be
obtained from the measurement of the residual shear value.
(vi) The tangent of the effective angle of internal friction of a sample is given by the
ratio of the peak shear stress to the corresponding normal stress. The average of
the three angles so obtained from the three samples shall be reported as the peak
effective angle of internal friction of the fill.
(vii) The tangent of the residual effective angle of internal friction of a sample is
given by the ratio of the residual shear stress (at Constant Volume Condition) to
the corresponding normal stress. The average of the three angles so obtained
from the three samples shall be reported as the residual angle of internal friction
of the fill. Shear stress and normal stress shall be plotted on the vertical and
normal stress shall be plotted on the vertical and horizontal axis respectively.
(b) Procedure for testing the coefficient of friction between the fill and strip reinforcing
elements shall be as for Clause 24.14.2 (a) above except that:
(i) Reinforcing element material shall be cut to fit the interior
plan shape of the shear box. It shall be fixed so that the top face of the material is
flush with the top edge of the lower half of the box and aligned, so that shearing
occurs in a direction parallel to the longitudinal axis of a reinforcing element.
The fill sample shall occupy the top half of the box.
S20 - 45
(ii) For each sample, the ratio of the peak shear stress and the residual shear stress to
the corresponding normal stress shall be recorded. The mean of the six ratios so
obtained from the three samples shall be reported as the peak coefficient of
friction and the residual coefficient of friction between the till and the
reinforcing elements respectively.
(c) Additional information to be recorded for each test:

(i) Normal stress applied kN/m2
(ii) Peak shear stress kN/m2
(iii) strain at peak shear stress %
(iv) Residual shear stress kN/m2
(v) Strain at residual shear stress %
20.9.14.3 Testing of Chloride Content (Reinforced Earth and Deadman Anchor Walls)
Testing of chloride content of the fill shall be carried out in accordance with the requirements
of Clauses 2722 or Specification for Road and Bridge Works, Department of Transport UK,
1976 for fine aggregate except that each test sample referred to in sub-clause 6 of that
Specification shall consist of approximately 1000g of the dry sample.
20.9.14.4 Testing Of Resistivity (Reinforced Earth and Deadman Anchor Walls)

Testing of resistivity of fill shall be in accordance with the four electrode method described in
Clause 402 of BS CP 10 L3 at the site of the cutting or of the proposed borrow pit.
Additionally:
(a) The row of electrodes shall be orientated in a different direction at each location within
the area of the proposed excavation;
(b) The spacing of adjacent electrodes in each row shall be not less than 1.5m and this
spacing shall be increased by increments of approximately 2m, for successive tests. The
maximum spacing shall be equal to the depth to which material is to be excavated;
(c) The fill resistivity for a particular rest shall be obtained from the expression:
f = 200 x a R
where f = Resistivity (ohm-cm)

a = Spacing of adjacent electrodes (metres)
R = Resistance measured (ohms)
20.9.14.5 Testing of Redox Potential (Reinforced Earth and Deadman Anchor Walls)
(a) The redox potential of fill shall be determined at the site of the cutting or of the
proposed borrow pit or the stockpiles by measuring the potential of a platinum electrode
with respect to a saturated calomel reference electrode.
(b) Apparatus
(i) One platinum probe of an approved robust design having two separate platinum
electrodes embedded in the nose-piece;
(ii) One refillable ceramic junction calomel reference probe;
S20 - 46
(iii) One pH/millivoltmeter complete with circuit wiring;
(iv) Three plastic bottles, wide mouthed, screw topped, 500 ml capacity, one
containing 70% alcohol, two containing distilled water;
(v) One rubber stopper having a hole to suit the platinum probe and of outside
diameter to fit the plastic bottles above;
(vi) Small quantity of scouring powder;
(vii) Saturated solution of potassium chloride in screw topped plastic bottle of 500 ml
capacity;
(viii) One 25 ml pipette;
(ix) One plastic bottle, wide mouthed, 250ml fitted rubber stopper having a hole to
suit the reference probe.
(c) Storage
The calomel reference probe shall be cleaned, filled with a saturated solution of
potassium chloride and stored so that the porous plug is immersed in distilled water.
(d) Preparation of Probes For Test

The calomel reference probe shall be filled with a saturated solution of potassium
chloride. The platinum probe electrodes on the nosepiece shall be cleaned using
scouring powder and gentle abrasive action. The nosepiece shall be washed once in
70% alcohol and twice in distilled water.
(e) Method
For each test:
(i) Excavate a hole, not less than 1m square in plan, down to the required depth;
(ii) A sample shall be taken from the base of the excavation for determining pH
value of the fill;
(iii) The probes shall be located 300 mm apart and pushed into contact with the fill at
the base of the excavation;
(iv) The electrical circuit shall be completed, connecting one of the electrodes of the
platinum probe and the reference probe to the position and negative terminals of
the millivoltmeter respectively. If no reading can be obtained the leads shall be
reversed; the subsequent readings being treated as negative values;
(v) Each platinum electrode shall be included in the circuit separately; readings
being recorded immediately after the platinum probe have been rotated through
one revolution under firm hand pressure. The two electrode readings shall be
discarded when they differ by more than 10mV and the electrodes shall be
cleaned;
(f) The mean of two acceptable readings shall be obtained from the expression:
E = Ep + 250 + 60 (pH - 7)
where E = Redox potential (mV)

Ep = Potential of the platinum probe (mV)
pH = Value of the acidity of an aqueous solution of fill
S20 - 47
20.9.15 Galvanization Tests for Reinforcing Elements (Reinforced and Deadman Anchor Walls)
Galvanization tests to be carried out in accordance to BS 729 Part 1:1971 includes the
following:
(a) Stripping Test to determine the weight of coating given in Appendix A, BS 729.
The coating weight shall comply with the minimum values quoted in Table 1, BS 728.
(b) Copper Sulphate (Preece) Dip Test for the uniformity of coating given in Appendix B,
BS 729.
The coating shall withstand four one-minute dips in the standard copper sulphate
solution without the formation of an adherent red spot of metallic copper upon the base
metal.
20.9.16 Pull Out Tests for Reinforcing Elements

The Contractor shall carry out pull out tests on selected reinforcing elements to be determined
on site by the S.O.
The Contractor shall measure accurately the applied tensile loads and the corresponding
deflection of the strip.
The Contractor shall submit test details for the approval of the S.O.
20.10 RUBBLE MASONRY WALL

20.10.1 Description
This work shall consist of the construction in rubble masonry of minor structures such as
culvert headwalls, retaining walls, drop Inlets, toe wall, apron scour protection, etc. in
accordance with this Specification and details shown on the Drawings or as directed by the
S.O.
20.10.2 Materials
Stone for rubble masonry shall consist of field stone or rough uneven quarry stone. The stone
shall be dense, resistant to the action of air and water and suitable in all other respects for the
purpose intended.
The stones shall, in general, have their largest faces parallel. The maximum thickness of the
stone shall in no case exceed the thickness of the wall or portion of the structure into which it
is being built. The median size of the stone shall be not less than 200 mm, unless otherwise
indicated in the Drawings.
Mortar shall be composed of one part of cement and two parts of sand by dry loose volume and
sufficient water to make mortar that can be easily handled and trowelled. Re-tempering of
mortar that has been mixed for period of 30 minutes or longer shall not be permitted.
20.10.3 Construction Methods

Rubble masonry shall comprise hard, clean fragments of natural stone complying with
Specification Clause 20.4.2 bonded with cement and sand mortar to form a dense homogenous
mass. The sizes and shapes of the individual stone fragments or stones shall be chosen so that
the gaps formed between adjacent stones as finally placed can be properly filled with mortar.
Stone located at external faces of walls shall be all of similar sizes with the average dimension
of the exposed face of each stone not less than 200 mm for mortared stone masonry retaining
walls. All points on the external faces of walls shall be in their designated positions within a
S20 - 48
tolerance of minus 0 plus 150 mm measured outside the limits of the walls. Exposed stone
faces shall be free of surplus mortar with all mortared joints neatly finish.
At the time of positioning and mortaring, all stones shall be cleaned of all soil or material
which would otherwise reduce the bond between the stone faces and the mortar. Mortared
stone walls shall be constructed in vertical lifts of approximately uniform thickness across the
width of the wall. A blanket of mortar shall be placed in stages over each lift so that when
stones in the succeeding lift are placed, all gaps between the lifts are completely filled with
mortar. As stones are placed, or on completion of each lift, mortar shall be worked into place in
the gaps between adjacent stones so that at least 75 per cent of the volume of each void formed
between adjacent stone is filled with mortar.
20.11 HORIZONTAL DRAIN

20.11.1 General
This work specification for horizontal drain shall cover all the necessary resources for
fabricating and installing horizontal drain to the details as shown in the Drawings or as
directed by the S.O. The drains shall consist of a Polyvinyl Chloride (PVC) pipe wrapped in a
suitable filter cloth inserted into a drill hole.
20.11.2 Setting Out

Setting out shall be as shown in the Drawings or as directed by the S.O. Before drilling or
installation of horizontal drain, the drain position shall be marked with suitable identifiable
pegs or markers on the ground for necessary inspection by the S.O. The maximum allowable
deviation for drill hole shall not exceed 150mm in any direction.
20.11.3 Materials
20.11.3.1 Polyvinyl Chloride (PVC) Pipes Technical Properties
The horizontal drain shall be of Polyvinyl Chloride (PVC) pipe of in accordance with the
specification of MS 628: Part 1, 2 and 3. Classification of PVC pipe shall meet or exceed the
minimum values specified in the Drawings.
20.11.3.2 Perforations of PVC Pipe

