Hanson Precast Products Retaining Walls Featuring the unique Hanson QuickLift system
Bespoke mouldage facility Rigorous quality assurance About us The Facility The QuickBuild range of products is manufactured at our Somercotes facility in Derbyshire, which has been manufacturing heavy precast products for over 50 years. Continuing investment means that it has some of the most modern facilities in the country. With a production capacity of over 70,000 tonnes a year, products of up to 24 tonnes can be manufactured routinely, and significantly heavier on a bespoke basis. Engineering and Design With customers ranging from the nuclear industry through to waste recycling, product performance requirements vary greatly. A dedicated team of engineers and designers, based at Somercotes, can advise on all aspects of a project from outline design through to final value engineering. They are supported by Hanson s specialist technical teams in areas such as concrete mix design and steel fabrication. No other precast manufacturer can offer this level of support. Quality Assurance From initial design through to on-site logistics, all aspects of the Somercotes operation meet the most exacting quality standards. These are maintained by Hanson s own in-house Quality Inspectors, and audited by external certification bodies. Somercotes meets the requirements of ISO 9001, ISO 14001, ISO 6001 and ISO 18001. All precast engineering is carried out in accordance with British Standards or EC 2 as required. Mouldage and Cage Facility As well as standard products, a wide range of bespoke products are designed and manufactured at Somercotes. This is achieved quickly and cost-effectively by maintaining a highly skilled in-house mould joinery team, and a steel reinforcement bending and fabrication facility. Fixing Services Hanson provides a variety of fixing services for precast products. Installation teams operate in line with all current Health and Safety regulations, and can supply all required equipment including craneage. Customer Service and Support We are committed to providing an excellent product and service to our customers. Support and advice is available at every stage in the project cycle from engineering design through to on-site logistics. Purpose-built, high quality mouldage Bespoke cage making facilities 2 Hanson Retaining Walls Hanson Retaining Walls 3
Retaining Walls Technical Information We are proud to introduce our new range of QuickBuild retaining wall products, which have been specifically engineered using our 50 years of experience within the precast and contracting sectors. We understand that as a client you are looking for the most efficient fixing solution for your project, hence our design utilises a number of key features which focus on saving time and resource by up to 20%. The Range 1.00m wall Height: 1000mm Depth: 500mm Weight: 450kg Embedment: 150mm 1.50m wall Height: 1500mm Depth: 750mm Weight: 650kg Embedment: 150mm The Hanson QuickLift System Unlike many other systems we have no hidden costs for expensive lifting gear. 1.75m wall Height: 1750mm Depth: 875mm Weight: 1013kg Embedment: 220mm The QuickLift System has been developed to minimise lifting times, as well as eliminate working at height issues. Unlike many other systems we have no hidden costs for expensive lifting gear, or the requirement to fit lifting attachments. Using a standard lifting hook, a telehandler can complete a lift from delivery vehicle to final position with minimal secondary operations, increasing efficiency against alternative solutions by some 20%. In addition all lifting positions are located within working height zones eliminating the need to work at height. 2.00m wall Height: 2000mm Depth: 1000mm Weight: 1138kg Embedment: 250mm Finishes To further enhance efficiencies on-site we also offer cast-in finishes. Using state-of-the-art form liner technology the QuickBuild retaining wall unit can be cast with a preformed finish to provide an aesthetically pleasing appearance to the end user. Please see our Finishes and Textures section on page 10 for further information. 2.50m wall Height: 2500mm Depth: 1250mm Weight: 1370kg Embedment: 250mm Corner Unit We offer a range of economical corner details. For further information call or email: 3.00m wall Height: 3000mm Depth: 1500mm Weight: 1800kg Embedment: 250mm QuickBuild Joint Profile All our standard units are provided with a unique interlocking detail which further enhances installation times through accurate and fast alignment. The added benefits of this detail also ensure a strong and reliable connection detail which can be made waterproof with an appropriate sealant. 