Reinforced Earth India P. Ltd.

IND HA 01

TECHNICAL SPECIFICATION

FOR

REINFORCED EARTH STRUCTURES WITH

HA/ HAR GALVANISED STEEL STRIPS

The present document is the exclusive property and confidential to “Reinforced Earth India Pvt. Ltd.
(REIPL)". Its distribution is controlled and it should not be used, modified, reproduced or transferred, even
partially, in any way or any format, without REIPL's prior written consent.
R5
R4
R3
R2
R1 16/06/09 Construction SC AA SB
Requirement Modified
Orig 01/07/2008 First issue AA DC SB
Rev. Date Modification Design/ Checked by Approved by
prepared by
STRICTLY CONFIDENTIAL
 Reinforced Earth India P. Ltd.

Rev-00
Document No. : IND HA 01 Date : 1st July 2008

TECHNICAL SPECIFICATIONS
FOR
REINFORCED EARTH STRUCTURES WITH
HIGH ADHERENCE/ HIGH ADHERENCE
REINFORCED GALVANISED STEEL
STRIPS
A. DESCRIPTION

This work shall consist of Reinforced Earth Structures as per originally patented
Reinforced Earth Technology and consisting of precast discrete cruciform concrete
facing, High Adherence (HA)/ High Adherence Reinforced (HAR) galvanized steel
strips with accessories / fittings and backfill material in accordance with the
specifications and in reasonably close conformity with the lines, grades design and
dimensions shown on the approved drawings.

The guarantee period for the Reinforced Earth Structure shall be ten (10) years from
the date of completion of the work irrespective of defect liability period of Twelve (12)
months specified elsewhere in the tender document. The contractor(s) shall furnish
the guarantee bond as directed by the Engineer-in-Charge.

Design and construction of Reinforced Earth retaining wall shall include loading from
traffic or pavement, seismic activity, drainage subsystem, provision of friction slab
crash barrier and precast RCC discrete facia panel element of nominal 140-180mm
thickness (140mm without any finish), PCC leveling pad, toe protection etc.,
necessary foundation treatment, if required to ensure meeting deficiency of the
bearing capacity of the underlying soil for adequate and uniform distribution of the
stresses induced due to the incident loads to the base, besides ensuring stability
against slip circle failure. The contractor shall need to assess and substantiate the
availability and design adequacy of soil safe bearing capacity under the location of
the wall before execution of the work.

No geosynthetic / plastic reinforcements, steel bar mat or mesh reinforcements or tie

back anchored earth systems shall be allowed for use. Only HA/ HAR ribbed carbon
steel strips with cruciform-shape panels are accepted for reinforced earth works.

All Reinforced Earth works shall be executed as per ISO: 9001:2000 scope of
registration for “The Structural design, procurement and supervision of installation for
Mechanically Stabilized Earth and Prefabricated Concrete Arch Structures for
overpasses, underpasses, interchanges and other similar applications” by the
specialized agency.

B. MATERIALS

1. General

Since Reinforced Earth is a proprietary system, the contractor shall make his own
arrangements to secure the supplies and services needed from the technology
supplier.

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Document No. : IND HA 01 Date : 1st July 2008

2. Precast Concrete Facing

R.C.C Precast concrete facing elements shall be of rectangular/cruciform/Tee shape

and the dimensions shall conform to the details shown on the final construction
drawing. However, all dimensions shown below are typical. Concrete shall be of
grade shown on the drawings and shall conform to the requirements specified in
section 1700 “Structural Concrete” of MORT&H.

The grade of concrete shall be either M-30 or M-35. The shape of panels shall be
cruciform 1.5m x 1.5m with nominal thickness 18 cm.

Reinforcement shall be placed as shown on the plan and shall conform to the
requirements specified.

SECTION A-A
SECTION C-C SECTION B-B

TYPICAL VIEW ON REAR FACE OF PANELS

(a.) Casting

The elements shall be cast on flat area of a specially prepared mould. Lug
connectors and lifting devices shall be cast in place to the dimensions and tolerances
shown on approved System drawing and lug connectors shall be set on the rear face,
prior to casting. The concrete in each unit shall be placed without interruption and
shall be compacted by the use of an approved vibrator supplemented by such hand-
tamping as may be necessary to ensure that the concrete reaches into the corners of
the forms and prevent formation of stone pockets or cleavage planes. Clear form oil
of the approved and only from single manufacturing source shall be used through out
the casting operations to avoid colour variation.

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Document No. : IND HA 01 Date : 1st July 2008

(b.) Curing

The precast elements shall be cured for a sufficient length of time as approved by
Engineer so that the concrete develops the required compressive strength. Only
fresh potable water shall be used for curing.