Perforations consist of two rows of slots on 120-degree centres cut around the circumference
of the pipe. A special type of cutter or disc cutter shall be used to cut slots in the PVC pipes.
Unless otherwise shown in the Drawings, or directed by the S.O., make each slot 5mm wide
and 100 mm length with a minimum of 5000 square mm of slot opening per linear meter of
slotted pipe.
The slotted perimeter of the pipe shall be positioned at the top to allow inflow of underground
water into the pipe and the uncut section of the pipe shall be laid at the bottom to drain the
water out from the hole.
20.11.3.3 Filter Cloth Technical Properties

The synthetic filter cloth shall be a non-woven type of approved manufacture having the
following properties:-
(a) Chemical Composition Requirements – Fibres used in the manufacture of the

engineering fabric shall consists of chemically inert polymer polypropylene or polyster
with anti-oxidant additives and stabiliser to resist temporary exposure to ultra-violet
light and to minimise heat absorption from exposure to sunlight during preparation and
installation process.
S20 - 49
(b) Physical Property Requirement – The physical properties in term of mass per unit area
shall comply or exceed the minimum values specified in the Drawings.
(c) Filtration Requirement – Equivalent opening size of the filter cloth shall be two or three
times greater than the D85 size of the surrounding soil or as specified in the Drawings.
(d) Permeability Requirement – The permeability of the filter cloth shall be greater than ten
times the permeability of the soil to be drained or as specified in the Drawings.
20.11.4 Product Quality Assurance PVC Pipe and Filter Cloth

The contractor shall submit certificate of approval from the manufacturer to confirm that their
manufacturing factory production and management system of both the PVC pipe and filter
cloth are certified to be operating under quality management system consistent with at least the
quality standard BS EN ISO 9002:2000 or equivalent. Prior to the procurement of materials,
the contractor shall provide manufacturer‟s certificate of Independent Test Report (ITR),
showing full compliance of both PVC pipe and filter cloth to all the above properties, for the
approval of the S.O. The independent tests shall be carried out at reputable institutions or other
accredited independent laboratories. All tests shall be carried out in accordance with the
Standard Code of Practice.
Consignment Certificate – For the purpose of ascertaining that each consignment of PVC pipe
and filter cloth supplied to site is of the approved type and quality from the same manufacturer
and batch as indicated, the contractor must furnish with every consignment, an original
consignment certificate from the manufacturer giving the following information:
(a) Name and address of the manufacturer
(b) Contact telephone/fax/email address of the manufacturer
(c) Consignment certificate reference number and date
(d) Title of the contract and name of the project owner
(e) Name and address of the purchaser
(f) Product types and quantities, corresponding to each consignment
20.11.5 Handling and Storage

The PVC pipe and filter cloth shall be supplied with the manufacturer‟s label/logo on each roll
showing the following identification:-
(a) Product brand name
(b) Product type
(c) Panel diameter and length
(d) Batch serial number

The PVC pipe and filter cloth shall be supplied in panels, labelled and wrapped in packaging
materials to protect against water and photo-degradation by ultraviolet light.
S20 - 50
The contractor shall ensure that the PVC pipe and filter cloth is properly stored in a covered
area at the worksite. If no covered area is available, the PVC pipe and filter cloth may be
stored on raised platform and covered with a waterproof canvas.
The contractor is solely responsible for the good condition of the PVC pipe and filter cloth
stored at the worksite and in the event of damages or deteriorations of the PVC pipe and filter
cloth due to improper storage, he shall be liable to replace the affected materials at his own
cost when directed to do so by the S.O.
20.11.6 Installation
The location of the drains shall not vary by more than 6 inches (152.4mm) from the locations
indicated on the Drawings or as directed by the S.O.
Drains that are out of their proper location by more than 6 inches (152.4mm) or drains that are
damages in construction, or drains that are improperly completed shall be rejected by the S.O,
and no compensation will be allowed for any materials furnished or for any work performed
on such drains.
The contractor shall provide the S.O. with suitable means of making a linear determination of
the quantity of drain material used.
20.11.6.1 Drilling
The contractor shall deploy suitable drilling equipment plus skilled operator and supervisor
that have adequate capacity and experience to produce the drill hole according to the size,
length and accuracy as shown in the Drawings and as specified in this specification.
The position of each horizontal drain shall be marked and pegged clearly on the ground/slope
before the commencement of drilling works. If necessary, survey equipment shall be used to
locate the position of horizontal drains.
The temporary drilling platform shall be erected firmly on the ground/slope, such that no
excessive movements or sway occurs during drilling. The drain holes shall be drilled at an
inclined angle into the ground/slope. The minimum angle of inclination shall be at least 2.5
degrees upwards.
Dry rotary drill, auger or down-the-hole hammer shall be used. Suitable drill bit slightly larger
that PVC pipe shall also be used. In ground likely to collapse, the drilled shaft shall be
protected by suitable temporary casing. Drill holes shall be flushed clean on completion of
drilling and the opening protected or sealed to prevent the entry of any foreign matter.
Drilling for the whole design length of horizontal drain shall be carried out uninterrupted and
completed with necessary hole cleansing within one hour. To ensure effective cleansing of the
drill holes, an additional drilled length of about 0.3m to the design length shall be provided so
that cleansing of cutting and debris towards the bottom of the drill holes by the compressed air
through the drill rods can be effectively and eventually carried out. All drill rods shall be
properly jointed without leakage.
20.11.6.2 Pipe Installation

Splice or connection of PVC pipe shall be done in a workmanlike manner and so as to ensure
continuity. Where joints are required between the pipes, the smaller end of one pipe shall be
slotted into the bigger end of the other and securely bonded with a bonding material
recommended by the pipe manufacturer. Slotted PVC pipe shall then be tightly wrapped in
filter cloth such that the entire length of the pipe is covered by the cloth, inclusive the inner
end of the pipe. All joints of the cloth shall have an overlap of at least 100mm. Install the
perforated plastic pipe in the drilled hole with the perforations on top.
S20 - 51
20.11.6.3 Horizontal Drain beside Soil Nail/Ground Anchor/Rock Bolt
In the area where horizontal drains are to be installed together with soil nail/ground
anchor/rock bolts, the installation of soil nail/ground anchors/rock bolts shall be completed
first before the commencement of horizontal drains.
20.11.6.4 Concrete Lined Chutes

Where necessary or specify in the Drawings, provide concrete (Grade 20) lines chute with
minimum thickness of 75mm to drain the water from the mouth of the horizontal drain to the
nearby drain .
20.11.7 Submittals
The contractor shall keep records for each horizontal drain installation and shall submit one
signed copy to the S.O. not later that noon of the next working day after the horizontal drains
have been installed. The record for each horizontal drain shall include horizontal drain
reference number, date/time of manufacturer and completion of drilling and inserting of pipe,
names of supervisor and operators, plus the necessary drilling details. Drilling records shall
include:-
(a) Description of drilling debris returns
(b) Observed exceptions and peculiarities
(c) Size, length and class of PVC pipe
(d) Type of filter cloth
(e) Drilled hole diameter and total drilled length
(f) Time of start and completion of drilling
20.12 SOIL NAILING

20.12.1 Scope
This section contains requirement which, where relevant to this contract, shall apply to soil nail
installation works including all associated slope stabilization works such as guniting, dowels
etc.
This specification is intended to be a step by step sequential ordering of all the operations
entailed in the manufacture, drilling, installation, grouting and stressing of the soil nail and
construction of gunite.
20.12.2 Reference Standard

Unless otherwise specified, rock bolts and soil nails installation works shall comply with the
following Reference Standards.
BS 4 Hot rolled steel sections

BS 916 Black bolts, screw and nuts.
BS 2994 Cold rolled steel sections
BS 3643 ISO metric screw threads
BS 4360 Weldable structural steels
BS 4848 Hot rolled steel sections
BS 4449 Hot rolled steel bars for the reinforcement of concrete.
BS 8081 Ground Anchorages
S20 - 52
BS 4483 BRC mesh and reinforcing fabric
20.12.3 Method of Construction

The Contractor shall submit to the S.O. at least 21 days before he proposes to commence slope
stabilization works details of his proposed method of slope support measures, including:
(a) The position and location of the slope protection measures
(b) The equipment for excavation and spoil removal
(c) Method of temporary support and temporary staging
(d) Method of working acceptance test and suitability test of slope reinforcement e.g. soil
nails
(e) Construction of gunite including placement of reinforcing fabric.
(f) Safety measures for slope stabilization works
Agreement by the S.O. with the proposed method of construction shall not relieve the
Contractor's obligation under the Contract.
20.12.4 Material Certification

The Contractor shall submit manufacturers and suppliers certificates of compliance with the
relevant standards. He shall also submit welders test certificates.
The Contractor shall provide test certificates for the steel members and grout material relevant
to the construction and slope stabilization.
20.12.5 Workmanship Responsibility

