USING GEOSYNTHETICS P I PEL I NES & WATER CONTA I NMEN T APPL I CAT I ON S I N SOUTH AFR I CA

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1 USING GEOSYNTHETICS P I PEL I NES & WATER CONTA I NMEN T APPL I CAT I ON S I N SOUTH AFR I CA

2 Contents 1.0 INTRODUCTION GEOSYNTHETICS IN PIPELINE CONSTRUCTION Pipelines in waterlogged conditions: bidim /aggregate, support/subsoil drainage systems Drainage alongside pipelines: Flo-Drain geocomposite subsoil drainage systems Drainage to pipe road crossings - MEGAFLO Geosynthetic protection techniques for pipelines bidim concrete pipe ogee joint wrapping Gabsabag protection systems Geocontainer applications SUBSOIL DRAINAGE SYSTEMS UNDER RESERVOIRS Strip Subsoil Drainage Systems Stone Subsoil Drains Composite Subsoil Drains - MEGAFLO MEGAFLO placed vertically MEGAFLO placed horizontally Full-width Horizontal Blanket Drains Stone Subsoil Blanket Drains Stone Subsoil Blanket Drain & MEGAFLO Collectors Composite Subsoil Drain and Stone Strip Drain Collectors Composite Blanket Subsoil Drain with MEGAFLO Collectors DAM LINING SYSTEMS Sealmac bitumen compound impregnated surface membrane EnviroFix X800 Geosynthetic Clay Liner system SPILLWAYS, DOWN CHUTES AND LINER PROTECTION Multi-Cell multiple applications bidim protection to plastic liners EROSION CONTROL Erosion control mats SoilSaver biodegradable jute mat ECC-2B biodegradable erosion control blanket ECC-2 coconut, double net erosion control blanket ECP-2 permanent turf reinforcement mat GrassRoots erosion control mat... 19

3 6.2 GrassFence Multi-Cell GEOSYNTHETIC SOIL REINFORCEMENT INFILTRATOR CHAMBER SEPTIC TANK AND STORMWATER SOAK AWAY SYSTEMS Quick4 Infiltrator Chamber French drain system Quick4 Infiltrator Chamber stormwater attenuation and soak away... 24

4 1.0 INTRODUCTION Kaytech has been supplying geosynthetic solutions to the mining, civil engineering, building and environmental sectors for 40 years, and employs over 100 people including a highly experienced technical sales and marketing team. Kaytech is affiliated to sister geosynthetics company, Geofabrics Australasia, in Australia and between them are able to offer geosynthetic solutions on a worldwide basis. The use of geosynthetics in water and wastewater engineering is not as well recognised as is their use in road and general civil engineering construction. This document provides an overview of various geosynthetic applications used in pipeline and reservoir applications and should be read in conjunction with Kaytech brochures, specification sheets and technical literature available in the Kaytech product handout catalogue or on the Kaytech website at The applications are divided into the following chapters: 2. Geosynthetics used in pipeline construction 3. Subsoil drainage systems under reservoirs 4. Dam Lining Systems 5. Spillways, down chutes and liner protection. 6. Erosion control 7. Geosynthetic soil reinforcement 8. Infiltrator Chamber septic tank & stormwater soakaway systems Chapter 2 covers applications which are used directly within the pipe trench and include bedding separation and support; subsoil drainage; protection; jointing and geocontainers, which are used to weigh down pipes and protect the working area. Chapter 3 provides various techniques for subsoil drainage under concrete reservoirs and pump stations. Two types of geosynthetic dam linings are explained in Chapter 4, while chapter 5 looks at various systems for liner protection. Chapters 6 and 7 address methods to prevent erosion and geosynthetic soil reinforcement respectively, which are applications common to pipelines and to reservoirs. Chapter 8 introduces the Quick 4 Infiltrator Chamber, a factory manufactured wastewater or stormwater soakaway system with an inspection port access. All the products referred to in this document are available nationally form the nearest Kaytech depot or distributor. For any technical assistance please contact the local Kaytech sales representative. 1

