CONSTRUCTION MANUAL 2.5 x 5 UNITS www.neelco.com 8328-D Traford Lane, Springfield, VA 22152 703 913 7858
T-WALL Retaining Wall System CONSTRUCTION Manual Contents Part I earthwork... 1 The Structure depends on it! Part II General Overview... 2 Work to be Performed by the Contractor... 2 Basic Construction Procedures... 2 Crew Size and Production Rates... 2 Materials & Services supplied by The Neel Company and/or the Licensed Producer... 2 Equipment, Materials and Tools Supplied by the Contractor... 2 Part III CONSTRUCTION Procedures...3-10 Site Preparation... 3 Leveling Pad Construction... 4 T-WALL Unit Delivery... 5 Lifting the Units... 5 Layout on the Leveling Pad... 6 Erection of the First Course... 6 Constructing Subsequent Courses and Backfilling... 7-9 Staged Construction...10 Part IV CONSTRUCTION details...10-12 & Inside Back Cover Terraced Walls & Culverts...10 Barriers & Corners...11 Fences, Railings & Integration with Structures...12 Pipes, Basins & Utility Poles... Inside Back Cover NOTE TO THE READER This manual has been prepared as a guide to building T-WALL Retaining Wall structures. Its contents should be thoroughly reviewed by the contractor and the superintendent responsible for construction prior to the delivery of the T-WALL units to the job site. The Neel Company and/or its Licensed Producers will provide job site technical assistance to help the contractor implement correct construction procedures. Compliance with this manual does not relieve the Contractor of the responsibility to adhere to contract plans and specifications. The T-WALL Retaining Wall System should never be built without drawings stamped by a Professional Engineer. Copies of the T-WALL Construction Manual can be downloaded from www.neelco.com The T-WALL Retaining Wall System is Patented 2012 The Neel Company
EARTHWORK THE STRUCTURE DEPENDS ON IT! PART I The concrete T-WALL units are only half of the structure; the earth is the other half. This combination makes the wall stand up. Single Unit Stem Length (ft) T-WALL UNIT WEIGHTS Single Unit Weight (#) Double Unit Weight (#) 6 1850 3700 8 2100 4200 10 2350 4750 12 2600 5250 14 2900 5750 16 3150 6250 18 3400 6750 20 3650 7350 22 3925 7850 24 4200 8300 26 4450 8850 28 4700 9350 30 4975 9850 The following earthwork items are critical: FoundATIOn The foundation should be inspected and approved by the owner s engineer before the leveling pad is poured. If the foundation is soft, the wall will settle. Select backfill gradation AND DENSITY This is critical to the structure s stability. See the T-WALL shop drawings for project backfill gradation and density. It is important that gradation tests be performed throughout construction to ensure that the backfill meets the specifications. The select backfill gradation affects the friction on the stems, drainage and settlement. compaction Proper compaction of the backfill between and behind the stems is required to prevent settlement which will affect paving at the top of the wall. Compaction tests are required throughout construction. Double Unit Specifications are printed on the T-WALL shop drawings. Failure to meet the specifications of any of the above items may result in wall movement. 1 2012 The Neel Company
PART II GENERAL OVERVIEW WORK PERFORMED BY THE CONTRACTOR: Site preparation, including excavation Forming and pouring the leveling pad Wall construction including backfilling Testing: backfill gradation and compaction Installation of fences, guardrails or other necessary items BASIC CONSTRUCTION Sequence: Prepare the foundation Form and pour leveling pad Set first course of units Place and compact select backfill Place joint material and shear keys Set subsequent courses of units CREW SIZE: A typical wall erection crew includes: One operator for excavator/crane for setting units & backfill placement One working foreman to check alignment Two men for setting units, placing joint materials, spreading and compacting backfill One front-end loader and operator to deliver backfill and T-WALL units EQUIPMENT, MATERIALS AND TOOLS SUPPLIED BY THE CONTRACTOR: T-WALL unit lifting equipment: backhoe or small crane. Equipment for hauling, dumping and spreading backfill: dump trucks, front-end loaders and dozers. Compaction equipment: small walk-behind vibratory roller or plate compactor Tools: Lifting device & rigging Chalk line Four-foot carpenter s level Surveyor s level to check grade Shims Crow bars & pinch bars Duct tape (for shear keys and filter cloth) Broom to sweep leveling pad Power drill (10 x 3/4 carbide bit for drilling bolt holes in corner units) 3/8 rod for gauging vertical joints PRODUCTION RATES: Construction rates for T-WALL depend upon the site access and rate at which select backfill can be delivered, placed and compacted. Setting the first course on the leveling pad MATERIALS AND SERVICES SUPPLIED BY THE NEEL COMPANY AND/OR THE LICENSED PRECAST MANUFACTURER: Engineering and design of the structure On-site technical assistance Delivery of the following wall materials to the site: Precast concrete T-WALL units Filter fabric for vertical T-WALL joints Shear keys Shear key wrap material Horizontal joint material Connection hardware (when required by the design) 2 2012 The Neel Company
