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SECTION 02834
MODULAR CONCRETE RETAINING WALLS
NOTE ** This section is based on products manufactured by
authorized licensed producers of Keystone Retaining
Wall Systems, which is located at the following
address:
NOTE ** 4444 West 78th Street
NOTE ** Minneapolis, MN 55435
NOTE ** Telephone 612-897-1040
NOTE ** Fax 612-897-3858
NOTE **
NOTE ** Keystone retaining walls of low height may be
constructed without reinforcement using simple
techniques, while high walls and walls with
surcharge may be constructed with geogrid
reinforcement and compacted backfill to suit a wide
range of engineering requirements.
NOTE **
NOTE ** SECTION 02834 - MODULAR CONCRETE RETAINING WALLS,
Copyright 1997, The Architect's Catalog, Inc.
PART 1 GENERAL
1.1 SECTION INCLUDES
A. Work includes furnishing and installing concrete modular
block retaining wall units to the lines and grades shown
on the construction drawings and as specified herein.
B. Work includes preparing foundation soil, furnishing and
installing leveling pad, unit fill and backfill to the
lines and grades shown on the construction drawings.
NOTE ** Delete the following paragraph if all retaining
walls are unreinforced.
C. Work includes furnishing and installing geogrid
reinforcement and backfill to the lines and grades
designated on the construction drawings.
1.2 RELATED SECTIONS
A. Section 02300 - Earthwork.
B. Section 03300 - Cast-In-Place Concrete.
1.3 REFERENCES
A. ASTM C 33 - Standard Specification for Concrete
Aggregates.
B. ASTM C 150 - Standard Specification for Portland Cement.
C. ASTM C 331 - Standard Specification for Lightweight
Aggregates for Concrete Masonry Units.
D. ASTM C 618 - Standard Specification for Fly Ash and Raw
Calcined Natural Pozzolan for Use As a Mineral Admixture
in Portland Cement Concrete.
E. ASTM C 989 - Ground Granulated Blast-Furnace Slag for Use
in Concrete and Mortars.
F. ASTM D 698 - Standard Method of Laboratory Compaction
Characteristics of Soil Using Standard Effort (12,400 ft-
lbf/ft3) 600kN-m/m3)).
G. ASTM D 1557 - Standard Specification for Laboratory
Compaction Characteristics of Soils Using Modified Effort
(56,000 ft-lbf/ft3 (2,700 kN-m/m3)).
1.4 DEFINITIONS
A. Structural Geogrid: A structural element formed by a
regular network of integrally connected tensile elements
with apertures of sufficient size to allow interlocking
with surrounding soil, rock, or earth and to function
primarily as reinforcement.
B. Modular Unit: A concrete retaining wall element machine
made from Portland cement, water, and aggregates.
C. Unit Fill: A drainage aggregate which is placed within
and immediately behind the modular concrete units.
D. Reinforced Backfill: A compacted soil which is placed
within the reinforced soil volume as outlined on the
plans.
1.5 SUBMITTALS
A. Submit under provisions of Section 01300.
B. Product Data: Submit manufacturer's product data for
proposed materials and method of installation.
C. Samples: Submit samples of each product used in the work
of this section.
D. Certifications: Submit a manufacturer's certification,
prior to start of work, that the retaining wall system
components meet the requirements of this specification.
1. Contractor's submittal package shall include but not
be limited to actual test results for tension/creep,
durability/aging, construction damage, geogrid/facing
connection, pullout, and quality control.
2. Contractor shall submit certification, prior to start
of work, that the retaining wall system (modular
concrete units and specific geogrid):
a. Has been successfully utilized on a minimum of
five (5) similar projects, i.e., height, soil
fill types, erection tolerances, etc.; and
b. Has been successfully installed on a minimum of 1
million (1,000,000) square feet (92,000 sq m) of
retaining walls.
E. Test Reports: Submit test reports documenting strength
of specific modular concrete unit and geogrid
reinforcement connection. The maximum design tensile
load of the geogrid shall be equal to the laboratory
tested ultimate strength of geogrid/concrete retaining
wall unit connection at a maximum normal force limited by
the "Hinge Height" of the structure divided by a safety
factor of 1.5. The connection strength evaluation shall
be performed in accordance with NCMA test method SRWU-1.