The Contractor shall be responsible for all methods of working on the slope, including the
design, provision and erection of all things necessary to safeguard the works and workmen. In
particularly, the Contractor shall be responsible for the support of all excavation and slope
during construction, which shall include making good after falls.
All procedures necessary to safeguard the works and workmen, except for any emergency
measures that may have to be taken by the Contractor to ensure safety, shall be subject to prior
approval to the S.O., but such approval shall not relieve the Contractor of any of his
responsibilities.
This specification is intended to be a step by step sequential ordering of all the operations
entailed in the manufacture, installation, grouting and stressing of the soil nail.
20.12.6 Reinforcement
The effective reinforcement for a soil nail comprises of one number yield steel bar produced by
local mill conforming the relevant standard. All outer bars are to be cleaned and free from
rust. Steel bars shall come in full length of 12.0 m. Centralizers shall be provided at specified
interval. When splicing of steel bar is required, it shall be in general accordance to the S.O.'s
Specification. When welding is required, only low hydrogen welding electrode shall be used
conforming to E7018.
Full length of reinforcement complete with centralizers shall be inserted into the drill hole
immediately after drill hole is flushed clean. The protruding end of the re-bar shall be threaded
to receive the bearing plate assembly and in specified length.
S20 - 53
20.12.7 Slope Trimming
Localized uneven slope profile shall be trimmed with "cangkul" where necessary. To prevent
excessive disturbance to the existing slope, large-scale slope trimming is prohibited.
20.12.8 Temporary Staging

All drilling machines and equipment shall work on a temporary platform fabricated at site with
GI pipes. Sufficient bracing, strutting and tie back shall be fixed to ensure that the staging is
rigid and firm.
20.12.9 Drilling
100 mm diameter nominal (or as shown on the Drawings) of drill holes are to be drilled at the
correct locations with rotary augering machine to the required design length. Drilling shall be
of dry method rotary. Temporary steel casing is to be used when necessary where the drill hole
is likely to collapse. Rotary percussion drilling shall be used when boulder is encountered.
Drill holes are to be flushed as clean as possible during drilling with air.
20.12.10 Grouting
Grouting shall be carried out without unnecessary delay. The grout is to be mixed for
approximately two minutes in a high speed mixer and then pumped into the drill hole by tremie
method though either a PVC or steel pipe inserted into the bottom of the drill hole until it is
full.
Grouting is to be continued until neat cement grout flows out from the drill hole. The pumping
of grout shall be continued while the tremie pipe is withdrawn to prevent formation of cavities
in the grout. If temporary casing is used, the casing shall be removed by either jacking or
rotating immediately after grouting is completed. During and after removal of casing, the
grout column is to be topped up where necessary. Unless otherwise specified, the grout mix
shall consist of w/c ratio of 0.5 by weight. The characteristic strength of the grout at 28 days
shall be 25 N/sq. mm.
20.12.11 Construction of Gunite

Gunite with weepholes, reinforcement and thickness that in accordance with Drawings shall be
constructed after grouting of all soil nails has completed. All soil nail‟s head shall be covered
to ensure that the nails are free from the gunite structure.
20.12.12 Corrosion Protection of Soil Nail Head and Steel Plate

Steel bearing plate, locknuts and other exposed metal parts and in contact with the ground shall
be treated to prevent corrosion. Firstly, a layer of red oxide undercoat shall be applied after all
dirt and loose dusts are removed from all metal surfaces by wirebrushing. Before installation
of the steel plate and soil nail head, a layer of coal tar epoxy paint Jotaguard 85 or equivalent
shall be applied, followed by spraying the metal parts with a layer of bitumen.
20.12.13 Fitting of Soil Nail Head

During the period of gunite curing, local trimming and roughening of the gunite surface to seat
the concrete seating pad squarely to the soil nail shall be carried out. The bearing plate/pad
shall be fixed onto the seating pad perpendicular to the soil nail after the seating pad formwork
is removed and grout has gained sufficient strength (about 3 days after grouting).
20.12.14 Soil Nail Stressing

Stressing of soil nail shall commence after a minimum of 5 days after grouting. Stressing shall
be executed by using a suitable torque wrench to fasten the locknut to the required level.
Bearing plates shall be installed perpendicular to the soil nail.
S20 - 54
20.13 GUNITING
20.13.1 General
(a) The Contractor as instructed shall carry out guniting of specified thick including
provision of materials, dowels, reinforcing fabric or BRC and concrete spacer on the
slope surface as shown in the Drawings.
(b) Gunite is defined as concrete or mortar pneumatically applied at high velocity on to a

surface.
20.13.2 Materials
(a) The cement for gunite shall conform to the requirements of BS 12. All aggregates shall
be cleaned, hard, strong, durable and free from clay, organic or other impurities.
(b) The fine aggregate for gunite shall be cleaned, natural, sharp fresh-water river sand free
from clay and any other impurities and well graded from 5mm sieve down to No. 100
BS sieve.
(c) The coarse aggregate for gunite shall comply with BS 882, 1201 and 1193-1200.
(d) Reinforcing fabric or BRC mesh shall be hard-drawn steel wire reinforcing fabric with a
wire diameter of 4.0mm and pitch of 200mm in each direction complying with the
requirements of BS 4483:1983.
(e) Admixtures as approved by the S.O. shall be added in accordance with manufacturer‟s
recommendation.
(f) Dowels of length and size specified in the Drawings shall be of deformed high yield
steel complying with BS 4449 requirements.
20.13.3 Proportioning
(a) The gunite shall have a minimum cement content of 330 kgs. per cubic meter as
discharged from the nozzle, a minimum water-cement ratio of 0.4 by mass, and shall
have a minimum compressive strength of 30 MPa at 28 days when tested by means of
100mm diameter cores taken from in-place gunite or from test panels. The cores shall
be prepared and tested for compressive strength in accordance to BS 1881, Part
120:1983.
(b) The relative proportions of fine aggregate, coarse aggregate, cement and the moisture
content of the ingredient when mixed shall be proposed by Contractor and to submit for
approval by the S.O. The fine and coarse aggregates shall be thoroughly mixed in an
approved mixer and fed with the cement at the correct rate to achieve the required
proportions and shall enter the gunite machine in such a way as to achieve proper
mixing.
(c) Mixed dry aggregates and cement which are not placed within 30 minutes after mixing
shall be discarded. Payment will not be made for such discarded materials.
20.13.4 Equipment and Workmanship

(a) Not less than 30 days prior to applying any gunite, the Contractor shall submit for
approval Drawings showing his proposed plant arrangement together with a general
description of the equipment he proposed to use, the methods of operation and the 3 mix
proportions for testing. Mixing of ingredients by hand will not be allowed.
S20 - 55
(b) The Contractor shall prepare test panel in the presence of the S.O. for each mix
proportion to be used. The test panels shall be made by applying at least 150mm in
thickness of gunite to a hardboard panel approximately 800mm square. The gunite shall
be applied to the panels in the same manner, using material including reinforcing fabrics
where applicable, equipment and pressures that will be used in the works and shall be
cured in accordance with Section 9: Concrete. The panels shall be submitted to the S.O.
for examination and for test in sufficient time to obtain and test the cores.
(c) No gunite shall be applied to the works until the quality of workmanship and the
compressive strength of the gunite as determined from the test panels meets the
specified requirements.
(d) The Contractor shall employ only skilled nozzlemen and before being permitted to
perform any production application of gunite, each nozzleman shall demonstrate to the
S.O. his ability to apply gunite to the required standard, including the required water-
cement ratio.
(e) Air and water shall be provided in sufficient volume and under such pressure as may be
necessary for the best operating conditions. In applying the gunite, the discharge nozzle
shall be held so that the stream of the material shall impinge as nearly as possible at the
optimum angle to the surface for minimum rebound, and the velocity of discharge from
the nozzle, the distance of the nozzle from the surface and the amount of water used in
the mix and shall be regulated so as to produce a coating with a minimum rebound of
the material and no sagging. Obstructions such as service lines shall be removed to
enable direct application of gunite to the surfaces. Rebound material shall not be used
again shall be removed from the work and disposed off by the Contractor as part of the
work.
(f) During the application of gunite, the Contractor shall provide adequate ventilation
facilities and take such other measures as are necessary for the safety of his workman,
including provision of face protection for nozzlemen.
20.13.5 Preparation
(a) The location where gunite is to be used will be as shown in Drawings.
(b) Wherever gunite is required the Contractor shall clean and prepare the surfaces to
receive the coating. Loose or shattered rock, rock debris, loose concrete soil or other
loose material shall be removed from the surfaces. Material in clay seams shall be cut
back to a depth as directed to provide a key. After the loose material has been removed,
the surface shall be washed where required with a strong air-water jet or by other
approved means.
(c) The reinforcing fabric or BRC mesh shall be set on slope surface using cement-sand
spacer block and shall not touch the ground surface. The fabric or BRC mesh shall be
fixed to the ground using dowels spaced at both directions at distance as shown in the
Drawings.
(d) Dowels shall be fixed to the ground using cement grout. The drill holes for the dowels
shall not less than 50mm diameter. The grout with dowels in it shall gain a sufficient
strength before application of gunite.
20.13.6 Application
(a) Gunite shall only be applied in the presence of the S.O. and shall be built up in
successive layers, each layer generally not exceeding 50mm in thickness, such that
sagging and bleeding does not occur. Care shall be taken to ensure that cavities
resulting from cutting back to clay seams, as described in sub-clauses (5) of this Clause
are completely backfilled with gunite. Where reinforcing fabric support is used, the
mortar shall cover the fabric to a depth of at least 30mm.
S20 - 56
(b) All rebound and other loose material shall be removed by air jets or other suitable
means from the surface of each layer as work proceeds.
(c) During the application of gunite, any water flowing over or seeping through the surface
to which the gunite is to be applied, shall be diverted by the use of panning, pipes, felt
strips or other approved means. Where directed, formed holes or pipe outlets shall be
provided in the coating to relieve water pressure on the coating.
(d) Gunite shall be not be applied to an area until all blasting within 50 M of the area has
been completed, unless otherwise approved or directed by the S.O.
20.13.7 Curing
All gunite shall be cured with water and shall be cured continuously for at least 7 days
immediately following placement. Natural curing may be allowed if atmospheric conditions
surrounding the gunite are satisfactorily, such as when the relative humidity is at or above 85
percent.
20.13.8 Safety of Works

