ROGER - MS Gabion System For Slope Stabilization - Rev. Draft

KAYSAKAT RAW WATER TRANSMISSION LINE-TUNNEL WORKS

Method Statement for Gabion System of Slope Stabilization

KAYSAKAT RAW WATER TRANSMISSION

LINE-TUNNEL WORKS
SITIO APIA, CALAWIS, ANTIPOLO CITY
METHOD STATEMENT
FOR GABION SYSTEM OF SLOPE
STABILIZATION
REV DATE DESCRIPTION Prepared by Reviewed by Approved by
1
Rogelio D. Del Rosario

QA/QC Engineer
TABLE OF CONTENTS
Sec. Item Page No.

1 INTRODUCTION 3
2 SCOPE 4
3 PROPOSED TYPE OF GABION SYSTEM 5
Mechanically Woven, Double-Twisted Hexagonal Wire
3.1 5
Mesh Gabion
Wire Mesh, Lacing Wires, Stiffeners and Fasteners
3.2 6
Minimum Requirement
3.3 Rocks for Filling the Gabion 7
4 INSTALLATION METHODOLOGY OF GABION WALLS 7
4.1 Delivery and Storage 7
4.2 Procedure of Installation 8
4.2.1 Preparation of Base, Formation and Setting Out 9
4.2.2 Preparation of the Gabion Material 9
4.2.3 Filling of Gabion Boxes with Rocks/Stones 12
4.2.4 Closing and Completing the Gabion Boxes 13
5 EQUIPMENT 15
6 SUPERVISION AND MANPOWER 15
7 MANAGEMENT AND SUPERVISION RESPONSIBILITIES 15
8 HAZCON ASSESSMENT 19
2
1. INTRODUCTION
The inlet portal of the proposed Kaysakat Tunnel is located in Sitio Apia, Barangay Calawis,
Antipolo City. The TBM entry point to bore this tunnel is through the Inlet Portal. To facilitate
timely and efficient delivery of completed concrete segments, the following are to be done:
 The Concrete Segment Production Plant shall be constructed at a location close to the
Tunnel Inlet.
 A temporary Service Road (Macadam) shall be constructed connecting the Tunnel Inlet
TBM Entry Point and the Concrete Segment Production Plant.
It is noteworthy that the Concrete Segment Production Plant and the Service Road (Macadam)
are both located above sloping grounds, where the soil was a compacted fill. Also, a portion of
the temporary macadam road will cross above pipe culverts diversion of the existing creek.
Since, the sloping soil is a compacted fill, it is not fully in a natural state of equilibrium and will
be exposed to external forces such as weathering, erosion, and mass movement. See Fig. 1-a.
Fig. 1-a. Vicinity Plan
To stabilize the sloping soil, Gabion System shall be used. A Gabion system is prepared from a
pre-assembled rectangular cages made of double twisted hexagonal wire mesh filled with
rocks/stones. The advantages of the Gabion System are as follows:
3
 It is a simple gravity retaining structure, which retains soil with its weight and is in use in
highways, bridges, canal linings, buildings, shore protection works, etc.
 The porosity of Gabions prevents the pore-water pressure development behind the walls.
 These structures blend with the surroundings and allow vegetation to take roots through
the structure which enhances the life of the structure.
Fig. 1-b. Details of Proposed Gabion System Installation
2. SCOPE
This Method Statement will discuss in detail the process and sequence of the Gabion System
for Soil Stabilization. Along the course of this document, significant specifics are being
denoted to ensure that the work will be implemented as per internationally accepted Codes and
Standards, and in a safe and timely manner.
3. PROPOSED TYPE OF GABION SYSTEM

3.1 Mechanically Woven, Double-Twisted Hexagonal Wire Mesh Gabions
Gabion is a rectangular box made from mechanically woven double-twisted hexagonal