F. Contractor shall submit engineering plans prepared by a
professional engineer experienced with Mechanically
Stabilized Earth retaining wall systems and registered in
the state of the project location. The engineering
designs, techniques, and material evaluations shall be in
accordance with the KEYSTONE Design Manual, 1995, NCMA
Design Guidelines For Segmental Retaining Walls, 1997, or
the AASHTO Standard Specifications for Highway Bridges,
Section 5.8, 1993 Interim, whichever is applicable.
G. Submit a list of previous projects totaling of 500,000
square feet (46,000 sq m) or more where the specific
retaining wall system has been used successfully. Contact
names and telephone numbers shall be listed for each
project.
1.6 QUALITY ASSURANCE
A. Owner will engage and pay for independent soil testing
services during earthwork operations.
1.7 DELIVERY, STORAGE AND HANDLING
A. Contractor shall check the materials upon delivery to
assure that proper materials have been received.
B. Contractor shall prevent excessive mud, wet cement,
epoxy, and similar materials (which may affix themselves)
from coming in contact with the materials.
C. Contractor shall protect the materials from damage.
Damaged materials shall not be incorporated into the
retaining wall structure.
NOTE ** Delete the following two paragraphs if all
retaining walls unreinforced.
D. Geogrids shall be stored above minus 20 degrees F.
E. Rolled geogrid material may be laid flat or stood on end
for storage.
PART 2 PRODUCTS
2.1 MANUFACTURER
A. Provide modular concrete retaining wall units and
accessory materials fabricated by authorized licensed
manufacturers of Keystone Retaining Wall Systems, 4444
West 78th Street, Minneapolis, MN 55435. Telephone 612-
897-1040. ASD. FAX 612-897-3858.
1. Substitutions will not be acceptable.
2.2 MODULAR CONCRETE RETAINING WALL UNITS
A. Modular concrete units shall conform to the following
architectural requirements:
NOTE ** Delete one of the two following paragraphs. If
custom color is required, edit to indicate color.
1. Modular concrete unit color: Manufacturer's standard
color.
2. Custom modular concrete unit color: _______________.
NOTE ** The following paragraph specifies the standard
convex face shape. Straight faces are available
upon request.
3. Face finish: Sculptured rock face in angular
multiplanar configuration. Other face finishes will
not be allowed without written approval.
4. Bond configuration - running with bonds nominally
located at midpoint vertically adjacent units, in
both straight and curved alignments.
5. Exposed surfaces of units shall be free of chips,
cracks or other imperfections when viewed from a
distance of 20 feet (6.1 m) under diffused lighting.
6. Corners: Provide 90 degree corners, finished two
sides, where indicated.
7. Cap units: Provide solid cap units with parallel
sides for straight walls and convex walls, angular
sides for concave walls.
B. Modular concrete units shall conform to the following
material requirements:
1. Cement: Materials shall conform to the following
applicable specifications.
a. Portland Cement: ASTM C 150.
b. Modified Portland Cement: Portland cement
conforming to ASTM C 150, modified as follows:
1) Limestone - calcium carbonate, with a minimum
85 percent content, may be added to the
cement, provided these requirements of ASTM C
150 as modified are met:
a) Limitation on insoluble residue 1.5
percent.
b) Limitation on air content of mortar by
volume: 22 percent maximum.
c) Limitations of loss of ignition: 7
percent.
c. Blended Cements: ASTM C 618.
d. Pozzolans: ASTM C 618.
e. Blast Furnace Slag Cement: ASTM C 989.
2. Aggregates: Conform to the following specifications:
a. Normal Weight Aggregates - ASTM C 33.
b. Lightweight Aggregates - ASTM C 331.
3. Other Constituents: Air entraining agents, coloring
pigments, integral water repellents, finely ground
silica, and other constituents shall be previously
established as suitable for use in modular concrete
retaining wall units and shall conform to applicable
ASTM standards or, shall be shown by test or
experience to be not detrimental to the durability of
the modular concrete units or any material
customarily used in retaining wall construction.
C. Modular concrete units shall conform to the following
structural and geometric requirements:
1. Compressive strength: 3000 pounds per square inch
(20MPa) minimum.
