Ig 011 B 0030 0801 Ya

NARUITELJ / CLIENT:
REPUBLIC OF KOSOVO
MINISTRY OF TRANSPORT AND COMMUNICATIONS

PROJEKT / PROJECT:
MORIN TO MERDARE
KOSOVO MOTORWAY PROJECT

DIONICA / SECTION:
Section 1 - km 0+750 3+000

VRSTA / TYPE:
GEOTEHNIKI PROJEKT
GEOTECHNICAL DESIGN

RAZINA / LEVEL:
MAIN DESIGN

SADRAJ / TITLE:

GEOTEHNIKI PROJEKT TERRAMESH ZIDA
OD KM 2+580 DO KM 2+720
GEOTECHNICAL DESIGN
TERRAMESH WALL FROM KM 2+580 TO KM 2+720

GLAVNI PROJEKTANT / MAIN DESIGNER:

MIRJANA MAALA-BUHIN, dipl.ing.gra.

PROJEKTANT / DESIGNER:

IVANKA BRUNETTA, dipl.ing.gra.

PROJEKTANTI SURADNICI / ASSOCIATES DESIGNERS:

MARKO BIAN, dipl.ing.gra.
JELENA FILI, dipl.ing.gra.

DATUM / DATE:
listopad / October 2010

OZNAKA DOKUMENTA / FILE CODE:
IG 011 B 0030 0801 YA REVISION YA
KONZULTANT / CONSULTANT:

INSTITUT IGH
10 000 ZAGREB, J. RAKUE 1
File Code: IG 011 B 0030 0801 - YA INSTITUT IGH d.d.
Type: GEOTECHNICAL DESIGN
GEOTECHNICAL
DEPARTMENT
Zagreb, Janka Rakue 1

KOSOVO MOTORWAY PROJECT, SECTION 1
GEOTECHNICAL DESIGN REPORT
Terramesh_km 2+580-2+720_eng.doc Page 2 of 24

The following persons have participated in the realization of the Geotechnical Design for the
detailed design of Terramesh wall on the Kosovo Route 7, Morine - Merdare Motorway, Section
1 (from km 2+580 to km 2+720):

Designer: Ivanka Brunetta, B.Sc. (Civ.Eng.)

Associates: Marko Bian, B.Sc. (Civ.Eng.)
Jelena Fili, B.Sc. (Civ.Eng.)

GEOTECHNICAL
DEPARTMENT


Prepared by:
INSTITUT IGH d.d.
GEOTECHNICAL DEPARTMENT
Project:
MORIN TO MERDARE MOTORWAY
Assignment:
MAIN GEOTECHNICAL DESIGN FOR
TERRAMESH WALL ON
MORIN TO MERDARE MOTORWAY
SECTION 1
FROM KM 2+580 TO KM 2+720

TECHNICAL REPORT
Place and date: Zagreb, October 2010
GEOTECHNICAL
DEPARTMENT


CONTENTS
1. TECHNICAL DESCRIPTION.............................................................................. 5
1.1. INTRODUCTION ................................................................................... 5
1.2. DESIGN SOLUTION ................................................................................ 5
1.3. DESCRIPTION OF DESIGNED WORKS............................................................ 5
2. EMBANKMENT STABILITY ANALYSIS .................................................................. 7
3. TECHNICAL REQUIREMENTS FOR WORK EXECUTION AND QUALITY ASSURANCE AND
CONTROL PROGRAM..................................................................................12
3.1. GENERAL..........................................................................................12
3.1.1. Introduction................................................................................12
3.1.2. Staking our and topographic works.....................................................12
3.1.3. Clearing the terrain.......................................................................12
3.2. EXCAVATIONS ....................................................................................12
3.3. DISPOSAL OF MATERIAL.........................................................................13
3.4. PREPARATION OF FOUNDATION SOIL .........................................................13
3.5. GABIONS WITH TIE RODS .......................................................................13
3.5.1. Introductory notes ........................................................................13
3.5.2. System ......................................................................................13
3.5.3. Wire for production of mesh ............................................................13
3.5.4. PVC lining...................................................................................14
3.5.5. Mesh.........................................................................................14
3.5.6. Production and quality control..........................................................14
3.5.7. Delivery, storage and handling..........................................................15
3.5.8. Installation .................................................................................15
3.5.9. Installation procedure....................................................................15
3.5.10. Testing of the material used in the gabion with tie rods system....................16
3.5.11. References....................................................................................16
3.6. GABION STONE FILL .............................................................................16
3.7. GEOTEXTILE ......................................................................................17
3.8. FILL ON THE MESH AND FILL BEHIND THE MESH ............................................17
3.8.1. Material and installation .................................................................17
3.8.2. Quality control.............................................................................17
3.9. SLOPE PROTECTION BY STONE REVETMENT OF EMBANKMENT ...........................17
3.10. SOLUTION AND CONSTRUCTION SITE rEMEDIATION .....................................17
3.11. CONCLUSION ..................................................................................18
4. STAKEOUT.................................................................................................19
5. BILL OF QUANTITIES .....................................................................................22

GEOTECHNICAL
DEPARTMENT


1. TECHNICAL DESCRIPTION

1.1. INTRODUCTION
Part of the route from chainage km 2+580 to km 2+720 of the motorway through Kosovo,
from Morine to Merdare, Section 1, requires construction of an embankment with slope
inclination steeper than 1:1,5.
In order to resolve the problem of embankment on the subject location, it was decided that
the embankment should be constructed applying gabions with tie rods (Maccaferri Terramesh
system), enabling construction of slope steeper than 1:1,5.

