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Transcript of Paper Geoshanghai08
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Design and installation of rock fall barrier for the Pos Slim project,
Malaysia
Tiru Kulkarni & Kenneth ChooRegional Manager Managing Director
Maccaferri Asia Regional Headquarters Maraputra Sdn Bhd.Kuala Lumpur, Malaysia Ipoh, Malaysia
ABSTRACT
Rock fall protection systems are a key element in the design and maintenance of
infrastructure networks. These systems are generally categorized as either activesystems ( ie ) where the system acts before the initiation of rock mass detachment , or
passive systems ( ie ) where the system acts after the detachment of the rock mass.
Rock fall barriers comprise of a complex system of energy absorption devices thatfunction as a passive rock fall mitigation mechanism. The design of such systems is
based on a combination of site simulations and field crash tests. Due to recentdevelopments in standardizing design and testing criteria for rock fall barriers, thesesystems are rapidly gaining acceptance due to reasons of site adaptability and economy.
This paper deals with the various design and construction issues encountered on the Pos
Slim rock project in Malaysia. The project is located in a geo-morphologically unstableregion and involved several measures undertaken for the protection of a highway from
unstable rock and soil slopes.
Key words: active and passive rock fall mitigation systems, rock fall barriers.
INTRODUCTION
The concept of utilizing rock fall barriers is relatively new in Asia. Even in Europe,where these systems and applications are more common, the field of rock fall engineering
is widely considered to be an evolving code of practice ( ie ) the design and installation of
these systems depends largely on the experience and expertise of the engineer and thevisualization of the problem.
The main parameters affecting the design of a rock fall barrier system are:
Falling energy Falling velocity Height of impact
Falling energy and Falling velocity are related by the equation :
E = 0.5*m*v + 0.5*I*
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where:
m is the mass of the block
v is the translational velocity of fall
I is the moment of inertia of the block
is the angular rotational velocity
Generally, for large block sizes the component of rotational energy ( given by the factor
0.5*I*) is minimal, and can be neglected in practice.
Therefore,
E = 0.5*m*v
Falling velocity ( ie ) velocity of free fall can be estimated from the following graph
The height of impact depends on:
Morphology of the slope and Trajectory of the block
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The trajectory of rocks which bounce while falling is more difficult to forecast as
compared to unstable rock wedges which follow primarily a sliding pattern, as theirtrajectories are defined by the morphology of the slope.
A rock fall barrier is a complex system consisting of:
Posts Connection structures which act to transfer the energy to the energy dissipation
devices Energy Dissipation Devices which help in the dissipation of the generated energy
on impact. Intervention structure which acts to catch the falling rock mass Foundations and anchors
A typical rock fall barrier is shown in the figure below
The mechanism of energy dissipation in a rock fall barrier is a complex process and very
difficult to simulate and compute analytically. A live crash test is hence the accepted
norm for certifying a stipulated capacity for the rock fall barrier.
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THE POS SLIM PROJECT
The Pos Slim project involved slope stabilization works in Cameron Highlands, in the
state of Pahang in Malaysia. The geology of Cameron Highlands comprises mainly
granite rocks followed by small portions of metamorphic rocks and alluvium.
The geomorphology of this area is mainly dominated by denudational process as it is
situated in a mountainous area and has constituent of deep highly weathered martial.
Most parts, especially the exposed unprotected areas like slope-cut abandoned agriculturesites and slope-from agriculture sites, are highly affected by this process. Therefore,
erosion feature such as rill gullies can be clearly seen, and as a consequence, in certain
areas the phenomenon of mass movement is predominant as these features worsen. Thiscan be clearly seen from the photograph below
The site was located between
Northing 507975.593 and 508139.493 and
Easting 372754.721 and 372656.941 for the lower berm
And
Northing 507975.593 and 508139.493 and
Easting 372754.721 and 372656.941 for the lower berm
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Northing 508161.910 and 508337.210 and
Easting 372724.410 and 372638.040 for the upper berm
Total length of the site was 400 m.
Boreholes taken at five locations on the site showed a mix of stiff gravel and silt up to a depth
ranging from 10m 20m followed by highly fragmented slate. The table below gives a summaryof the borehole findings at the site:
Borehole number 0-10 m depth 10-20 m depth 20m + depth
BH 1 Stiff sandy gravel Weathered slate. End
of BH @ 13.0 m due
to bed rock
BH 2 Stiff sandy gravel Stiff sandy gravel Stiff sandy gravel till
22.0m. Weathered
slate from 22.0m. End
of borehole @ 37.0mdue to bed rock.
BH 3 Sandy gravel Stiff sandy gravel Weathered slate. End
of BH @ 22.1m due
to bed rock
BH 6 Stiff sandy gravel.
End of BH @ 6m due
to bed rock.