3.75m wall Height: 3750mm Depth: 1875mm Weight: 2700kg Embedment: 375mm DESIGN SCOPE / PHILOSOPHY The reinforced concrete precast retaining wall unit has been designed in accordance with the latest set of Eurocodes in particular BS EN 1997-1:2004 - Eurocode 7 - Geotechnical Design with the UK National Annex and BS EN 1992-1-:2004 - Eurocode 2 - Design of concrete structures with the UK National Annex have been used. STORAGE CAPACITY The unit will be designed to be loaded from either side with the following conditions: retained material level with the top of the wall and with an applied surcharge of 10kN/m 2 or a sloping backfill with a maximum angle of 35º without an imposed surcharge. The retained material will be assumed to be granular and drained with a specific maximum moist density of 18kN/m 3. For more information on specific material densities see table 1. When installed with a suitable joint sealant the wall becomes waterproof. Table 1 Storage material densities Material Density (kn/m 3 ) Medium dense sand Loose sand / gravel Grain Woodchip 18 16 8 8 11 EXPOSURE CONDITIONS Due to a nominal cover of 45mm (including c of 5mm) and C50/60 concrete used in the manufacture of the retaining wall units they are suitable for the following exposure conditions XC3/XC4, XD3, XS3, XF4 as defined in BS8500-1:2006. These cover severe conditions such as tidal splash / spray zones and de-icing salts. The limiting crack width will be taken as 0.3mm and the design life span will be at least 50 years. OVERALL STABILITY The primary job of the unit is to retain the material behind and to do this the stem and the base have been designed to withstand the applied forces. However, to resist overturning and sliding with a factor of safety of 2 for overturning and 1.5 for sliding respectively the units require anchoring into a mass or reinforced insitu concrete base which can be designed by Hanson Concrete or other manufacturers to give enough resistance to the overturning and sliding forces. The grouted anchor bolts will be post fixed into the suitable base below and secured with a washer plate on top of the unit to increase the bearing capacity onto the base slab and prevent punching shear of the bolt head through the unit. The resistance of the anchors into the base must be checked by others. In addition to the overturning and sliding resistance of the supporting insitu base, the overall ground bearing pressure must be checked by others and considered when designing the insitu support base. Sewage waste Rolled Silage 4+72z (see note 1) Paper waste Note 1 z = depth below rolled surface of grass silage or the compacted surface of bedding (in m). Silage loading is in accordance with BS 5502-22: 2003 Note 2 For other material bulk densities please refer to Table 7 within BS 5502-22: 2003 Composted green waste PFA 6 5 10 HOLDING DOWN BOLTS M20 (grade 8.8) Anchor with 200mm minimum embedment into the insitu foundation with 100x100x10mm washer plate with 22mm diameter hole. Hole to be grouted up using non-shrink grout with minimum strength of 40N/mm 2. For more detailed downloadable section drawings please see our website hanson-precast.co.uk/range For more information on Hanson ready-mixed concrete visit hanson.com/uk/concrete FOUNDATION TYPE Assumed to be uncracked, mass / reinforced concrete base of minimum strength 25N/mm 2. This can be designed by Hanson Concrete or other manufacturers to resist the overturning and sliding forces exerted by the retaining wall unit and to consider the allowable ground bearing pressure to the relevant site. STEEL GRADES All steel to be grade S275 UNO All Anchor Bolts to be grade 8.8 UNO See detailed bolt calculations. CONCRETE SPECIFICATION The concrete shall be produced in accordance with BS8500-2. Compressive strength class C50/60 Maximum water/cement ratio 0.35 Minimum cement/ combination content 380 kg/m 3 Allowable cement/combinations types IIB-V IIIA IIIA+SR IIIB IIIB+SR (DC-4m) Maximum aggregate size 20mm Aggregates Freeze thaw resisting Chloride content class Cl 0,40 Consistence class S3 REINFORCEMENT NOTES All reinforcement to be high yield with a yield strength of 500N/mm 2. All reinforcement to be Type 2 deformed bars including any specified mesh. Minimum lap length to be 40 x smallest lapped bar diameter. LOADING OPTION 1 BACKFILL POSITIONED OVER BASE OF UNIT LEVEL BACKFILL 10KN/M 2 SURCHARGE DRAINAGE ASSUMED TO REAR OF WALL STEM LOADING OPTION 2 BACKFILL POSITIONED OVER BASE OF UNIT SLOPING BACKFILL - 35º NO SURCHARGE DRAINAGE ASSUMED TO REAR OF WALL STEM LOADING OPTION 1 LOADING OPTION 2 4 Hanson Retaining Walls Hanson Retaining Walls 5 Hanson Retaining Walls 6
