REINFORCED EARTHWORK APPROACH

EMBANKMENT USING KOLOGRID FOR ROB AT

MURTIZAPUR (M.S.) : A CASE STUDY
P.S. Lande
Lecturer in Civil Dept.
College of Engg. & Tech., Akola.

Abstract
Reinforced earth is the composite material formed by embedding reinforcement
in soil at regular intervals. It is one of the most significant civil engineering development
of the last three decades. It is one of the modern trend in construction of retaining walls,
bridge abutments and approaches to bridge and flyovers is to use reinforced earth for
embankments. Reduced construction cost, rapid construction, reduced land requirement,
flexibility and ease in construction and high resistance to dynamic loadings are some of
the advantages which render reinforced earth work technique far superior to conventional
construction.
In Maharashtra Murtizapur is a taluka place located on Mumbai – Hawrah
railway line where construction of road over bridge (ROB) is undertaken by Govt. of
Maharashtra. This paper presents one of the latest state of the art construction of
reinforced earthwork embankment using “KOLOGRID’ (which is high strength mono
continuous filament polyester yarns pretensioned, knitted and stitched together to form a
closely spaced apertures developed by kolon design cell Seoul Korea ) at ROB
Murtizapur. The paper also highlights details of construction, method of analysis, design
criteria, and role of different agencies involved in the construction of this reinforced earth
work embankment.

INTRODUCTION
Geotextiles in particular and geosynthetics in general are being
increasingly used as a construction material around the World as a long lasting and cost
effective construction material for different civil engineering applications. In India use of
reinforced earth technique is the latest trend particularly in the construction of retaining
walls bridge abutments approaches to bridges and flyovers. Soil reinforcement
construction technique includes, piles, stone columns, use of metallic or non metallic
elements like rods, flats, strips etc. in the soil. These soil inclusions which are embedded
in the soil to improve its strength to manifold for making it strong to carry out desired
functionality satisfactorily. The resulting soil is named as ‘reinforced earth’. Now a days
woven wire nettings, welded wire meshes, woven or nonwoven synthetic fabrics (i.e.
Geotextiles, Geogrid and Geomebranes ) are used as soil reinforcement. Reduced
construction cost, rapid construction, reduced land requirements, flexibility, ease in
construction and high resistance to dynamic loadings are some of the advantages which
makes reinforced earth technique far superior to conventional construction.

Maharashtra State Road Development Corporation (MSRDC) is one of the

first Govt. agency to introduce reinforced earth embankments in place of conventional
retaining walls in the construction of bridges and flyovers in India. Many flyovers in
Mumbai are constructed using reinforced earth work for embankments. In Maharashtra
Murtizapur is a Taluka place located on Mumbai – Howrah railway line where
construction of Road over bridge (ROB) is undertaken by Govt. of Maharashtra to avoid
congestion of traffic. In the portion of approaches of bridge reinforced backfill is done to
minimise the expensive land a acquisition for slope construction in embankment. The
‘KOLOGRID’ (high strength, mono continuous filament polyester yarn pretensioned,
knitted and stitched together, developed by kolon design cell Seoul Korea ) is used as a
reinforcement. This paper discusses in brief the case study of reinforced earth approach
embankment using KOLOGRID as reinforcement.

FIG. SHOWING LOCATION OF ROB SITE

2. LITERATURE REVIEW

Due to increasing use of soil reinforced technique since last 20 years

British standards Institution (BSI) set up a technical committee to formulate appropriate
code to cover various aspect of this reinforced earth technique. B. S. 8006 – 1995 was
published titled “Code of practice for strengthed/reinforced soils and other fills”. Though
In India No I.S. code on this subject is published yet, in 1996 Indian Road Congress
Highway Research Board New Delhi has published a special report – 16 titled “ state of
the art : Reinforced Soil Structures Applicable to Road Design and Construction’. French
National standard had published NFP 94 – 220 applicable to structures using inextensible
and flexible reinforcing strips or sheets arranged in horizontal layers in a direction
usually perpendicular to facing. All the above documents adopt limit state method with
partial factor of safety for design.

Besides code, specialised product literature published by the

manufacturers is now available covering details of reinforced soil technique including
method of construction and design. This includes literature available from AMIL Ltd,
KOLON International, Z Tech Pvt Ltd. Netlon (India) etc.

3. ROLE OF DIFFERENT AGENCIES

MSRDC is the major Govt. agency which plays a major role in

construction of ROB at Murtizapur (M.S.). Public Works Department (PWD) is local
agency working under MSRDC, which provides engineers for conducting various
surveys, supervision, administration at work site. IRCON International Ltd. the major
client of the project has undertaken the assignment of construction of reinforced soil
approaches to ROB from PWD. It has handed over the work to M/s ASHOKA Buildcon
Pvt. Ltd. Nasik. KOLON Design Cell, Seoul, Korea is the design consultant and it has
been the first agency to get approval from MSRDC for using high strength polyester
geogrids. IRCON has entrusted the design and supervision of installation for the
reinforced soil technology to KOLON International which is providing the concept of
earth reinforcement technology and geogrid.