BH 7 Weathered slate. End
of BH @ 4.5m due to
bed rock
The photograph below depicts the type of weathered slate formation prevalent at the site
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DESIGN OF THE ROCK FALL BARRIER
One of the first steps in the design of the rock fall barrier involved deciding the capacityand the height of the barrier. This involved a rock fall trajectory analysis carried out on a
standard cross section at the site, whose results are shown below
Assumed weight of the rock mass considered 1800 kg 350 kgs
Coefficient of tangential restitution considered 0.4 with a standard deviation of 0.04
Coefficient of the normal restitution considered 0.85 with a standard deviation of 0.04
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Total Kinetic Energy on LOWER BERM
0
50
100
150
200
250
300
1.7
2E+
03
1.6
0E+
04
3.0
3E+
04
4.4
6E+
04
5.8
9E+
04
7.3
2E+
04
8.7
5E+
04
1.0
2E+
05
1.1
6E+
05
1.3
0E+
05
1.4
5E+
05
1.5
9E+
05
1.7
3E+
05
1.8
8E+
05
2.0
2E+
05
2.1
6E+
05
2.3
0E+
05
2.4
5E+
05
2.5
9E+
05
2.7
3E+
05
Total Kinetic Energy [J]
NumberofRocks
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Using a Kolmogorov Smirnov distribution with a cutoff percentage of 95, the design
kinetic energy was established at 146.99 KJ along with a design height of 1.287m for thecentre of gravity of the boulder.
Hence, keeping a minimum accepted Factor of Safety of 1.5, the capacity of the rock fall
barrier proposed was 250 KJ with a design height of 2.0m
FOUNDATION AND ANCHOR DESIGN
The foundation design was carried out using a force vector analysis. Rakered micropiles
were designed to resist a force of 213 KN.
There is no specific standard for micropile design. Relevant standards for individual
design components were followed for the purpose of this design. These standards are BS
8081 and BS 449. Also referred was Micro pile and anchor design by MichelBustamante.
The steps involved in the design were as follows:
The force on each micropile was calculated using a Force Vector diagram, basedon the measured upslope anchor force of 300 KN in the live crash test.
The micropile was designed to resist this force considering the strata encounteredfor each borehole.
The maximum micro pile length of 13m ( encountered for BH 2 & 3 ) wasselected as the standard length for all micropiles.
Given under are is the micropile analysis for Borehole 2 & 3
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FORCE VECTOR DIAGRAM FOR MICROPILES ( NTS )
Considering the anchorage angle as 45 degrees ( w.r.t ) horizontal plane , we get
Horizontal component of Force = 300 Cos 45
= 212.13 KN
Say 213 KN
From the force vector diagram, the components of the force on the micropiles are 213 KN
each ( equilateral triangle ).
For Borehole 2 & 3
Consider pile diameter = 0.1 m
Tl = [ * Ds1 * Ls1 * qs1 * 1000 ( KN )] + [ * Ds2 * Ls2
* qs2 * 1000 ]
Where Ds1 = * Dq1
= 1.1 * 0.1= 0.11
Ls1 = 5m ( consider top 4m as free length )
qs1 = 0.05 ( refer Bustamante : Fig 16 )
Ds2 = * Dq2
= 1.2* 0.1
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= 0.12
Ls2 = 4 m
qs2 = 0.20 ( refer Bustamante : Fig 16 )
Therefore,
Tl = 387.98
Say 388KN
Therefore FS = 388 / 213
= 1.82 > 1.5
Therefore OK
Therefore total micro pile length at BH 2 = 4m + 5m + 4m = 13m
Tendon design
Consider 40mm rebar ( min yield stress lim = 600 N / sq mm )
Assume sacrificial thickness 8mm
Net diameter of rebar = 32 mm
Yield force of rebar = * D / 4 * lim
= 482 KN
FS = 482 / 213
= 2.26 >> 1.5
Hence OK
Provide 40 mm dia rebar for micropile.
Micro pile details
Diameter of micropile 100 mm
Diameter of bore 120 mmLength 13 m
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Anchors were designed on a similar methodology for a force of 300 KN.
Summary for anchors
Diameter of micropile 100mmDiameter of bore 120 mm
Length 14m
A typical cross section is shown in the figure below
CONSTRUCTION ISSUES
Construction started in July 2007. Some of the issues encountered during construction
were:
Difficulty in drilling at 45 angle Drilling proved to be very difficult due to thefragmented strata present at the site. The fragments would choke up the drill hole
and slow down the progress. This was circumvented by bringing in high powereddrilling rigs and increasing the number of drilling machines. In total, two
mechanized drilling rigs were used for the project.
Difficult topography and terrain Simple tasks like provision of water forconstruction became difficult due to the location of the site. As there was nohabitation nearby, temporary accommodation was constructed for the labourers
on site. Frequent labour turnover caused delays, as the labour force was not used
to working in such harsh conditions.
Some photos showing construction work in progress
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Picture shows installation of the posts in progress
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Picture shows material sorting at site
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Picture shows a monkey wrench being used for tensioning the diagonal wire ropes.
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Picture shows installed barrier on the upper berm
The construction and installation work for the entire stretch of 400 m was completed inOctober 2007, four months after commencement.
Conclusion
The efficiency of a rock fall barrier is decided by its performance during a rock fall
event. Since the construction of the barrier is quite recent, and there have been no rock
fall events after it was installed it is difficult to comment on this aspect.However, the design and installation of the rock fall barrier provided a number of
engineering and project management challenges which were met successfully, thus
completing a successful installation.