Construction Procedures PART III SITE PREPARATION: Excavate the site to the elevation shown on the contract plans for the entire footprint of the T-WALL structure (including the area covered by the select backfill between the stems). Under special condtions, the excavation may be done in increments to minimize the amount of open cut. Proof roll and inspect the foundation in accordance with the project specifications. Typical Vertical T-WALL Section All unsuitable materials below subgrade must be removed and replaced with select, compacted backfill at the direction of the owner's engineer. Foundation is to be inspected and approved by the owner/ owner s engineer for required bearing capacity as shown on the approved T-WALL drawings. Where possible the width of excavation should allow sufficient room to set the longest stem with some space behind the stem to access the space between the stems. Excavate for the leveling pad. Preparing the site Any under-drains, drainage piping or drainage blankets should be installed at this time. Compaction of the soil prior to placing units Drain inlet between stems 3 2012 The Neel Company
PART III construction Procedures (continued): LEVELING PAD CONSTRUCTION: The leveling pad is typically 12 inches wide and a minimum of 6 inches deep unless otherwise shown on the wall drawings. Form the leveling pad similar to forming a sidewalk. The edge forms are the screed rail. They must be checked with a level to assure proper elevation and tolerance. Top of leveling pad elevation shall be + 1/4 inch in any 10 foot length. Contractor must take corrective action or plan to shim the first course to the highest point. Shimming will greatly increase the installation time of the first course. STEPPED Leveling Pad: Steps in the Leveling Pad - Construct the lower leveling pad. Leave a 6 to 8" gap before constructing the higher pad. This gap will assure that the higher pad does not interfere with the placement of the units on the lower pad. Check for alignment. The front edge of the pad should be 3" out side the front face line of the wall. The leveling pad is for construction alignment only. The concrete may be low strength, 2,500 psi and there is no rebar in the leveling pad. Stepped leveling pad The leveling pad shall be cured for 24 hours prior to installation of T-WALL units. Pour the leveling pad. The concrete surface finish must be smooth and flat. Check the leveling pad for line, grade and tolerance with an instrument level. If the leveling pad is out of tolerance, make corrections at this time. An out of tolerance pad will slow down the installation rate. For a vertical wall, the typical step (change in elevation ) is 2'-6 1/2" for standard units or 5'-1" for double height units (top of pad to top of pad). For a battered wall - ask for/or download a T-WALL Battered Wall Supplement. 4 2012 The Neel Company
(continued) CONSTRUCTION PROCEDURES PART III T-WALL UNIT DELIVERY: Prior to the start of construction, the Contractor and The Neel Company or the Precast Manufacturer shall develop a schedule for material deliveries. This timetable will allow the producer to match unit production with the construction schedule. Unloading units from truck UNLOADING THE UNITS: Under normal circumstances, a two hour unloading time is allowed for each delivery. During this period of time, the units may be unloaded and stacked on the ground. If the time allows, the units may be placed directly into the wall structure. Care must be exercised during handling to protect the units and joint materials from damage. Do not stack units more than two high. Dunnage and plastic edge guards are the property of the Precast Manufacturer and must be collected and returned as soon as possible. Lifting the UNITS: Lifting a long unit at the balance points LIFTERS: for units without lifting inserts stem lengths 6 14 use 1 lifter stem lengths 16 & up use 2 lifters If the units are precast with lifting inserts the Contractor will provide his own lifting devices. The lifting devices are to be compatible with the lifting inserts specified in the approved shop drawings. If the units are precast without lifting inserts the Contractor may be loaned, upon agreement, a lifting device: The lifting device must be kept in good working order for safe lifting. If the device has excessive wear or broken parts, DO NOT USE. Contact the Licensed Precast Manufacturer and/or The Neel Company for a replacement device. It is the Contractor s responsiblity to see that the lifter(s) is returned to the Precast Manufacturer. If the device is lost, damaged or stolen the Contractor will be responsible for the cost of the device. 5 Lifting a double unit which was precast with lifting inserts 2012 The Neel Company