2 4.0 4.2 4.1 4.3 20% increase in efficiency against alternative lifting solutions. 5 3 Retaining Walls Storage Estimator 1 The quick way to calculate your project. hanson-precast.co.uk QuickLift Handling Guide Hanson has developed a unique online tool that calculates storage capacity and the number of Hanson QuickBuild retaining walls you need, helping you to plan your project quickly and easily. 1 The Hanson QuickLift system has been developed to ensure that no additional lifting equipment is needed other than conventional chains and hooks for the three lifting points. Unlike many other systems we have no hidden costs for expensive lifting gear. Using a standard lifting hook attachment a handler can complete a lift from wagon to final position with minimal secondary operations, increasing efficiency against alternative solutions by some 20%. 2 The QuickBuild walling system is delivered on a flat bed wagon, nestled for maximum efficiency. 3 The QuickBuild walling system can be lifted off the wagon using either the three point QuickLift system or a traditional fork lift methodology. NB: Ensure that the loader is of an appropriate capacity to lift the units. For individual unit weights please see unit specification. Lifting units with the three point QuickLift system allows the units to be easily manoeuvred and rotated 180 degrees, thus enabling units to be placed directly adjacent to their final position. NB: when determining the appropriate handler the radial dimension required to rotate the unit must be considered and chains set to a max angle of 65 degrees. A banks man should be used at all times to ensure units are safely spotted and manoeuvred. 4.0 Once unit is in position adjacent to its final location the lifter to the toe should be removed and the chains to the two main wall lifters are shortened and secured to equal lengths ensuring a level and safe lift. 4.1 The unit can then be lifted slowly balancing the weight on the back of the heel. NB: if lifting off a hard surface then a block or mat should be used to protect from damage. 4.2 As the unit is lifted the vehicle should move forward slowly ensuring that the lifting chains are vertical at all times. 4.3 Once the unit is upright the third lifter can be re-attached to provide additional stability and maneuverability, allowing the units to be lifted clear of the ground into final position. 5 The QuickBuild wall can then be easily located into its final position. When positioning adjacent to another unit the male connection joint of the suspended unit should be inserted into the female then lowered slowly into position ensuring the units remain interlocked. Hanson Storage Estimator Smartphone scan code Hanson Retaining Walls 7 8 Hanson Retaining Walls Hanson Retaining Walls 9
Finishes & Textures Using state-of-the-art form liner technology the QuickBuild retaining walls or bespoke precast items can be cast with a preformed finish to its outside face providing an aesthetically pleasing finish to the end user. We have over 200 designs to choose from and are happy to work with bespoke designs. In association with For further information please call or email our dedicated sales team. QuickBuild Brick Finishes The Hanson QuickBuild walling system is an innovative, factory fabricated brick and block wall panel fascia system. Utilising high performance bonding mortar a single brick panel is created which can be used to finish our QuickBuild retaining walls or other bespoke concrete such as abutments, flood defence systems and parapet walls. Fixing up to 150m of panel a day makes this an efficient and labour saving way of finishing structures. Working with our bricks business we are able to offer a vast selection of colours layouts and textures. For further information call or email: Rough & textured finishes Stone & rock finishes Brick & masonry Rib & wave patterns Sample colours from the A-Z Guide To see our A Z guide visit hanson.com/uk/bricks and click on Brick range Marne Bretagne Esterel Zyclop Browns Reds Nil Santa Cruz Andulca Tigris Isar Romanche Kolcher Fulda Buffs Yellows Blues & Greys 10 Hanson Retaining Walls Hanson Retaining Walls 11