(c.) Removal of forms

The forms shall remain in place until they can be removed without damaging the
elements. The scheme of removal of form work shall be as per relevant MORT&H
specifications.

(d.) SCRIBING

The date of manufacture and nomenclature shall be clearly scribed on the rear face
of each unit.

(e.) CONCRETE FINISH

The front (exposed) face of the elements shall have the finish approved by the
Engineer. The rear face shall have the finish of unformed surface and shall be
roughly screened to eliminate open pockets of aggregates.

(f.) TOLERANCES

All elements shall be manufactured within the following tolerances:

- All dimensions within 5 mm

- Evenness of the front face : ± 5 mm over 1500mm
- Difference between lengths of two diagonals: 10mm max.
- Thickness : ± 15 mm

(g.) HANDLING, STORAGE AND TRANSPORTING

All elements shall be handled, stored and transported in such manner as to eliminate
the danger of chipping, cracks, fracture and excessive bending stresses. Elements
in storage shall be supported on firm blocking located adjacent to the tie-strips to
avoid bending.

(h.) ACCEPTABILITY

Acceptability of the precast elements shall be determined on the basis of

compression tests, as per MORT&H. specifications and visual inspection. A
minimum of one sample of 6 cubes shall be taken for each lot of 5 cum or 12 cubes
above 5 cum per day. Elements shall be acceptable for placement in the structure if
the strength at 10 days, or before, exceeds 75% of the 28 days requirements.

(i.) REJECTION

Elements shall be subject to rejection in case of failure to meet any of the

requirements specified above. In addition, defects, which indicate imperfect
moulding, or defects indicating honeycombed or open textured concrete, shall be
sufficient cause for rejection.

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Reinforced Earth India P. Ltd.

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Document No. : IND HA 01 Date : 1st July 2008

3. Leveling Concrete

A PCC leveling pad shall be provided under walls as seat beam just to rest the facing
panel on leveled surface. Concrete shall have a grade either M-15 or M-20.
Maximum size of aggregates shall be 20 mm. The pad shall be cured for at least 05
days prior to placing panels. The top surface shall be leveled at ±3mm tolerance

4. High Adherence (HA)/ High Adherence Reinforced (HAR) hot dip galvanized,
earth reinforcing steel strips and Tie Strips

HA/ HAR Strips shall be galvanized, hot rolled steel strip with transverse ridges. The
steel strips with minimum tensile, bearing and shear strength of 490Nmm-2 complying
with the requirements of BS EN 10025:1993, except the elongation (on base metal)
for which minimum 18 % is acceptable.

The panel lugs are manufactured from hot-rolled steel strip. The steel strip is quality
with minimum tensile, bearing and shear strength of 490Nmm-2, complying with the
requirement of BS EN 10025:1993, except the elongation (on base metal) for which
minimum 18 % is acceptable.

After fabrication, the High Adherence Strips and panel lugs are hot-dip galvanized to
BS 729:1971 requirements or IS 4759: 1996, except that the average zinc coating
weight is not less than 600gm-2.

Reinforcing strips shall be cut to the lengths and tolerances shown on approved
drawings. Holes for bolts shall be punched in the locations shown. They shall be
carefully inspected to ensure they are true to size and free from defects that may
impair their strength or durability.

These requirements shall also generally conform to MORT&H specifications.

Nominal dimensions and the design strength of the HA/HAR Strips and Panel lugs
are given in table below.

Design Strength(1&2), TD (kN)

Nominal Width Nominal Thickness
Type
(mm) (mm) Main Body Connection
405 HA
40 5 40.87 30.42
Strip
405 HA
40 4 - 39.02
Lug
455 HAR
45 5 44.9 44.9 (3)
Strip
455 HAR
45 4 - 47.56
Lug

(1) Assumes a design life of 100 years.

(2) Includes for partial factor fn = 1.1, to allow for ramifications of failure – see BS 8006 :
1995, Table 3.
(3) Connection capacity limited by main body strength.

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 Reinforced Earth India P. Ltd.

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Document No. : IND HA 01 Date : 1st July 2008

HIGH ADHERENCE CARBON STEEL STRIP

5. Fasteners

Bolts and nuts shall be hexagonal in shape and high strength screw conforming to
European norms BS 3692 CLASS 10.9. They shall be 12mm in diameter 40mm in
length with shank, hot-dip Galvanized conforming to BS 729: 1971.

6. Joint Fillers

i. Bedding material between the horizontal joints (excluding the joint between the
PCC base and the bottom most panel) of the panels shall consist EPDM
(Ethylene Propylene Diene Monomer) material.

ii. Sealing material for filling joint gaps, if required, other than bedding joints shall
consist of close cell polyurethane foam strip or non woven polypropylene
Geotextile of unit weight not less than 125 g/m2.

iii. For facia drainage and prevention of soil leaching wherever necessary, non-
woven polypropylene geotextile strips shall be provided against the vertical and
horizontal joints on the back face of the facia, as shown in the approved drawing.