The application of gunite as temporary or permanent, support shall not be considered as
relieving the Contractor of his responsibility to maintain portions of Works in a safe condition.
20.13.9 Testing and Repairs

The Contractor shall take 100mm diameter test cores from in-place gunite at locations as
directed by the S.O. Cores shall be drilled though the full thickness of gunite at the rate of one
suitable core from every 200 sq.m of completed gunite. The S.O. will test cores for compliance
with the Specification. The drill holes shall be backfilled with our approved dry-pack mortar.
20.14 STONE PITCHING SLOPE

20.14.1 Description
This work shall consist of the construction of all structures or parts of structures to be
composed of cement mortared stone pitching as shown in the Drawings or as directed by the
S.O. for slope erosion protection. The work shall be carried out all in accordance with this
Specification and details shown on the Drawings or as directed by the S.O.
20.14.2 Materials
20.14.2.1 Stone
Stone shall be clean rough quarry stone, or pit or river cobbles, or a mixture of any of these
materials, and shall be essentially free from dust, clay, vegetative matter and other deleterious
materials. Individual pieces of stone shall be approximately cubical or spherical. The
maximum thickness of the stone shall in no case exceed the thickness of the wall or portion of
the structure into which it is being built. The size of the stone shall be > 100 mm and <
200mm, unless otherwise indicated in the Drawings. The stone shall be hard, tough, durable
and dense, resistant to the action of air and water, and suitable in all respects for the purpose
intended.
20.14.2.2 Cement Mortar

Mortar shall be composed of one part of cement and three parts of sand by dry loose volume
and sufficient water to make mortar that can be easily handled and trowelled. The constituent
materials of the mortar shall comply with the appropriate requirements of Section 9 of this
Specification.
S20 - 57
The ingredients for mortar shall be measured in proper gauge boxes and mixed on a clean-
boarded platform or in an approved mechanical batch mixer.
All mortar shall be used within 30 minutes of mixing and no reworking of mortar shall be
permitted thereafter.
20.14.2.3 Draining Material behind Stone Pitching Slope

The draining material behind the stone pitching slope shall comply with the grading limits for
free draining material given in the Specification for Earthworks.
20.14.3 Construction Methods

Prior to constructing mortared stone pitching, the surfaces against which it is to be placed shall
have been finished in accordance with the appropriate provisions of this Specification.
Notwithstanding any earlier approval of these finished surfaces, any damage to or deterioration
of them shall be made good to the satisfaction of the S.O. before mortared stone pitching is
placed.
Construction of mortared stone pitching shall commence at the lowest part of each structure or
section of a structure and continue progressively upward. Long structures of slope surface
protection shall be constructed in section of practicable length, to the satisfaction of the S.O.
The surface against which the work is to be placed shall be moistened with clean water little in
advance of construction, and covered with a layer of cement mortar about 50 mm thick. Stones
shall then be firmly set by hand into the mortar, densely packed against adjacent stones and
built up to form a stone structure of more or less uniform thickness which shall nowhere be
less than 300 mm (measured perpendicularly to the surface covered). All the while that stones
are being placed, all voids in the structure shall be packed solidly with mortar and stone spalls;
however the surfaces of stones in the exposed faces and edges shall not be covered with
mortar. The exposed surfaces and edges of the structure shall be constructed such that they
have as large a proportion as practicable composed of stone faces. Weep holes shall be
provided as shown on the Drawings or as directed by the S.O.
Mortar which has been mixed for more than 30 minutes shall not be used in the works. Nor
shall mortar be laid against the supporting surface more than 2 minutes before pitching stone
and building up the structure to full thickness is commenced on any section of the work, as the
construction advances.
The work shall be carried out and finished all to the satisfaction of the S.O.
20.15 GEOCELL
20.15.1 Scope
This specification covers the general and technical requirements for the supply and installation
of Cellular Retention System as described herein. All materials used and the works shall meet
the requirements of this specification and details shown on the contract drawings.
20.15.2 Contractor to Provide

plants/equipment to execute and complete the works related to supply and laying of Cellular
Retention System as shown on the drawings.
20.15.3 Setting-Out
Cellular Retention System is to be placed and for the correctness of the lines, widths, levels
and slopes as shown on the contract drawings.
S20 - 58
20.15.4 Locally Produced Products
The Cellular Retention System to be used in this contract shall be fully of Malaysian
origin unless otherwise approved by the designer. The Cellular Retention System shall be
produced by local factory with ISO certification and equipped with testing laborato ry,
where sampling and testing can be readily carried out.

The Cellular Retention System shall be supplied with Manufacturer‟s Label/Logo on each
roll showing the following identifications:
(a) Product Brand Name

(b) Product Type Panel
(c) Width and Length
(d) Batch Serial Number

The Cellular Retention System shall be supplied in panels, labelled and wrapped in packaging
materials to protect against water and photo-degradation by ultraviolet light.

The Contractor shall ensure that the Cellular Retention System is properly stored in a covered
area at the worksite. If no covered area is available, the Cellular Retention System may be
stored on raised platform and covered with a waterproof canvas.
The Contractor is solely responsible for the good condition of the Cellular Retention System
stored at the worksite and in the event of damages or deteriorations of the Cellular Retention
System due to improper storage, he shall be liable to replace the affected materials at his own
cost when directed to do so by the S.O.
20.15.6 Testing
20.15.6.1 General
Cellular Retention System to all the above-specified property values corresponding to their
respective test methods, for the approval of the S.O.
SIRIM, IKRAM, UTM, UKM, UPM, UM or other accredited independent laboratories
Routine sample testing, when required and specified, shall be carried out at factory or at
independent laboratory witnessed by the S.O.'s representative. The Contractor shall submit test
such as listed above or an accredited laboratory approved by the S.O.

For the purpose of ascertaining that each consignment of Cellular Retention System supplied to
site is of the approved type and quality and are fully from the same Manufacturer and batch as
S20 - 59
indicated, the contractor must furnish with every consignment, an original Consignment
Certificate from the Manufacturer giving the following information:-
(a) Name and Address of the Manufacturer

(b) Contact telephone/fax/email address of the Manufacturer
(c) Consignment Certificate Reference Number and Date
(d) Title of the Contract and Name of Project Owner
(e) Name and Address of the Purchaser
(f) Name Types and Qualities, corresponding to each consignment
20.15.7 Material Properties

20.15.7.1 Product and Applications
The cellular retention system is a flexible three-dimensional mattress and shall be made from
high-density polyethylene (HDPE) strips, which are ultrasonically bonded to form multiple
cellular openings.
The structure provides lateral confinement of the infill materials. The enhanced system works
on the principle of friction between the infill materials and the cell walls as well as the lateral
confinement forces generated by the applied load thus minimising deformation and
subsequently improving the stability of the overall structure. The newly filled structure acts to
redistribute the load, sustain the erosive forces to protect the underlying soil layers and
reinforce the fill materials. When the Cellular Retention System is applied with suitable infill
materials, it offers cost-effective solutions to the following applications:
(a) Load Support

- by improving the bearing capacity of the sub-grade
(b) Slope Protection

- by providing a cost-effective slope protection solution where vegetation growth is
difficult or impossible such as in the case of acidic soils or rocky edges, etc.
(c) Earth Retention

- by providing confined stiffness with its cellular structure
(d) Channel and Pond Bank Protection

- by enhancing vegetation growth, providing confined support and preventing the
downward migration of soil particles
20.15.7.2 Technical Properties

The properties of the Cellular Retention System shall meet or exceed the minimum values
corresponding to the respectively test methods as shown in Tables 20.18a and Tables 20.18b
below:
Table 20.18a: General Properties of Cellular Retention System
Physical Properties Test Standard Test Value / Data

Base Polymer - HDPE
Polymer Density ASTM D1505 0.938 – 0.960 g/cc
Colour - Black
Carbon Black Content ASTM D1603 1.3% - 2%
Env. Stress Crack Resistance ASTM D1693 > 2000 hr.
Wall Thickness ASTM D5199 > 1.30 mm
S20 - 60
Table 20.18b: General Properties of Cellular Retention System
Type
Property Units
K4 K6 K8
Cell Height, H mm 100 150 200
Minimum Cell Seam Peel
N 1450 2140 2850
Strength
Dimension: Expended Piece
Width m 2.2 2.4 2.8
Length m 3.05, 6.1 or as specified
Dimension: Expended Cell
Width mm 203 203 203
Length mm 244 244 244
Area mm2 248 248 248
20.15.8 Installation
20.15.8.1 General
Installation of Cellular Retention System shall be carried out by qualified and experienced
workers under the supervision of a qualified engineer.
20.15.8.2 Installation of Cellular Retention System