4
mesh wire filled with rock or stones (Fig. 2-c). A terminal 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 (Fig. 2-a). The hexagonal shape of the mesh helps in
achieving uniform distribution of forces. Mesh should not easily corrode and must
possess high tensile strength. The details of the different mesh types, sizes and
various tests are available in IS 16014 and are given in Table 1. The wires of the mesh
should be galvanized with zinc and/or polymeric coating like polyvinyl chloride (PVC),
polyamide (PA6) or other polymers to prevent corrosion. Better coatings of Zn-Al alloy
like 95%Zn+5%Al and 90%Zn+10%Al are used which are better than only Zinc.
Similarly, better polymeric coatings like polyamide are used.
Fig. 2-a. Details of Mesh Wire, Selvedge and Edge Wire Fig. 2-b. Mesh Type and Nominal Size “D”
Table 1. Technical Specification of Gabion
5
3.2 Wire Mesh, Lacing Wires, Stiffeners and Fasteners Minimum Requirement
Gabion Boxes are generally transported in collapsed condition and are restructured
into boxes of required dimensions at site. These boxes are joined using stainless steel
fasteners or lacing wires or galvanized rings depending on the specifications.
The tensile strength of mesh wire, lacing wires, stiffeners and fasteners should be in
at minimum elongation of 10% on test performed on a gauge specimen length of
200mm. The minimum tensile strength of the wire mesh and the zinc/polymeric
coating are listed in Table 2.
Table 2. Minimum Strength Requirements of Mesh and Connections
3.3 Rocks for Filling the Gabion
6
An un-weathered (sound) naturally occurring angular or crushed hard rock material

can be used for filling. Stone for the Gabion facia shall be hard, angular to round,
durable and of such quality that they will not disintegrate on exposure to water or
weathering during the life of the structure. The minimum size of the rock to be filled
in the boxes is governed by the mesh opening “D” as shown in Fig. 2-b. The maximum
and minimum sizes of the stone used for filling shall be 1.5 to 2.5 times the mesh
opening. Each range of sizes may allow for a variation of 5% oversize rock by number
of particles, or 5% undersize rock by particles, or both. The rock pieces should be
properly hand-placed and packed with their larger dimension in the horizontal position.
The size of any oversized rock shall allow for the placement of minimum of three (3)
layers of rock must be achieved when filling the 1-m high units and a minimum of two
(2) layers for the 0.50-m high Gabion unit. Please refer to Table 4.
Table 4. Properties of Rocks to Fill the Gabion
4. INSTALLATION METHOHOLOGY OF GABION WALLS

4.1 Delivery and Storage
Gabions are delivered at worksite collapsed and in bundles along with lacing wires.
These bundles are unloaded using machines with lifting capacity such as Palfinger
Boom Truck or Fork Lift. They are stored at a location close to the site where they are
to be installed. During unloading, care must be taken to prevent damage to Gabion
bundles. A maximum of four (4) bundles can be stacked together. Gabion bundles
shall be stacked on level ground with wooden rafters/sleepers between them to
facilitate easy handling and prevent damage to the mesh and other components like
the selvedge wires. Storage can be outdoors as long as the bundles are not laid over
abrasive or chemically aggressive surfaces (corrugated asphalt, oils, grease, etc.).
7
Fig. 3. Collapsed Gabion Boxes Delivered in Bundles
4.2 Procedure of Installation
There are two (2) main Gabion walls to be constructed, designated in the drawing as
Gabion Wall 01 (GW-01) and Gabion Wall 02 (GW-02) for easy reference. See Fig. 4.
GW-01 is located at coordinates X=311066.0770/Y=1626245.608 with a total length of

26.0m. The height of the wall is 2.0m while the top and bottom widths are both 2.0m.
The purpose of GW-01 is to prevent the collapse of soil supporting the foundation of the
Concrete Segment Production Plant and to avoid erosion of soil to the upstream of the
existing creek where concrete pipe culverts are to be laid for flow diversion.
GW-02 has two (2) segments. One segment is located at coordinates

