GEOFABRICS Dump Walls & Retaining Structures QUALITY - SUPPORT - EXPERTISE
Mine engineers face numerous challenges when designing haul roads and dump structures. It is common for open cut mines to be dug on benches with the walls of the pit dug at angles less than vertical. The steps in the walls may help prevent rock falls continuing down the entire face of the wall, but in some instances additional wall face support is required. Depending on the type of rock and degree of weathering, the use of geotechnical solutions can minimise damage and danger from rock falls. Similarly dump walls (or dump structures) are widely used in mining operations to create a stable platform from which heavily laden trucks can tip their loads into a primary crusher. The large amount of rock found on most mine sites is ideal for use in the packing of a mechanically stablised earth system. The various configurations of geotechnical solutions offer benefits that are ideally suited to the sometimes remote, harsh and demanding environments that are encountered at most sites. For example, modular systems allow for relatively quick and easy installation and corrosion resistant coatings ensure optimum performance and long term design strength. Geofabrics Australasia offers a range of products that, when used in conjunction with the soil materials, have the ability to retain, protect and reinforce. COMPANY PROFILE Our use of highly skilled people, equipped with the leading geosynthetic brands, supported by superior technical marketing tools will ensure our customers have access to world-class geosynthetic solutions for their infrastructure projects. Geofabrics Australasia has been providing geotextiles and geosynthetic solutions to engineering problems since 1978. Our core products are manufactured in Australia to the highest quality standards. Our experienced sales and marketing team are able to provide detailed application based product information. With branches located in all major cities and some regional areas we are able to provide unsurpassed support. NATA Accredited Laboratory The National Association of Testing Authorities (NATA) is Australia s national laboratory accreditation authority. Geofabrics has an established, well equipped NATA-accredited laboratory available, which is staffed by skilled technicians, to carry out project specific quality control testing where required. 2 Queensland Brisbane Townsville Gold Coast Bundaberg New South Wales Sydney Newcastle Victoria Melbourne Western Australia Perth South Australia Adelaide Tasmania Hobart Northern Territory Darwin
INDEX Page 4 - Dump Walls Gabion wire baskets Tensar RE geogrids Tensar reinforced gabion mine dump wall Page 5 - Hydraulic Structures Gabions & Reno Mattress baskets Ecocell cellular confinement system Reno mattress channel lining Page 6 - Rockfall Protection Rockfall Netting Catch Fences High energy absorbtion catch fence Page 7 - Slope & Wall Reinforcement Tensar RE geogrids Tensar reinforced retaining wall 3
Dump Walls Dump and head walls form an integral part of many mines around the world and the structures can be in excess of 25m high. The combination of reinforcement and facing options can be designed such that the structure withstands high vertical and horizontal loading from heavy vehicles and seismic activity. The large amount of rock readily available on most mine sites for packing of the Gabion facing makes the Gabion - Tensar system an effective solution. Gabions Tensar RE Geogrids Gabions A Gabion is a rectangular mesh cage, manufactured using galvanised, double-twist wire, which is typically filled with rock and used to form blocks to construct a wall. Gabions are widely used to create dump walls for mine sites, as they create a vertical face from which the mined ore is tipped into the crusher system. Using locally available rock, Gabion dump walls are easily and economically constructed. Gabion dump walls are being used in various mine sites around the world, with vertical structures up to 22m high being constructed. Gabion dump walls minimise any settlement of the structure by using soil reinforcement solutions to increase the shear parameters of the backfill soil and to restrain the front face from movement. Gabions combine flexibility and strength Tensar RE Tensar RE is an extruded polyethylene geogrid, which has long slim apertures, orientated in one direction. The uniaxial orientation ensures high strength in the direction of roll length. RE geogrids by Tensar are used to reinforce soils in the construction of bridge abutments, dump walls and steep slopes. Tensar Wall Systems comprise a soil mass, reinforced with Tensar RE uniaxial geogrids and finished with facing units selected by the designer to meet the client s requirements. Designers have a wide choice of facing options at their disposal to meet the aesthetic and economic needs of the project. 4 Tensar RE provides high strength reinforcement
Hydraulic Structures Modern design of flood protection and training works in cases of natural rivers and creeks requires a fine balance between a sound engineering approach on one hand, and an environmentally acceptable solution on the other. Hydraulic design incorporating different factors including hydraulic modeling, development and use of suitable materials and construction methods results in best practice in river training structures. A number of specialist products are available to designers and asset owners to provide effective and economical river training solutions. Gabions Ecocell Cellular Containment Reno Mattreses Gabions & Reno Mattresses Gabions and Reno mattresses are rectangular mesh cages, manufactured using galvanised, double-twist wire and are typically filled with rock and used to protect channel banks and other sloping areas from erosion. Gabions and Reno mattresses are widely used in hydraulic applications, such as channel lining applications as well as weirs and other drop structures. Gabions and Reno mattresses provide versatile, durable structures designed to provide engineered outcomes. Being flexible type structures, Gabions and Reno mattresses are able to accommodate differential settlements and due to their porous nature, also dissipate water energy. Ecocell Gabions withstand high flow velocities Ecocell is an expandable, flexible, polymeric, 3-dimensional cellular structure into which infill material is placed and compacted. The confinement action improves the structural and functional behaviour of aggregate infill materials. The flexibility and versatility of Ecocell enables a wide range of infills including concrete, rock, gravel and vegetation, to be used depending on the aesthetic, hydraulic and economic requirements of the system. In addition, customised installation methods can be utilised depending on the site conditions and required performance. Ecocell can provide solutions for aspects of stormwater and runoff management ranging from channels, swales, spillways, drop structures and culvert headwalls. Ecocell provides flexible protection 5