The Cellular Retention System shall be installed in accordance with the Manufacturer‟s
instructions. This also includes the earthworks preparation before the installation of the
Cellular Retention System. All jointing and anchorage dowels shall be constructed according
to Manufacturer‟s instructions.
20.15.8.3 Infill Material Placement
Suitable infill materials shall be specified on contract drawing or shall consist of one of the
following:
(a) Well graded aggregates with maximum size not exceeding 50mm
(b) Fertilised soil
(c) Concrete Grade 25
The infill materials shall be well compacted within the cells, in accordance with the
requirements of the Works Specification and the Manufacturer's instructions as shown on the
contract drawing.
20.16 ROCK STABILIZATION WORKS

20.16.1 General
(a) Rock stabilization works on final excavated rock slopes shall include, but shall not be
limited to: breaking up and removing loose or overhanging rocks, supporting loose rocks
with dowels or bolts, providing masonry infill, buttresses or reinforced concrete supports,
securing loose areas with sprayed concrete (reinforced with mesh or plain), infilling joints
S20 - 61
with mortar, removing soft material and backfilling with concrete and providing adequate
drainage measures. Typical details of these items are shown in the Drawings.
(b) No blasting is permitted for the works under this Clause unless approved by the S.O.
(c) If, in the S.O.'s opinion, the rock stabilization works are required solely as a result of the
Contractor's standard of workmanship (for example poorly aligned pre-split drill holes) the
Contractor shall bear the cost of such stabilization measures as are required by the S.O.
(d) The S.O. will inform the Contractor of the extent and nature of rock stabilization work
required for any slope, or portion of slope, within two weeks of access being provided to
that slope or portion of slope. The S.O. will also inform the Contractor which of these
items, if any, he considers to be necessary as a result of the Contractor's standard of
workmanship.
20.16.2 Access to Rock Slopes

(a) The Contractor shall, where ordered by the S.O., provide access to the rock slopes for the
S.O. Access shall consist of a rigid temporary structure that will allow the S.O. to safely
examine all parts of the rock slope.
(b) Where the slope stabilization details include the removal of rock or other materials the S.O.
may wish to carry out an additional inspection of the area of the slope from which rock or
other materials has been removed. If required by the S.O., the Contractor shall re-erect or
repairs the access to allow the additional inspection to take place.
(c) The Contractor shall make due allowance in his programming for the time required to erect
and maintain access to rock slopes.
20.16.3 Removal of Unstable Rock Mass

(a) Where directed by the S.O., the Contractor shall remove potentially unstable rock masses
by line drilling, expansive grouts, rock breakers or other means acceptable to the S.O.
(b) Such removal shall be carried out carefully so as to prevent boulders, rock fragments or
other materials from falling down the slope. Removal shall also be carried out in such a
manner as to prevent damage to other parts of the ground surface, slope drainage channels
or pipes, road surfaces, fencing and any other temporary or permanent works.
20.16.4 Preparation of Rock Surfaces

(a) Rock slopes to be in contact with buttresses, reinforced concrete pads or other concrete
work shall be wire brushed, scraped or otherwise cleaned in order to remove vegetation and
loose material.
(b) Where ordered by the S.O., the Contractor shall remove all vegetation from joints and the
joints shall be sealed with a 1:2 cement/sand mortar.
20.16.5 Sprayed Concrete

(a) The plant used for sprayed concrete shall be of the dry mix delivery type with water added
at the nozzle and shall be equipped with weigh-batching facilities. Only skilled operators
experienced in the use of sprayed concrete shall be employed as nozzlemen. The
Contractor shall submit the names and details of the experience of the operators who will
be employed on the Works for approval by the S.O. not later than two weeks prior to the
commencement of sprayed concrete works.
(b) Before sprayed concrete is used, the Contractor shall submit his mix design for approval
and shall demonstrate the process that he will use by spraying trial panels to establish the
S20 - 62
suitability of the plant, the materials and the operators to be used. The trial panels should
consist of two types:
(i) A trial panel of 40mm thick spray not less than 3000mm x 3000mm located within
the Site as directed by the S.O.
(ii) A 1000mm x 1000mm x 100mm thick test panel sprayed at the same time and
cured in accordance with Sub-clause 9(ix).
Cores cut from trial panels shall be used to determine the density that can be achieved and
the tolerance within which the density can be maintained. Tests shall be made to determine
the average percentage of rebound for concrete of various thicknesses. The results of the
rebound tests shall be used in calculations of the cement content of the applied concrete.
The Contractor shall provide two copies of the copies of the results of all tests to the S.O.
Once the trial panels have been approved, the Contractor shall not alter the mix or means of
application without the S.O.'s written consent.
(c) Sprayed concrete shall be applied in layers not exceeding 40mm thick. The Contractor shall
put forward his proposals for achieving the required thickness to the S.O. for approval.
(d) All materials used shall comply with and shall be stored tested and used in accordance with
the provisions of the relevant Clauses in the Specification. The Contractor shall ensure that
a sufficient supply of material of uniform quality corresponding to the samples submitted is
available.
(e) The moisture content of the mix before use shall not exceed 10%, the remaining water
being added at the instant of application. The air and water supply, the rate of application
and all other factors affecting the quality of the work shall be adjusted by the operator so as
to produce dense concrete with no sloughing. No mix shall be used more than two hours
after any water has been added to it. Rebound material shall not be reused and, when so
required by the S.O., shall be removed within 8 hours of spraying.
(f) The rock slope or any previously sprayed concrete surface shall be cleaned down with an
air jet before being sprayed with concrete. Surplus water shall be removed by air jet and if
any water is flowing from or across the rock or existing sprayed concrete and is liable to
reduce the adhesion of the concrete it shall be diverted by the pipes, hoses or other
approved means before spraying starts. Where ordered or approved by the S.O., weep holes
shall be formed, or pipes and hoses built in to relieve water pressure behind the concrete
and to divert the water from the face.
(g) 50mm diameter weepholes shall be formed with PVC pipes at 1.2 metre centres in each
direction or otherwise as directed by the S.O.
(h) A record shall be kept of the quantities of all material used at each slope and shall be
submitted daily to the S.O.
(i) Immediately after application and for 3 days thereafter, sprayed concrete shall be protected
from the effects of weather, either
(i) after thorough wetting, by completely covering with approved waterproof paper or
plastic membrane maintained in contact with the concrete; or
(ii) by completely covering the concrete with layer of hessian, sacking, canvas or
similar absorbent material kept constantly wet.
(iii) The strength of the applied concrete shall be determined by crushing 100mm
diameter cores cut from 100mm thick test panels sprayed at the same time and
cured in the same manner as the in-situ concrete. Moulds for unreinforced test
panels shall be 1000mm x 1000mm x 250mm thick rigidly fixed alongside the
works to the approval of the S.O. One test panels shall be sprayed per 500m² or
more frequently as the S.O. may direct.
S20 - 63
Six cores shall be cut from each panel, three of which shall be crushed at 7 days and
three at 28 days. Cores shall not be taken within 125mm of the edges of the panel.
Prior to crushing the density of each core shall be measured. The minimum
equivalent cube strength of the core shall be:
at 7 days - 10 MPa;
at 28 days - 20 MPa.
(j) In addition to provision of test panels, complete areas of sprayed concrete shall be tested
from time to time by sounding them with a wooden mallet. Hollow sounding areas shall be
removed and resprayed or, at the discretion of the S.O. a second layer of sprayed concrete
shall be added. Any such remedial work shall not be measured for payment.
20.16.6 Protective Screen/ Rockfall Netting

(a) Where directed by the S.O., a protective screen shall be secured on the rock slope after
sealing and other rock stabilisation works as required by the S.O.
(b) This protective screen shall be a chain-linked steel net type and shall not be subject to
unravelling when individual links are broken.
The complete assembly of protective screen shall include the following:
(i) Chain Link Mesh: plastic coated, galvanised mild steel to BS 1722 Part 10, wire
core: 3.55mm diameter. Wire overall 4.75mm diameter, mesh: 50mm aperture, roll
width 2400mm, colour dark green, 14C 39 to BS 4800.
(ii) Line Wire : plastic coated galvanised mild steel to BS 4102, core diameter 3.55mm
diameter, wire overall 4.75mm diameter, colour dark green, 14C 39 to BS 4800.
(iii) Dowel bars of 25mm diameter mild steel to BS 4449 of generally 2000mm length
galvanised to BS 729 or equivalent.
(iv) Galvanised steel wire rope of 16mm diameter to BS 365.
(v) Steel Fixings: Eyebolt strains, ring nut fixings, bulldog clamps, anchor plates, etc all
to be galvanised to BS 729.
(c) The protective screen shall generally be fixed onto the final rock face in the following
manner as directed by the S.O.
(i) Drill 50mm diameter holes in the rock along the top of the rock face at 1000mm
centres and 1500mm depth.
(ii) Dowel Bars to be installed, with approved resin or cementitions grout approved by
the S.O., such that 500mm of the dowel projects above the rock surface.
(iii) Chain Link Mesh netting to be hung vertically in 2400mm wide strips to cover the
face with 300mm overlaps between adjacent strips.
(iv) Galvanised steel wire rope is to be threaded through the top mesh and secured to the
projecting dowel bars.
(v) Bottom and sides edges of chain link mesh to be secured by threading 16mm dia.
galvanised steel wire rope through the mesh and fixed to rock bolts by bulldog
clamps and anchor plates.
S20 - 64
(vi) Vertical joints in the chain link mesh are to be secured by threading line wire down
through the overlap, the line wires being clamped at the top to dowel bars and
tensioned by means of an eyebolt strainer at the bottom fixed to a rock bolt.
(vii) Rock bolts as directed by the S.O. to be used to tie down bottom, side edges and
general areas. Vertical lap jointing line wires are to pass under the anchor plates.
20.16.7 Pre-stressed Rock Bolts