4. COMPONENTS OF KOLOGRID REINFORCED EARTHWORK

APPROACH EMBANKMENT

Principally the ROB consists of following three component parts.

i) Main and obligatory span provided for traffic crossing at lower level.
ii) Viaduct portion
iii) Approach embankment (Solid ramp) of varying height

Reinforced soil approach embankment comprises of the following components. Each

component is briefly discussed.

(a) FOUNDATION SYSTEM

The facing system is placed on a anchored leveling pad such as ‘U’ shaped
reinforced concrete bed block having 0.3 m thickness. Differential settlement is
considered of less significance. [refer fig.1]

(b) BACKFILL SOIL

The backfill soil is used is free draining murum (Sand-Gravel) which is

having good frictional properties and pore pressure free zone. The fill is also provided
with drainage system. The mechanical and physical properties of the fill confirm to B.S.
8006-1995.
 The fill material is deposited, spread leveled and compacted in horizontal
layers. The ground water table is well below the base of the wall base. The fill has angle
of repose > 380, standard proctor density between 2000-2150 kg/m3 and moisture content
between 8 – 11 %. The unit weight of fill is 20KN/m3 and cohesion is zero.

(c) REINFORCING ELEMENTS

The reinforcing element used in this project is ‘KOLOGRID’ which is high

strength polyster geogrid with high resistance with design life of more than 200 years.
KOLOGRIDs are manufactured with high strength mono-continuous filament polyester
yarn, pretensioned, knitted and stitched together to form closely spaced apertures. They
are coated with pvc/polyamide to enhance durability. Depending upon long term
allowable design loads (LTADL), the KOLOGRID of different ultimate strengths (KN/m)
are used throughout the height of fill. The types varies from KOLOGRID KGR 40 at top
to KOLOGRID KGR 150 at the bottom of fill. The KOLOGRID is resistant to damage
during construction, handling and degradation due to chemical, ultraviolet and biological
action. The KOLOGRID is available in the form of rolls.

(d) CONCRETE FACIA

The facia in this project comprises of cast in situ full height retaining
panels. These panels are made in M35 R.C.C. mix for a thickness of 250 mm. The panels
are placed inside the foundation beams at bottom. The facia wall is casted at 2-3 degree
batter from external face wall. The wall contains hooks and pipes arrangement which
holds the KOLOGRID. Proper drainage facility is provided to release the pore water
pressure developed in reinforced earth fill. [Refer fig. 2].

(e) DRAINAGE SYSTEM

The drainage system consists of 300 mm wide drainage zone behind facia
wall consisting of gravels/metals (size 9 mm to 19 mm ). At the bottom perforated PVC
pipes are laid longitudinally and transversally (150-200 m c/c ). This chimney drain is
placed just behind the facing unit upto 90% height of the wall.

5. TECHNICAL SPECIFICATIONS

Technical specifications and quality control measures for the construction

of reinforced earth approach embankments of ROB confirm to following standards.

• The ‘KOLOGRID confirms to international standards for testing

ASTM D 4595, ASTM D 5262, GRI-GG 4(b), ASTM D 5261.
• Material joining confirms to FH WA – RD – 89-043 manual.
• The delivery, storage and handling is as per ASTM D-4873 and
AASHTO M 288-96
• Method statement for foundation preparation confirms to BS 8006-95.
• Method statement for fill material placing and compaction confirms to
IS-2720 (part – 8) (MOST clause – 703.5.5)
 • Quality control of backfill confirms to AASHTO – 1990, AASHTO T-
99.
• Facia element standard confirms to B S 8006, BS 8110, BS 5400 part 4
and I.S. 456.
• Facia element fasteners and connectors confirms to B S 8006, ASTM
A 536, ASTMA 325, AASHTO M-164
• Concrete test for panels confirms to AASHOT T 141 ( for random
sampling ), AASHTO T – 23 (for specimen preparation ), AASHTO T-
22 or I.S 456 (Compressive strength), AASHTO T 152 ( Air content ).
• Concrete leveling pad shall confirm AASHTO division II section 4.5
for class B concrete.

6. ANALYSIS AND DESIGN

For the purpose of analysis and design the factors like wall geometry,
foundation conditions, water table, soil fill, external loading (vertical & horizontal),
reinforcement type are taken in to consideration. Analysis and design confirms to B.S.
8006-95. Some of important aspects considered in analysis are as below.
• The long term allowable design load (LTADL) is determined by
applying partial factors of safety to the ultimate tensile strength of
reinforcement to account for creep, chemical and biological resistance
and installation damage.
• The pullout interaction coefficient, Ci, between geogrid & soil is
determined by Lab. testing. The ‘Ci’ helps in determining length of
geogrid.
• Stability analysis is done to determine the unbalanced forces which are
resisted by
(i) geogrid to create a stable reinforce zone .
(ii) the entire reinforced soil zone to assure a stable reinforced soil wall
system.
(iii) The foundation and retained soil to prevent deep seated failures.
• Each stability calculation incorporate an appropriate factor of safety.
• Stability analysis includes internal stability analysis, external stability
analysis, global stability analysis (Using KGRSS computer
programme) and seismic analysis. Two part wedge analysis method is
used for stability analysis (Using computer programme and Jewel
charts)

DESIGN CALCULATION
A design process using chart method in confirmity to the
recommendations of BS 8006-95 includes the following parameters.
(i) Determining configuration of structure.
The structure is configured as a slope with simple geometry.
(ii) Determination of partial factor of safety for appropriate limit states and long term
design strength for all KOLOGRID grades.
(iii) Determination of lateral force and reinforcement coefficients.
(iv) Determination of reinforcement lengths.
(v) Determination of reinforced grade and spacing.

