Installation Manual Terramesh System ENG 15112016

TMS INSTALLATION MANUAL
Rev: 0, Date 15.11.2016
TERRAMESH SYSTEM
INSTALLATION MANUAL
AUTHOR: MACCAFERRI (REFERRED TO OFFICINE MACCAFERRI S.p.A.)
EMEA Technical Division Corp. DT Sect. Specialist EMEA Technical Manager

0 15/11/2016 D. Tubertini P. Di Pietro M. Vicari
REV. DATE PREPARED BY CHECKED BY APPROVED BY
DESCRIPTION OF REVISIONS SINCE THE LAST VERSION
The information contained in this Manual is subject to change by MACCAFERRI without prior notice Page 1
Rev: 0, Date 15.11.2016
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NOTICE 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 SERVICES PROVIDED BY MACCAFERRI................................................................................................ 12
3. FOUNDATION .................................................................................................................................... 13
3.1 FOUNDATION PREPARATION ................................................................................................................. 13
3.2 SETTING OUT............................................................................................................................................ 13
4. TERRAMESH SYSTEM ASSEMBLY ................................................................................................. 15
4.1 FLATTENING THE UNITS.......................................................................................................................... 15
4.2 ASSEMBLY AND LACING THE INDIVIDUAL UNITS ................................................................................. 15
4.3 GEOGRID REINFORCEMENT (IF PRESENT) .......................................................................................... 17
4.4 PLACING THE TERRAMESH SYSTEM UNITS ......................................................................................... 19
4.5 PLACEMENT OF THE STRUCTURAL FILL............................................................................................... 26
4.6 COMPACTION OF THE STRUCTURAL FILL ............................................................................................ 27
4.7 BACKFILLING ............................................................................................................................................ 29
5. CONSTRUCTION DETAILS ............................................................................................................... 30
5.1 INSTALLATION IN CORNERS AND CURVES .......................................................................................... 30
5.2 SHAPING AND ENDING OF STRUCTURES ............................................................................................. 31
5.3 INTERFERENCES, OBSTRUCTIONS AND FACING PENETRATIONS ................................................... 31
5.4 INTERNAL AND EXTERNAL DRAINAGE .................................................................................................. 34
6. CAUSE-EFFECT RELATIONS ........................................................................................................... 36
6.1 CAUSE-EFFECTS TABLE.......................................................................................................................... 36
6.2 TOLERANCES ........................................................................................................................................... 37
7. MAINTENANCE ................................................................................................................................. 38
7.1 IRREGULARITIES ...................................................................................................................................... 38
7.2 CONTROLS PERFORMED BY QUALIFIED PERSONNEL ....................................................................... 38
7.3 MAINTENANCE MADE BY QUALIFIED PERSONNEL .............................................................................. 39
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8. WORKING AT HEIGHT ...................................................................................................................... 40
8.1 DESCRIPTION OF THE SAFETY DEVICE (EXAMPLE) ............................................................................ 40
8.2 POSITIONING OF THE SAFETY DEVICE ................................................................................................. 42
8.3 CONSTRUCTION IN SAFETY ................................................................................................................... 43
9. INSTALLATION PRODUCTIVITY ...................................................................................................... 44
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NOTICE 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 also 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 in respect of 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.
At regards, 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-13/0295. The
management and production system is certified in compliance with ISO 9001 and ISO 14001.
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.
When requested 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 80 cm 80
Height of 1 m 60
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.
Stones
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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 SERVICES PROVIDED BY MACCAFERRI

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.
2.5 MATERIALS PROVIDED BY MACCAFERRI

• Terramesh System units
• Ring fasteners and tools
• Paragrid, Paralink, Paradrain and Macgrid geogrid reinforcements (if necessary –
determined by 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 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.
Exceeding 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 of foundation soil are essential.
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.
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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 PARALINK should be placed and spread in the longitudinal
direction of the PARALINK only (direction of the resisting strips). If this operation results in some
undulation of the PARALINK 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
Fig. 18 – Detail on the mesh openings (minimum 2) to be braced
Fig. 19 – Tie on 1 mesh (left side - wrong) and tie 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.
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When there is the overlapping of the geotextile, ensuring a minimum overlap of 300 mm.
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.
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Fig. 26 – Non staggered Terramesh units
Fig. 27 – Staggered Terramesh units
Fig. 28 – Front view of staggered and non-staggered Terramesh units in case of variable height and sloped foundation
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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.
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
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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) near (>1.0 m) to facing: a free area (50-60 cm width) for vegetative soil shall be left
3) back area
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 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).
Rev: 0, Date 15.11.2016
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:
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.
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Fig. 32 – Heavy compactors always kept at minimum 1 m distance from the facing
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.
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Fig. 37 – Hydraulic crossing through TMS
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. 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 the stability
Rev: 0, Date 15.11.2016
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 ∆S / ∆L.
compressibility: ratio ∆H / H.
Fig. 39 – Alignment, foundation settlements, compressibility.