X=311130.1360/Y=1626255.7650 to X=311104.5770/Y=1626282.2970, end-to-end,
with a total length of 46.0m. The other segment is located at coordinates
X=311103.3680/Y=1626291.9920 to X=311123.5540/Y=1626336.7480 with a length of
49.0m. For both segments the height of wall is 2.0m while the top and bottom widths are
both 1.0m. The purpose of GW-02 is to prevent collapse of soil into the fence of the
existing water treatment plant (WTP) and concrete open channel downstream of creek
diversion of the WTP.
8
FigFi
Fig. 4. Drawing of Proposed Gabion Wall Installation
4.2.1 Preparation of Base, Formation and Setting Out
 Initially, clearing, grubbing and excavation are done to prepare the existing
ground to required level and formation and to provide adequate
working/construction space. Existing excavated slope is also trimmed to
provide space for the wall inclusive of the working space.
 The surface of formation should be free from deleterious material and
foreign objects.
 Loose pockets, if any, should be excavated and filled with suitable granular
or backfill materials.
 The place should be cleared of standing water to ensure proper placement
of gabions.
 Earth fill is completed to maintain slopes of 1:1 for both GW-01 and GW-
02.
 Compact the formation using Vibro-Roller, preferably 8-10 tonnes
capacity.
 The outer alignment of the Gabion facia should be marked by the Surveyor
as specified in the drawings.
4.2.2 Preparation of the Gabion Material
 The Gabions should be opened out flat on hard surface (compacted ground)
and stretched to remove all kinks and bends. One or two persons may be
deployed for the straightening of the mesh panels.
9
Fig. 5. Opening the Gabion on Flat, Hard Ground (Compacted Soil)
 The side panels are opened up to form a box by tying the upper corner of
each pair of side panels using the thick selvedge wire. Fig. 6.
Fig. 6. The Gabion is Formed into a Box
 The edges are laced together starting from top corner in a continuous
operation using alternate single and double loop at a spacing of one mesh
length, i.e. 100-125mm. The ends of the lacing wire are secured at each
corner by bending it into the Gabion. Individual ties of lacing wire should
not be used. Alternatively, steel C-rings can be used employing mechanical
tools. Figs. 7-a & 7-b.
 Similarly, all other sides are tied up and the box structure made with the top
ends open to fill the boxes.
10
Fig. 7-a. Assembling Details with Lacing Wires
11
Fig. 7-b. Assembling Details with C-Rings
4.2.3 Filling of Gabion Boxes with Rocks/Stones
 Filling is then carried out with stones of dimensions larger than that of the
mesh opening making sure that there are minimum voids. For better finish,
the stone fill to the front face is selected and placed carefully to give a nice
appearance. When using quarried/crushed rock, rock shall be selected in
such a way that at least one face is flat-shaped. This will not be applicable
when using rounded stones from river. Front Loaders, Back Loaders or
Excavators can be used to fill Gabions maintaining porosity. For a better
alignment of the face, it is preferrable to include internal tie wires while
filling the Gabions. These horizontal tie wires prevent Gabion deformation
during filling stage.
 For 1.0m-high boxes, Gabions should be filled to one-third height and the
tie wires fixed. Fig. 8. The same sequence is repeated at two-thirds height.
Fig. 8. Bracing Wire Details
12
 The filled layer should not be more than 300mm than any adjoining cell.
To avoid such circumstances, the filling pattern in Fig. 9 should be
followed. The Gabion is overfilled by approximately 25-50mm to allow
for settlement of the infill (due to self-weight).
Fig. 9. Filling Pattern of Gabion Boxes
 If applicable, MS pipe/frame formwork shall be provided at Gabion

facia for achieving a good aesthetic appearance and keeping the bulges
within specified tolerances. The formwork enables to achieve uniformity
in the Gabion Box dimensions during the filling and placement of
stones.
4.2.4 Closing and Completing the Gabion Boxes
 The lids are folded back and laced first to the front panels. Then, to the
side ones and to any existing diaphragms to close the Gabions. The
Gabions in the upper layer shall be connected to 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. See Fig. 11.
 Other boxes are also placed and packed in position following the same
procedure to complete the wall.
13
Fig. 10. Putting in Place, Connecting and Rock-Filling of Gabion Boxes
Fig. 11. Completed Gabion Wall
14
5. EQUIPMENT
Hereunder list denotes the equipment to be used to undertake the installation of Gabion
System of slope stabilization, but not limited thereto.
o Excavator 1 o Vibro-Roller 1
o Dump Truck 1 o Crane 1
o Palfinger Boom Truck 1 o Payloader 1
o Hammer/Rammer 1 o Crane 1
6. SUPERVISION AND MANPOWER