5 2.0 GEOSYNTHETICS IN PIPELINE CONSTRUCTION 2.1 Pipelines in waterlogged conditions: bidim /aggregate, support/subsoil drainage systems Aggregate is placed under pipelines in waterlogged, soft areas to create a stable bedding for the pipe. Encapsulating the stone in bidim prevents subsidence and eliminates contamination of the stone by the surrounding soil. Cost savings are attained by eliminating the loss of stone by mixing with the in-situ soil. (Figure 1 and Plate 1) Alternatively, Rockgrid PC can be used in areas where high strength at low strain is required below the stone layer to bridge the pipe in its length. Figure 1 Plate 1 2

6 2.2 Drainage alongside pipelines: Flo-Drain geocomposite subsoil drainage systems Flo-Drain consists of a Flownet drainage core encapsulated in bidim, with a flap provided at the bottom for inserting the Geopipe component. Geopipe is supplied in 6.0 m lengths, while Flo-Drain is manufactured in 30 m rolls by various heights. Geopipe is assembled with Flo-Drain on site. The Flo-Drain system provides a cost effective method compared to conventional aggregate drains as the aggregate is completely eliminated. Flo- Drain is simple to install adjacent to pipelines and installation can be done in a fraction of the time. (Plates 2 and 3) Plate 2 Plate 3 Figure 2 3

7 2.3 Drainage and joint sealing to pipe road crossings - MEGAFLO MEGAFLO provides the high compressive strength composite drain to collect groundwater within the sub-base and base layers where road pipe crossings create a lower permeability barrier. MEGAFLO has a superior compressive strength, quick drainage response time and a controlled invert, even where bedding installation is restricted. The internal height provides a head to encourage flows. Sealmac provides a flexible, impermeable waterproofing sealing layer over the road surfacing joint. (Figure 3 & Plate 4) Figure 3 Plate 4 4

8 2.4 Geosynthetic protection techniques for pipelines bidim and/or Flownet is used for protection of pipe coatings (such as epoxy coated steel pipes) from coarse bedding materials. The pipe is completely encased in the geosynthetic and held in place by plastic strapping or similar. (Plate 5) Plate bidim concrete pipe ogee joint wrapping 300 mm to 500 mm bidim A2 geotextile strips are used to wrap around concrete ogee pipe joints. The bidim A2 can be sealed with bitumen to make the joint watertight or left uncoated if the pipeline is intended to collect subsoil water along the pipeline. (Plate 6) WRAPPED JOINTS FOR OGEE CONCRETE STORMWATER PIPES Figure 4 5

9 Plate Gabsabag protection systems Gabions are regularly specified as erosion protection systems along pipelines. bidim A4 gabion bags offer a solution where the quantity of hand-packed stone can be drastically reduced. Gabion stone is often expensive, awkward to get to some sites and time consuming to install. The bidim Gabsabags are placed into the none-exposed area of the gabion basket with the closure facing the rear of the basket. A single layer of hand-packed stone is placed along the exposed faces and the bags lightly compacted by hand. The process is continued until the basket is filled. bidim Gabsabags should not be over-filled as it is important that the bag flattens and deforms to the voids in the basket during light compaction. (Plate 7 and Figure 5) Plate 7 6

10 Figure Geocontainer applications Geocontainers are manufactured to order for any size and geotextile grade or composites thereof. Geocontainers are often used for temporary protection to construction works including coffer dams, platforms for river crossings (Plate 8), marine outfalls (Plate 9) etc. Sometimes they are used for permanent applications such as marine shore protection to pipelines or pump stations or as ballast to prevent uplift in saturated conditions. The standard size is 2.3 by 2.0 m (500 mm filled height). Filling is done with a hydraulically compacted non-cohesive material. EnviroRock Geocontainers are used where the Geocontainers are exposed to long-term harsh conditions while temporary bags can be manufactured from cheaper light-weight bidim. Plate 8 Plate 9 Plate 8 7