1.2. DESIGN SOLUTION
A slope with inclination 1:1,5, approximately 1,5 m height, is designed from the motorway
edge. The toe consists of a berm followed by two gabion blocks with ties, slope of facing
10:1, with a berm 1,5 m wide in between.
The gabion blocks are constructed of elements height 1,0 m. The highest gabion construction
on the subject embankment section is 10 m.
Protection of the embankment slope with gabions and tie rods (Maccaferri Terramesh
system) proposes the use of the following elements (height x width x length):
1,0 m x 2,0 m x 6,0 m,
1,0 m x 2,0 m x 8,0 m,
The elements are made of mesh with the following characteristics:
Mesh type 8x10, hexagonal, double laid,
Tensile strength 46 kN (without creep),
Wire 2,7 mm, galvanized, PVC coated,
The wire can be treated with galfan zinc prior to PVC coating (galfan - 95% zinc, 5 %
aluminum),
Tensile strength of wire used for mesh is between 350 and 550 N/mm
2
, with minimum
10% yield during cracking.

Beginning of the embankment is secured with gabions which help in the formation of slope
10:1, with mesh tied to them as tie rods.
All used material must be in accordance with the defined technical requirements for work
execution, all in accordance with the GTC. The defined quality control and quality assurance
program must be followed for individual works.

1.3. DESCRIPTION OF DESIGNED WORKS
Preliminary works mark the beginning of the works on embankment. Approach roads must be
ensured as well as working plateaus for mounting of gabions with tie rods.
Machinery and other equipment must be ensured for execution of work on the subject
embankment and gabions with tie rods.

Cleaning of the terrain surface is done to remove the shrubs and trees, roots and loose
surface layer. Cleaning of terrain is done on the complete surface where the embankment is
to be constructed.
Prior to placing the gabions with tie rods, the excavation, i.e. the basic embankment must be
completed on the part which ensures free ongoing of work activities

Excavation is to be done in material category A, as wide excavation and one part (Sections 13
and 14) in material category C, where the soil replacement must be done shown on Figure 3
and appendix 1507 and 1508. Construction of gabion system with tie rods can start upon
completion of the required part of excavation, i.e. embankment.
The material from excavation can be placed on the gabion mesh and the embankments of the
gabion structure, i.e. material with adequate grading.
GEOTECHNICAL
DEPARTMENT


Preparation of the foundation plateau for construction of the lower gabion rows with tie
rods is done upon completion of excavation works. Since the excavation is done in rock
material - Category A and one part (Sections 13 and 14) in material category C, where the soil
replacement must be done shown on Figure 3 and appendix 1507 and 1508 - prior to
construction of gabions with tie rods, leveling of the surface must be done in all as in
construction of road subgrade.

Placing of gabions with tie rods can be done after preparation of foundation plateau which
must be leveled horizontaly in the transverse direction. The first gabion mesh with tie rods is
placed on the prepared foundation plateau.
Gabion baskets are filled with crushed stone material. Stone material placed on the gabion
facing must have particle size 20-25 cm and must be placed manually. The gabion fill must
have a minimum particle size of 15 cm, to ensure that the material will not fall out through
the mesh.
During the procedure of gabion arrangement, the difference between the fill height in
adjacent elements must not be greater than 1/3 of the gabion height (33 cm). Gabion baskets
and the horizontal mesh of adjacent elements are interconnected by< galvanized rings
(distance between rings is 20 cm). Gabions are tied to other gabions in the previous and the
following/next rows.

Execution of embankment on the tie rods and behind the gabions with tie rods is done
simultaneously, but after installation of gabions. Embankment slope above the gabions is
done with an inclination of 1:1,5, with a stone lining on the surface. Thickness of layers
during embankment construction must not exceed 50 cm, and after spreading and
compaction, in accordance with the technical requirements.
Maximum difference in height between the rock fragments placed on the anchored mesh and
the embankment behind the anchor mesh, in relation to the gabion must not exceed 1m.

Geotextile is placed behind the gabion baskets. Geotextile is placed according to the
characteristic profile.

Finishing works include removal of all excess material, terrain leveling and site clearance
and rehabilitation.
GEOTECHNICAL
DEPARTMENT


2. EMBANKMENT STABILITY ANALYSIS

Stability analyses were done with the SLOPE/W (Geo-Slope International Ltd. Calgary,
Alberta, Canada) program of the GEOSLOPE software, according to the Spencer Method
(1967). Analyses were done for permanent load, along with the seismic stability control.

For the purposes of analysis, characteristics of gabions with tie rods were taken according to
the specifications of the Terramesh system, obtained from the WERKOS d.o.o. Company.
This is why the system to be used for work execution must correspond to Maccaferri
Terramesh system specifications.

