TMS INSTALLATION MANUAL

Rev: 1, Date 01.10.2018

TERRAMESH SYSTEM
INSTALLATION MANUAL
AUTHOR: MACCAFERRI (REFERRED TO OFFICINE MACCAFERRI S.p.A.)

Corp. Technical Department Corp. DT Sect. Specialist EMEA Technical Manager

2 01/10/2018 S. Sordo P. Di Pietro M. Vicari
EMEA Technical Division Corp. DT Sect. Specialist EMEA Technical Manager
1 12/04/2017 D. Tubertini P. Di Pietro M. Vicari
REV. DATE PREPARED BY CHECKED BY APPROVED BY

Rev. DESCRIPTION OF REVISIONS SINCE THE LAST VERSION

2 Dimensions in Fig.1; number of rings; English check;
1 ETA Certification; Construction site management; Inclined foundation pad; Placement of structural fill; Gabion repair;
Installation productivity

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NOTICES AND ASSUMPTIONS ................................................................................................ 5

1. INTRODUCTION .................................................................................................................... 7

2. IMPORTANT INFORMATION ................................................................................................ 8

2.1 RESPONSIBILITIES ..................................................................................................................................... 8

2.2 CONSTRUCTION DESIGN .......................................................................................................................... 8

2.3 MATERIALS AND REQUIREMENTS BEFORE STARTING ........................................................................ 8

2.4 CONSTRUCTION SITE MANAGEMENT ................................................................................................... 12

2.5 REQUIRED MACHINERY FOR INSTALLATION ....................................................................................... 12

2.6 REQUIRED EQUIPMENT FOR INSTALLATION........................................................................................ 12

2.7 ESTIMATED WORKING TEAM .................................................................................................................. 12

2.8 WORK TO BE DONE BY THE CONTRACTOR ......................................................................................... 12

2.9 SERVICES PROVIDED BY MACCAFERRI................................................................................................ 13

2.10 MATERIALS PROVIDED BY MACCAFERRI ............................................................................................. 13

3. FOUNDATION ...................................................................................................................... 14

3.1 FOUNDATION PREPARATION ................................................................................................................. 14

3.2 SETTING OUT............................................................................................................................................ 15

3.3 INCLINED FOUNDATION PADS................................................................................................................ 15

4. TERRAMESH SYSTEM ASSEMBLY ................................................................................... 17

4.1 FLATTENING THE UNITS.......................................................................................................................... 17

4.2 ASSEMBLY AND LACING THE INDIVIDUAL UNITS ................................................................................. 17

4.3 GEOGRID REINFORCEMENT (IF PRESENT) .......................................................................................... 19

4.4 PLACING THE TERRAMESH SYSTEM UNITS ......................................................................................... 21

4.5 PLACEMENT OF THE STRUCTURAL FILL............................................................................................... 28

4.6 COMPACTION OF THE STRUCTURAL FILL ............................................................................................ 29

4.7 BACKFILLING ............................................................................................................................................ 31

5. CONSTRUCTION DETAILS ................................................................................................. 32

5.1 INSTALLATION IN CORNERS AND CURVES .......................................................................................... 32

5.2 SHAPING AND ENDING OF STRUCTURES .............................................................................................. 33

5.3 INTERFERENCES, OBSTRUCTIONS AND FACING PENETRATIONS ................................................... 33

5.4 INTERNAL AND EXTERNAL DRAINAGE .................................................................................................. 36

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6. CAUSE-EFFECT RELATIONS ............................................................................................. 38

6.1 CAUSE-EFFECTS TABLE.......................................................................................................................... 38

6.2 TOLERANCES ........................................................................................................................................... 39

7. MAINTENANCE ................................................................................................................... 40

7.1 IRREGULARITIES ...................................................................................................................................... 40

7.2 CONTROLS PERFORMED BY QUALIFIED PERSONNEL ....................................................................... 40

7.3 MAINTENANCE MADE BY QUALIFIED PERSONNEL .............................................................................. 41

8. WORKING AT HEIGHT ........................................................................................................ 43

8.1 DESCRIPTION OF THE SAFETY DEVICE (EXAMPLE) ............................................................................ 43

8.2 POSITIONING OF THE SAFETY DEVICE ................................................................................................. 45

8.3 CONSTRUCTION IN SAFETY ................................................................................................................... 45

9. INSTALLATION PRODUCTIVITY ........................................................................................ 46

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NOTICES AND ASSUMPTIONS

MACCAFERRI (also the “Company”) supplies all components and accessories which shall be used
for construction of the TERRAMESH SYSTEM reinforced soil structures described in detail in the
Construction Designs approved and accepted by the Contractor.

This manual (hereinafter referred to as the “Manual”) represents a guide to the construction of
TERRAMESH SYSTEM and gives practical guidance for the organization and control of the related
operations. The Contractor’s personnel (site agent, foreman in charge of the works, etc..) and the
Engineer’s staff shall be aware of the contents of the manual before the delivery of the materials to
site.

The Manual is addressed to the Contractor only. The content is confidential and, save as provided
below, is for discussion with, and use by, the Contractor (and no one else) and the latter shall not be
entitled to assign, transfer or charge any information and/or interest it may have in the Manual. No
other person/entity is entitled to rely on the Manual for any purpose whatsoever and MACCAFERRI
accepts no responsibility, duty or liability to any other person with respect to the contents of the
Manual.

Neither this Manual nor the data contained herein shall be reproduced, used or disclosed to anyone
without the written authorization of MACCAFERRI; in this regard the Manual should not be provided,
without our prior written specific consent, to anyone other than the Contractor and only on the basis
that it is strictly confidential; it being understood that MACCAFERRI accepts no liability to them, they
should not rely on it and they should not provide copies of it to any other person.

The instructions given in the Manual are of a general nature, and do not, therefore, exempt the
Contractor from the obligations and responsibilities for the definition and correct execution of all the
specific operations required for implementation of the project (construction sequence, loading and
unloading procedures, safety plans, etc.). In such respect, MACCAFERRI will not be liable for any
inaccuracies or omissions in the execution results and will not bear the consequences of any
connected liability. The details given in this manual do not exempt the Contractor from compliance
with the Construction Designs, Technical Specifications, Conditions of Contract provided by third
parties and safety requirements related to the site. In any case, the Manual does not replace the
Construction Designs realized by the appointed project designer.