11 Plate 10 Plate 11 High strength PS Bags are used for pipe support. PS Bags are filled with soil and are supplied with lifting handles for ease of placement. (Plates 10 & 11) 3.0 SUBSOIL DRAINAGE SYSTEMS UNDER RESERVOIRS Subsoil drains under reservoir floors can be classified as strip drains or blanket drains. In less critical applications, it is often sufficient to place a standard 300 mm x 300 mm stone drain under a floor in a grid pattern between columns. Where a high Factor of Safety is required, a continuous subsoil drain is introduced, consisting of either a stone or no-fines concrete blanket. 3.1 Strip Subsoil Drainage Systems Stone Subsoil Drains The traditional method used consists of a 300 mm x 300 mm stone drain (Plate 12). This is limited to areas where: Ground water flows are negligible The speed of installation is not critical The outfall invert is low enough to tie into and The drain clashes with services/structures Plate 12 8

12 3.1.2 Composite Subsoil Drains - MEGAFLO MEGAFLO placed vertically MEGAFLO offers a cost-effective alternative to a 300 x 300 mm stone drain as it provides a pre-manufactured complete system that eliminates stone and is considerably quicker to install. MEGAFLO yields 0,92 litres/s/m and 1.75 litres/s/m at 1 % grade for 170 mm and 300 mm high respectively. Placed vertically it provides a controlled invert, even where bedding installation is restricted, while the internal height provides a head to encourage flows (Plate 13). MEGAFLO is very flexible in the horizontal plane, which is useful when installing drains around column bases etc. (Figure 6 and Plate 13) CONCRETE FLOOR 20mm COARSE SAND COVER 150 OR 300 MEGAFLO 150 OR 300 COARSE SAND BACKFILL 40 Plate 13 >60 SECTION: MEGAFLO PLACED VERTICALLY UNDER FLOORS Figure MEGAFLO placed horizontally MEGAFLO is used horizontally where depth of excavation or outlet level for subsoil drainage is restricted. The flow rate for MEGAFLO laid horizontally at 1% grade is 0.92 litres/s/m and 1.63 litres/s/m for the 170 and 300 mm width respectively. The sub-grade is prepared to grade prior to installation of MEGAFLO. MEGAFLO provides a crush resistance of > 250 kpa when placed horizontally. (Figure 7) 9

13 COARSE SAND BACKFILL MEGAFLO 170 OR 300 CONCRETE FLOOR 40 >75 SUBGRADE PREPARED TO GRADE SECTION: MEGAFLO PLACED HORIZONTALLY UNDER FLOORS Figure Full-width Horizontal Blanket Drains Stone Subsoil Blanket Drains A typical blanket drain is typically only 100 mm thick and constructed of either nominal selected aggregate or no-fines concrete. The whole base is underlain with a bidim A2 separation layer prior to placing the stone/no fines concrete. Collector drains are spaced at regular intervals. (Figure 8 and Plate 14) SECTION: STONE BLANKET DRAINS UNDER FLOORS Figure 8 10

14 Plate Stone Subsoil Blanket Drain with MEGAFLO Collectors MEGAFLO offers an economical alternative by eliminating any extra excavation required for collector drains as the MEGAFLO can be laid flat within the 100 mm stone blanket drain. (Figure 9 and Plate 15) SECTION: STONE BLANKET DRAINS UNDER FLOORS WITH MEGAFLO COLLECTORS Figure 9 Plate 15 11

