CONSTRUCTION MANUAL

MI/MP/19 Rev:00 / Date 01.02.2010

MACCAFERRI Gabion

MACCAFERRI GABION
CONSTRUCTION MANUAL
MACCAFERRI ENVIRONMENTAL SOLUTIONS PVT. LTD.

CONSTRUCTION MANUAL FOR MACCAFERRI GABIONS

Prepared By:

Document Author(s) Project/Organizational Role

Mr. Thomas Cherian Manager - Technical
Mr. Prashant Navalakha General Manager - Technical

Approved By:

Ms. Minimol Korulla Chief Technical Officer

Revision No. Date Change Description

0 01.02.2010
 Contents

Sr. Topics Page

No. No.

1. Components of MACCAFERRI Gabion 3-6

2. Material Handling and Storage 7 - 12

3. Construction Sequence 13 - 22

4. QA plan & Construction Tolerances 23 - 26

5. Annexure – I : Monitoring Formats 27 - 33

 1. Components of MACCAFERRI Gabion
Introduction:

The MACCAFERRI Gabion is a rectangular cage made of hexagonal woven steel

wire mesh. They are uniformly partitioned, of variable sizes, interconnected with
adjacent cages and filled with stone at the site of use, to form flexible, permeable,
monolithic structures such as retaining walls for road and railway projects.
The Reno mattresses can be described as a Gabion of which the depth is small in
proportion to its length and width. They are used for protection against scouring in
water-front structures, erosion control applications, channel linings, bank protections,
groynes and weirs.

Fig.No.1.1 MACCAFERRI Gabion Retaining Wall

Fig.No.1.2 MACCAFERRI Reno Mattress application for river bank protection

MACCAFERRI Gabion:
The MACCAFERRI Gabion is a rectangular box fabricated from heavily galvanized
Double Twisted (DT) steel woven wire mesh as shown in Fig.No.1.3. The box is
divided into cells by transverse diaphragms. For using the Gabions in harsh and
aggressive environments additional PVC coating is done over the heavily galvanized
steel wire.
The MACCAFERRI Gabion comprises of the following main components:
L ID

D IA P H R A G M

END

BACK

END H

FRONT

L
W

Fig.No.1.3 Components of a MACCAFERRI Gabion

1. The DT wire mesh is a non ravelling mesh made up of a set of continuous

steel wires, wherein adjacent pair of wires are twisted through two and half
turns and hexagonal shaped openings are formed by weaving process.

The typical pattern of the Double Twisted wire mesh is as shown in the
Fig.No.1.4

Fig.No.1.4 Double Twisted (DT) Wire Mesh

2. A Selvedge wire is used to edge the wire mesh perpendicular to the double
twist by mechanically wrapping the mesh wires around it at least 2.5 times.
3. An Edge wire of the same diameter as the selvedge wire is used to edge
the wire mesh parallel to the double twist by continuously weaving it
mechanically into the wire mesh.
4. A Lacing wire (as shown in Fig.No.1.5) is used to assemble and
interconnect empty units, to close and secure stone-filled units, and for
internal stiffeners. The same wire is used as Stiffener for support of facing
by connecting the front panel to the back panel of a gabion.
 Fig.No.1.5 Lacing wire

The MACCAFERRI Gabion is manufactured with all components mechanically

connected at the production facility. The external face and top lid is made from the
same mesh. The ends, back, and diaphragm are connected to the base at the
installation site. All perimeter edges of the mesh forming the basket are selvedged
with wire having a larger diameter.
The MACCAFERRI Gabions are supplied to project site from factory with its
components folded flat, collapsed and packed in bundles as shown in the Fig.No.1.6

Fig.No.1.6 A stack of folded MACCAFERRI Gabion bundles.

Reno Mattress:

The Reno Mattress is also fabricated from heavily galvanized Double Twisted (DT)
steel woven wire mesh as shown in Fig.No.1.7. The distinguishing feature of the
mattress is the thickness/height of the box. The thickness of the box is less than 0.5 m
thereby providing a much planar nature of application as compared to the gabion box.
The box is divided into cells by transverse diaphragms. The lid for the mattress is
supplied in the form of DT mesh rolls.