When the structure to be installed has some special details, these will be defined in the Construction
Design drawings. In the case of ambiguities or discrepancies between the Construction Design
documents and this manual, the former documents will take priority.

If requested, MACCAFERRI will send a technician to site at the start of construction to assist the
Contractor in setting up the correct execution procedures, being understood that such activity shall
not entail any obligation of result for MACCAFERRI

This installation Manual is not intended to provide to the Contractor an exhaustive summary of
guidance for the organization and control of the related operations regarding TERRAMESH SYSTEM.
All possible issues which may arise in connection with this Manual shall not be attributed to
MACCAFERRI

Where the installation Manual reproduces or summarizes any information and/or description
concerning the TERRAMESH SYSTEM, MACCAFERRI does not accept any responsibility, duty or
liability for the truth, accuracy or completeness of such information or opinion in any way whatsoever
(including whether or not such information or opinion is misleading, by omission or otherwise).

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1. INTRODUCTION

Terramesh® System is a modular system having vertical facing used for soil reinforcement made of
pre-assembled units fabricated with hexagonal double twisted wire mesh 8x10 made of Galmac (Zn-
Al5% alloy) and polymer coated steel wire. The tensile forces are transferred to the reinforcement by
friction. Terramesh System is an environmentally friendly modular system used for soil reinforcement.
Terramesh® System units are produced in compliance with CPR - Construction Product Regulation
305/2011, having EC marking in compliance with ETA-16/0767. The management and production
system is certified in compliance with ISO 9001 and ISO 14001.
1.00/0.80/0.50 m

Fig. 1 – Terramesh System

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2. IMPORTANT INFORMATION

2.1 RESPONSIBILITIES
The Contractor is responsible for a correct execution of the works in compliance with the Construction
Design documents, the Technical Specifications and the Contract Documents (not provided by
MACCAFERRI). In order to assist the Contractor, MACCAFERRI provides the recommendations
contained in this manual, but they in no case relieve the Contractor of the responsibility to comply
with all the current safety regulations and procedures. MACCAFERRI will not be liable for any
inaccuracies or omissions in the execution results and will not bear the consequences of any
connected liability.

The Contractor and the Client must check that the site personnel appointed for performance
of the works are in possession of a copy of this Manual and are aware of its contents.

If previously agreed with the Contractor, the Technical Representative of MACCAFERRI will be
present on site during the initial phases of the works. The Technical Representative will assist the
Contractor in planning the deliveries and will provide advice on the installation procedures
recommended for the Green Terramesh as described in this Manual, being understood that the
Technical Representative’s assistance shall be considered as mere support to the Contractor and it
shall not be binding for the latter, which shall assume all responsibility connected to installation and
execution procedures.

This Technical Representative will not be present on site for the entire duration of the works,
and shall not be considered as a substitute of the supervision and quality control staff
appointed by the Contractor and the Client.

2.2 CONSTRUCTION DESIGN

Before starting any operations on site, the Contractor shall ensure that the latest version of the related
Construction Design, duly approved for Construction, is used in the construction of the structure.

The Contractor shall also carry out topographical survey checks to ensure that the structure is
constructed in the required position.

2.3 MATERIALS AND REQUIREMENTS BEFORE STARTING

This work shall consist of furnishing, assembling and filling of TMS with soil as specified in the contract
to the dimensions, lines and grades shown on the plans, or determined by the engineer.

Terramesh System (TMS) units

Terramesh System are reinforcing elements made up of hexagonal double twisted steel wire mesh
type 8x10, wire 2,70/3,70 m as per EN 10223-3:2013, forming a facing gabion and a variable length
reinforcement according to the project.
The steel wire used for manufacturing Terramesh System units is heavily galvanized with Galmac
(Zn-5%Al alloy) in compliance with EN 10244-2.
A polymer coating in compliance with EN 10245-1 having a nominal thickness of 0,50 mm is then
applied to provide added protection.
The reinforcement base panel, front panel and gabion box lid of the Terramesh System are
manufactured from one continuous panel of mesh; the back panel is factory connected to the base
panel. The facing section of the unit is formed by connecting the back panel and diaphragms to the
main unit; the gabion facing is divided into uniformly partitioned cells by internal diaphragms.

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Units are delivered to site folded and compressed in bundles weighting differently according to the
unit and wire/mesh size and measuring approximately 3.1x2.1 m in plan and 0.4 m in height; type and
size determine the number of units per bundle.

Ensure that the correct sizes are selected for the different structures by checking the labels attached
to each bundle.

Fig. 2 – Bundles of Terramesh System

Ring fasteners
To increase the installation productivity, steel ring fasteners are used to connect units and to close
and secure them (Fig. 3).
The rings shall comply with EN 10223-3 and are supplied in box (1600 rings/box); these rings are
available Galmac coated for the use with the corresponding type of material or stainless steel for use
with polymer coated mesh in highly corrosive environments. The indicative amount of rings is shown
in Table 1.

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20 cm
Max Ring before fastening

Ring after fastening

Fig. 3 – Fastening rings

TERRAMESH SYSTEM RINGS

Height of 50 cm 50-60

Height of 80 cm 30-40

Height of 1 m 25-30
Table 1 – Suggested number of rings per square meter of facing

Alternatively, lacing wire can be used to interconnect the units; sufficient Galmac and polymer coated
lacing wire (2.2/3.2 mm diameter) is supplied in coils with each unit to enable assembly (Fig. 4).

Fig. 4 – Lacing wire: coil

Geotextile
A nonwoven geotextile (Mactex) must be placed at the soil-gabion interface for separation/filtration
purposes. The MacTex range of geotextiles has been developed specifically for gabion related
applications and is available in various grades for different applications.

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Stones
Ensure that the correct quality, grading and quality of rock is available for the completion of the works.
Rocks for filling the Terramesh System shall be obtained by any suitable quarrying method.

Rocks shall be hard, angular to round, durable and of such quality that they do not lose their integrity
on exposure to water or weathering during the life of the structure.
Rocks shall range between 100 mm and 200 mm. The range in sizes may allow for a variation of
5% oversize and/or 5% undersize rock, provided it is not placed on the exposed surface. In all cases,
the oversize rock shall not be larger than 250 mm and the undersize rock shall not be smaller than
50mm.