2. Absorption: 8 percent maximum for standard weight
aggregates.
3. Unit width to height ratio: 2.25 to 1.
NOTE ** In the next four paragraphs concerning unit depth,
weight, shear strength, and connection strength,
delete the requirement for Standard or Compact
units, respectively, if only one type is required.
If both types are required, retain both.
4. Unit depth:
a. Standard units: 20 inches (508 mm) minimum.
b. Compact units: 12 inches (305 mm) minimum.
5. Unit weight:
a. Standard units: 90 pounds (40 kg) per unit
minimum for standard weight aggregates.
b. Compact units: 75 pounds (34 kg) per unit
minimum for standard weight aggregates.
6. Inter-unit shear strength:
a. Standard units: 1500 pounds per linear foot
(21,000 N/m), minimum, at 2 pounds per square
inch (13 kPa) normal pressure.
b. Compact units: 400 pounds per linear foot (5800
N/m), minimum, at 2 pounds per square inch (13
kPa) normal pressure.
7. Geogrid/unit peak connection strength:
a. Standard units: 1000 pounds per linear foot
(14600 N/m), minimum, at 2 pounds per square inch
(13 kPa) normal force.
b. Compact units: 600 plf minimum at 2 psi normal
force. 600 pounds per linear foot (8700 N/m),
minimum, at 2 pounds per square inch (13 kPa)
normal force.
8. Maximum horizontal gap between erected units: 1/2
inch (13 mm).
D. Modular concrete units shall conform to the following
constructibility requirements:
1. Vertical setback: 1/8 inch (3 mm) plus/minus per
course (near vertical) or 1-1/4 inch (31.3 mm)
plus/minus per course per the design drawings.
2. Alignment and grid positioning mechanism: Fiberglass
pins, two per unit minimum.
2.3 SHEAR CONNECTORS
A. Strength of shear connectors between vertical adjacent
units shall be applicable over a design temperature range
of minus 10 degrees F (minus 23 degrees C) to plus 100
degrees F (plus 38 degrees C). Shear connectors shall be
1/2 inch (13 mm) diameter thermoset isopthalic polyester
resin-pultruded fiberglass reinforcement rods.
Connectors shall have a minimum flexural strength of
128,000 pounds per square inch (882 MPa) and short beam
shear of 6,400 pounds per square inch (44 MPa).
B. Shear connectors shall be capable of holding the geogrid
in the proper design position during grid pre-tensioning
and backfilling.
2.4 ADHESIVE
A. Construction Adhesive: Keystone Kapseal as supplied by
manufacturer of modular concrete units.
2.5 BASE LEVELING PAD MATERIAL
A. Material shall consist of a compacted crushed stone base
or non-reinforced concrete as shown on the drawings.
2.6 UNIT FILL
A. Unit fill shall consist of clean 1-inch minus crushed
stone or crushed gravel meeting the gradation listed
below.
1. 1 inch (25 mm) sieve, 100 percent passing.
2. 3/4 inch (19 mm) sieve, 75-100 percent passing.
3. No. 4 (4.75 mm) sieve, 0 - 10 percent passing.
4. No. 50 (300 micro-m) sieve, 0 - 5 percent passing.
B. Pea rock (3/8 inch to 1/2 inch (9.5 mm to 13 mm) round
stone) is not acceptable.
2.7 REINFORCED BACKFILL
A. Reinforced backfill shall be free of debris and meet the
following gradation requirements:
1. 2 inch (50 mm) sieve, 100-75 percent passing.
2. 3/4 inch (19 mm) sieve, 100-75 percent passing.
3. No. 4 (4.75 mm) sieve, 100-20 percent passing.
4. No. 40 (425 micro-m) sieve, 0-60 percent passing.
5. No. 200 (75 micro-m) sieve, 0-35 percent passing.
6. Plasticity Index (PI) les than 10 and liquid limit
less than 40.
B. The maximum aggregate size shall be limited to 3/4 inch
(19 mm) unless field tests have been or will be performed
to evaluate potential strength reductions to the geogrid
design due to damage during construction.
C. Material can be site excavated soils where the above
requirements can be met. Unsuitable soils for backfill
(high plastic clays or organic soils) shall not be used
in the backfill or in the reinforced soil mass.