Therefore, the mesh strength, for which the tensile strength is defined as P
c
=46 kN/m for a
designed life period of 60 years, has the following safety factors:
For a design period of 60 years f
m
=1,20
For mechanical damages during construction works f
d
=1,25
For aggressive influence of environment f
e
=1,10,

Therefore, maximum design load taken over by the reinforcement is:
P
des
= P
c
/ (f
m
x f
d
x f
e
) = 27,9 kN/m

Analysis of stability ware done for the greatest height of gabion with tie rods (10 m) located
on limestone and for the highest (9 m) located on the clay with rock debris, delluvium,
quaternery, which are to be constructed on the subject section.

Analyses are given in Figures 1 and 3. A geotechnical model and results of analysis for
permanent load are given.

GEOTECHNICAL
DEPARTMENT


Analysis of stability for the highest gabions with tie rods (H=10 m) located on the
limestone

1
.
6

1
.6

1
.
7

2
.
6

1.561
333,834 m
R
o
a
d

a
x
i
s
P=27,9 kN/m
q=33 kN/m'
10:1
10:1
Soil Model: Mohr-Coulomb
Unit Weight: 19
Cohesion: 4
Phi: 45
Unit Weight: 20
Cohesion: 0
Phi: 45
Unit Weight: 19
Cohesion: 15
Phi: 25
Description: RMR=39, cs=64 MPa, mi=7
Soil Model: Shear/Normal Fn.
Unit Weight: 25
Shear/Normal Fn. #: 2
Ru: 0.23
Unit Weight: 27
Ru: 0.23
KM 2+690
Fromroad axis (m)
-70 -65 -60 -55 -50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
H
e
i
g
h
t

(
m
)
295
300
305
310
315
320
325
330
335
340
345
350

Figure 1: Geotechnical model and results of stability analyses

Safety factor for the static load Fs=1,561, which is satisfactory.

Table 1 shows results of the slide stability analyses at the bottom of individual gabion block
with tie rods.

Safety factor - F
S
Bottom of GABION 1 -
Bottom of GABION 2 2,943
GEOTECHNICAL
DEPARTMENT



Table 1: Results of the Stability Analyses

For analyses under dynamic conditions, the maximum horizontal acceleration for a 200 year
recurrence interval was taken as:
g a
H
= 20 , 0
max

g a
V
= 10 , 0
max

1
.
1
9
4

1
.
5
4
4

1
.
8
4
4

1.094
333,834 m
R
o
a
d

a
x
i
s
P=27,9 kN/m
10:1
10:1
Unit Weight: 19
Cohesion: 4
Phi: 45
Unit Weight: 20
Cohesion: 0
Phi: 45
Unit Weight: 19
Cohesion: 15
Phi: 25
Unit Weight: 25
Ru: 0.23
Unit Weight: 27
Ru: 0.23
KM 2+690
Fromroad axis (m)
-70 -65 -60 -55 -50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35
H
e
i
g
h
t

(
m
)
295
300
305
310
315
320
325
330
335
340
345
350

Figure 2: Analyses of stability under dynamic conditions

Figure 2 shows the analysis for seismic load, without traffic load.
The analysis gave the safety factor of F
s
=1,094.
GEOTECHNICAL
DEPARTMENT


Analysis of stability for the highest gabions with tie rods (9 m) located on the clay with
rock debris, delluvium, quaternery
1.73
1
.8
3

2
.
1
3

2
.
1
3

1.630
333,958 m
R
o
a
d

a
x
i
s
P=27,9 kN/m
q=33 kN/m'
10:1
10:1
Unit Weight: 19
Cohesion: 4
Phi: 45
Unit Weight: 20
Cohesion: 0
Phi: 45
Unit Weight: 19
Cohesion: 15
Phi: 25
Unit Weight: 25
Ru: 0.23
Unit Weight: 27
Ru: 0.23
KM 2+710
From road axis (m)
-70 -65 -60 -55 -50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
H
e
i
g
h
t

(
m
)
295
300
305
310
315
320
325
330
335
340
345

Figure 3: Geotechnical model and result of stability analyses

Safety factor for static condition is Fs=1,630, which is satisfactory. It is necessary for stability
of the wall to replace low bearing soil, under the wall, as shown on Figure 3 and on appendix
1507 and 1508.

Table 2 shows results of the slide stability analyses at the bottom of individual gabion block
with tie rods

Safety factor - F
S
Table 2: Results of stability analyses
GEOTECHNICAL
DEPARTMENT


For analyses under dynamic conditions, the maximum horizontal acceleration for a 200 year
recurrence interval was taken as:
g a
H
= 20 , 0
max

g a
V
= 10 , 0
max

1
.
3
5
9

1
.
3
5
9

1
.
5
5
9

1
.
8
5
9

1
.
9
5
9

1.259
333,958 m
R
o
a
d

a
x
i
s
P=27,9 kN/m
10:1
10:1
Unit Weight: 19
Cohesion: 4
Phi: 45
Unit Weight: 20
Cohesion: 0
Phi: 45
Unit Weight: 19
Cohesion: 15
Phi: 25
Unit Weight: 25
Ru: 0.23
Unit Weight: 27
Ru: 0.23
KM 2+710
Fromroad axis (m)
-70 -65 -60 -55 -50 -45 -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30
H
e
i
g
h
t

(
m
)
295
300
305
310
315
320
325
330
335
340
345

Figure 4: Analysis of stability under dynamic conditions

Figure 4 shows the analysis for seismic load, without traffic load.
The analysis gave the safety factor of F
s
=1,259.