Structural soil
The reinforced soil structure shall be built utilizing soils from groups A1-a, A1-b, A3, A2-4, A2-5 based
on AASHTO M145. The structural soil material should not contain particles ≥150 mm.
The percentage of the examined sample bigger that 100 mm shall be less than 15%. In any case the
particles > 150 mm must be excluded and the soil that, after tests, has shown frictions angle lower
than those assumed in the design.
Typical recommendations for structural soils (such as the FHWA-NHI-10-024) limit the fine contents
to avoid plasticization of the soils and to allow for their compaction. Usually these limits are defined
as follows:
a) The embankment material will be suitable when the percentage of material passing an 80 micron
sieve (0.08 mm) in a sieve analysis is less than 15%.
b) If the material does not comply with condition a), the material will still be considered suitable when:
b-1) the percentage of the sample passing a 15 micron sieve (0.015 mm) in a sedimentation test is
less than 10%;
b-2) the percentage on the sedimentation test is between 10% and 20% and the internal friction
angle, measured with shear tests on saturated samples, is greater than 25°.
Soils outside of this range may be suitable, providing they have been approved by a geotechnical
engineer.

Geogrid reinforcement (if necessary - determined by design)

Paragrid, Paralink, Paradrain and Macgrid geogrid reinforcements are supplied in rolls from 50 to 200
m long depending upon the strength of the reinforcement. The Paragrid geogrids have a width of 3.90
m and a variable weight between 90 and 150 kg, while Paralink geogrids have a width of 4.50 m and
a variable weight between 500 and 900 kg. Paradrain geogrids have a width of 3.90 m and a variable
weight between 90 and 170 kg. Macgrid geogrids have a width from 3.60 m to 5.30 m (see realted
technical data sheets).

Tools
Available tools suitable for fasteners rings are shown in figure 5: Pneumatic (to be connected to a 6-
7 bar air compressor, air pipe Φ max 10 mm and max length 30 m) or manual lacing guns.

Fig. 5 – Pneumatic and manual lacing gun

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Delivery and storage of materials on job site

The Terramesh System units are delivered to the warehouse storage or construction site. The staff of
the contractor is responsible for checking that the materials are supplied carefully in order to:
1. Ease loading and unloading operations
2. Avoid risk of damage during transportation
3. Keep the area accessible for any inspection controls
4. Promptly report any anomaly for the acceptance of the goods.
The delivered material is labelled so that the characteristics can be read and the products can be
properly identified and used by the staff responsible for installation.

2.4 CONSTRUCTION SITE MANAGEMENT

Terramesh System installation shall be managed as earthworks. The installation productivity will
depend directly on the optimal management of the construction site. Installation includes facing,
geogrid reinforcement placing (if present) and earthworks.

The height of Terramesh System is 50 cm, 80 cm or 1 m, the minimum number of soil compaction
layers will be two for 50 cm high units and three for 1 m high units.

2.5 REQUIRED MACHINERY FOR INSTALLATION

• Terramesh System units – The units can be transported by a minimum of two workers. Their
unloading from trucks shall be carried out with the help of handling equipment (mechanical
shovel, manuscopic…)
• Filling – The soil fill shall be transported by trucks and unloaded with the help of mechanical
shovels. The choice of the machinery is left to the contractor as it depends on the condition of
access to the site and the volume of soil fill. It is strictly prohibited to use the heavyweight
machinery close to the facing (within 1 m from the facing) and track vehicles in contact with
geogrid reinforcement.
• Compaction – Vibratory rollers of adequate dimensions shall be used in function of the filling
material (A1-a, A1-b, A3, A2-4 or A2-5 as per ASTM D3282). For uniformly distributed fine
sand, it is suggested using non vibrating rollers. For the compaction of the soil fill close to the
facing, within a minimum width of 1 m, lightweight compaction devices, such as vibratory
compactors and small vibratory rollers shall be used.

2.6 REQUIRED EQUIPMENT FOR INSTALLATION

• Equipment for topographic location
• Pliers, pincers, scissors
• Ring fasteners and lacing guns
• Safety devices

2.7 ESTIMATED WORKING TEAM

• 1 foreman (responsible for installation)
• 4 workers

2.8 WORK TO BE DONE BY THE CONTRACTOR

• Preparation of the construction site, including the foundation level, if necessary replacement

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of foundation soil and installation of drainage systems, impermeable membranes, geotextiles
if they are included in the construction drawings.
• Preparation of the laying surface for soil fill and Terramesh units
• Safety devices installation
• Unloading and stock of materials
• Installation of Terramesh System units and soil fill
• Preparation of the systems required for the access and the maintenance of the construction
site (access roads, banks, lateral draining channels, protections against bad weather)

2.9 OPTIONAL SERVICES PROVIDED BY MACCAFERRI

If requested, MACCAFERRI can provide the following services:
• Drawings used to obtain the BOQ of the elements required to build Terramesh System.
• Delivery to the site of the material provided (F.O.B.), considering an unloading time, from the
arrival at site, of maximum two hours.

2.10 MATERIALS PROVIDED BY MACCAFERRI

• Terramesh System units
• Ring fasteners and lacing guns
• Geotextile Mactex
• Paragrid, Paralink, Paradrain geogrid reinforcements (if necessary – depending on the design)

The Certificate of conformity for the above-mentioned materials are supplied by MACCAFERRI It is,
however, the Contractor’s responsibility to check that all the materials received comply with the
Delivery Documentation and the Construction design requirements.

Any discrepancy must be recorded on the Delivery Documentation (or proof of delivery) at the
time of unloading and immediately notified to MACCAFERRI

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3. FOUNDATION

3.1 FOUNDATION PREPARATION

• The foundation on which TMS are to be placed shall be levelled and graded to the elevations
as shown on the project construction drawings (Fig. 6).
• The foundation for TMS shall be dry, smooth and free from surface irregularities, holes, loose
material and vegetation or organic material, in accordance with the project specifications.
• The foundation should be compacted to the engineering specification to ensure uniform
bearing capacity and minimize differential settlements.
• The design foundation level shall be levelled without ruts and undulations.
• The outer alignment of the wall shall then be marked on the foundation in accordance to the
design drawings.
• To ease the construction, the foundation shall be sloped at a maximum 4% gradient in the
longitudinal direction.
• In presence of backwater or softened soil or high organic content (this will have to be
reclaimed, for full replacement), all operations required to run off the water shall be carried
out.
• In case the laying surface is locally depressed and it is in favourable conditions to water
ponding, lateral draining channels with adequate slope should be realised.
• Excessive material will be removed and brought to landfills authorized by current regulations.
• Provisional excavations for the realization of the foundation plan have to be made in
agreement with the project specifications.