Reno mattresses are used in river bank and scour protection, channel linings, erosion
control and embankment stability.
For using the Reno Mattresses in harsh and aggressive environments additional PVC
coating is done over the heavily galvanized steel wire.

LID

SIDE END

DIAPHRAGM

BASE

H
SIDE L
END
W

Fig.No.1.7 Components of Reno Mattress

Rock:
Rocks (as shown in Fig.No.1.8) for filling the Gabions or Reno Mattresses
should be obtained by any suitable quarrying method. Rocks should 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. The size of
the rocks should range between 150 and 250 mm.

Fig.No.1.8 Random sized rocks supplied from quarry

 Material Handling and Storage

2. Material Handling and Storage

The storage yard shall be developed or located in a suitable-sized area depending on
the quantity of the MACCAFERRI Gabions / Reno mattresses required in the project.
The layout of the storage yard should be planned with due consideration to the
movement of trucks and other heavy equipments that would be involved in the
handling i.e. loading and unloading. For areas experiencing heavy rainfall it is
recommended to construct warehouses.

The following procedure shall cover storage activities for the materials required
in the application of Gabions.

• Receipts, handling, identification and traceability, Inspection acceptance of

materials and MTC.
• Documentation
• Storage & Preservation
• Material issue, return, reconciliation.

The following aspects shall be considered for efficient handling and safe
storage of materials.

1. Proper illumination shall be provided at important places to facilitate loading and

unloading operations of materials during the night.
2. Special instructions for the handling of each component shall be provided to the
Stores department. The loading and unloading guidelines shall be meticulously
followed for the different components. For e.g. A Fork-lift or Hydra crane is
necessary for the handling of DT wire-mesh products which are stacked in bundles.
Wooden rafters are placed at the bottom and in between each bundle to facilitate the
handling of each bundle with the Fork-Lift.
3. The equipment used for loading and unloading shall be as per the guidelines for the
particular component. The arrangements for the same shall be made at the yard and
project site.
4. The open storage area in the yard shall be leveled properly and capable of taking the
load of the material stacks. The ground shall be developed such that even during
rainy season the material stacks are accessible. All the materials shall be kept on
wooden planks or pipes to avoid direct contact with the ground. The wooden planks
or pipes shall also ensure that the stacks remain stable
5. Fire can inflict huge loss and damages to the materials stored in the yard. Therefore,
adequate numbers of fire extinguishers shall be available inside the warehouse. The
entire storage yard shall be considered a ‘No Smoking’ zone.
6. Ensure physical verification of the whole consignment as per packing details &
check for any visual damage. The damaged or defective materials should be
immediately segregated and shifted to a separate area dedicated for such storage.
7. Storing of material should be done by item category, size and grade. Adequate space
(1m) should be made available between the stacks; sufficient enough to allow
movement of store/project staff for routine inspection.

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 Material Handling and Storage

8. Each type of material should be kept location wise for easy tracking and subsequent
movement of material. The material shall be identified from the identification label
attached to every bundle.
9. Tagging and display boards shall be maintained for each type of material.
10. Routine activities such as sweeping, cleaning, dusting must be undertaken
and daily check list to be marked daily kept at each covered area.
11. Water and moisture acts as catalyst for deterioration of material. Storage
place should be free from any water leakages and must have security
arrangements with a gate for restriction of unauthorized entry.
12. Fair amount of damage occurs to material during handling. Entrances, exits,
pathways must be kept clean and free from material. Keep height and weight
restrictions in mind while stacking material and damage due to tear and shear.
13. Provide proper drainage system and the yard should be cleared of debris.
14. The storage yard shall be provided with a permanent constructed or fabricated
mobile ramp.

WORK INSTRUCTION FOR UNLOADING AND STORAGE OF DT

PRODUCTS

This Work Instruction is a guide to unload the material at the project and it covers
the MACCAFERRI Gabions and Reno mattresses.