The safety factor F
s
>1 is taken as satisfactory for all stability analyses under dynamic
conditions. Therefore is can be concluded that the confirmed geometry of embankment and
gabions with tie rods has a satisfactory factor of safety under dynamic conditions.

GEOTECHNICAL
DEPARTMENT


3. TECHNICAL REQUIREMENTS FOR WORK EXECUTION AND QUALITY
ASSURANCE AND CONTROL PROGRAM

3.1. GENERAL
3.1.1. Introduction
In order to execute the embankment works successfully, respective Laws and regulations
must be respected, as well as Technical requirements, given in the text.
The Quality Assurance and Quality Control Program, as well as the Technical requirements are
given per individual works.
The Technical Requirements are in accordance with:
Applicable Design and work execution principles applied in civil engineering,
General Technical Conditions for road works (IGH, Zagreb, 2001.)
Technical conditions can be supplemented and changed during work execution, but only
within the framework defined by the design and in agreement with the Designer and Client.
These supplements and changes are an additional obligation for the Contractor. If they
require a change in conditions defined by the Contract, then an Annex to the Contract is
required.

3.1.2. Staking our and topographic works
Staking out must be done prior to start of works. Staking out of the embankment elements
shall be done in accordance to this design.
Design profiles and excavation line shall be staked out, followed by staking out of the
structure itself. Staking out of the profile and structure of the gabions with tie rods must be
secured from destruction, it must be clearly marked during the complete duration of works.
Works are to be executed according to the GTC.
Compliance of the staking out works with the Staking out Survey Report and the Design is
checked by the Supervising Engineer, the required exactness of the staking out works is 1cm.
During work execution, the compliance of works and design is checked. The required level of
exactness is given for every group of works.
During the excavation stage the dimension of foundation plateaus are checked and recorded.
During construction, the achieved elevation levels per profile are checked for every row of
gabions, as well as the compliance of the constructed facing of slope with the designed.

3.1.3. Clearing the terrain
Terrain clearance, including cutting of low, sporadic shrubs and removal of the loose, surface
rock material and fragments.

3.2. EXCAVATIONS
Excavation of the subject embankment shall be done in soil category A, as wide excavation
and one part (Sections 13 and 14) in material category C, where the soil replacement must be
done shown on Figure 3 and appendix 1507 and 1508.
Excavation is doe according to the levels and measurements given in this design. The works
are executed, checked and calculated in accordance to the GTC.
Topographic staking out is done according to the measurements and levels given in this design
profiles. Staking out exactness of 1 cm is requested. Upon completion of individual stages of
excavation, geodetic control of executed works is done, with the same measuring exactness.
The following must be checked during excavation works:
Excavation to be done according to profiles and elevation levels given in this design,
Slope inclination must be in accordance with the design,
That the evenness of excavation bottom is 5 cm,
The excavation dimensions are checked geodetically and for some section are entered into
the site diary.
GEOTECHNICAL
DEPARTMENT


3.3. DISPOSAL OF MATERIAL
Material which is transported to the construction site to be used in construction and material
from excavation (suitable for use) is stockpiled on the site itself for subsequent use, i.e. until
subsequent transport (material not suitable for use).
Stockpiling must be done in a secure and safe manner, without consequences (landslides,
demolition).

3.4. PREPARATION OF FOUNDATION SOIL
Foundation soil surfaces need to be prepared for mounting of the system of gabions with tie
rods. Excavations are done in rock material, category A, therefore prior to installation of the
gabion system with tie rods, contact surfaces between the mesh and the foundation soil must
be leveled, in all similar to the preparation of road subgrade. Works are executed, checked
and calculated in accordance with the GTC Item 2-10.3 for subrgrades in rock material and in
cuts.
Controls must be done in accordance with the GTC for subgrades.
Foundation plateau levels are checked through surveying, with an exactness of 1 cm.

3.5. GABIONS WITH TIE RODS
3.5.1. Introductory notes
The manufacturer's specifications of the adopted system must be confirmed by respective
certificates of conformity and Reports of respective tests which confirm the required
properties, as well as validation tests. The product must be in accordance with the already
mentioned Technical Conditions and the Maccaferri Terramesh system specifications.
Gabions with tie rods consist of elements made of woven double twisted hexagonal mesh type
8x10, made of galvanized and plastic coated wire diam. 2,7 mm with PVC lining
Elements width 2,0 m, height 1,0 m and length 6,0 and 8,0 m are adopted for the subject
embankment.

3.5.2. System
Partial safety factors for the system must be in accordance with the design partial safety
factors for the 60 year service life of structure:
f
m
= 1,2 safety factor of production and exploitation of data,
f
d
= 1,25 safety factor for mechanical damage, for the use of rock material for fill,
f
e
= 1,1 safety factor for environmental influence.

3.5.3. Wire for production of mesh
Wire for production of mesh must have a tensile strength between 350 and 550 N/mm
2
with a
minimum yield strength during fracture of 10%, it must be galvanized (or galfan zinc
treated),all in accordance with respective relevant standards (BS, DIN or ASTM).