Fig. 6 – TMS foundation: levelling

Note: The assessment of the foundation soil and its bearing capacity is within the Construction
Manager’s responsibility. Foundation soil which is unsuitable has to be removed and replaced with
a suitable material and compacted in accordance with the Construction Manager. Monitoring and
evaluation
The of foundation
information contained soil isare
in this Manual essential.
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3.2 SETTING OUT

Points marked should be start of the wall, end of wall and any internal/external angle changes or
steps. Points required to be marked out must be at the front of the toe wall i.e. front base of wall at
top of foundation level.

3.3 INCLINED FOUNDATION PADS

In order to minimize the possible bulging problems or in case of specific requests (i.e. architectural
applications) it might be necessary to assure a wall batter to the gabion facing.
This can be achieved by means of inclined foundation pad at the bottom of the wall gabion facing.
The remaining part of the wall including geogrids reinforcement and structural fill may remain
horizontal.
The foundation pad has got also a levelling function and it is generally made in reinforced concrete.

Inclined foundation pad under construction and after construction with inclined facing

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TMS facing

Geogrid
reinforcement

Filtration
TMS unit geotextile

Structural fill

Inclined foundation pad

Cross section of inclined foundation pad and wall batter

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4. TERRAMESH SYSTEM ASSEMBLY

4.1 FLATTENING THE UNITS

Workers shall ensure to have a safe open level area adequate for opening the units. Each unit will be
taken from the bundle, opened, unfolded, pressed out to the original shape and stretched making
sure all creases are in the correct position for forming the box. During the unfolding of the components
of the Terramesh System unit care shall be taken to straighten the wire mesh wherever required.

Fig. 7 - Opening of TMS units

4.2 ASSEMBLY AND LACING THE INDIVIDUAL UNITS

Open and unfold each unit of TMS, and stretch the wire mesh panel to get a smooth and flat unit free
of kinks. Front, back and end panels of the gabion facing shall be lifted to a vertical position to form
an open box shape, making sure tops of all four sides are at the same level. Panels shall be fastened
together with the projecting heavier wire by firmly wrapping the selvedge wire around the selvedge or
edge of the intersecting panel, or back panel; inner diaphragms shall be lifted into vertical position
and secured in the same manner (Fig. 8).
Note: it is essential that the top corners meet.

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Fencing
pliers

Fig. 8 – Erection of the back and sides panel (upper left) and the diaphragm (upper right) and assembly (bottom)

Secure the lacing at the top corners of the panels to be joined and laced from the top down; to
assemble and connect all the elements, pneumatic or manual lacing gun, C rings, compressor system
(6-8 bar) will be required as an alternative to lacing wire.
Rings shall be installed at the top, bottom, side connections and for diaphragms; a maximum spacing
of 200 mm along all edges shall be used (Fig. 9), in order to guarantee a homogenous soil reinforced
structure.

Fig. 9 – Lacing details

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Fig. 10 – Placing of rings by pneumatic lacing gun to connect two adjacent wire mesh tails

Fig. 11 – In presence of obstruction the DT mesh is folded back

4.3 GEOGRID REINFORCEMENT (IF PRESENT)

If the design requires the use of geogrid reinforcements in addition to the TMS units, geogrids are
arranged before the TMS units, from the front of facing up to the length required by the design. If the
geogrids are unidirectional, special attention will be given to the laying direction, the direction having
greater resistance has to be placed perpendicularly to the facing.

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Fig. 12 – TMS with geogrid reinforcements

The roll should be unwound and the reinforcement layers shall be cut in segments having length
according to the project requirements. Each segment shall be placed in its final position ensuring that
no slack or undulations occur in the reinforcement as it is laid. If these do occur they should be
corrected immediately before proceeding.
The run of reinforcement should be reasonably straight and all strip elements should be flat and not
twisted. No undulations in the reinforcement should be evident.
Structural Fill in direct contact with the geogrid reinforcement should be placed and spread exclusively
perpendicularly to the direction of the resisting strips of the geogrid reinforcement. If this operation
results in some undulation of the geogrid reinforcement the undulation shall be removed.
We always recommend to install the geogrids on a horizontal surface, avoiding wrinkles and vertical
steps. Furthermore, no longitudinal gaps must be left between 2 adjacent installed rolls and the edges
of the 2 grids should be placed in contact (i.e. no gaps).

Fig. 13 – Mistakes to be avoided: wrinkles (left) and no contact (right)

Note: Particular care must be taken to ensure that geogrids are installed without wrinkles.
Wooden stakes can be used to keep the geogrid flat during installation. An overlap of 15 to 20
cm between adjacent rolls has to be provided.

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4.4 PLACING THE TERRAMESH SYSTEM UNITS

Place a number of individually laced units side by side in the required position. Care must be taken
to avoid damaging the polymer coated wire mesh.
All TMS structures should be aligned and constructed accurately using standard engineering methods
and procedures e.g. fishing lines, dumpy levels or formwork; alignment of each layer should be done
before the units are filled, as the units are almost impossible to move afterwards.
The empty Terramesh units shall then be placed along the outer line of wall facing previously
marked on the foundation level.
The units are placed with the gabion portion forming the facing of the wall and the double twist
hexagonal wire mesh tail laid flat (Fig. 14).

Fig. 14 – Placing of the assembled units to their final position

The Terramesh units shall be connected to the adjacent units along all the vertical and top+bottom
edges of their contact surfaces by steel lacing rings as shown in Fig. 15.
Connection of the tails are not necessary but they can be connected for a better stability of the units
during the installing operations.

Fig. 15: adjacent Terramesh units connected along the edges

Note: All TMS units to be laced to each other on all contact surfaces. Each TMS layer must be
securely laced to the TMS layer below.

Gabion construction frame

For ease of alignment of the structures, both horizontally and vertically, and to obtain the correct lines
and levels, the use of a gabion construction frame is recommended (Fig. 16).
The construction frame is composed of 6 elements used to stiffen the facing.
The frame further assists in minimizing bulging during filling and ensures that the finished structure is
aesthetically pleasing.