D. Contractor shall submit reinforced fill sample and
laboratory test results to the Architect/Engineer for
approval prior to the use of any proposed reinforced fill
material.
NOTE ** Delete the following article if all retaining walls
are unreinforced.
2.8 GEOGRID
A. Material: Geogrid products shall be high-density
polyethylene or polypropylene expanded sheet or polyester
woven fiber materials, specifically fabricated for use as
soil reinforcement.
B. Tal, Allowable Tensile Design Load, shall be determined
as follows:
1. Tal = Tult/(Rfd x Rfcr x Rfcd x FS)
2. Tal shall be evaluated based on a 75 year design
life.
C. Rfcr, Reduction Factor for Creep Limited Tensile Load:
Rfcr shall be determined from 10,000 hour creep testing
performed in accordance with ASTM D 5262.
D. Rfd, Reduction Factor for Durability/Aging: Rfd shall be
determined from polymer specific durability testing
covering the range of expected soil environments.
E. Rfcd, Reduction Factor for Construction Damage: Rfcd
shall be determined from product specific construction
damage testing performed in accordance with GRI-GG4.
Test results shall be provided for each product to be
used with project specific or more severe soil type.
F. FS, Overall Factor of Safety: FS shall be 1.5 unless
otherwise noted.
G. The maximum design tensile load of the geogrid shall not
exceed the laboratory tested ultimate strength of the
geogrid/facing unit connection as limited by the "Hinge
Height" divided by a factor of safety of 1.5. The
connection strength testing and computation procedures
shall be in accordance with NCMA test methods.
H. Soil Interaction Coefficient, Ci: Ci values shall be
determined per GRI:GG5 at a maximum 0.75 inch (19 mm)
displacement.
I. Manufacturing Quality Control: The geogrid manufacturer
shall have a manufacturing quality control program that
includes QC testing for each 40,000 square feet (3700 sq
m) of production, each lot, or each production day. The
QC testing shall include:
1. Tensile Modulus
2. Specific Gravity
3. Melt Flow Index (PP & HDPE)
4. Molecular Weight (PETP)
PART 3 EXECUTION
3.1 EXAMINATION
A. Verify that layout dimensions are correct and substrate
is in proper condition for installation. Do not proceed
with installation until unsatisfactory conditions have
been corrected.
3.2 EXCAVATION
A. Contractor shall excavate to the lines and grades shown
on the construction drawings. Obtain the
Architect/Engineer's approval of excavation prior to
placement of leveling material or fill soils.
B. Over-excavation of deleterious soils and replacement with
suitable fill, when approved in advance by the
Architect/Engineer, will be paid at unit cost rates.
C. Contractor shall be careful not to disturb embankment and
foundation materials beyond lines shown.
3.3 BASE LEVELING PAD
A. Leveling pad material shall be placed to the lines and
grades shown on the construction drawings.
NOTE ** Select one of the following three paragraphs for
desired base leveling pad, or leave more than one
if contractor may choose. Note that Proctor
testing is not possible for crushed stone option.
B. Granular leveling pad material shall be compacted to a
minimum of 95 percent Standard or 90 percent Modified
Proctor.
C. Crushed stone leveling pad shall be compacted to yield
(Proctor testing does not apply).
D. Concrete leveling pad shall be minimum ______ inches of
unreinforced concrete.
E. Leveling pad shall be prepared to ensure full contact to
the base surface of the concrete units.
3.4 MODULAR UNIT INSTALLATION
A. First course of units shall be placed on the leveling
pad, and alignment and level checked. Pins or molded
surfaces of modular concrete units shall be used for
alignment control; do not attempt alignment from
rockface split surface.
B. Ensure that all units are in full contact with base and
properly seated.
C. Install fiberglass connecting pins and fill all voids in
and around the modular units with unit fill material.
Tamp or rod unit fill to ensure that all voids are
completely filled.
D. Sweep excess material from top of units and install the
next course. Ensure that each course is completely unit
filled, backfilled and compacted prior to proceeding to
next course.
E. Place each subsequent course ensuring that pins protrude
into adjoining courses a minimum of 1 inch (25 mm). Two
pins are required per unit. Push next course unit
forward, away from the fill zone, locking against the
pins in the previous course and backfill as the course is
completed. Repeat procedure to the extent of wall
height.