PROCEDURE:

1. Verify the documents of the consignment and take the vehicle to the unloading
destination.

8
 Material Handling and Storage

2. Untie the chain/rope/belts etc. which are used for holding material firmly in the
vehicle.

3. Use preferably the Hydra Crane or Forklift for unloading the material.

9
 Material Handling and Storage

4. Use the hooking arrangement on the 3rd and 5th wires while unloading the
material. The 3rd and 5th wires are indicated by arrows as shown below.

Use these two wires (3rd and 5th) for hooking purpose.

5. Never push the bundles manually, it will lead to damages.

6. For closed type of trucks, ramp & Forklift is preferred for the unloading of the
material. A ramp can be either constructed or fabricated.

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 Material Handling and Storage

7. Unloaded bundles to be kept as shown below, to avoid the probable damages in

the future handling. If the vehicle contains different products/ different sizes of
the product, storage product wise/size wise is recommended for easy
identification & retrieval.

8. Product can be identified from the identification label attached to every bundle.

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 Material Handling and Storage

The label shows size, quantity and bundle no., lot no. and the weight. This can
be traced to packing list/invoice and confirmed.

9. The cover lid for the Reno Mattress is supplied in the form of rolls.

Insert wire around the roll circumference and form a closed ring.
The rings can then be lifted by the slings.

10. It shall be noted that any deviation with respect to quantity, specification,
damages should be informed in writing along with the evidence proof such as
photographs of the consignment received within seven days of delivery at project.

11. The received quantity must be acknowledged on the delivery challan cum
packing list. This has to be properly authenticated with seal & signature of the
authorized person, with name & designation.

12
 Construction Sequence

3. Construction Sequence

The following sequence shall be followed in the construction with the MACCAFERRI
Gabions:

1. Excavate the formation to the required level as shown in the drawings. If good
bearing stratum is not observed after the excavation up to mentioned levels then,
the same should be brought to the notice of Engineer-in-charge for further advice.
The surface of formation should be free from any deleterious material and
unwanted foreign objects. Loose pockets if any, should be excavated and filled
with suitable granular or backfill material.

2. Roll the formation using Vibro-roller of 8 to 10 tonnes (Refer Fig.No.3.1)

capacity. The design requirements with respect to bearing capacity should be
achieved and verified before proceeding further. Density of compacted formation
should be greater than or equal to 95% of the modified Proctor value.

Fig. No. 3.1 Vibro-roller

3. The formation prepared should be levelled without ruts and undulations as shown
in Fig. No. 3.2 below.

Fig.No. 3.2 Formation

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 Construction Sequence
4. The outer alignment of the fascia should be marked by the survey team as per the
requirements in the section and plan drawings.

5. The bundles of MACCAFERRI Gabions shall be supplied to the installation site

from the stores and stacked in the same manner as in the storage yard.

Fig.No. 3.3 At project site, a Stack of

MACCAFERRI Gabion bundles.

These bundles shall be stacked on a leveled ground with wooden rafters/sleepers

in between them for easy in handling and preventing any damage to the DT mesh
and other components like the selvedge wire.

6. The bundles may be opened at the storage yard for supplying the exact quantity of
gabions to the construction site. The individual folded gabion units shall be
handled properly as shown in Fig.No.3.4 to avoid any damage to the DT mesh
and other components.

Fig.No. 3.4 At project site, a

folded MACCAFERRI
Gabion unit is unloaded
manually.

7. The folded gabion unit shall now be opened by placing it on a flat surface or
leveled ground and straightening out the
various end panels as shown in the Fig.
No.3.5. One or two persons may be
deployed for the straightening of DT mesh
panel activity depending on the size of
gabions.

Fig.No.3.5 Straightening out of DT

mesh panels of folded gabion unit.

14
 Construction Sequence

8. The back, front, end panels along with the diaphragms shall now be folded along
the lines after verifying the required correct dimension of the base from the
section drawings. The diaphragm is secured in position to the base so that no
additional lacing is necessary at the site. The resulting arrangement is as shown in
the Fig.No.3.6 below.

diaphragm
projecting selvedge wire

folding lines

Fig.No.3.6 Straightened out Gabion with diaphragm fixed in position.