15 3.2.3 Composite Subsoil Drain and Stone Strip Drain Collectors The composite drain as shown in Figure 10 provides an effective alternative to aggregate / nofines concrete at significantly lower cost. To ensure continued long-term performance, a base layer of selected granular material (minimum G7 quality) is required. Kaytape S120 or Bentostrate is a high strength/low elongation geotextile that is installed above the Flownet to ensure that the 250 micron DPC does not bag into the voids of the Flownet drainage spacer during placing of the concrete. (Plate 16) 250 MICRON DPC CONCRETE FLOOR SLAB KAYTAPE S120 OR BENTOSTRATE FLOWNET BIDIM A2 19mm NOMINAL AGGREGATE 100Ø PERFORATED PIPE OR GEOPIPE M X 300 COLLECTOR DRAIN AT 10m C/C SUBGRADE (G7 MOD AASHTO DENSITY SECTION: COMPOSITE UNDERFLOOR DRAINAGE SYSTEM Figure 10 Plate 16 12

16 3.2.4 Composite Blanket Subsoil Drain with MEGAFLO Collectors This technique provides the most cost effective system that takes minimal time to install as there is no aggregate and almost no excavation required for collector drains. It is ideal for areas where excavation is restricted i.e. hard rock. (Figure 11 and Plate 17) 250 MICRON DPC CONCRETE FLOOR SLAB KAYTAPE S120 FLOWNET BIDIM A2 50 MEGAFLO 150 or or 350 SECTION: COMPOSITE UNDERFLOOR DRAINAGE SYSTEM WITH MEGAFLO COLLECTORS SUBGRADE (G7 COMPACTED TO 93% MOD AASHTO DENSITY Figure 11 Plate DAM LINING SYSTEMS Kaytech offers two types of lining systems a surface liner and a buried liner. Surface liners allows installation on steeper slopes, but are susceptible to vandalism, theft, and damage while buried Geosynthetic Clay Liner (GCL) lining systems are limited to flatter slopes and require 300 mm of soil cover. GCL liners are robust and are protected from vandalism, theft, construction damage and damage due to stray animals by the soil cover and provide a natural, aesthetically pleasing shoreline. Both systems are easily installed by a civils contractor and can be placed under most conditions. 13

17 4.1 Sealmac bitumen compound impregnated surface membrane This easy to install dam lining system is constructed using a Sealmac, geotextile impregnated with three coats of a mineral filled, modified latex emulsion sealing compound, providing a robust, flexible bitumen coating that is non-toxic and impermeable to water. The system is simple to install and requires no special skills or equipment. It is highly flexible, mounds easily around corners and simple to flash to structures. The system is simple to repair. (Plates 18, 19 and 20) Plate 18 Plate 19 Plate 20 14

18 4.2 EnviroFix X800 Geosynthetic Clay Liner system EnviroFix Geosynthetic Clay Liner (GCL) buried lining system, comprises natural sodium bentonite encapsulated by two layers of geotextiles needled together. Joining rolls is done by simply overlapping the 300 mm longitudinal joints which are pre-impregnated with bentonite powder. Short joints, cuts or any repairs are sealed using bentonite paste as per the Kaytech installation guidelines. The entire liner is covered immediately with 300 mm of fine soil. (Figure 12, Plates 21 and 22) Figure 12 Plate 21 Plate 22 15

19 5.0 SPILLWAYS, DOWN CHUTES AND LINER PROTECTION Concrete-filled, cast-insitu Multi-Cell has been successfully used for road and canal applications for a number of decades. This effectively provides a flexible concrete system with tight, interlocking joints of low permeability that distribute loads laterally. 5.1 Multi-Cell multiple applications Multi-Cell is used as a flexible, interlocking concrete or soilcrete protection cover layer to plastic liners (Plate 23). Multi-Cell is also ideal for use for concrete or vegetated canal linings (Plate 24) or concrete-filled for dam spillways (Plates 25 and 26). Multi-Cell flexible concrete stormwater down chutes offer cost savings as less concrete is required (Plate 27). It is used as erosion protection to pond banks when filled with concrete or soilcrete (Plate 28). Plate 23 Plate 24 Plate 25 Plate 26 16