Pictures taken from EN14475, which are the same for the execution of any reinforced fill.
Rev: 0, Date 15.11.2016
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 floating tree trunk (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
• 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.
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.
Rev: 0, Date 15.11.2016
8. WORKING AT HEIGHT
This paragraph can be used as a basis for the editing of Risk Assessment document, whose final
contents have to be adopted country by country depending on the local regulations.
In the following the technical details are explained and suggestions for the safety device used as a
personnel protection in the Terramesh System installation in order to assure a high installation
productivity without affecting the safety of the workers.
Support for the construction site manager that supervise the personnel, the work execution and
control the using of protection device and equipment (individual and collective) on the working site
will be presented.
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
Rev: 0, Date 15.11.2016
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.
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Fig. 44 – Safety device in TMS construction (example)
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
Rev: 0, Date 15.11.2016
8.3 CONSTRUCTION IN SAFETY

The operation of assembly and filling of TMS, must be made in safety.
Fig. 47 – TMS, positioning of the safety device (can be supported by formwork) and filling operation
Rev: 0, Date 15.11.2016
9. INSTALLATION PRODUCTIVITY
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
5 200 m2 of facing 250 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
5 60 m2 80 m2
Rev: 0, Date 15.11.2016
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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Installation Manual Terramesh System ENG 15112016

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TMS INSTALLATION MANUAL

Rev: 0, Date 15.11.2016

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

DESCRIPTION OF REVISIONS SINCE THE LAST VERSION

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

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

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

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

2.4 SERVICES PROVIDED BY MACCAFERRI................................................................................................ 12

3.1 FOUNDATION PREPARATION ................................................................................................................. 13

3.2 SETTING OUT............................................................................................................................................ 13

4. TERRAMESH SYSTEM ASSEMBLY ................................................................................................. 15

4.1 FLATTENING THE UNITS.......................................................................................................................... 15

4.2 ASSEMBLY AND LACING THE INDIVIDUAL UNITS ................................................................................. 15

4.3 GEOGRID REINFORCEMENT (IF PRESENT) .......................................................................................... 17

4.4 PLACING THE TERRAMESH SYSTEM UNITS ......................................................................................... 19

4.5 PLACEMENT OF THE STRUCTURAL FILL............................................................................................... 26

4.6 COMPACTION OF THE STRUCTURAL FILL ............................................................................................ 27

4.7 BACKFILLING ............................................................................................................................................ 29

5. CONSTRUCTION DETAILS ............................................................................................................... 30

5.1 INSTALLATION IN CORNERS AND CURVES .......................................................................................... 30

5.2 SHAPING AND ENDING OF STRUCTURES ............................................................................................. 31

5.3 INTERFERENCES, OBSTRUCTIONS AND FACING PENETRATIONS ................................................... 31

5.4 INTERNAL AND EXTERNAL DRAINAGE .................................................................................................. 34

6. CAUSE-EFFECT RELATIONS ........................................................................................................... 36

6.1 CAUSE-EFFECTS TABLE.......................................................................................................................... 36

6.2 TOLERANCES ........................................................................................................................................... 37

7.1 IRREGULARITIES ...................................................................................................................................... 38

7.2 CONTROLS PERFORMED BY QUALIFIED PERSONNEL ....................................................................... 38

7.3 MAINTENANCE MADE BY QUALIFIED PERSONNEL .............................................................................. 39

8.1 DESCRIPTION OF THE SAFETY DEVICE (EXAMPLE) ............................................................................ 40

8.2 POSITIONING OF THE SAFETY DEVICE ................................................................................................. 42

8.3 CONSTRUCTION IN SAFETY ................................................................................................................... 43

9. INSTALLATION PRODUCTIVITY ...................................................................................................... 44

NOTICE AND ASSUMPTIONS

Fig. 1 – Terramesh System

2.2 CONSTRUCTION DESIGN

2.3 MATERIALS AND REQUIREMENTS BEFORE STARTING

Terramesh System (TMS) units

Fig. 2 – Bundles of Terramesh System

Ring after fastening

Fig. 3 – Fastening rings

TERRAMESH SYSTEM RINGS

Fig. 4 – Lacing wire: coil

Geogrid reinforcement (if necessary - determined by design)

Fig. 5 – Pneumatic and manual lacing gun

Delivery and storage of materials on job site

2.4 SERVICES PROVIDED BY MACCAFERRI

2.5 MATERIALS PROVIDED BY MACCAFERRI

3.1 FOUNDATION PREPARATION

Fig. 6 – TMS foundation: levelling

3.2 SETTING OUT

4. TERRAMESH SYSTEM ASSEMBLY

4.1 FLATTENING THE UNITS

Fig. 7 - Opening of TMS units

4.2 ASSEMBLY AND LACING THE INDIVIDUAL UNITS

Fig. 9 – Lacing details

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

4.3 GEOGRID REINFORCEMENT (IF PRESENT)

Fig. 12 – TMS with geogrid reinforcements

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

4.4 PLACING THE TERRAMESH SYSTEM UNITS

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

Fig. 15: adjacent Terramesh units connected along the edges