9. The gabion box shall then be assembled by making the end panels on either side
meet with the front and back panels. The upper corners at each of the pair of side
panels shall now be tied with the lacing wire. The diaphragm panel used for
creating the cells within the gabion shall also be tied to the front and back panels
as shown in the Fig.No.3.7 below.

Fig.No.3.7 Gabion formed by

connecting all the end panels
with diaphragm fixed in fasten diaphragms
position. to front and back
fasten ends to side

15
 Construction Sequence

10. The lower side of the gabion edges and of the existing diaphragms shall then by,
connected from bottom to top by the lacing procedure explained as in the next
step no.11.

11. The procedure for using lacing wire consists of cutting a sufficient length of wire,
and first looping and/or twisting to secure the lacing wire to the wire mesh.
Proceed to lace with alternating double and single loops through every mesh
opening approximately every 150 mm pulling each loop tight and finally securing
the end of the lacing wire to the wire mesh by looping and /or twisting. Refer
Fig.No.3.8.

Fig.No.3.8 Lacing procedure

12. Adequate care shall be taken during the lacing operation to ensure that the base
panel of gabion measures the inner dimension required in the section drawings.
While ensuring the base dimension, proper arrangements shall be done to ensure
that the side panels form a right angle with the base and the gabion box achieves a
proper geometry. For this purpose, a right angle corner template arrangement
made from wood/Mild steel/Aluminium section shall be used as shown in the
Fig.No. 3.9.

Right angle Corner

template

Fig.No. 3.9 Right angle corner template made from wood

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 Construction Sequence
13. Similarly, the required numbers of gabions can be assembled in the available open
space near the proposed gabion retaining wall structure as shown in the Fig.
No.3.10 below.

Fig.No. 3.10 Assembled gabions ready for placement

14. The gabions shall now be placed manually at the proposed structure location with
the front face along the outer facia alignment marked by the survey team.

Fig.No. 3.11 Placement of gabions at proposed location

15. The facing sections of the gabions are matched individually as per the required
alignment and their heights checked at the junctions of adjacent gabions. All the
gabions placed shall be connected to each other by the lacing procedure.

The top and bottom ends of

the panels shall now be
stretched along the
longitudinal direction with
Max-Puller arrangement as
shown in Fig.No.3.12. The
Max-Puller arrangement
will keep the front and back
panels in tension during the
rock filling operation.

Fig.No. 3.12 Stretching the gabions by the Max-Puller arrangement.

(Please note that the Geotextile shown is not a standard requirement).

17
 Construction Sequence
16. Rocks for filling the gabion shall be obtained by any suitable quarrying method.
Rocks should 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. The size of the rocks should range between 150 and 250 mm. The rocks
shall be selected in such a way that at least one face is flat-shaped as shown in the
Fig.No.3.13.

Fig.No. 3.13 Selection of rocks with flat face at Quarry

Rocks ranging between 100 and 40 mm shall also be used for packing the voids
and reducing the porosity. A template for 250 mm (as shown in the Fig.No.3.14)
shall be used at the quarry loading point to avoid supply of large size boulders to
the site. Alternately, the larger sized stones supplied from the quarry shall be
broken down by skilled labor to achieve the flat shape using the hammer and
chisel.

Fig.No. 3.14 Template for screening rocks greater than 250 mm in size.

17. MS pipe/frame formwork (as shown in Fig.No. 3.15) shall be provided at the
gabion facia for achieving a good aesthetic appearance and keeping the bulges
within the specified tolerances. The formwork enables to achieve uniformity in
the gabion box dimensions during the filling and placement of stones. As far as
possible a fair face of large flat stone should be placed at the exposed faces only.
This also enhances the appearance and reduces the risk of construction induced
damage.