20.16.7.1 General
This work shall consist of furnishing, drilling, installing, and testing pre-stressed, grouted rock
bolts and accessories at the locations and in the patterns shown on the plans or as ordered. On
this project, it may be necessary to install rock bolts at any location on the rock face. A detail
for the rock bolt is attached as Figure 20.3.
20.16.7.2 Materials
20.16.7.2.1 Rock Bolt Bars
(a) Rock bolt bars shall be straight shaft, deformed, solid, continuous thread bar, new, and
undamaged. Rock anchor steel shall be protected from dirt, rust and deleterious
substances.
(b) Rock bolt bars shall be ASTM A722 Grade 150 steel, galvanized. The diameter of
the rock bolt as specified in the Drawings. All exposed parts of the rock anchor, shall
be galvanized in accordance with ASTM A123/ASTM A153.
20.16.7.2.2 Anchorage Assembly, Couplers, Trumpets, Covers and Centralizers

(a) The anchorage, couplers and bearing plate shall be capable of developing a minimum
of 100 per cent of the guaranteed minimum ultimate tensile strength of the steel rock bolt
bar and shall be galvanized in accordance with ASTM A123/ASTM A153.
(b) Surface Bearing Plates. Surface bearing plates shall be fabricated from A36 steel
and shall have a minimum size of 7” (177.8mm) x 7.5” (190.5mm) x 1.75” (44.45mm).
(c) Beveled Washers, Flat Washers and Wedges. Beveled washers, hardened flat
washers, and wedges for the anchorage shall be designed to preclude premature
failure of the pre-stressing steel due to notch or pinching effects.
(d) Heavy 2H Hex Nuts. Heavy 2H hex nuts shall be constructed for threaded
engagement with the outer end of the rock bolt bar. The nut should be heavy duty
type with round head, conforming to ASTM A-325. Anchor nuts shall develop an
ultimate strength not less than 100 per cent of the guaranteed ultimate strength (GUTS) of
the bar and conform to ASTM A436.
(e) Centralizer. Centralizers are required and shall be fabricated from Schedule 40
PVC, or other material not detrimental to the steel rock bolt bar (wood shall not be
used) and shall be capable of being securely attached to the bar. The centralizers shall be
sized to meet the tolerance requirements for the grout cover defined in sub-section
20.16.7.3.2.
(f) Coupler Protection. The coupler and any exposed bar section next to it shall be
covered with a corrosion proof compound or wax impregnated cloth tape. The coupler
area shall be covered by a smooth plastic tube complying with the requirements set forth
in section 2.5, overlapping the adjacent sheathed bar by at least 1 inch (25.4mm). The two
joints shall be sealed each by a coated heat shrink sleeve of at least 6 inches (152.4mm)
length, or approved equal. The corrosion proof compound shall completely fill the
space inside the cover tube.
S20 - 65
20.16.7.2.3 Cement Grout.
(a) Rock bolt grout shall be non-shrink neat cement with a maximum water to cement
ratio of 0.45 by weight.
(b) Water for mixing grout shall be potable and free from substances which might be
deleterious or corrosive to concrete or steel.
(c) Grout strength accelerators shall not be used. Admixtures which control bleed and
retard set may be used. Admixtures shall be mixed and placed in accordance
with the manufacturer‟s recommendations.
(d) The cement grout mix shall provide a minimum compressive strength of 3000 psi at
the time of stressing.
(e) Appropriate measures shall be taken to preclude freezing of the grout prior to its
reaching design strength.
(f) Cement shall conform to AASHTO M 85/ASTM C 150, Type I, II, or III Portland
cement.
20.16.7.2.4 Sheathing
Sheathing used over the rock bolt bar in the unbonded (free stressing ) zone shall be made
of material with the following properties: resistant to chemical attack from aggressive
environments, grout or corrosion inhibiting compounds; resistant to aging by ultraviolet light;
non-detrimental to the rock bolt bar and capable of withstanding abrasion, impact and
bending during handling and installation. The minimum wall thickness for the sheathing
shall be 0.060 inch (1.524mm) for polyethylene or polypropylene, 0.040 inch (1.016mm) for
PVC tubing and 0.20 inch (5.08mm) for steel tubing or pipe. The sheathing shall permit the
unobstructed elongation of the unbonded length during stressing.
20.16.7.3 Construction Requirements

20.16.7.3.1 Contractor Qualifications
The work defined in this section is specialty construction requiring a Contractor who is
highly knowledgeable and experienced in the installation of rock bolts. The Contractor
performing the work in this section shall submit proof of five projects within five years on
which the Contractor has successfully installed rock bolts of similar types and capacities
required for this project. A brief description of each project with the owner‟s name and
current phone number shall be included.
20.16.7.3.2 Design Load, Tolerance and Construction Criteria

(a) Design Load The design load for the rock bolts for this project as specified in the
BQ and/or Drawings unless otherwise directed by the S.O.
(b) The minimum hole diameter shall be selected such that a minimum of 1.25 inches
(31.75mm) of grout cover is provided around the rock bolt bar within the anchor zone.
(c) The bonded length and associated hole diameter shall be large enough to provide a
capacity of at least 1.33 times the design load or as directed by the S.O.
(d) The unbonded length as shown on the Drawings.
(e) Centralizers shall have a maximum spacing of 7 feet (2.13m) and the lowest
centralizer shall be located 3 feet (1m) or less from the end of the rock bolt bar.
(f) The deviation of the drilled hole entry angle from the specified inclination and
direction shall be no more than 3 degrees.
S20 - 66
20.16.7.3.3 Drilling
Rotary percussion equipment shall be used to drill the holes. The drill hole diameter shall
conform to the requirements of this special provision. As a minimum, the drill hole shall
extend 12 inches (304.8mm) below the design depth of the rock bolt bar. In down bolting
situations, the drill holes shall extend 16 inches (406.4mm) beyond the length of the rock
bolt bar. Care shall be taken to insure an accurate and straight hole. Drilled holes shall be
cleaned of all drill cuttings, sludge and debris before the rock bolt bar is inserted into the hole.
(a) As a minimum, the bottom of the rock bolt bar shall be positioned 12 inches
(304.8mm) above the bottom of the drilled hole. In down bolting situations, the bottom
of the rock bolt bar shall be positioned 16 inches (406.4mm) above the bottom of the
drilled hole.
(b) The threaded outer end of the rock bolt bar shall extend the minimum length beyond the
anchorage that will be capable of accepting the proof test and lift off equipment. The
anchorage nut shall be tightened using an approved post tensioning hydraulic jack,
which permits tightening of the nut during tensioning.
(c) All equipment used for placing shall be such that it will not damage the rock bolt or
its accessories.
(d) Chipping out the rock or building a pad may be required to provide a level surface
for the bearing plate. Pads must be constructed of materials that will withstand the
applied lock offload without loss of strength over the life of the rock bolt. The
design, method of construction and materials used for the pad must be submitted to
the S.O. for approval.
(e) The contractor shall keep and provide a borehole log for each borehole drilled for rock
anchors. The log shall include, but not limited to the following: hole location, hole
diameter, hole length, angle from horizontal, date/time of drilling, drilling equipment
used, encountered subsurface conditions (groundwater, joints, voids, soil/weak rock,
etc.), and name of driller. The borehole logs shall be submitted to the S.O. on a daily
basis.
(f) All damage to the galvanized surfaces, and threaded portions of all fittings and
fasteners and cut ends of bolts after assembly, shall be repaired by thoroughly wire
brushing the damaged area and painting it with two to four coats or to a thickness
equivalent to the surrounding galvanizing, of an approved organic zinc-rich repair
paint containing 92 per cent (min) zinc by weight.
20.16.7.3.5 Grouting
(a) Grouting of the annular space around the rock bolt shall be accomplished by pressure
grouting with a grout pump, providing a minimum of 90 psi capacity. Mixers and
pumps shall have adequate capacity and hoses shall be sized to allow continuous
grouting of an individual bolt within one hour or less.
(b) All grout pipes, tubes and fittings shall be clean and free from dirt particles, grease,
hardened grout, or other contamination before grouting is commenced for any bolt. All
surplus water and diluted grout shall be flushed or blown from all lines before
commencing injections. The grout line shall be attached to the grout injection tube with
suitable fittings such that leakage is entirely prevented.
(c) The grout shall be injected at a pressure, which is sufficient to overcome hydrostatic
head. The pressure, which is used, shall be approved by the S.O. Dewatering or pre-
grouting may be required for proper grouting of the rock bolt in groundwater or poor
rock conditions.
(d) Bolts in upward inclination shall use a sealing grout to seal the opening around the bolt
prior to grouting through a short tube, which extends through the sealing grout. Such
S20 - 67
bolts shall be considered grouted when there is a full return of grout through a vent hole
within the sealing grout.
(e) The anchor bond length shall be grouted by injecting grout at the lowest point in the
anchor.
20.16.7.3.6 Proof Tests, Acceptance Criteria and Lock Off Procedures.