20 Plate 27 Plate bidim protection to plastic liners bidim is often prescribed as protection to the underside of plastic liners. As a rough guide for protection up to 15m head use bidim A5, A6, A7 and A10 for a subgrade maximum stone diameter size of 13 mm, 19 mm, 25 mm and 35 mm respectively (ref Geosynthetics 1999, pg 367) 6.0 EROSION CONTROL The removal of vegetation cover often leads to extensive erosion problems on construction sites. The loss of topsoil, subsequent damage to the site and off-site clogging of drains is often ignored to the detriment of the environment. This hampers efficient construction practice and is not aesthetically pleasing to the public eye. Kaytech offers various cost effective systems to alleviate the problem. 6.1 Erosion control mats Erosion control mats are available in a number of different grades, ranging from 100% biodegradable to long term more permanent mats. Erosion control mats are typically pegged down over the exposed area. The exposed area is either topsoiled and seeded before placing the mat or planted by excavating holes through the placed mats. Hydroseeding can also be applied on top of installed mats. (Plate 29) Plate 29 17

21 6.1.1 SoilSaver biodegradable jute mat SoilSaver is a laid flat mat, intended to retain imported topsoil mixtures, hydroseeding, fertilizers, seedlings etc. SoilSaver is manufactured from 100% biodegradable jute yarn, consisting of a 65% coarse open mesh structure. SoilSaver prevents erosion by absorbing raindrop splash impact and retarding overland flow while retaining moisture during dry spells. (Plate 30) Plate ECC-2B is a biodegradable erosion control blanket manufactured from 100% coconut fibre and two polypropylene nets sewn together with biodegradable thread ECC-2B offers up to 24 months life for use in drainage channels and on 1:1 slopes. (Plate 31) Plate ECC-2 is a coconut, double net erosion control blanket manufactured from 100% coconut fibre and two polypropylene nets sewn together with UV stabilized thread. ECC-2 offers up to 36 months life, with a maximum flow velocity resistance of 2.13 m/s and is ideal for use in drainage channels and 1:1 slopes. (Plate 32) Plate 32 18

22 6.1.4 ECP-2 permanent turf reinforcement mat Manufactured from 100% green polypropylene fibre and two heavyweight polypropylene nets sewn together with UV stabilised thread ECP-2 offers up to 36 months, with a maximum flow velocity resistance of 2.77m/s and is ideal for use in high flow drainage channels and 1:1 slopes. (Plate 33) Plate GrassRoots erosion control mat Providing a more permanent green solution, GrassRoots is installed where concentrated flows occur such as channels, headwall outlets, spillways etc. (Plate 34) Plate 34 ECP-2 or GrassRoots is ideal for areas where there is periodic flow of water and a more permanent scour protection system is required. (Plate 35) Plate 35 19

23 6.2 GrassFence GrassFence reduces flow velocities and limits transportation of sediment by retarding water flow velocity. Sediment is trapped by the silt fence while water of reduced velocity passes through the Grassfence. As the silt fences are spaced apart, the actual cost benefit per square metre of ground protected should be calculated by dividing the area by the spacing of Grassfence lengths. Stay-wires can be installed to prevent collapse in extreme applications (Figure 13). Grassfence can be placed to protect exposed soil above pipelines on steep slopes (Plate 36); to prevent sediment washing into catchpits (Plate 37) and to prevent contaminated sediment washing off construction sites. (Plate 38) Grassfence offers multiple re-uses X 4m - 5m 3m - 4m TYPICAL CROSS SECTION ISOMETRIC VIEW DETAIL A Figure 13 Plate 36 Plate 37 20

24 Plate Multi-Cell Multi-Cell is used as an erosion control formwork for vegetated soil embankments. Each 200 mm by 200 mm pocket provides a mini barrier to retard runoff velocity. The cell wall heights also allow the soil to be placed at a flatter angle in each pocket than the natural angle of the slope. (Figure 14 and Plate 40). Multi-Cell is a long term solution that is non-biodegradable and less susceptible to animal or fire damage as it is partially buried. Plate 39 is taken of an embankment that has been in operation for approximately 20 years. Plate 37 Plate 40 Plate 39 21