Hereunder list denotes the composition of supervision and manpower who will undertake
the installation of Gabion System of slope stabilization, but not limited thereto.
o Site Engineer 1 o Crane/Lifting (HE) Operator 2
o QA/QC Engineer 1 o Foreman/Leadman 1
o Surveyor 1 o Rigger 2
o Safety Officer 1 o Labor/General Workers 10
7. MANAGEMENT/SUPERVISION RESPONSIBILITIES
Construction Manager
Main duties and responsibilities are as follow, but not limited thereto:
 Ensures the identification and analysis of the technical requirements at the project.
 Ensures that the organization is equipped with adequate resources and information
to achieve quality.
 Assists the Site Engineer in all aspects of the engineering and other technical
requirements.
 Provides the practical methods for work execution.
 Controls the manpower and equipment resources.
 Coordinates with QA/QC Department regarding inspection and testing plans
(ITPs).
15
Site Engineer/Supervisor
 Prepares the work procedure for site implementation.
 Refers to approved documents and drawing in the execution of works at site.
 Coordinates with QA/QC Engineer regarding ITPs, WIRs, WRs, Material Testings,
etc.
 Regularly checks and reviews the project schedule.
 Manages and controls manpower and equipment at site.
 Coordinates with Construction Manager, especially for MSs, WRs and WIRs with
revisions.
 Assists the Construction Manager in all aspects related to engineering and technical
matters.
Safety Officer
 Over-all in charge of Safety, Health and Environment (SHE) at the area of
assignment.
 Ensures project staff have attended the DOLE-required safety orientation seminars.
 Ensures that all project staff were issued with PPEs.
 Conducts daily toolbox meetings and physical exercises of project field staff.
 Reports and documents all accidents/incidents related to Safety.
QA/QC Engineer
 Prepares the Method Statements (MSs), ITPs, WRs and WIRs of Project activities in
coordination with the Consultant.
 Conducts day-to-day QA/QC inspection activities (concrete and its pouring,
formation of steel reinforcement, material and concrete test, production stage for
segment, etc.).
 Constantly coordinates with the Consultant for documents and inspection activities
needing corrections and revisions.
 Documents all QA/QC activity reports, preferably with accompanying photos.
Surveyor
 Creates the miniature of the construction plans that would serve as the source of site
plans.
 Periodically updates the Design and Construction Departments.
 The Surveyor being part of Field Management Team is responsible for various
aspects of field engineering and surveying for the project - all construction layouts
16
and survey documentation (structure alignment before, during and after the concrete
placement).
 Works directly with the Field Engineer for the initial project layout requirements,
means and methods of establishing project survey control, and field reporting.
 Works with Field Engineer with the following tasks: site layout, construction
planning, scheduling, quality control, and job site safety.
 Provides and maintains horizontal and vertical survey control by use of a level or total
station, etc., including structured documentation of survey notes.
 Assists in the preparation of final records for the project including as-built drawings.
 Works with Site Engineer/Foreman to ensure structures are built in conformance with
the design alignment and contractual requirements.
Heavy Equipment Operator
 Drives and operates properly the heavy equipment he is assigned to complete tasks at
the construction site.
 Always conducts checking of his heavy equipment before and after utilization
 Reports to the Motorpool In-Charge for any operational problem the heavy equipment
is experiencing, as it might need to be repaired urgently.
 Obeys the safety standards and procedures in the driving and operation of moving
plants and equipment.
Foreman
 Coordinates the day-to-day activities of field crews and is responsible for the quality
of production at the workplace.
 Attentively listens to the instructions of the Site Engineer/Supervisor and implements
the works with precision through his crew.
 Implements HSE practices to his crew as instructed by the HSE Manager, specifically
the wearing of PPEs and use of other safety gadgets, such as safety harness, etc.
General workers
 Carries out the instructions of the Foreman for the proper execution of activities.
 Assists the skilled workers (welders, mason, carpenters, etc.) in doing specific works.
 Always wears properly the prescribed personal protective equipment (PPE) issued by
HSE and obeys all safety rules and policies.
17
8. HAZCON Assessment
Please see attached.
18
HAZCON ASSESSMENT FORM