Different types of wire are as follows:
Main: Minimum weight of galvanization 275 g/m
2
, minimum diameter of steel core 2,70 mm
(0,06), minimum diameter with lining 3,7 mm.
Ends and borders: Minimum weight of galvanization 275 g/m
2
, minimum diameter of steel
core 3,40 mm (0,08), minimum diameter with lining 4,4 mm.
Connections and joints: Minimum weight of galvanization 240 g/m
2
, minimum diameter of
steel core 2,20 mm (0,06), minimum diameter with lining 3,2 mm.
GEOTECHNICAL
DEPARTMENT


3.5.4. PVC lining
PVC material for lining of wire must have the following characteristics:
Specific weight 13,0-13,5 kN/m
3
, hardness 50-60 , tensile strength exceeding 210
kN/m
2
,
Elongation 200-280%, weight loss less than 5% after 24 hours at temperature of 105
o
C,
satisfactory abrasion resistance.
Furthermore, the material must satisfy the quality and durability requirements:
Resistance to salt,
Resistance to UV rays,
Resistance to high and low temperature exposure.
The requirements are that the required initial characteristics do not significantly change after
the implemented tests:
That no cracks, air bubbles or unacceptable color changes appear,
That the change in specific weight does not reach 6%,
That the change in hardness does not reach 10%,
That changes in tensile strength and elongation do not reach 25%,
That the change in resistance to abrasion doe not reach 10%,
That the temperature at which material becomes brittle does not fall under 20
o
C.
All the mentioned properties must be proven according to some relevant standard (BS, DIN
and ASTM).

3.5.5. Mesh
Every mesh board must be strengthened at the edges and connected with galvanized, PVC
lined wire. Front board (gabion facing) must be strengthened on the inside, minimum with a
wire used for ends and borders, in order to reach the required firmness during mounting.
The front and upper board of the gabion basket are overlapped during production. The back
and lateral sides of the gabion basket are made of special mesh peaces, fixed to the board
during production. Additional, special mesh board which serves as a diaphragm wall is fixed to
the front and lateral sides at the construction site, at every 1m length.
The dimensions oft he board must be in accordance with the design, with a tolerance in
length of 1%.
The tensile strength f mesh must be at least 46 kN/m, without creep.
All required properties must be in accordance with one of the relevant standards (BS, DIN or
ASTM).

3.5.6. Production and quality control
Gabion mesh with tie rods must be delivered directly from the manufacturer or from the
authorized supplier, with all required certificates and the certificate of conformity with the
manufacturer's specifications.
The mesh is made of double twisted hexagonal wire, with edges strengthened with larger
diameter wire. The mesh is cut to required length, while the thicker wire, used for
strengthening, is folded toward the board after cutting and woven into the wire fabric.
Lateral boards are fixed to the main board, the diaphragm wall is not connected to the main
board during production but is delivered separate with the main board and connected at the
construction site.
Factory quality control includes visual control and control of dimensions of the wire, control
of the galvanization percentage, thickness of plastific coating and control of the dimensions
of woven mesh.
Production must be controlled in accordance to ISO 9002.
GEOTECHNICAL
DEPARTMENT


3.5.7. Delivery, storage and handling
Upon delivery to the construction site, the elements must be stored at a place distanced from
the construction site traffic to prevent accidental damage. The elements must remain in their
packages until their installation or mounting.
A label bearing the certificate number, name of manufacturer, number of batch and number
of product must be on every pile.
The piles must be handled with care to avoid damage oft he wire lining. Individual elements
can be manually handled.
During installation the elements are to be connected with anti corrosion protected steel rings
at every 20 cm. The rings must be at least 3 mm diameter, tensile strength 170 kg/m
2
.

3.5.8. Installation
The following must be considered Prior to and during installation works:
Preparation of foundation soil and construction of embankment in accordance with the
technical requirements of the design.
Properties of material used for fill must satisfy the design requirements.
The product must be protected from damage caused by traffic at the construction site
and equipment used for installation purposes.
Connection of elements must be done with anti corrosion protected steel, daim. 3
mm, are every 20 cm.
The elements shall be placed longitudinally, parallel to the direction of main stress.
Positions for installation are defined by surveying and staking out according to the
measurements and dimension lines given in the cross sections. Staking out must be exact to
1 cm. Geodetic control of installation is continuously done during work execution, and
surveying of the executed work after installation of each gabion row, all according to equal
exactness level.

3.5.9. Installation procedure
Gabion elements are opened, the front side is shaped into a gabion basket, connected by
rings, the mesh is extended into the required direction, in accordance with the design.
Gabion baskets and the horizontal mesh of the adjacent elements are interconnected in
rows by galvanized rings (distance between rings is 20 cm). The gabions are also
connected with the gabions in the previous row.
The diaphragm wall of the gabion is installed (separate mesh board dividing the element
in two parts each 1 m length).
The facing of the gabion is filled first with crushed stone material, followed by
mechanical filling of the remaining part of the gabion, followed by a fill over the
reinforcing mesh.
At approximately 1/3 and 2/3 of the gabion height, tie rods are mounted, longitudinally 2
tie rods on each gabion half (the diaphragm wall is in the middle of the element - 2 m
long, thus every element has 8 tie rods.
Geotextile is placed behind the gabions, 300 g/m
2
, according to the normal cross section.
Geotextile is placed on the lower mesh, approximately 1,0 m width, vertically along the
back of the gabion, and horizontally under the upper mesh , again 1 m wide. Geotextile is
overlaping. Width of the overlap is 20 cm.
The fill is placed on the mash, minimum 150 mm thick. The mesh must be adequately
covered by the fill material prior to compaction or drive over. The vehicles must not pass
directly over the mesh.
Maximum thickness of the layers to be compacted depends on the type of fill material, as
well as on the machinery available at the construction site, but it must not exceed 500
mm.
GEOTECHNICAL
DEPARTMENT