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The formwork enables to achieve the uniformity in the TMS facing box dimensions during the filling
and placement of stones.
As far as possible a fair face of large flat stone shall be placed at the exposed faces only; this also
enhances the appearance and reduces the risk of construction induced damage.

Fig. 16 – Use of a steel frame to avoid gabion bulging

Stone filling
To minimise the voids ratio use a well graded stone filling and avoid large stones in order to achieve
a dense, compacted compartment.
Fill each gabion cell in 1/3 layers between which bracing wires are installed.
A minimum of four bracing wires per square meter of gabion front face is recommended; these should
be fixed at one third and two thirds the total depth of a 1 m deep gabion as shown in Fig. 17.
For 0.5 m high units, bracing wires should be fixed at height of 0.25 m.
Thread the wire around two mesh openings on the front and rear faces of the basket and twist the
ends together at the middle (Fig. 18).
Tension the brace by windlassing with the plier handle until the front face is in line; this procedure
should be repeated across all exposed faces of the gabion structure.

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Fig. 17 – Bracing layout (left side) and MacTie application (right side)

Fig. 18 – Detail on the mesh openings (minimum 2) to be braced

Fig. 19 – Bracing wire on 1 mesh (left side - wrong) and bracing on 3 meshes (right side- correct)

Fill each row gabions in stages when placing a number of gabion units next to each other.
Fill the entire row, except the last cell to a third.
Thereafter brace the entire row and proceed with filling the row up the two third mark.
Again brace the entire row at the two third mark and then fill the remainder of the cells to the top.
At no time should the difference in height of a gabion rock between adjacent cells be more than a
third of a meter; this is done so as to prevent bulging of the diaphragms.
If more gabions are to be added to a row, the last cell in each row should be left empty to facilitate
wiring.

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1 2 3

2/3

1/3
1/3

Fill the gabions only 1/3 full first, with level surface on top Fix bracing again and finish filling
Fig. 20 – Filling do be done in 3 steps (2 steps for 0.5 m high gabions)

To ensure a good finished appearance, all visible faces should be hand-packed carefully.
Gabions should be overfilled by 3-5 cm to allow for natural settlement of the rock fill whilst keeping
the top edge of the diaphragm visible so as to lace it to the lid.
The top filling shall be done with the smaller fractions of the fill.
The diaphragm position and the overall dimensions of the gabion shall be checked during the process.
When filling the cages, it is necessary to ensure that adjacent cages do not have more filling height
difference of 30cm, sides and diaphragms risking to deform.

Fig. 21 – Overfilling scheme

Fig. 22 – Filling sequence

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Fig. 23 – Oversized stones (left) and good grading selection of stones (right)

Closing
Fold the lid down, stretch into position with the aid of a suitable tool (Fig. 24), lace the lid to the front,
the ends and the top of the diaphragm. Staple the edges every 8 to 12 cm.

Fig. 24 – Closing tool

The lid of the gabions shall be matched properly along with the required alignment of the facing.
The Terramesh unit in upper layer shall be connected to the top of Terramesh unit in the lower layer
along the front and back edges of the contact surface and along the bottom ends using the same
connecting procedure.

Placing of geotextile
At the interface between the back face of the Terramesh unit and the structural soil filling, a non-
woven geotextile shall be fixed extending 25 cm towards the backfill at top and bottom as shown in
Fig. 25.
This prevents the passage of fine materials from the ground behind the gabion facing to the filling stones
and at the same time avoids the increase of the hydrostatic pressure on the back of the structure. The
lack of the geotextile is generally detrimental to the integrity of the structure as a whole.
Make sure that the geotextile will not be torn or rolled up during the placement and the filling of the gabion
facing.
During construction, ensure the contact between the geotextile and the rear face of the facing. If required,
tie the geotextile to the top of the structure to facilitate the construction.
When there is the overlapping of the geotextile, ensuring a minimum overlap of 300 mm.

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Unless geotextile specifications are provided, the minimum requirements of the geotextile are:
• Mass per unit (EN ISO 9864): ≥ 120 g / m²
• Tensile strength (EN ISO 10319): ≥ 8 kN / m
• Opening pore size (EN ISO 12956): ≤ 130 μm

Fig. 25 – Placing of geotextile at the back of the gabion facing

Vertical alignment of Terramesh units (staggering)

If the lacings and the Terramesh units filling are made in accordance with the requirements, non-
staggered Terramesh units have the same performance of staggered ones, from a structural point of
view. It can be stated that staggering, when realized, can only improve the monolithic behaviour of
the Terramesh units.

Fig. 26 – Non staggered Terramesh units

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Fig. 27 – Staggered Terramesh units

Fig. 28 – Front view of staggered and non-staggered Terramesh units in case of variable height and sloped foundation

Terramesh System batter angle

A batter angle of 6° (equivalent to a backing value of 10 cm every 1 m vertical step) for TMS should
always be adopted; vertical facing should be adopted solely for TMS structures walls lower than 4-
5 m.

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Fig. 29 – Vertical facing (left) and offset of Terramesh System units (right)

4.5 PLACEMENT OF THE STRUCTURAL FILL

The structural fill shall be made of a good quality, free draining, granular or selected fill. The
recommended soils are A1-a, A1-b, A3, A2-4 or A2-5 as per ASTM D3282; the use of other soils will
be possible only if approved by the Geotechnical Engineer.
The structural fill shall be carefully placed and compacted in the area behind the Terramesh
System units extending up to the end of design reinforcement length.
The soil shall be installed in layers approximately 30 cm thick and dumped in the middle section of
the anchor mesh panel.