7. CONSTRUCTION

The construction procedure a for Reinforced earth embankment is as

below

A) Foundation Preparation
The preparation involves the removal of unsuitable material from the area
to be occupied by the retaining structure including all organic materials, vegetation and
slide debris if any. The depth of foundation below finished ground level is at least 450
mm. Several passes of roller are applied prior to placing fill material. An additional
trench excavation is provided at foundation level for mass concrete leveling pad below
hard facing to facilitate errection.

B) Fill material placing and compaction

i) The fill material is deposited, spread leveled and compacted in horizontal layers of 600
mm thickness to achive 95% of maximum Lab. density. This process is carried out in
direction parallel to facia block and in stages to alternate with placing and fixing of
KOLOGRIDs and facings.
ii) The KOLOGRID reinforcement is pulled out and anchored prior to placing backfill
material.
iii) At least 150 mm thick blanket layer is laid over KOLOGRID before rolling.
iv) The fill within 1.5 m of the face wall is compacted by vibra tamper having weight not
less than 75 kg or by vibratory plate compacter of maximum weight 1000 kg.

C) Drainage System
A 12” thick layer of 9.5 mm to 19.1 mm well graded free draining gravels
are placed behind the facing unit to collect and drain away excess water in reinforced
zone. This chimney drain is placed up to 90% height of the wall.

D) Placing and fixing of KOLOGRID and Facing with backfill.

Construction sequence for fixing of flexible KOLOGRID (which is in the
form of roll) with facia system using FHR wall is as below
i) The excavation for leveling pad and drainage fill is done as per the construction
drawings.
ii) PCC leveling pad of specified dimensions and grade is laid.
iii) The concrete pedestal is casted over leveling pad in proper line and level
iv) Drainage fill is provided behind concrete facia.
v) 1st layer KOLOGRID is laid over the firm subgrade and inserted through PVC pipes
which is embedded to concrete facia.
vi) 2nd layer of KOLOGRID is laid over the firm subgrade at 0.6 m above from the 1 st
layer which extends from 1st layer.
vii) The reinforcement fill is laid over the KOLOGRID from the sides, so that no moving
load comes directly on the KOLOGRID. After 150-200 mm blanket layer over
KOLOGRID, compaction is done for required depth.
viii) The above procedure is repeated for other KOLOGRID layers.
ix) Concrete facing vertical tolerances and horizontal alignment tolerances are checked
for their permissible values. The tolerances shall not exceed ¾ inch (19 mm) when
measured with a 10 ft (3m) straight edge. The overall vertical tolerance shall not exceed
½ inch (12.7 mm) per 10 ft.(3m) of wall height.
Fig No 3,4,5,6,7 shows the constructional details.

8. ACKNOWLEDGEMENT

“ Reinforced earth work approach embankment using KOLOGRID for

ROB at Murtizapur : A case study” is the project work undertaken by Final year B.E.
Civil students (Yr 2000-2001) of College of Engg and Tech. Akola under the guidance of
the author. The author wishes to acknowledge the efforts of the students working on this
project. Greatful acknowledgments are also due to Mr.Nagesh Kale ( M/s Ashoka
buildcon Nasik ) and his associates for providing every essential information, field and
Lab. data to complete this project.

REFERENCES
1. Technical Specifications for reinforced soil structures, Seoul, Republic of Korea.
2. B.S. 8006 – 1995
3. State of the Art.. Reinforced soil structure applicabled to road design and construction, a special report
vol.16 1996 – IRC Highway Research Board New Delhi.
4. Flyover using geogrid at Mumbai vol.6, Civil construction and building materials 1998.
5. Flyover using geogrid at Jaipur vol. 13 IRC 1999.
6. Construction of road approach at Jammu , NBM and CW Oct. 1999.
 FIG. 3: APPROACH FILLING FIG. 4 : FIXING OF KOLOGRID WITH PVC

FIG. 5: COMPACTION OF FILLING MATERIAL FIG. 6 : COMPACTION NEAR FACIA WALL BY VIBRATOR
USING A PNEUMATIC ROLLER

FIG.1 : REINFORCEMENT DETAILS OF FOOTING FIG. 2 : REINFORCEMENT AND FORM WORK OF FACIA
OF FACIA WALL
FIG.7 : KOLOGRID PRIOR TO LAYING