During the arrangement of gabions, the difference in the height of fill between adjoining
gabion elements must not exceed 1/3 of the gabion height (33 cm).
Reinforced bottom surface and the embankment behind are executed simultaneously but
parallel to the execution of gabions.
Gabion facing is designed as vertical. Inclination toward the front is not acceptable but an
inclination of 5% toward the back can be tolerated.

3.5.10. Testing of the material used in the gabion with tie rods system
Quality control includes:
Initial testing of the reinforcing steel
Initial testing of the reinforcing steel must satisfy all criteria declared by the manufacturer
and the number of tests is defined by the greater of the following values: one test for every
delivered group, or a minimum of 3 test cycles.
Control test and validation tests of the reinforcing steel
Tests on reinforcing steel must satisfy all criteria declared by the manufacturer and the
number of tests is defined by the greater of the following values: one test for every delivered
group: one test for every delivered group, or a minimum of 6 test cycles

3.5.11. References
Along with the proof that he has fulfilled all technical requirements, the manufacturer shall
also give references of similar structures where their product was used or installed.

3.6. GABION STONE FILL
Stone used for the gabion facing must have a grain size of 20-25 cm, and is manually
arranged. The gabion fill must have a minimum grain size of 15 cm, in order to ensure that it
does not fall out through the mesh. Maximum tolerated particle size is 25 cm.
The following tolerances are allowed for the stone fill:
Grain size over 25 cm diam. Under the condition that the overall quantity does not
exceed 5% of the cell volume,
Grain size smaller than the minimum allowed, but not smaller than 8 cm diam., up to
10% of the cell volume.

The quality of technical-building stone must be in accordance with the following standards:
1. Determination of frost resistance EN 12 371
2. Determination of resistance to crystallization (15 cycles) EN 12 370
3. Determination of compressive strength (dry condition and water saturated state)
EN 1926
4. Determination of water absorption at atmospheric pressure EN 13 755
5. Spatial masses EN 1936
6. Density EN 1936
7. Porosity EN 1936

The following values are required: minimum density 2600 kg/m
3
, water absorption max. 2,5%,
compressive strength min. 80 MPa, consistency: Percent by mass loss, max. 10%.
GEOTECHNICAL
DEPARTMENT


3.7. GEOTEXTILE
Geotextile is placed between the embankment and the gabion, in accordance with the
characteristic cross section.

Characteristics of geotextiles:
PROPERTY UNIT VALUE
Mechanical
Tensile Strengt kN/m

18,5
Tensile Elongation % >55
Resistance to static puncture N
Dynamic pyramid puncture resistance mm
3000
<17
Hydraulic
Apparent Opening Size mm

0,1-0,2
Permittivity sec-1 >1

The placement of geotextile is visually inspected.

3.8. FILL ON THE MESH AND FILL BEHIND THE MESH
3.8.1. Material and installation
In order to be installed into the fill on the mesh and behind the mesh, the material must
satisfy all the GTC requirements for construction of stone material fill (Item 2-09 and 2-09.3).
Installation is performed in accordance with the GTC (Item 2-09.3), under the condition that
the layers are not more than 50 cm thick.

3.8.2. Quality control
Control tests are the responsibility of the Contractor, validation tests are approved by the
Supervising engineer (GTC, Item 2-09). Control and validation tests include:
Control of the dimensions and slope of fill,
Determining the modulus of compressibility (Ms) by circular plate, or the degree of
compaction S
z
in relation to the standard Proctor's Procedure,
Determining the grain size distribution of the material used for fill.
Quality control is done in accordance with the GTC (Item 2-09). Criteria that need to be
fulfilled are the GTC criteria (Item 2-09.3).

3.9. SLOPE PROTECTION BY STONE REVETMENT OF EMBANKMENT
Above the gabions to the shoulder height, the embankment with inclination 1:1.5 of a slope is
constucted. For the surface protection of a slope, stone revetment is applied. Selected larger
stones from the stone material, provided for incorporation into the embankment, is applied
for this slope protection (must meet requirements for stone filling gabions). The thickness of
this slope protection is 30-50 cm.

3.10. SOLUTION AND CONSTRUCTION SITE REMEDIATION
After completion of construction works according to design, and remediation of possible
faults, the terrain surrounding the construction site needs to be rehabilitated and the
executed works incorporated into the surroundings as best as possible.
All equipment, excess construction material and excess material from excavation need to be
removed from the construction site and adequately managed. The surface terrain needs to be
as designed, and the surrounding terrain needs to be brought to its original state.
The approach roads to the construction site need to be remedied in accordance with the
visual requirements of the environment, and the roads that shall be permanently used must
be rehabilitated and improved according to the criteria applicable during the maintenance
stage of structure.
Control is implemented during work execution and upon completion of all works.
GEOTECHNICAL
DEPARTMENT


3.11. CONCLUSION
The works have been designed on the basis of forecasted data determined during
geotechnical investigations. If discrepancies from the forecasted situation are determined
during work execution, the design solutions need to be adjusted to the actual situation. All
changes in the design can be done only upon the approval by the Designer.
Due to the nee to adjust to the construction technologies, the contractors can propose
changes and adjustments of designed works, but all such changes must be approved by the
designer and supervising engineer prior to implementation.
Continuous supervision must be ensured during work execution.