7. Drainage

Drainage shall be very strictly followed as per drawing and specifications in detail.
The Reinforced Earth backfill is considered a self-draining media, having sufficient
permeability to relive hydrostatic pressures. However, water logging in the reinforced
fill increases the pore pressure coefficient thereby resulting in tensile forces in
Reinforced Earth Structure, reducing the stability of the structure. Wherever, there is
a probability of such occurrence, drainage outlets at the bottom level joints of panels
with provision of non-woven geotextile backing shall be provided along the facia for
drainage redundancy. The reinforced fill shall have drainage bay, 600mm wide, with
19.5mm to 9.1mm well graded crushed aggregate to allow free draining of the
reinforced fill along with the retained fill.

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 Reinforced Earth India P. Ltd.

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Document No. : IND HA 01 Date : 1st July 2008

8. Backfill Requirements

Backfill materials used in the Reinforced Earth volume shall be reasonably free from
organic or otherwise deleterious materials and shall conform to the following
mechanical and physico-chemical requirements.

(a.) Mechanical requirements

Sieve size Percent passing

100mm 100%
75mm more than 75%
75 micron less than 15%

Coefficient of uniformity Cu = (D60/D10) ≥ 2

Acceptance limits for materials with more than 15% passing 75 micron are related to
the percentage of particles smaller than 15 microns as follows:

• materials with more than 15% passing 75 micron sieve but less than 10% of particles
smaller than 15 microns are acceptable.

• materials with more than 15% passing 75 micron sieve and more then 20% of
particles smaller than 15 microns are inadequate and shall not be used except as
specified in (e) below.

• materials with more than 15% passing 75 micron sieve and 10 to 20 % of particles
smaller than 15 microns are acceptable provided that the internal friction angle is not
smaller than 30°.

(b.) Physico-Chemical Requirements

Materials with a resistivity of 5000 Ωcm or more, are acceptable, based on a

standard test as directed by the Engineer.

Materials with resistivity less than 1000 Ωcm are inadequate and shall not be used
except as specified in (e) below.

Materials with resistivity above 5000 Ωcm are acceptable provided that in water
extracted from soil-water mix, the content of chlorides does not exceed 200ppm, the
content of sulphates does not exceed 1000ppm, and the pH value is in the range of 5
to 10.

The foundation soil physico-chemical requirements should also meet the above
criteria. If not, special consideration will be given to the foundation detailing or
design of reinforcing strips in bottom layers and facing panels.

(c) Quality Control

Initially at approval of source and subsequent at each change of source, backfill is to
be checked for sieve analysis, resistivity and angle of internal friction. The results will
indicate what further tests are needed, if any.

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 Reinforced Earth India P. Ltd.

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Document No. : IND HA 01 Date : 1st July 2008

(d) Water for Compaction

Water of minimum resistivity exceeding 700Ωcm shall be used for compaction.

(e.) Materials not conforming to the above

Materials not conforming to the above requirements may be used with the written
consent of Engineer after carrying out test. Such materials shall be tested for their
functional properties to assure that they are consistent with the parameters used in
the design calculations.

C. CONSTRUCTION REQUIREMENTS

The wall shall be measured from the bottom of the panel up to formation level on the
top of the pavement. The depth of the foundation below the finished ground level at
the foot of the slope or wall shall not be less than 1000mm.

The plan area of the wall/shape shall be excavated to provide a nominally level base,
with suitable plinth protection as required to receive the horizontal reinforcing
element.

A strip footing as trough guide, made of PCC shall be provided at founding level to
receive the facia or the bottom most Panel tier. This Plinth shall have adequate soil
cover against erosion and scour in particular cases of lower wall heights less than
6.0m.

1. Orientation

The reinforcing strips shall be placed at right angles to the face of the wall, with
greater cross sectional dimension in the horizontal plane. The reinforcement shall be
placed in the cross-sectional slope of 2.5 to 5% away from the facing towards the tail
end to drain-out storm water away from facing element.

If for any reason this is not possible (e.g., wing wall to a curved facia), then allowance
shall be made in the design for overlapping due to divergence of reinforcement.

Clear vertical spacing between the reinforcement shall not be less than 200mm
except for cross walls / return walls and in general reinforcement spacing shall not
exceed 800m.

2. Facing batter

With panel RCC facia initial batter (or set batter) shall be necessary for practical
installation as per proprietary design guidelines.