Fig. 30 – Discharge of the fill material away from the wall facing

Compaction shall proceed parallel to the slope face, ensuring that compacting machine will remain at
least 1 m away from the face element.
The homogeneity of the fill and the required level of compaction required shall be as per the project’s
specification.
The materials will be placed systematically in layers with a constant thickness using procedures and
equipment which will prevent segregation and sudden changes in grain size and water content.
At the end of each day's work the surface of the compacted fill should be left at a slight inclination (2
% - 4 %) away from the facing or the sloped face and sealed with a smooth compactor to ensure that
any surface water is guided away to a suitable outlet.
The loose thickness of every individual embankment layer must not be more than 50 cm.
The placing must always be carried out parallel to the outer facing.
Order of lying of structural backfill (Fig. 31):
1) middle area;
2) back area;
3) near to facing (at least >1 m from the facing);
4) within 1 m from facing: light weight compaction;

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Ordre de
Compaction
compactage
order

SensCompaction
de
compactage
sense

Largeur
Width

Fig. 31 – Structural backfill lying

Note: Never spread or compact the material in the reinforcement direction

4.6 COMPACTION OF THE STRUCTURAL FILL

Compaction shall be performed to min 95% of Standard Proctor or as indicated on the construction
drawings. Compaction may only take place after checking that the water content of the soil is the
optimum value (± 1.5%). If the water content is higher, the material must be dried by aeration. If it is
lower, it must be increased in a manner which guarantees a uniform distribution of the water within
the entire thickness of the layer.
The type, characteristics and quantity of the compaction machines, and the relevant detailed
procedure (number of passes, operating speed, frequency) must be approved in advance by the
Engineer.
The compaction procedure shall include heavy rolling and subsequent compaction of the fill material
up to 1 m from the facing.
Large vibratory rollers must not operate within a distance of 1 m from the faces of reinforced soil.
Within this distance only lightweight compaction plant must be used, such as vibratory compactors
and small vibratory rollers, taking care to ensure the specified density (Fig. 33).

Note: It is necessary to perform a control of the alignment of the facing once the compaction is
completed. If excessive displacement of the facing appears during compaction, the current
operations shall stop right away and it shall be understood the reason of the problem of
compaction comes from.

The degree of compaction shall be verified by plate bearing tests, whose frequency and acceptable
E modulus values shall be defined by the Geotechnical Engineer.
The following values, which depend upon the adopted plate bearing test procedure, are provided as
general indication:

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ITALIAN PLATE BEARING TEST (CNR B.U. n°146/92)

First layer of embankment: Md > 15 MPa
Formation levels: Md > 20 MPa

BELGIAN PLATE BEARING TEST (C.R.R. – MF 40/78)

First layer of embankment: M1 ≥ 11 MPa.
Formation levels: M1 ≥ 17 MPa.

FRENCH PLATE BEARING TEST (NF P 94-117-1)

For every layer of embankment: EV2 ≥ 50 MPa and EV2 / EV1 < 2

WARNING NOTICE: In case of high energy level compaction causing the bulging of the front
face, compaction activities must be stopped and procedure must be changed.

Compact the structural fill according to design documents. Great care should be taken when placing,
spreading and compacting fill to ensure that heavy machinery is kept away from the area immediately
behind the Terramesh System units for 1 m. Compact the soil to the required level and make sure
that the roller always moves in a direction parallel to the direction of the wall.
The roller shall never move in a direction perpendicular to the direction of the wall.
In no circumstances shall the fill be pushed directly towards the Terramesh units, particularly in the
area immediately behind the units, the filling material shall be spread out with a grader or suitable
equipment.

Fig. 32 – Heavy compactors always kept at minimum 1 m distance from the facing

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Fig. 33 – Lightweight compactors shall be used for the area close to facia (within 1.0 m)

4.7 BACKFILLING
Compaction of the backfill shall be done simultaneously at each layer of TMS.
Care must be taken not to damage the geocomposite for drainage (if present) when placing and
compacting the backfill.

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5. CONSTRUCTION DETAILS

5.1 INSTALLATION IN CORNERS AND CURVES

Curved structures create special considerations with Terramesh System details and different
placement procedures are generally required for convex and concave curves (Fig. 34).

- Concave Curve Building Construction Detail

- Convex Curve Building Construction Detail

Fig. 34 – Realization of convex curves

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5.2 SHAPING AND ENDING OF STRUCTURES

The TMS units shall be cut and shaped to the required geometry; usually the cut units are kept apart
for their reuse in other locations of the structure where small units (in width) are required.

Fig. 35 – Realization of TMS whose top is inclined

5.3 INTERFERENCES, OBSTRUCTIONS AND FACING PENETRATIONS

Interferences and obstructions can be vertical or horizontal:

Vertical obstructions are structures that are embedded in or extend vertically through the reinforced
soil mass. Examples of vertical obstructions are a catch basin, grate inlet, sign foundation, bridge
foundation, light poles, guardrail post, or culvert. Additional consideration shall be given to
obstructions that exert a load on the wall (e.g., deep foundations, overturning of signs and light poles).
Such applications may require additional reinforcement and facing support to resist the local increase
in lateral stress. Likewise, the wall may exert lateral earth pressure or vertical downdrag stress on the
obstruction due to movement of the wall, the consequences of which to the obstruction design and
performance must also be evaluated.

Horizontal obstructions are structures which are embedded in or extend horizontally through the
reinforced soil mass for a substantial length along the wall. The horizontal obstructions are commonly
due to utilities such as storm drain pipes. In some cases, pipes must penetrate the TMS facing or
pass through the filling. Penetrations through the reinforced soil and/or the facing units maybe at skew
or perpendicular angles from the facing. If a pipe must penetrate through the face of the wall, the wall
facing elements should be designed to fit around the pipe such that the facing elements are stable
and the wall backfill is not spilt through the wall face where it joins the obstruction.

Pipes of small dimensions (diameter < 400mm)

The steel wire mesh and welded mesh siding will be cut in order to make way for the pipe through the
siding.

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Fig. 36 – Small diameter pipes crossing through TMS

Hydraulic structures of greater dimensions

TMS facing should be shaped in such a way that the hydraulic structure fits best to the openings.
Concrete hollow precast elements should preferably have a rectangular cross section and height
which is multiple of TMS unit height.

Fig. 37 – Hydraulic crossing through TMS

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Bridge abutments
In the case of bridge abutments construction, it is common that the supporting piles pass through the
reinforced soil. The steel wire mesh reinforcement must be cut around the piles (or openings should
be left waiting for the casting of the piles) and fastened to each other beyond the interferences and
obstructions. In case of bridge abutments, it is not possible to beat the piles or drill the piles through
the reinforcement layers.
SUPPORTING PILE CUTS RINGS

Fig. 38 – Supporting piles passing through the reinforced soil

Tree trenches
In case of plantation of trees at the back of the front face (at least 3 m from the facing), trenches up
to 2x2x2 m are allowed.