GEOTECHNICAL
DEPARTMENT


4. STAKEOUT

No Point X Y Z
1 S1L_01 7464973,77 4669521,55 327,70
2 S1L_02 7464976,43 4669517,58 327,70
3 S1L_03 7464976,60 4669517,33 331,70
4 S1L_04 7464986,40 4669502,75 -
5 S1R_01 7464983,20 4669525,44 327,70
6 S1R_02 7464984,73 4669523,16 327,70
7 S1R_03 7464984,90 4669522,91 331,70
8 S1R_04 7464995,13 4669507,70 -
9 S2L_01 7464982,37 4669526,67 326,70
10 S2L_02 7464985,10 4669522,62 326,70
11 S2L_03 7464985,32 4669522,29 331,70
12 S2R_01 7464991,79 4669530,58 326,70
13 S2R_02 7464993,39 4669528,20 326,70
14 S2R_03 7464993,62 4669527,87 331,70
15 S2R_04 7465003,79 4669512,75 -
16 S3L_01 7464990,94 4669531,85 325,70
17 S3L_02 7464992,98 4669528,83 325,70
18 S3L_03 7464994,04 4669527,25 331,70
19 S3R_01 7465000,35 4669535,77 325,70
20 S3R_02 7465001,28 4669534,40 325,70
21 S3R_03 7465002,34 4669532,83 331,70
22 S3R_04 7465012,39 4669517,88 -
23 S4L_01 7464999,48 4669537,08 324,70
24 S4L_02 7465001,50 4669534,07 324,70
25 S4L_03 7465002,61 4669532,41 331,70
26 S4R_01 7465008,19 4669542,04 324,70
27 S4R_02 7465009,80 4669539,65 324,70
28 S4R_03 7465010,91 4669537,99 331,70
29 S4R_04 7465020,92 4669523,11 -
30 S5L_02 7465010,08 4669539,24 324,70
31 S5L_03 7465011,19 4669537,58 331,70
32 S5R_01 7465016,76 4669547,22 324,70
33 S5R_02 7465018,37 4669544,82 324,70
34 S5R_03 7465019,49 4669543,16 331,70
35 S5R_04 7465029,39 4669528,43 -
36 S6L_02 7465018,65 4669544,40 324,70
37 S6L_03 7465019,77 4669542,74 331,70
38 S6R_01 7465025,11 4669552,73 324,70
39 S6R_02 7465026,95 4669549,98 324,70
40 S6R_03 7465028,07 4669548,32 331,70
GEOTECHNICAL
DEPARTMENT


41 S6R_04 7465037,81 4669533,84 -
42 S7R_01 7465034,08 4669557,30 324,70
43 S7R_02 7465035,25 4669555,56 324,70
44 S7R_03 7465036,37 4669553,90 331,70
45 S7R_04 7465046,15 4669539,34 -
46 S8L_01 7465033,26 4669558,52 323,70
47 S8L_02 7465035,20 4669555,64 323,70
48 S8R_01 7465042,00 4669563,45 323,70
49 S8R_02 7465043,49 4669561,22 323,70
50 S8R_03 7465044,67 4669559,48 331,70
51 S8R_04 7465054,44 4669544,94 -
52 S9L_02 7465043,21 4669561,64 323,70
53 S9L_03 7465044,39 4669559,90 331,70
54 S9R_01 7465050,18 4669569,20 323,70
55 S9R_02 7465051,51 4669567,22 323,70
56 S9R_03 7465052,69 4669565,48 331,70
57 S9R_04 7465062,67 4669550,63 -
58 S10L_01 7465048,60 4669571,56 321,70
59 S10L_02 7465051,12 4669567,80 321,70
60 S10L_03 7465052,41 4669565,89 331,70
61 S10R_01 7465057,60 4669576,08 321,70
62 S10R_02 7465059,42 4669573,38 321,70
63 S10R_03 7465060,70 4669571,47 331,70
64 S10R_04 7465070,83 4669556,41 -
65 S11L_02 7465059,14 4669573,79 321,70
66 S11L_03 7465060,43 4669571,89 331,70
67 S11R_01 7465066,45 4669580,84 321,70
68 S11R_02 7465067,44 4669579,37 321,70
69 S11R_03 7465068,72 4669577,47 331,70
70 S11R_04 7465078,95 4669562,25 -
71 S12R_01 7465069,73 4669593,89 321,70
72 S12R_02 7465075,74 4669584,95 321,70
73 S12R_03 7465077,02 4669583,04 331,70
74 S12R_04 7465087,01 4669568,19 -
75 S13L_01 7465072,54 4669589,71 322,70
76 S13L_02 7465075,38 4669585,49 322,70
77 S13L_03 7465076,60 4669583,67 331,70
78 S13R_01 7465076,77 4669601,34 322,70
79 S13R_02 7465083,68 4669591,07 322,70
80 S13R_03 7465084,90 4669589,25 331,70
81 S13R_04 7465095,03 4669574,19 -
82 S14L_01 7465082,25 4669593,20 324,70
83 S14L_02 7465083,37 4669591,53 324,70
84 S14L_03 7465084,48 4669589,87 331,70
GEOTECHNICAL
DEPARTMENT