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 Construction Sequence

Fig.No. 3.15 Formwork

18. The rocks should be placed in lifts of 300 mm. The filled layer should never be
more than 300 mm higher than any adjoining cell. To avoid such circumstances
the filling pattern shown in Fig.No.3.16 should be followed.
DETAIL OF THE SAME LAYER BEING FILLED

Fig.No. 3.16 Filling pattern of gabions boxes

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 Construction Sequence
19. After the placement of a layer of rock in the cell, sufficient hand manipulation
should be performed to minimize voids and achieve a maximum density of the
rock fill. For vertical or near vertical structures the exterior of the basket shall be
carefully hand placed to give a neat, flat, and compact appearance. Small sized
stones shall be provided only at the centre of box. No small stone shall be placed
at the corner of box. Care shall be taken when placing fill material to ensure that
the sheathing on the PVC coated baskets is not damaged.

Fig.No. 3.17 Placement of rocks in Gabions

20. Internal cross-ties (as shown in Fig.No.3.18) using lacing wire shall be installed
after every 300 mm of fill connecting the front and back faces of any supported or
exposed face.

Fig No. 3.18 Cross-ties

a. The diaphragm position and the overall dimensions of the gabion shall be
checked during the process.

b. It is also recommended to slightly overfill the baskets by 25 to 50 mm to

allow for settlement of the rock. The filling shall be done with the smaller
fractions of the fill.

c. The lid of the gabions shall be matched properly along with the required
alignment of facia.

20
 Construction Sequence

d. The subsequent unit shall be placed at an offset as specified in the section

drawing from the face of lower unit.

e. The gabions in upper layer shall be connected to the top of gabions in the
lower layer along the front and back edges of the contact surface using the
same connecting procedure. Facia of adjoining units must be securely joined
together, along the vertical facing and top edges of their contact surfaces.

f. At the back face of the gabion a non-woven geotextile shall be fixed

extending 250 mm into the backfill at top and bottom in the form of C-shaped
wrapping. This will prevent the structural fill from being washed into the rock
voids in the event of a rainfall and to drain off excess water from the structural
fill.

g. Now the soil for structural fill shall be placed and compacted to 95% of
modified Proctor density in the area behind the gabion units. The soil used as
structural fill shall be free draining granular fill

h. Compact the structural fill using Vibro-roller of 8 to 10 tonnes capacity.

Compacted density shall not be less than 95% modified Proctor density for the
formation. The movement of vibro-roller shall not be permitted in the area up
to 1.5m from the rear face of the unit. The compaction within 1.5m of the rear
of the face element shall be carried out using vibratory plate compactors or
walk behind rollers having 1 tonne capacity as shown in Fig. No.3.19 below.

Fig.No. 3.19 Walk-behind roller

Special Note:
The average void ratio of the Gabion boxes can be found out by weighing the boxes. The
weight of the box can be compared with calculated weight of box.

E.g.: Let the density of the stone = 26 kN/cum.

Let the void ratio of the filled Gabion box be around 30-40%.
Assuming 35% porosity the net weight of the stone fill = 16.9 KN /cum.
The weight of 1.5 x 1 x1 m Gabion box = 1.5 x 16.9 ~ 2.5 tonne.
The weight of the filled Gabion box should be approximately equal to
the calculated weight.

21
 Construction Sequence

Fig.No. 3.20 Completed Maccaferri gabion structures

22
 QA Plan and Tolerances

QUALITY ASSURANCE PLAN

MACCAFERRI GABIONS
Name of Project :

Contractor :

Client :

Consultant :

Material or Process / Acceptance / Reference Level of

Sr.No. Frequency
Characteristics Standard Check
1 Zinc + PVC Coated Wire (Material)
i Dimensions - Diameter EN 10223-3
ii Tensile Strength and elongation EN 10223-3
iii Zinc Coating Thickness EN 10244-2
One test for every 5000 numbers
iv Zinc Coating Adherence EN 10244-2 One, two and
of units (wall or sloped)
Zinc Coating Uniformity EN 10244-2 four
v delivered at site.
vi PVC Coating: Thickness ASTM - A 975
PVC Coating: Resistance to sodium
vii As per Contract Specification
chloride solution

2 Mesh (Material)

One test for every 5000 numbers

i Size ('D' - dimension) EN 10223-3 One and two
of units delivered at site.