Safety and noise barriers

In some cases the top edge of TMS structures may require the construction of crash or noise barriers.
Safety barriers shall be specifically designed. Construction details are provided by standards and
national annexes. Before driving the posts, the Designer has to account for the damage on the
reinforcement (depending on both the size of the posts and the installation method) in order to assure

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the stability of the structure.

5.4 INTERNAL AND EXTERNAL DRAINAGE

Good drainage is essential to the proper performance of Terramesh System. There are two types of
drainage considerations, internal and external. Internal drainage considerations are related to control
of surface or subgrade water that may infiltrate the reinforced soil mass. The internal drainage of TMS
depends on the characteristics of the backfill used in the reinforced soil mass. External drainage
considerations deal with water that may flow externally over and/or around the facing taxing the
internal drainage and/or creating external erosion issues. The external drainage depends on the
location of the TMS with respect to local hydrogeological factors and generally deals with diverting
water flow away from the reinforced soil structure. Regardless of the source of the water, the cardinal
rule in the design of TMS is to remove water before it enters the zone of influence to prevent the
following:
• build-up of hydrostatic forces that increase lateral pressures,
• piping, i.e., erosion of one soil into another, which creates paths for additional water flow or
clogging of drainage aggregate, and
• external soil erosion from the toe, around the edges or at the top of the TMS.
It is recommended that adequate drainage features be required unless the engineer determines that
such features are not needed for a specific project. During a determination of the need for drainage
features, the engineer must include consideration for both subsurface (e.g., ground water, perched
water, flooding and tidal action) and surface infiltration water (e.g., rain, runoff, and snow melt).
Surface drainage is an important aspect of ensuring TMS performance and must be addressed during
design. Appropriate measures to prevent surface water from infiltrating into the backfill should be
included in the design. This typically requires coordination with designers of other project elements.
When possible, finished grading at the top of the structure should provide positive drainage to prevent
or minimize infiltration of surface water into the reinforced fill.

Overleaf drainage to prevent build-up of hydrostatic forces that increase lateral pressures

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Drainage swale at top

A drainage swale is a man-made depression in the ground surface used to intercept surface water
and direct it in a controlled manner to an outlet. Drainage swale can also be used to reduce the
potential for surface water from overtopping the TMS. When a drainage swale is used, the project civil
engineer and the designer should address and detail the outlet(s) for the swale. For example, the
swale can be detailed to discharge water at the end of the structure or to low overflow points along
the TMS length. Overflow points should be detailed on the construction drawings.

Grade at toe and ends

The final grade at the toe and ends of TMS, both as designed and as constructed, is an important
consideration for water flow conditions. Surface water flow along the toe may occur around the ends
or along the face of the structure and has the potential to erode the soil. Erosion of soil at the toe
eventually may undermine the facing units. Thus, design and construction details normally should
direct flow away from the toe of structures. This can be accomplished with site grading and with a soil
berm or slope at the toe. Erosion control details are required where water will flow adjacent to the toe.
The ends that terminate in or intercept embankment slopes should also be protected from erosion.
TMS that terminate in slopes should be adequately keyed into the slope and a swale used to divert
water away from the ends to mitigate erosion.

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6. CAUSE-EFFECT RELATIONS

The Terramesh System structures must be constructed in compliance with the structural requirements
shown in the drawings and technical specification of the construction design and in the contract
documents. The required result is obtained by the use of high-quality materials, correct installation
procedures and careful constant supervision of the works. In case improper practices or inacceptable
deformations are observed, the necessary corrective measures must be adopted right away to ensure
that the structure is brought back to the acceptable level.

6.1 CAUSE-EFFECTS TABLE

Some of the most common and probable cause-effect relations are given in the following table.

CAUSES EFFECTS
• Foundation soil with insufficient bearing
capacity
• Foundation soil with non-uniform bearing
capacity
• Foundation soil with moisture content too
high
• Foundation soil not well compacted
• Foundation scour

• Backfill material not well compacted

• Thickness of the backfill layers greater than
30 cm
• Backfill material with a moisture content
higher than the optimal value
Settlements and distortions
• Backfill material with too high fines content
of the structure

• Construction frame not used

• Inadequate filling material
• Pre-formed braces not used
• Pre-formed braces not completely tensioned

• Compaction was not carried out parallel to

the front face
• Excessive compaction energy
• Vehicles and construction equipments kept
within 1 m from the front face
• Fill surface not left with a slight inclination
(2% - 4%) away from the facing and not
sealed at the end of each work’s day
Bulging of the front face

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6.2 TOLERANCES
Care should be taken to ensure that predicted construction and design life deformations will meet
specified tolerances. For Terramesh System structures reference can be made to Table C.9 of
standard EN 14475 “Execution of special geotechnical works” taking into account the limits specified
for reinforced soil structures having gabion baskets as facing elements.
The values reported in Table 2 are indicative of the construction tolerances which are commonly
achieved, or the deformations which are normally withstood without any significant structural damage
or any effect on the stability of the structure.

Deformation Tolerance

Alignment ± 100 mm

Longitudinal differential settlement 2%

Compressibility 5%
Table 2 – Deformation tolerances

They should be understood as follows:

alignment: local variation in comparison with a 4 m long straightedge placed in the outer plane of
the wall face.
longitudinal differential settlement: ratio ΔS / ΔL.
compressibility: ratio ΔH / H.

Fig. 39 – Alignment, foundation settlements, compressibility.

Pictures taken from EN14475, which are the same for the execution of any reinforced fill.

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7. MAINTENANCE

Analysis of detectable irregularities and relative interventions

7.1 IRREGULARITIES

Water seepage
Infiltration of significant water flows which can reach the embankment from the nearby soil.

Denting and/or facing rupture caused by impacts

Change of the outer profile of the Terramesh System units which can occur in case of impact of
vehicles or machineries against the facing of the units. These events could cause the emptying of the
stone filling or, in extreme cases, of the structural fill.