Bespoke Products Expertise and capabilities In addition to our core product ranges Hanson can provide a comprehensive design, manufacturing and fixing service to meet the requirements of both building and civil engineering clients for bespoke precast concrete products. Specialist stair flights Hanson has been designing precast products and system solutions for over 50 years using a dedicated in-house engineering team who specialise in precast development. We are committed to supporting our prospective clients with this expertise from the initial outline plan of a project to full design implementation. We will ensure that we support and listen to you our client, providing valued engineering input throughout the process to ensure the most efficient and cost effective solution. Our precast facility is based at Somercotes, Alfreton. We have the capability of manufacturing units up to 24 tonnes and have in-house capability for mould manufacture and cage production. Recent projects include: Ground beams Flood defence walls Structural building frames Parapet units Precast floor slabs Railway platform units Digester tanks and other large bespoke structures Walling and cloaking Barriers The Hanson QuickBuild Barrier is available in two standard sizes of 1500mm and 2500mm, although we are happy to produce bespoke lengths if required. The Hanson QuickBuild Barrier is ideal for protecting sites that are no longer in use for a short or long-term period. The units can be painted with high visual warning colours, contact phone numbers to aid with security or simply company branding. For details on this, please contact our sales team. All concrete security barriers are manufactured with precast grooves in the bottom of the unit to enable easy handling using a forklift. We can provide the option to remove these grooves providing screw out lifters to the tops of the units to further aid security if required. Please note: the QuickBuild Barrier is not suitable for highway or structural use. Barrier weights and dimensions 715mm High x 850mm Wide x 1500mm Long 1683kg 715mm High x 850mm Wide x 2500mm Long 2805kg For further information please call or email our dedicated sales team. Escape shafts QuickBuild retaining walls and flood defence QuickBuild box culverts and channel sections Bridge parapets Columns and beams Omnia Bridge Deck Should you have a project that you wish to discuss, please contact our engineering and sales department either via email or by calling: Tel: 01773 602 432 Email: precastuk@hanson.com 12 Hanson Retaining Walls Hanson Retaining Walls 13
Hanson Cement Our companies and products Hanson UK is the leading supplier of heavy building materials to the UK construction industry. We are split into three business lines Hanson Cement, Hanson Building Products and Hanson Quarry Products. Hanson UK is owned by the HeidelbergCement Group, which employs over 53,000 people and operates worldwide. Hanson UK employs around 5,000 people across over 300 sites. For detailed information on all areas of Hanson and our products visit: hanson.com/uk Hanson UK products and services Concrete Ready-mixed concrete Ready-mixed mortar Dry silo mortar Screed EcoPlus Bulk cement products Grey White Blends Regen (GGBS) Aggregates Sand Gravel Crushed rock Recycled aggregates Packed products Cement Ready to use concrete, mortars, asphalt, aggregate and sand Asphalt Hot rolled asphalt Stone mastic asphalt Asphalt macadams Contracting Highway maintenance Road surfacing Civil engineering Wind farm construction Waste to energy facilities MOD works Bricks Clay bricks and brick specials Clay pavers Bespoke clay products Blocks Aircrete Aggregate Precast concrete Retaining walls Culverts Barriers Floors Stairs Structural walls Basements Off-site solutions Cladding and render systems Cladding and render systems External Wall Insulation (EWI) Structural EWI Fastbrick Other products and services SUDS Geothermal Roofing Chimneys Brick and block laying contractors Hanson Precast Products Hanson House, 14 Castle Hill, Maidenhead, Berkshire SL6 4JJ hanson-precast.co.uk 11/2012/2777MICH