3 Gabion (Material)

One test for every 5000 numbers

i Dimension ASTM - A 975 One and two
of units delivered at site.

4 Backfill (Material)
2 samples per 3000 cu.m or IS: 1270 & Contract
i Gradation Three
change in source/ fill material Specification
2 samples per 3000 cu.m or IS: 1270 & Drawings BS : 8006
ii Direct Shear Test Three
change in source/ fill material
2 samples per 3000 cu.m or IS: 1270 & Contract
iii Modified Proctor Density Three
change in source/ fill material Specification
2 samples per 3000 cu.m or IS: 1270 & Contract
iv Atterberg's limits (LL and PI) Three
change in source/ fill material Specification

5 Stones (Material)
Supervisory staff shall monitor
i. Stone Size As per contract specification Three
the operation continously
2 samples per 3000 cu.m or
ii. Rock density As per contract specification Three
change in source
2 samples per 3000 cu.m or
iii. Crushing Strength As per contract specification Three
change in source
2 samples per 3000 cu.m or
iv. Maximum Water absorption As per FHWA-NHI-00-043-1 Three
change in source

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 QA Plan and Tolerances

QUALITY ASSURANCE PLAN

MACCAFERRI GABIONS
Name of Project :

Contractor :

Client :

Consultant :

6 Non- Woven Geotextile (Material)

a Mechanical Properties
i Grab Tensile Strength ASTM D 4632
ii Mullen Burst Strength ASTM D 3786
iii Puncture Strength ASTM D 4833
iv Trapezoidal Tear Strength ASTM D 4533
One test for every 5000 sqm Four
b Hydraulic Properties
i Apparent Opening Size ASTM D 4751
ii Permeability ASTM D 4491

c Physical Properties
i Unit Weight As per contract specification

7 Foundation Preparation
In a grid of 5m centre to centre As per approved construction
i Level Three
after compaction drawings
1 set of 10 tests per 500 sq.m of
ii Field Density As per contract specification Three
compacted area per layer

8 Placing of Gabions
Before unpacking of bundles at
i Type of unit As per drawing Three
storage yard
After placement of unit, before
Line, level and verticality /slope of facia As per drawing/ construction
ii filling and after compacting first Three
unit manual
layer of structural fill.
iii Lacing operation
Before and after placing stones As per drawing/ construction
a For Gabions Three
in the gabion manual
After placement of first layer of
stones 0.3 m thick and after As per drawing/ construction
iv Bracing operation Three
subsequent 0.3 m layer of stones manual
for 1.0 m height of gabion

9 Placement of stones in gabions

At the start of filling operation
i Porosity and regular intervals or change As per contract specification Three
of source of stone.

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 QA Plan and Tolerances

QUALITY ASSURANCE PLAN

MACCAFERRI GABIONS
Name of Project :

Contractor :

Client :

Consultant :

10 Placement and compaction of structural fill

i Thickness of layer Before and after compaction As per contract specification Three
1 set of 10 tests per 500 sq.m of
ii Field Density As per MORT&H Three
compacted area per layer
1 set of 10 tests per 500 sq.m of
iii Moisture Content (during compaction) As per MORT&H Three
compacted area per layer

11 Placement of geotextile
i Interface geotextile Before placing of fill As per drawing Three

Level of Check
One - Manufacturer's test certificate by Maccaferri.
Two- Checks or confirmatory tests by Maccaferri and witnessed by Client and Consultant
Three - Checks or confirmatory tests by Client and witnessed by Maccaferri and Consultant
Four - Third Party testing.