3. Drainage

Drainage shall be very strictly followed as per drawing and specifications in detail.
The Reinforced Earth backfill is considered as a self-draining media, having sufficient
permeability to relive hydrostatic pressures. However, water logging in the reinforced
fill increases the pore pressure coefficient thereby resulting in tensile forces in
Reinforced Earth Structure, reducing the stability of the structure. Wherever, there is
a probability of such occurrence, drainage outlets at the bottom level joints of panels

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 Reinforced Earth India P. Ltd.

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Document No. : IND HA 01 Date : 1st July 2008

with provision of non-woven geotextile backing shall be provided along the facia for
drainage redundancy. The reinforced fill shall have drainage bay, 600mm wide, with
19.5mm to 9.1mm well graded crushed aggregate to allow free draining of the
reinforced fill along with the retained fill.

4. Excavations

Excavations shall be in accordance with the requirements of General and Special

Specifications and in reasonably close conformity to the limits and construction
stages shown on the drawings.

4.1 Foundation Preparation

The foundation for Reinforced Earth Structures shall be graded level for a width
equal to or exceeding the length of reinforcing element or as shown on the drawings.
Prior to wall construction, if required by the Engineer, the foundation shall be
compacted with a smooth wheel vibratory roller. Any foundation soils found to be
unsuitable shall be removed and replaced.

5. Erection

Precast concrete panels shall be placed vertically with the aid of a compatible light
crane. For erection, panels are handled by means of lifting devices set into the upper
edge of the panels. Panels shall be placed in successive horizontal lifts in the
sequence shown on the drawings as backfill placement proceeds. As fill materials is
placed behind a panel, the panels shall be maintained in vertical position by means
of temporary wooden wedges placed in the joint at the junction of the two adjacent
top rows of panels during construction. As construction proceeds, and a fourth row is
erected, the lowest row of wedges can be removed and so on.

External bracing may also be needed for the initial lift. However, bracings shall be
placed in an area not more than 2.0 meter wide beyond the outer face of panels.

Vertical tolerances (plumb ness) and horizontal alignment tolerance shall not exceed
50mm when measured along a 4 meters straight edge. The maximum allowable
offset in any panel joint shall be 25mm.

6. Laying and Compaction

Backfill placement shall follow closely the erection of each lift of panels. At each
reinforcing element level, backfill should be roughly leveled before placing and
connecting the reinforcing elements. Reinforcing elements shall be placed normal to
the face of the wall or as shown on the drawings. The maximum layer thickness shall
not exceed 200 mm. The Contractor shall decrease this thickness if that is
necessary to obtain the specified density.

At the end of each day’s operation, the Contractor shall shape the last level of backfill
as to permit runoff of rainwater away from the wall face. Backfill shall be compacted
in accordance to the project specifications for embankment to a minimum required
compaction of 95% of modified proctor density in the entire width of the embankment,
except up to 1.5m from the rear face of wall, where the required compaction shall be
minimum 90 % of maximum density and shall determined by the standard test and
that the moisture content shall be plus or minus 2% of the optimum Moisture Content
as determined. Backfill compaction shall be accomplished without disturbance or

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Document No. : IND HA 01 Date : 1st July 2008

distortion of reinforcing elements and panels. Compaction in a strip of the 1.5 meter
wide adjacent to the backside of the wall facing, shall be achieved by the use of a
manually operated vibrating compactor, such that adverse edge stresses are not
transferred to the facing panels during construction.

D. SUPERVISION

A technical representative of the patentee shall be present periodically on site during

the casting and erection phases to ensure that the quality of the works performed by
the Contractor is in accordance to the specifications.

All expenses relative to his presence on site shall be borne by the Contractor.

E. APPROVAL OF PROPRIETARY PRODUCT / PROCESS / SYSTEM AND

ELIGIBILITY CRITERIA

Only proprietary system proven by International usage in comparable projects with

minimum 25 years similar international experience shall be permitted to be used. The
agency executing such job shall have a minimum experience of 10 years in design,
supply and construction supervision of mechanically stabilized earth structures in
India by himself or through its licensee.

The agency executing the job shall submit fully authenticated details of licensing and
collaboration arrangement, where relevant at the time of tender submission by the
contractor. The agency must possess relevant BBA certification demonstrating
similar/ equivalent material being used for the construction of Mechanically Stabilized
Earth Structures.

Documented proof of construction over 2,50,000 m2 of Reinforced Earth Wall and

single project of minimum 50000 m2 in a project is eligible to qualify.

All Reinforced Earth works shall be executed as per ISO: 9001:2000 scope of
registration for “The Structural design, procurement and supervision of installation for
Mechanically Stabilized Earth and Prefabricated Concrete Arch Structures for
overpasses, underpasses, interchanges and other similar applications” by the
specialized agency.

Only ISO 9001: 2000 certified Indian companies are eligible to qualify for reinforced
earth works. Fully authenticated details of registration certificate shall be provided
prior to commencement of works.

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