PART III CONSTRUCTION PROCEDURES (continued) LaYOUT on the Leveling Pad: To establish wall alignment, snap a chalk line on the surface of the leveling pad to coincide with the survey line of the front face of the wall. This will be the front face of the wall and will center the unit on the leveling pad. Mark critical linear dimension points such as chords or angle points. (Contractor may nail 2x4 s along the line to act as a guide for alignment.) Board nailed on leveling pad to act as guide Grade and compact the subgrade material level with the top of the pad the full length of the stems so that the front face of the units will be plumb. After a unit is set, it is much easier to shim the stem up than to excavate down; therefore it is better to be low than high in this operation. ERECTION OF THE FIRST COURSE: Always begin erection at a fixed point such as a corner, step, or tie-in to an existing structure. If there is no fixed point, simply start on the lowest leveling pad. Use gauges to hold the 3/8" vertical space between units. A smooth 3/8" steel rod 18" long with a handle works best. Continually check the horizontal dimensions to ensure that the vertical joints can be held within tolerance. Joint material is not required between the leveling pad and the precast units. Set the first units on the leveling pad, using the chalk line as a guide for aligning the front face. First course of units on leveling pad Adjust the elevation of the back of the stem to plumb the front face of the unit. It is critical to the wall alignment that the bottom course of units be plumb. After aligning the front face, check the top of the front face for level and height with relation to the other units in this course. If the top of the unit is irregular, place the level on the line where the top of the front face is chamfered. Shim as necessary. Rechecking alignment, level and plumb to make sure that you have not disturbed one unit while adjusting the other. Periodically, before backfilling, step back and sight down the tops of the units. This visual check will allow you to fine tune the alignment. Checking alignment Every effort should be made to ensure that the first course of units is properly aligned and level. Construct the wall in horizontal courses. 6 2012 The Neel Company
CONSTRUCTING SUBSEQUENT COURSES AND BACKFILLING: (continued) CONSTRUCTION PROCEDURES PART III Prior to initial backfilling, the 12" wide filter fabric should be cut into lengths equal to the height of the wall at each vertical joint. Center these strips across the 3/8" vertical joints between the units at the rear face. This procedure prevents the migration of the backfill material through the joints. Throw the excess filter fabric over the top of the units during backfilling and pull it back on the backfill during setting operations. Filter fabric covering vertical joints on back face of top units Horizontal joint material is placed in the horizontal joints between the units at the face. This material acts as a cushion to prevent concrete-to-concrete contact and as a gasket to prevent backfill material leakage. Position the horizontal joint material so that it is flush with the rear face of the unit. Filter fabric placement Shear keys, wrapped twice with the provided shear key wrap, should be placed in the space between teeth where the top and bottom stems come together. The number of keys required per unit is shown in the actual section(s) on the T-WALL drawings for the project. Location of the keys is not critical. Place one in the front and one in the last blockout and then equally space the remainder in between. The purpose of the shear keys is to: provide an alignment guide prevent movement of the unit during backfilling and compaction provide additional pullout resistance at the top of the wall. Horizontal joint material and shear keys in shear key wrap 2012 The Neel Company 7