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 QA Plan and Tolerances

Tolerances in MACCAFERRI Gabions

Sr. Requirement/Tol Acceptance
Testing
No. erance Standard

Product: Gabions
Zinc + PVC coated wire mesh
Wire
1 Tensile Strength ≥ 350 N/sq.mm EN ISO:10223-3
2 Elongation ≥10% EN ISO:10223-3
3 Wire diameter
2.2 mm ± 0.06 EN ISO:10218
2.7 mm ± 0.06 EN ISO:10218
3.4 mm ± 0.07 EN ISO:10218

Zinc coating
Minimum Zn. Coating
2.2 mm 230 gm/sq.m EN ISO:10224-2
2.7 mm 245 gm/sq.m EN ISO:10224-2
3.4 mm 265 gm/sq.m EN ISO:10224-2

Mesh/ product tolerance for DT products

Length, width and height ±5% Manufacturer's Data
Mesh opening - 'D' 100 mm ± 10 % Sheet

PVC(Polyvinyl Chloride) coating

PVC coating thickness
Nominal 0.5 mm Manufacturer's Data
Minimum 0.38 mm Sheet
Specific Gravity 1.3 - 1.35 kg/dm3 ISO 1183
Hardness, Shore D 50 - 60 ISO 868
Tensile Strength ≥ 21 N/sq.mm ISO 527
Elongation ≥200 % ISO 527

Rockfill for Gabion box

Minimum density ≥ 22 kN/cum
As per contract
Maximum Porosity 40%
specification
Size of stone 150 - 250 mm
Maximum water absorption <5% As per FHWA-NHI-
00-043-1

Process: Construction with Gabions

Alignment in vertical and horizontal directions 15mm in 1m As per FHWA-NHI-
Bulging in Gabion box <50mm 00-043-1

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QA Plan and Tolerances

26
 Checklists

CHECK-LIST FOR MATERIAL HANDLING AND STORAGE

Project:
Client: Date:
1. Storage area / yard Yes No
Has the area / yard for storage of materials been properly levelled
and compacted?
Are the loading and unloading operations done by appropriate
means (machinery) or equipments?
Are the machinery or equipments having the required capacity and
configuration?
Has the area for storage been divided into different zones for
various materials?
Are the guidelines for handling and storage of every material
available with the stores department?

2. Inspection on delivery
Has the material supplied to project checked before unloading?
Is the Material Test Certificate (MTC) provided with the shipment
/ freight documents for every material supplied?
Does the MTC conform with the product specifications?

3. Storage of materials at yard

Are the materials stored as per the product guidelines?
Is covered protection provided for prevention of U-V exposure?

4. Transportation of materials to site

Are the materials handled and transported as per the guidelines
specified for the product?
Has any material been damaged during loading? (Record the type,
number and cause for damage)

5. Storage of materials at site

Is covered protection provided for prevention of U-V exposure?
Are the materials stored as per the product guidelines?

Remarks:

SITE ENGINEER

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 Checklists

CHECK-LIST OF TOOLS
Project
Client: Date:

Availibility
List of equipment required. Yes No
For measurement:
Steel tape (5m)
Steel tape (30m)
Plumb-bob
Level pipe
Right angle
Spirit level 1m and 30 cm
Line thread

For MACCAFERRI Gabion/Reno Mattress unit:

Wooden mallet
Heavily galvanized Lacing wire
MS pipes / frames as supports for face panels
Tools for lacing:
Cutter, Plier, crow bars.

For rock fill in gabion:

Chisel and hammer (small and big)

For Geotextiles:
Scissors

For safety:
Hand gloves
Protective eye-wear

Note: All the mentioned tools/plants should be either present or easily accessible at the
work-site when work is going on.

SITE-IN-CHARGE

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 Checklists

CHECK-LIST OF SITE-PREPARATION

Project: Date:
Wall No.:
Client: Ch: to
Structure:
1. Preparation of site Yes No
Has the alignment of the required structure been marked
before excavation?
Is the excavation done as per levels in drawing?
Has rolling been done in the excavated area for compaction of
loose soil?
In areas where roller cannot access, has a plate vibrator/ vibro
tamper been used?
Check if there are any weak pockets?

If yes, have the loose pockets been replaced with granular fill?

Has the bearing capacity been confirmed?

Has the density of formation been checked as per QA plan?

Is the density check done by Sand-replacement method ?

If no, mention the alternate method.