25 X 300 ANCHOR TRENCH MULTI-CELL 30 TYPICAL X-SECTION FILL MATERIAL = 20 PEG MAXIMUM SLOPE ANGLE CELL HEIGHT (mm) FILL MATERIAL ANGLE OF REPOSE ( ) PEG Figure GEOSYNTHETIC SOIL REINFORCEMENT The RockGrid PC combination geogrid / geotextile is typically used to reinforced fill slopes, permitting steepening from 30 up to 70 degrees. This type of construction offers an economical solution with a vegetated finish. (Figure 15 and Plate 41) Figure 15 22

26 Plate 41 Plate 42 Plate 42 shows a RockGrid PC sandwich temporary construction technique used to shore adjacent to a structure. RockGrid PC is also used in basal reinforcement applications where access is required over low bearing strength soils (typically CBR < 3). RockGrid PC provides high strength tensile reinforcement at low strain and fulfils a separation function between the low CBR insitu soil and cover material. (Plate 44) Plate 44 Plate 43 23

27 8.0 INFILTRATOR CHAMBER SEPTIC TANK AND STORMWATER SOAK AWAY SYSTEMS Quick4 Infiltrator Chamber is a pre-manufactured open underground unit that acts as a direct replacement for stormwater and wastewater aggregate drains. Plate Quick4 Infiltrator Chamber French drain system Quick4 Infiltrator Chamber is a specifically manufactured soak away system used in conjunction with a septic tank (Figure 16). The Quick4 Infiltrator Chamber system has the following advantages over conventional methods: It provides access for inspection after installation. It provides access for cleaning. It provides 3 times more volume storage capacity than a stone drain. It eliminates use of contaminated aggregate such as building rubble. It is lightweight, quick, simple, easy to install, easily expanded or even relocated. MOUND FOR PROPER DRAINAGE ESTABLISH VEGETATIVE COVER INSITU SOIL INSITU BACKFILL 300 min. NON-TRAFFIC AREAS LOUVRES 360 LOUVRED SIDEWALL 280 INLET SECTION: QUICK4 INFILTRATOR CHAMBER FRENCH DRAIN SOAKAWAY SYSTEM Figure 16 24

28 Plate Quick4 Infiltrator Chamber stormwater attenuation and soak away Quick4 Infiltrator Chambers provide a cost effective method for the underground disposal and attenuation of stormwater by not only providing a strong inexpensive arched underground cover structure, but also provides more volume capacity. The chambers can be placed on a single or double row of blocks to increase the volumetric area. (Figure 17 and Plate 47) MOUND FOR PROPER DRAINAGE ESTABLISH VEGETATIVE COVER OVERFLOW INSITU SOIL INSITU BACKFILL 300 min. NON-TRAFFIC AREAS LOUVRES 360 LOUVRED SIDEWALL 280 INLET 410 BIDIM GEOTEXTILE WRAP AROUND EXTERIOR OF BLOCKS STONE SPLASH PAD ON BIDIM A2 GEOTEXTILE VOID 390 x 190 x 190 CEMENT BLOCKS ON EDGE 900 BIDIM GEOTEXTILE WRAP AROUND EXTERIOR OF BLOCKS B STONE SPLASH PAD ON BIDIM A2 GEOTEXTILE 900 CAPACITY WITHOUT BLOCKS: 216 LITRES PER METRE SINGLE ROW BLOCKS: 368 LITRES PER METRE DOUBLE ROW BLOCKS: 501 LITRES PER METRE A A B SECTION: QUICK4 INFILTRATOR CHAMBER STORMWATER ATTENUATION AND SOAKAWAY SYSTEM Figure 17 25

29 Plate 47 26

30 Leaders in geosynthetic solutions w w w. k a y t e c h. c o. z a Kaymac (Pty) Limited t/a Kaytech 2015

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