(a) Each production rock bolt shall be proof tested in accordance with the requirements of
this specification. Testing of the rock bolts shall not be performed until the rock bolt
grout has attained at least 100 per cent of the minimum required compressive strength.
Rock bolts which do not meet the proof test criteria contained herein shall be rejected
and a replacement rock bolt shall be installed.
(b) The testing equipment shall include at a minimum one dial gauge, a dial gauge support,
and a jack with pressure gauge. The equipment shall be capable of stressing the rock
bolt to the maximum specified test load within the rated capacity. The pump shall be
capable of applying each load increment in less than 60 seconds. The equipment shall
permit the rock bolt to be stressed in increments so that the load can be raised or
lowered in accordance with the test specifications, and allow the bolt to be lift-off tested
to confirm the lock-off load. Stressing equipment shall have been calibrated by an
independent test laboratory within an accuracy of ±2% within 60 days prior to use.
Rock anchor testing will not be allowed until approval of the calibration report by the
S.O. The calibration certificate and graph shall be available on site at all times. The
production gauge shall have graduations not larger than 100 psi. The equipment that has
been calibrated shall be used which permit the measurement of total movement at every
load increment to be read to the nearest 0.001 inch (0.0254mm). The dial gauge shall
have sufficient travel to record the total rock bolt movement at the maximum test load
without the need to reset at an interim point.
(c) Testing Equipment Setup. Prior to setting the dial gauge, the alignment load shall be
accurately placed on the rock bolt. The alignment load shall be determined by the S.O.
as per cent of the design load. The dial gauge shall bear on the pulling head of the jack
and the stems shall be in alignment with the rock bolt direction. The dial gauge shall be
supported on an independent fixed frame, such as a tripod, which will not move as a
result of stressing or other construction activities during the test.
(d) Testing Schedule. Proof tests shall be performed by incrementally loading the rock
bolt to 133 per cent of the design load (DL). The rock bolt movement at each load
shall be measured and recorded by the S.O. At load increments other than the
maximum test load, the load shall be held long enough to obtain a stable reading.
Incremental loading for proof tests shall be in accordance with the following schedule:
AL
0.25DL
0.50DL
0.75DL
1.00DL
1.20DL
1.33DL
AL
Lock-off
Lift- off Reading
All load increments shall be maintained within 5 per cent of the intended load.
Depending on performance, either 10 minute or 60 minute creep tests shall be
performed at the maximum test load (1.33 DL). The creep period shall start as soon
as the maximum test load is applied and rock bolt movement shall be measured and
recorded at 1, 2, 3, 4, 5, 6, and 10 minutes. Where the rock bolt movement between 1
and 10 minutes exceeds 0.040 inch (1.016mm), the maximum test load shall be
maintained an additional 50 minutes and movements shall be recorded at 20, 30, 40, 50,
S20 - 68
and 60 minutes. Total creep movement must not exceed 0.080 inch (2.032mm) between the
6 and 60 minute readings.
(e) Proof Test Acceptance Criteria. Proof tests shall be considered acceptable when all
of the following criteria are met:
(i) A total creep movement of less than. 0.04 inch (1.016mm) is observed between the
1 and 10 minute readings or a total creep movement of less than 0.08 inch
(2.032mm) is observed between the 6 and 60 minute readings.
(ii) The creep rate is constant or decreasing throughout the creep test load hold
period.
(iii) The total movement at the maximum test load exceeds 80 per cent of the
theoretical elastic elongation of the rock bolt unbonded length.
(iv) A pull out failure does not occur at the maximum test load. Pull out failure is
defined as the load at which attempts to increase the test load simply result in
continued pull out movement of the rock bolt. The pull out failure load shall be
recorded as part of the test data.
(f) Lock Off Procedures. After completion and acceptance of the proof test, the rock
bolt shall be locked off at the design load or at a load as directed by the S.O. After
transferring the load to the anchorage and prior to removing the jack, a lift-off test
shall be conducted to confirm the magnitude of the load in the rock bolt. This load
shall be determined by reapplying the load to the rock bolt to lift off the anchor nut
without turning the anchor nut. The lift-off load shall be within 5 per cent the design
lock off load. If these criteria are not met, the rock bolt load shall be adjusted
accordingly and the initial lift-off reading repeated.
20.16.7.3.7 Submittals
Submit a rock bolt installation plan, for approval, that includes the Contractor‟s
qualifications, details the rock anchor type, couplings, face plate and nut, drilling operation, the
proposed rope access methods if applicable and safety plan, the assembly of the bolt with
its accessories, the method of bolt installation including grout mixes, testing procedures,
and the method for providing a level surface for the bearing plate ten days prior to
commencement of work. Submit manufacture‟s certificates of compliance for the
following: rock bolt thread bar, complete rock bolt head assembly including nuts, wedges,
washers, plates, covers and trumpet, smooth sheathing, centralizers, corrosion inhibitor
compound, and grout design with admixtures.
S20 - 69
Figure 20.3: Pre-stressed Corrosion Protected Grouted Rock Bolt
20.16.8 Rock Dowel (Untensioned Rock Bolts)

20.16.8.1 General
This work shall consist of furnishing, drilling and installing, grouted rock dowels and
accessories at the locations and in the patterns shown on the plans or as ordered. On this
project, it may be necessary to install rock dowels at any location on the rock face. A rock
dowel is a fully grouted, untensioned rock bolt.
20.16.8.2 Materials
20.16.8.2.1 Rock Dowel Bars
(a) Rock dowel bars shall be straight shaft, deformed, solid, continuous thread bar, new,
and undamaged.
(b) Rock dowel bars shall be galvanized ASTM A722 Grade 150 steel. The minimum
diameter as shown on the Drawings and/or as directed by the S.O.
20.16.8.2.2 Anchorage Assembly, Couplers, Covers and Centralizers

(a) The anchorage, couplers and bearing plate shall be capable of developing a minimum of
100 per cent of the guaranteed minimum ultimate tensile strength of the steel rock
dowel bar.
(b) Surface Bearing Plates. Surface bearing plates shall be fabricated from A36 steel and
shall have a minimum size of 7” (177.8mm) x 7.5” (190.5mm) x 1.25” (31.75mm).
S20 - 70
(c) Beveled Washers, Flat Washers and Wedges. Beveled washers, hardened flat
washers, and wedges for the anchorage shall be designed to preclude premature failure
of the steel due to notch or pinching effects.
(d) Heavy 2H Hex Nuts. Heavy 2H hex nuts shall be constructed for threaded engagement
with the outer end of the rock dowel bar. The nut should be heavy-duty type with round
head, conforming to ASTM A-325.
(e) Centralizer. Centralizers are required and shall be fabricated from Schedule 40 PVC,
or other material not detrimental to the steel rock dowel bar (wood shall not be used)
and shall be capable of being securely attached to the bar. The centralizers shall be sized
to meet the tolerance requirements for the grout cover defined in section 20.16.8.3.2.
(f) Coupler Protection. The coupler and any exposed bar section next to it shall be
covered with a corrosion proof compound or wax impregnated cloth tape. The coupler
area shall be covered by a smooth plastic tube complying with the requirements set
forth in section 2.5, overlapping the adjacent sheathed bar by at least 1 inch (25.4mm).
The two joints shall be sealed each by a coated heat shrink sleeve of at least 6 inches
(152.4mm) length, or approved equal. The corrosion proof compound shall completely
fill the space inside the cover tube.
20.16.8.2.3 Cement Grout

(a) Rock dowel grout shall be non-shrink neat cement with a maximum water to cement
ratio of 0.45 by weight.
(b) Water for mixing grout shall be potable and free from substances which might be
deleterious or corrosive to concrete or steel.
(c) Grout strength accelerators shall not be used. Admixtures which control bleed and
retard set may be used. Admixtures shall be mixed and placed in accordance with the
manufacturer‟s recommendations.
(d) The cement grout mix shall provide a minimum compressive strength of 3000 psi.
(e) Appropriate measures shall be taken to preclude freezing of the grout prior to its
reaching design strength.
(f) Cement shall conform to AASHTO M 85/ASTM C 150, Type I, II, or III Portland
cement.
20.16.8.3 Construction Requirements

20.16.8.3.1 Contractor Qualifications
The work defined in this section is specialty construction requiring a Contractor who is highly
knowledgeable and experienced in the installation of rock bolts and/or dowels. The Contractor
performing the work in this section shall submit proof of five projects within five years on
which the Contractor has successfully installed rock bolts of similar types and capacities
required for this project. A brief description of each project with the owner‟s name and current
phone number shall be included.
20.16.8.3.2 Tolerance and Construction Criteria