Is the density of compacted ground more than 95% modified
Proctor density?
Have the levels been checked for confirmation before placing
the gabions?

Remarks:

SITE ENGINEER

MI/QF/210
R00/01.02.2010

29
 Checklists

CHECK-LIST FOR INSTALLATION OF MACCAFERRI GABIONS

Project: Date:
Wall No.:
Client: Ch: to
Structure: Row:
1. Assembly of MACCAFERRI Gabion units Yes No
Are all the Gabion units received at site flat folded, collapsed and
packed in bundles ?
Is there any damage to the DT wire mesh of unit after opening ?
Has the unit been stretched for removal of fold/bend after opening?
Has the edge wire been straightened with wooden mallet?
Has the right angle bend formed at all four corners during prepararion
of the box?
Are all the panels of the unit vertical and their tops in one level before
the start of lacing?
Are all the corners formed by single double lacing pattern?
Are both sides of diaphragm joined to the front and back face panels by
single double lacing pattern?
Are the diaphragms in the correct position as per the drawings?
Are the dimensions of the units within tolerance?

2. Placement of MACCAFERRI Gabion units

Are the units placed as per the required alignment of facia?
Has the offset of required dimension (as per section drawing) been
provided to the newly placed unit from the face of lower unit?
Are all the connections of unit made by the correct diameter of lacing
wire and procedure ?
Are the units being laced with lower unit along the front and back
edge?
Has the Single Double lacing pattern done at the following locations?
At all vertical joints
At top and bottom
At bottom of front and back side
At bottom of all middle diaphragms
Are all the adjacent units connected to each other by the lacing
procedure?

30
 Checklists

CHECK-LIST FOR INSTALLATION OF GABIONS

Wall No.:
Ch: to
3. Placement of rocks in gabion box. Rock Layer:
Are the size and quality of the rocks as per the specifcations?
Is formwork/scaffolding provided at front and back side of gabion box
along with the end panels at start and end?
Is there any damage to the Gabion while placing the rock fill?
Are the placement of rocks in the gabions done in layers greater than
300 mm?
Are flat faced stones placed in the front face of gabion box for
providing good aesthetic finish?
Are the internal cross-ties using lacing wire provided after every 300
mm of fill?

Is the diaphragm position and the overall dimension checked regularly?

Is the lid of the unit matched as per the required alignment of facia?
Are levels taken at every 10 m chainage of wall length?
Remarks:

SITE ENGINEER

MI/QF/211
R00/01.02.2010

31
 Checklists

CHECK-LIST FOR BACKFILL PLACEMENT

Project: Date:
Client: Wall No.:
Structure: Ch: to
Layer:
1. Backfill Placement Yes No
Has the properties of backfill been conformed as per QA plan?
Has the Geotextile been fixed in position behind gabion box ?
Is the thickness of loose un-compacted soil more than 300mm?
Is direct dumping of fill taking place within 1 m of backside of Gabion
unit?
Is Vibro-roller used for compaction?
Only plate vibratory roller or baby roller is operated behind units for
width of 1m?
In areas where vibro-roller cannot access, has a 100kg plate vibrator/
vibro tamper been used?
Is Modified Proctor density and quality of backfill material checked as
per QA plan?
Is field density check done by Sand-Replacement method?
If no, mention the alternate method.___________________
Is density of compacted ground more than 95% modified Proctor
density?
Has the density of compacted ground been recorded in the monitoring
format?

Remarks:

SITE ENGINEER

MI/QF/212
R00/01.02.2010

32
 R00/01.02.2010
MI/QF/213

DAILY RECORD OF GABION INSTALLATION

Project:
Client: Date:
Structure: Ch: to
Wall No:
Date of stone filling in
Check for lacing, % compaction of structural
Unit
Total gabion box bracing and Bulge Maximum Alignment Checklist fill (1m height)
Layer
Date no.of support Observed size of check (Y or complete (Y
No.
From To units Layer 1 Layer 2 Layer 3 araangement (Y (mm) stone (mm) N) or N) 1 2 3 4 5
or N)

Checklists
Remarks:
33

SITE ENGINEER