Fig. 40 – Facing damages due to block impact (left) and car impact (right)

7.2 CONTROLS PERFORMED BY QUALIFIED PERSONNEL

Controls have to be performed after the completion of the work by qualified personnel (surveyors
and/or engineers, geologists).
The staff should have a maintenance manual where to record the detected problems, their extents
and the expected repair costs, each time there is a control.
The controls have to be made in order to ensure the stability of the reinforced soil structure and of the
units which compose it. Typical controls are:
• Check of the Terramesh System footing; the bottom of the reinforced soil structure has to be
intact and shall not show irregularities such as settlements, distortions, deformations and
bulging of the of the front face.
• Analysis of the facing; the units composing the facing have to be intact and the filling should
not have lost its content in other parts of the structure. In particular, the connection between
the surface of the last units and the ground have to be intact.
Checks have to be done every 6-12 months and the type of control is visual.

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7.3 MAINTENANCE MADE BY QUALIFIED PERSONNEL

M1 - Water seepage
In case of infiltration of significant water flows within the embankment, it is essential to perform an
immediate intervention with microslotted pipe (drainage pipe) covered with a filtering geotextile sock
having the function of removing the water towards the outside of the Terramesh System. Similarly, it
is required that the berms upstream of the reinforced soil structure maintain a slope of at least 2%
towards the outside to avoid water ponding.

M2 - Fixing units due to denting and/or facing rupture caused by impacts

In case of dent, impact of vehicles or machineries against the facing of the units, the interventions will
depend on the level of damage suffered by the facing units.
The intervention consists of:
• Cut and removal of damaged parts (wire mesh, geotextile)
• Fill the gaps with suitable size stones
• Filling of the soil empties (if any)
• Installation of two superimposed layers of double twisted wire mesh PVC coated ensuring to
have at least 20 cm of overlapping on the intact facing
• The cover panels should be connected to the nearby intact panels by means of Spenax clips
attached to the DT wire mesh or continuous lacing wire.

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Fig. 41 – Maintenance interventions after dent and impact damage

M3 - Excavations and works in correspondence of reinforcements

In case it is necessary to carry out excavations on top of the reinforced soil structure after the
completion of the work, it is appropriate that they are carried out as far as possible outside the area
where the reinforcements are present.
If it were necessary to dig in the reinforced area, the excavation should not affect a depth greater than
one meter and in general no more than a reinforcing layer should be involved in the excavation. In
any case, before proceeding with the backfilling of the dug area it is required to check the stability of
the facing and the mode of compaction of the soil.

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8. WORKING AT HEIGHT
This paragraph can be used as a basis for the editing of Risk Assessment document, whose final
contents must be adopted country by country depending on the local regulations.
In the following paragraphs, the technical details are explained and suggestions for the safety device
used as a personnel protection are given. These devices are used in the Terramesh System
installation to assure a high installation productivity without affecting the safety of the workers (Fig.42).

Fig. 42 – Safety device on the TMS units (examples)

Under no circumstances should anyone work from the front face of the wall. An appropriate edge
protection system shall be installed; as the wall progresses in height this edge protection system will be
lifted to ensure adequate protection.

8.1 DESCRIPTION OF THE SAFETY DEVICE (EXAMPLE)

The following paragraph describes a possible solution, to be verified on the basis of local regulations.
In the construction of TMS structures, each level must be provided of the protection device.
For Terramesh System installation, each protection device is made by:
- steel posts of suitable length and dimensions;
- num. 2 supports to hook for reach the protection made by wooden plank or building site fencing
- num. 2 anchors to fasten the device to the element or to the formwork

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Fig. 43 – Detail of the device (example)

LEGEND:
0. Steel Post
1. Support for the protection system such as wooden plank or building site fencing
2. Anchors to fasten the device to the element (inside DT mesh) or to the formwork

The posts are put in place manually through anchors, without the need of an excavator or of
mechanical equipment.
The distance to each other is ≥ 2 m.
This system must be installed when the reached height of the structure is ≥ 2 m and before laying the
next upper level.

Fig. 44 – Safety device in TMS construction (example)

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8.2 POSITIONING OF THE SAFETY DEVICE
The operation of installing/removing the safety device must be also made in safety and the worker
has to be fastened to an external weight support such as a concrete block or a static excavator.
Depending upon the use or not of the external formwork, the safety device can be supported by
formwork or positioned directly into DT mesh.

Fig. 45 – Safety device for TMS (example)

Fig. 46 – Anchor and positioning detail: inside DT mesh or supported by formwork

8.3 CONSTRUCTION IN SAFETY

The operation of assembly and filling of TMS, must be made in safety.

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Fig. 47 – TMS, positioning of the safety device (can be supported by formwork) and filling operation

9. INSTALLATION PRODUCTIVITY

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The installation productivity is highly dependent on volume, geometry and access to working area.
By making reference to a typical 5 men working team (1 foreman, 4 workers) operating 8 hours a day,
the following rates can be indicatively assumed for Terramesh System units 4x3x1 (in case of long facing
with ease of access, without considering the filling and compaction works):

Average daily yield per staff (without soil filling)

TMS spacing (m) Staff (men)
Minimum Maximum
2
5 30 m of facing 50 m2 of facing

The estimate takes into account:

• Unloading from the tracks
• Storage in order to have a stock for 5-6 working days
• Installation of TMS, without considering the structural filling
If filling and compaction of structural soil is taken into consideration, the installation productivity in
terms of m2 of facing indicatively becomes:

Average daily yield per staff (with soil filling)

TMS spacing (m) Staff (men)
Minimum Maximum
2
5 15 m 30 m2

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LIMITS OF RESPONSIBILITY OF MACCAFERRI

The installation manual is realized in order to show how the various elements that have to be
assembled in order to realize the Terramesh System.

The Company reserves the faculty to bring modifications, integrations or improvements to the Manual,
without that this can constitute reason to think inadequate the previous revision.

The Company declines every responsibility in case of:

• Accidents or incidents for improper use of the installation kit;

• Accidents or incidents that could happen during the installation of the elements;
• Wrong installation, lacked or wrong observance of the instructions supplied in the present
Installation Manual;
• Any modifications not authorized from MACCAFERRI;
• Installation done by staff not adequately trained and equipped.

This document ant the information contained cannot be copied or disclosed, entirely or in part, without
the written agreement of MACCAFERRI. The acquisition of this document does not give ownership
of it and of the information included in it.

The quality of the installation depends also from the scrupulous observance of the Installation Manual,
that it must be read before carrying out the installation of Terramesh System.

Are admitted only the geometrical configurations and of the components reported in the present
Manual. Eventual variations must be preliminary agreed with MACCAFERRI.

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