(a) The minimum hole diameter shall be selected such that a minimum of 1.25 inches
(31.75mm) of grout cover is provided around the entire length of the rock dowel bar
within the anchor zone.
(b) The length shall be as as shown on the Drawings.
(c) Centralizers shall have a maximum spacing of 10 feet (3.05m) and the lowest
centralizer shall be located 5 feet (1.52m) or less from the end of the rock dowel bar.
S20 - 71
(d) All damage to the galvanized surfaces, and threaded portions of all fittings and fasteners
and cut ends of bolts after assembly, shall be repaired by thoroughly wire brushing the
damaged area and painting it with two to four coats or to a thickness equivalent to the
surrounding galvanizing, of an approved organic zinc-rich repair paint containing 92 per
cent (min) zinc by weight.
(e) The deviation of the drilled hole entry angle from the specified inclination and direction
shall be no more than 3 degrees.
20.16.8.3.3 Drilling
Rotary percussion equipment shall be used to drill the holes. The drill hole diameter shall
conform to the requirements of this special provision. As a minimum, the drill hole shall
extend 12 inches (304.8mm) below the design depth of the rock dowel bar. In down bolting
situations, the drill holes shall extend 16 inches (406.4mm) beyond the length of the rock
dowel bar. Care shall be taken to insure an accurate and straight hole. Drilled holes shall be
cleaned of all drill cuttings, sludge and debris before the rock dowel bar is inserted into the
hole.
20.16.8.3.4 Borehole log

The contractor shall keep and provide a borehole log for each borehole drilled for rock
anchors. The log shall include, but not limited to the following: hole location, hole diameter,
hole length, angle from horizontal, date/time of drilling, drilling equipment used, encountered
subsurface conditions(groundwater, joints, voids, soil/weak rock, etc.), and name of driller.
The borehole logs shall be submitted to the S.O. on a daily basis.
(a) As a minimum, the bottom of the rock dowel bar shall be positioned 12 inches
(304.8mm) above the bottom of the drilled hole. In down bolting situations, the bottom
of the rock bolt bar shall be positioned 16 inches (406.4mm) above the bottom of the
drilled hole.
(b) All equipment used for placing shall be such that it will not damage the rock dowel or
its accessories.
(c) Chipping out the rock may be required to provide a level surface for the bearing plate.
All voids behind the bearing plate shall be completely filled with cement grout. Cement
grout shall be used to provide a smooth surface for the bearing plate.
(d) All damage to the galvanized surfaces, and threaded portions of all fittings and fasteners
and cut ends of bolts after assembly, shall be repaired by thoroughly wire brushing the
damaged area and painting it with two to four coats or to a thickness equivalent to the
surrounding galvanizing, of an approved organic zinc-rich repair paint containing 92 per
cent (min) zinc by weight.
20.16.8.3.6 Grouting
(a) Grouting of the annular space around the rock dowel shall be accomplished by pressure
grouting with a grout pump, providing a minimum of 90 psi capacity. Mixers and
pumps shall have adequate capacity and hoses shall be sized to allow continuous
grouting of an individual dowel within one hour or less.
(b) All grout pipes, tubes and fittings shall be clean and free from dirt particles, grease,
hardened grout, or other contamination before grouting is commenced for any rock
dowel. All surplus water and diluted grout shall be flushed or blown from all lines
before commencing injections. The grout line shall be attached to the grout injection
tube with suitable fittings such that leakage is entirely prevented.
S20 - 72
(c) The grout shall be injected at a pressure, which is sufficient to overcome hydrostatic
head. The pressure, which is used, shall be approved by the S.O. Dewatering or pre-
grouting may be required for proper grouting of the rock dowel in groundwater or poor
rock conditions.
(d) Rock dowels in upward inclination shall use a sealing grout to seal the opening around
the dowel prior to grouting through a short tube, which extends through the sealing
grout. Such rock dowels shall be considered grouted when there is a full return of grout
through a vent hole within the sealing grout.
(e) The rock dowel shall be grouted by injecting grout at the lowest point in the rock dowel
bar.
20.16.8.3.7 Submittals
Submit a rock dowel installation plan, for approval, that includes the Contractor‟s
qualifications, proposed construction sequence and schedule, proposed rope access methods if
applicable and safety plan, proposed drilling methods and equipment, the assembly of the rock
dowel with its accessories, proposed mix design for the grouting, the method of rock dowel
installation, and the method for providing a level surface for the bearing plate. The installation
plan shall be submitted ten days prior to commencement of work in accordance with 105.02.
Submit manufacture‟s certificates of compliance for the following: Rock dowel thread bar,
complete rock dowel head assembly including nuts, wedges, washers, plates, covers,
centralizers and grout design with admixtures.
20.17 APPENDIX 20A
GROUND TREATMENT PERFORMANCE MONITORING
MEASUREMENT OF SETTLEMENT OF SUBSOIL AND FILL AT INSTRUMENTED AREAS (IF

SPECIFIED):
- EXCAVATE AND REPLACE
- PREFABRICATED VERTICAL DRAIN
- SURCHARGE / PRE-LOADING
- STONE COLUMN
- OTHER AREAS AS SPECIFIED IN THE DRAWINGS AND/OR BY THE S.O. / ENGINEER.
1. Settlement Of Subsoil
Settlement of subsoil due to fill is to be measured by means of settlement plates. Settlement plates are
positioned before the fill is laid.
2. Location And Protection of Settlement Plates
The settlements plates shall be placed at locations indicated on the drawing. They shall be located in
areas that are least affected by construction vehicles and plant. They shall be properly protected with a
wooden barricade, 1m high and labelled with visible reference numbers. Heavy compaction plant shall
not approach within 1.5m of projecting instruments.
Damaged instruments shall be replaced or repaired by the Contractor at his own expense within seven
days.
3. Frequency of Measurement
S20 - 73
The frequency or the interval of measurement is dependent on the rate of settlement of subsoil. Close
intervals, are used during and shortly after fill has been laid. The intervals are increased with increase
in the duration of lapse time. The following can be used as a guide:
a) During filling
- Every morning before subsequent filling commences.
b) After a formation is reached
i) For first three months
- Every alternative day
ii) For fourth and subsequent months
- Between twice a week to once a fortnight depending on the rate of settlement, or as

instructed by the S.O./Engineer. The time interval should allow reasonable settlement to
be plotted.
4. Supply, Installation and Monitoring of Settlement Stations
Installation of precise instrument involves the supply and installation of the installation at positions as
indicated by the S.O./Engineer.
a) Temporary Bench Marks
The temporary bench marks will be installed at the nearby stable structure or remote from the
reclamation area and marked on an end bearing pile or similar structure.
b) Settlement Plates
The precise level settlement measurements shall be referenced to the temporary bench marks.
The measuring instruments shall be a precise level, capable of allowing readings to be read to
0.1 mm.
5. Plotting
The result should be plotted during the period of measurement.
S20 - 74

Section 20 - Geotechnical Works

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Section 20 - Geotechnical Works

Uploaded by

Copyright:

Available Formats

SECTION 20 – GEOTECHNICAL WORKS

20.1 REMOVAL AND REPLACEMENT OF UNSUITABLE MATERIAL ............................... S20-1

20.1 REMOVAL AND REPLACEMENT OF UNSUITABLE MATERIAL

Figure 20.1: General Arrangement of JKR Probe

Figure 20.2: Pointer Geometry of JKR and Mackintosh Probes

Type of Cone Dia. of Dia. of Weight Height Measured

20.1.2.4 Criteria for Removal Unsuitable Material

20.1.3 Materials for Replacement of Unsuitable Material

20.2.1.2 Types of geotextile

20.2.1.5 Locally Produced Products

20.2.2 Packaging and Storage

(a) Product brand name;

(b) Product type;

(c) Roll width and length; and

(d) Batch serial number

20.2.2.2 Product Packaging

20.2.2.3 Product Quality Assurance

20.2.2.4 Storage at Site

20.2.3.2 Consignment Certificate

(ii) Name and address of the manufacturer;

(iii) Contact telephone/fax/email address of the manufacturer;

(iv) Consignment certificate reference number and date;

(v) Title of the contract and name of project owner;

(vi) Name and address of the purchaser; and

(vii) Product types and quantities, corresponding to each consignment.

20.2.3.3 Routine Testing

20.2.4 Jointing the Adjacent Geotextile

Table 20.2 is provided as a guide for determining overlap requirements for

Table 20.2: Guidelines for Geotextile Overlap Requirements as a Function of Soil

Soil CBR Minimum Overlaps

>3 0.3 – 0.45 meters

20.2.4.2 Sewn Seams

(i) (ii) (iii)

20.2.5 Non-Woven Geotextile

The width of each roll of non-woven geotextile shall be 4m.

20.2.5.1.2 Technical Properties

Table 20.3: Properties of Non-woven Geotextile.

No. Description Test Standard Unit Limit NW 15 NW 9 NW 22

1. Tensile Strength ISO 10319 kN/m > 15 9 22

(a) Details of Test Certificates

(i) Tensile strength;

(ii) Elongation (longitudinal/transverse);

(iii) CBR Puncture Resistance.

(iv) Cone Drop

(vi) Vertical Water Flow / Permeability;

(vii) Mass per unit area;

(viii) Thickness (under 2 kPa pressure);

20.2.5.2 Installation of Non-Woven Geotextile

(b) Non-woven Geotextile Exposure Following Placement

(c) Site Preparation

(d) Installation of Non-woven Geotextile

(f) Backfill Placement

20.2.6 WOVEN GEOTEXTILE

20.2.6.1.2 Technical Properties

Table 20.4: Properties of Woven Geotextile

20.2.6.2 Installation of Woven Geotextile

(c) Woven Geotextile Placement

(f) Backfill Placement

However a minimum thickness of 300mm of cover shall be maintained between the

20.3.1.2 Contractor to Provide

20.3.1.4 Locally Produced Products

(a) Product Brand Name

(b) Product Type