PART III CONSTRUCTION PROCEDURES (continued) CONSTRUCTING SUBSEQUENT COURSES AND BACKFILLING: PLUMbing and alignment It may be necessary to plumb the units using shims between the stems at the back of the units. Shims may be small pieces of standard asphalt shingles, plastic or wood. If you encounter a unit that is out of square it is best to use the face as a guide to alignment. Keep in mind that this is purely an aesthetic concern, not a structural problem. However, difficulties with plumbing and alignment should be reported to The Neel Company. Vertical tolerance (plumbness) and horizontal alignment tolerance as the wall is constructed shall not exceed + 3/4 inch when measured with a 10 foot straight edge. The overall vertical tolerance of the wall (plumbness from top to bottom) shall not exceed + 3/4 inch per 10 feet of wall height (for vertical walls). BACKFILL Select backfill (material used between the T-WALL unit stems) Must meet project specifications for gradation, unit weight and Ø value unless otherwise specified. Granular material with 100% passing 3 screen, and maximum 25% passing No. 200 seive Minimum angle of internal friction (Ø) of 32 Typical unit weight ranges from 105 to 125 pcf Material can be sand, gravel, crushed rock, recycled concrete and aggregate blends Other materials may be considered based on availability, special design requirements (e.g. lightweight fills) or other factors. Walls have a tendency to grow or shrink in length depending on the amount of care taken to properly layout and align the first course! Placing top units into position Unclassified backfill (material used behind the T-WALL units) Must meet project specifications for gradation, unit weight and Ø value unless otherwise specified. Minimum angle of internal friction (Ø) of 30 Typical density range from 105 to 125 pcf Compaction requirements (for both select and unclassified backfill) Should be performed with heavy vibratory equipment sized to ensure proper compaction is achieve throughout each backfill zone (both select and unclassified) Minimum 95% Standard Proctor Density as determined by ASTM-698 (AASHTO T-99) For materials where on-site compaction testing is not practical, compaction shall be carried out until there is no movement of the backfill materials. 8 2012 The Neel Company
BACKFILL (continued) PART III CONSTRUCTION PROCEDURES (continued) (Continued) CONSTRUCTING SUBSEQUENT COURSES AND BACKFILLING: Placing and Compacting Dump select backfill material over the stems to ensure both sides are filled evenly, to prevent lateral movement. Spread the material evenly between the stems. Select material should be placed in a maximum of 12 loose lifts, then thoroughly compacted per project specifications before more material is placed. Compacting the backfill between the stems Placing the backfill Compaction testing (where applicable) should be carried out on a regular basis to ensure backfill mass is consistent. Backfill each course to within 6 of the top of the stem before setting the next course of units. Do not stack units more than one unit high without backfilling. Doing so may cause units above to shift creating safety hazards, and require resetting of units. Improper backfilling can result in post construction settlement of the backfill, poor wall performance, or wall instability. Unclassified backfill behind the wall should be placed and compacted at the same rate as the wall section, with maximum of 1 course differential between fill levels. Backfilling and compaction at the face of the wall should take place as soon as possible, and should be done once the wall has reached a maximum of 10 feet in height. Compaction Testing Compacting the backfill between the stems 2012 The Neel Company 9
(continued) CONSTRUCTION PROCEDURES PART III STAGED CONSTRUCTION: T-WALL should be constructed horizontally, one course at a time. However, there are some situations where staged construction may be necessary. Be aware that if the vertical height difference between adjacent columns is greater than one unit, the vertical joints will open due to the unbalanced earth pressure. In order to avoid problems with the wall alignment, you must contact The Neel Company for specific instructions when planning for staged construction. PART V CONSTRUCTION DETAILS see contract drawings for project specific details TERRACED WALLS T-WALL ON TOP OF CULVERT 10 2012 The Neel Company
(see contract drawings for project specific details) CONSTRUCTION DETAILS PART V BARRIERS Flush mounted barrier Barrier designed with a lip that extends over the top of the wall CORNERS Field installed connection as shown on the approved drawings. Corner with bolted connection Units have half stems allowing the courses to alternate direction. Alternating direction of stem 2012 The Neel Company 11
PART V CONSTRUCTION DETAILS see contract drawings for project specific details Railing Detail Chain Link Fence Guard Rail T-WALL Integration with other structures 12 2012 The Neel Company
see contract drawings for project specific details CONSTRUCTION DETAILS PART V CATCH Basin Utility Pole Bases Pipe PARALLEL TO Wall Face LARGE Pipe Penetrations Note filler panel - which can be used to accommodate pipes, inlets, or other obstructions. 2012 The Neel Company
T-WALL Retaining Wall System Construction Manual The Neel Company 8328 Traford Lane Ste. D Springfield, VA 22152 703-913-7858 ph. 703-913-7859 fax www.neelco.com 2012 The Neel Company