85 S14R_01 7465085,86 4669605,75 324,70
86 S14R_02 7465091,67 4669597,11 324,70
87 S14R_03 7465092,78 4669595,45 331,70
88 S14R_04 7465103,01 4669580,24 -

NOTE: The table give point staking. Point Sxx_01 is related to the start of excavation for each
section, Point Sxx_02 for the lower edge of the first row of gabions, Point Sxx_03 for the
upper edge of the last line of gabions and Point Sxx_04 is on the intersection of Terramesh
wall cross section with the centre line of the highway.
GEOTECHNICAL
DEPARTMENT


5. BILL OF QUANTITIES

Item Description Unit measure Quantity Unit price Total

1. Stakeout.
Prior to beginning of works, but after excavation of the gabion
structure, design profiles and excavation line must be staked out.
Stakeout of the structure profile must be adequately protected
and must be clearly marked during the complete period of works.
Works are executed, checked and calculated in accordance with
the GTC (Item 1-02).
Calculated per pc of staked out profile.
pcs 88 ............. .............

2. Excavation in material category A and one part (Sections 13 and
14) in material category C, where the soil replacement must be
done, for construction of gabion with tie rods. Executed as wide
excavation in the embankment toe. Transversely and
longitudinally a horizontal surface must be formed, for installation
of gabions
the GTC (Item 2-02.1).
Calculated per m
3
of excavation in natural state.
m
3
5740,00 ............. .............

3. Preparation of the excavation surface for installation of gabion
mesh. This is relevant for the contact surfaces between the mesh
and the foundation soil. Excavation is done in rock material,
category A, therefore prior to installation of gabions with tie rods,
leveling of the surface must be performed as for road subgrade.
the GTC (Item 2-10.3) for subrgade in rock material and cuts.
Calculation per m
2
of surfaces prepared for installation of gabion
mesh.
m
2
1622,00 ............. .............

4. Supply, delivery and installation of gabion with tie rods elements.
All elements and the system as a whole must be in accordance
with technical solutions given in the design.
Calculated per pc of element installed in the structure, with
defined dimensions (length x width x height).

6 m x 2 m x 1 m .
pc 240,00 ............. .............
8 m x 2 m x 1 m .
pc 285,00 ............. .............
GEOTECHNICAL
DEPARTMENT


5. Supply, delivery and placing of geotextile. Geotextile is placed
according to characteristic profile , between the gabion and
embankment.
Calculated per m
2
of placed geotextile.
m
2
3780,00 ............. .............

6. Supply, delivery and installation of crushed stone material used to
fill the gabion baskets.
Stone used for the gabion facing must have grain size 20-25 cm
and is manually arranged.
The gabion fill must have a minimum grain size of 15 cm, to
prevent the material from falling through the mesh. Maximum
allowed grain size is 25 cm.
Fill material is mechanically placed in the gabion.
The following discrepancies are tolerated for stone fill material:
- grain size larger than 25 cm, under the condition that the
overall quantity is less than 5% of the cell volume,
- grain size less than minimum but not less than 8 cm, up to 10%
of cell volume.
Diaphragm walls must be placed before filling the gabion baskets,
i.e. during placing of tie rods.
Calculated per m
3
of executed gabions.
m
3
1050,00 ............. .............

7. Supply, delivery and installation of stone material to be placed on
the system mesh.
Material must be in accordance with the GTC (Item 2-09.3) for
construction of stone material fill.
Installation is done in two layers minimum, at every distance
between the tie rod mesh, which bring the thickness of layer down
to 0,5 m, and the maximum grain size to 25 cm (half of the layer
).
the GTC (Item 2-09.3) for stone material fill.
Calculated per m
3
of executed fill on the mesh.
m
3
6390,00 ............. .............

8. Supply, delivery and installation of crushed stone for preparation
of stone lining of the embankment above the gabion, as protection
against erosion. The stone must satisfy all design requirements for
gabion fill material. It is mechanically arranged in a layer of 30-50
cm.
Calculated per m
2
of placed stone lining.
m
2
393,00 ............. .............
GEOTECHNICAL
DEPARTMENT


9. Measuring the modulus of deformation within the fill by a multi-
channel analysis of surface waves and the measurement of spatial
displacement at three points of the profile 2+690 road axis (0+110
gabion wall axis)
Works are executed in all according to the technical requirements
defined in the geotechnical design. Item includes supply, delivery
and installation of all materials and equipment, measurements and
preparation of reports, with the confirmation of design solution
according to the measurement results
Determining the modulus of deformation by multi-channel analysis
(measurement and data analysis) pc
Supply and installation of bench marks pc
Measurements and data analysis pc

Designer: Ivanka Brunetta, BSc.CE

Associate: Marko Bian, BSc.CE
Jelena Fili, BSc.CE

Ig 011 B 0030 0801 Ya

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