F. Follow wall erection and unit fill placement closely with
any other backfilling required.
G. Position vertically adjacent modular concrete units as
recommended by the manufacturer (in running bond
pattern).
H. Maximum stacked vertical height of wall units, prior to
wall unit fill, backfill placement and compaction, shall
not exceed two courses.
I. One cubic foot, minimum, of unit fill shall be used for
each square foot (0.30 cu m/sq m) of wall face. Unit
fill shall be placed within cores of, between, and behind
units to meet this requirement.
J. Whole, or cut, units on curves and corners to shall be
erected with running bond approximately centered on units
above and below.
K. Cap Installation: Apply adhesive to top surface of unit
below and place cap unit into position over projecting
pins from units below.
NOTE ** Delete the following article if all retaining walls
are unreinforced.
3.5 STRUCTURAL GEOGRID INSTALLATION
A. Geogrid shall be oriented with the highest strength axis
perpendicular to the wall alignment.
B. Geogrid reinforcement shall be placed at the elevations
and to the extent shown on the construction drawings or
as directed by the Engineer.
C. The geogrid shall be laid over the fiberglass pins of the
modular wall units and extended horizontally on compacted
backfill. Place the next course of modular concrete
units over geogrid. The geogrid shall be pulled taut,
and anchored prior to backfill placement on the geogrid.
D. Follow manufacturer's guidelines relative to overlap
requirements of uniaxial and biaxial geogrids.
E. Geogrid reinforcements shall be continuous throughout
their embedment lengths. Spliced connections between
shorter pieces of geogrid is not allowed unless pre-
approved by the Architect/Engineer prior to construction.
NOTE ** Delete the following article if all retaining walls
are unreinforced.
3.6 REINFORCED BACKFILL PLACEMENT
A. Reinforced backfill shall be placed, spread, and
compacted in such a manner that minimizes the development
of slack in the geogrid.
B. Backfill shall be placed from the wall back towards the
embankment to ensure that the geogrid remains taut.
C. Reinforced backfill shall be placed and compacted in
lifts not to exceed 8 inches (200 mm) where hand
compaction is used, or 12 inches (300 mm) where heavy
compaction equipment is used.
D. Reinforced backfill shall be compacted to 95 percent of
the maximum density as determined by ASTM D 698. The
moisture content of the backfill material prior to and
during compaction shall be uniformly distributed
throughout each layer and shall be within +1/-3
percentage points dry of optimum.
E. Place the top 8 inches (200 mm) of the structure fill
using low permeability soil.
F. Only lightweight hand-operated equipment shall be allowed
within 3 feet (900 mm)from the tail of the modular
concrete unit.
G. Tracked construction equipment shall not be operated
directly upon the geogrid reinforcement. A minimum fill
thickness of 6 inches (152 mm) is required prior to
operation of tracked vehicles over the geogrid. Tracked
vehicle turning should be kept to a minimum to prevent
tracks from displacing the fill and damaging the geogrid.
H. Rubber tired equipment may pass over geogrid
reinforcement at slow speeds, less than 10 miles per hour
(16 kph). Sudden braking and sharp turning shall be
avoided.
I. At the end of each day's operation, the Contractor shall
slope the last lift of reinforced backfill away from the
wall units to direct runoff away from wall face. The
Contractor shall not allow surface runoff from adjacent
areas to enter the wall construction site.
NOTE ** Delete the following article if all retaining walls
are reinforced with geogrid reinforcement.
3.7 UNREINFORCED BACKFILL PLACEMENT
A. Place and compact backfill in lifts not to exceed 8 (200
mm) inches (200 mm).
B. Backfill shall be compacted to 95 percent of the maximum
density as determined by ASTM D 698.
C. Place the top 8 inches (200 mm) of the structure fill
using low permeability soil.
D. Only lightweight hand-operated equipment shall be allowed
within 3 feet (900 mm) from the tail of the modular
concrete units.
E. At the end of each day's operation, the Contractor shall
slope the last lift of reinforced backfill away from the
wall units to direct runoff away from wall face. The
Contractor shall not allow surface runoff from adjacent
areas to enter the wall construction site.
END OF SECTION