Dump Walls & Retaining Structures Rockfall Netting Due to the nature of mining operations, the potential risk of rockfall is high. There are several ways that the hazard can be decreased using either active or passive rockfall protection systems. Passive systems control the impact of detached rock whilst active systems stabilise the rock mass by containing possible rock detachments. The choice of system depends largely on site characteristics and the level of risk mitigation required. Encapsulating vegetative soil pockets under a drapery system permits the establishment of vegetation if conditions permit. Rockfall Netting Catch Fences Rockfall Netting & Catch Fences Geofabrics Australasia offers a range of rockfall protection and catch fence products, designed to restrict or mitigate the risk of rockfall, to ensure a safer working environment. Our products are manufactured using various grades of corrosion resistant, coated, double twisted, hexagonally woven mesh. The woven mesh panels are reinforced using steel cables, which are incorporated biaxially or uniaxially depending on the tensile strength requirement of the design system. Catch fencing is constructed either vertically or at an angle to the vertical at the required off-set distance from the toe of a slope. The purpose of the catch fence is to catch any loose material falling from overlying blocky ground. A rockfall netting system is installed as a drapery system with the primary aim of restricting rock movement down the slope. Both systems are key components in reducing the risk to the workforce at the base of the pit walls. Rockfall Netting limits OH & S risk Geocomposite products are also available. These incorporate the strength benefits associated with the double twisted woven mesh rock fall netting, integrated with a synthetic erosion control mat. This unique combination offers end-users the dual benefit of controlled rock detachment whilst promoting vegetation growth. Catch Fences protect down slope structures 6
Slope & Wall Reinforcement Steepening of slope batters is often necessary to increase the amount of usable land footprint whilst also reducing the amount of structural fill required. Reinforcement of slopes from 45 on vertical walls to bridge abutments can be achieved by the use of Tensar RE geogrids. Tensar reinforced soil structures have a number of advantages including long term stability, proven system, simplicity, cost effectiveness and rapid construction methods. Concrete Panels Tensar RE Geogrids Tensar RE Tensar RE is an extruded polyethylene geogrid, which has long slim apertures, orientated in one direction. The uniaxial orientation ensures high strength in the direction of roll length. RE geogrids by Tensar are used to reinforce soils in the construction of structures such as bridge abutments, retaining walls and steep slopes. Considerable cost saving can be made by using Tensar RE geogrids for slope and wall reinforcement. We can provide technical support like preliminary design suggestions to support your own design. Tensar RE grids are independently certified products having long term design stability. Choosing a suitable soft facing for slopes can depend upon a number of elements, namely the desired finish, the constraints and circumstances of the local environment and, perhaps more importantly, the angle of the slope. Tensar International offers a range of construction techniques - the most popular using either grid wraparound or steel mesh panels (SMP) at the face. With a Tensar wraparound finish the facing element may be formed from the Tensar geogrid by extending the length, wrapping it around the face and subsequently anchoring it back into the fill. An internal bagwork support or temporary external support is required for the wraparound face details to control alignment and to provide the restraint necessary for good fill compaction. Tensar RE has a 120 year design life Tensar open structures allow plant growth 7
OTHER BROCHURES IN THIS SERIES For all your geosynthetic needs contact your nearest Geofabrics Australasia branch GEOFABRICS is a registered trade mark of Geofabrics Australasia Pty Ltd. MELBOURNE SYDNEY NEWCASTLE COFFS HARBOUR PERTH ADELAIDE (03) 8586 9111 (02) 9821 3277 (02) 4950 5845 (02) 6653 5706 (08) 9249 5411 (08) 8177 2055 Fax: (03) 8586 9186 Fax: (02) 9821 3670 Fax: (02) 4950 5895 Fax: (02) 6653 5706 Fax: (08) 9249 5447 Fax: (08) 8177 2044 HOBART BRISBANE TOWNSVILLE BUNDABERG GOLD COAST DARWIN (03) 6273 0511 (07) 3279 1588 (07) 4774 8222 (07) 4155 9968 (07) 5594 8600 (08) 8984 1600 Fax: (03) 6273 0686 Fax: (07) 3279 1589 Fax: (07) 4774 8655 Fax: (07) 4155 9968 Fax: (07) 5563 3727 Fax: (08) 8984 1614 GEOFABRICS.COM.AU IMPORTANT NOTICE - DISCLAIMER The information contained in this brochure is general in nature. In particular the content of this brochure does not take account of specific conditions that may be present at your site. Site conditions may alter the performance and longevity of the product and in extreme cases may make the product wholly unsuitable. Actual dimensions and performance may vary. If your project requires accuracy to a certain specified tolerance level you must advise us before ordering the product from us. We can then advise whether the product will meet the required tolerances. Where provided, installation instructions cover installation of product in site conditions that are conducive to its use and optimum performance. If you have any doubts as to the installation instructions or their application to your site, please contact us for clarification before commencing installation. This brochure should not be used for construction purposes and in all cases we recommend that advice be obtained from a suitably qualified consulting engineer or industry specialist before proceeding with installation. Copyright held by Geofabrics Australasia Pty Ltd. All rights are reserved and no part of this publication may be copied without prior permission. M135-02/08 SCS-COC-00836