Contractor China International Water & Electric Corporation （CWE）
Job Description Gabion System of Soil Stabilization near Segment Plant and Proposed Roadway Location KSK Tunnel Inlet
Equipment & Tools Start Date
HAZARD
CLASSIFICAT IMPACT RISK
NO. ACTIVITIES HAZARD IDENTIFICATION MITIGATION AND CONTROL MEASURE ACTION BY:
ION LEVEL
H S E P E A
 Injuries from being hit by
 Wear hardhats, safety glass & working gloves
moving plants.
in addition to hard hats, Hi-Viz vest and safety
 Fall when working at higher
shoes
portion of the sloping ground.
 On working on high places above 1.5m, wear
 Being hit by falling stones.
Preparation of Base, the safety harness. Site
1.0  Hand/arm Injuries from x x x Low
Formation and Setting Out  Install safety and warning signages around the Engineer/Supervisor
incorrect use of tools.
work area.
 Slip/Trip on protruding ground
 Assign traffic flagmen and spotters to direct
obstacles.
large moving plant/equipment.
 Eye injury due to light sands
carried by the wind
 Arm and/or hand injury due to
steel lace wires and selvedges,  Wear safety glass & working gloves in addition
mesh wire and edge wires. to hard hats, Hi-Viz vest and safety shoes
 Injury due to being hit by lifting  Do not wear loose clothing while working with
Unloading bundles delivered Medium Site
2.0 plant/equipment while unloading x x x x the drilling rig
collapsed Gabion boxes Risk Engineer/Supervisor
the Gabions.  Ensure that all workers are aware of the proper
 Bodily injuries due to accidental manual handling techniques
falling of bundles from lifting
equipment.
 Hand/arm or eye injuries due to
 Wear appropriate PPEs, such as Safety Glasses,
presence of selvedges, lacing
Working Gloves, in addition to other PPEs
and edge wires.
Opening of Gabion bundles  Discuss during Tool Box Meeting the proper
 Back/body injury or sprain due Site
3.0 and raising the edges, x x x x Low ergonomics for Manual Lifting.
manual lifting. Engineer/Supervisor
diaphragms and top cover  Always be aware of the materials being worked
 Clothing can be caught on
on.
protruding wires or the Gabion
itself.
4.0 Assembling and lacing the  Hand/arm or eye injuries due to x x x x Low  Wear appropriate PPEs, such as Safety Glasses, Site
Gabion boxes presence of selvedges, lacing Working Gloves, in addition to other PPEs Engineer/Supervisor
and edge wires.  Discuss during Tool Box Meeting the proper
 Back/body injury or sprain due ergonomics for Manual Lifting.
P a g e 19 | 21

HAZARD
CLASSIFICAT IMPACT
RISK
NO. ACTIVITIES HAZARD IDENTIFICATION ION MITIGATION AND CONTROL MEASURE ACTION BY:
LEVEL
manual lifting.
 Always be aware of you’re the work being done
 Clothing can be caught on
and the materials.
protruding wires or the Gabion
 Use appropriate tools and equipment in doing
itself.
the work
 Hand/arm injuries, cuts,
abrasions and sprains due to  Wear appropriate PPEs, such as Safety Glasses,
incorrect lifting of heavy stones Working Gloves, steel-toed safety shoes in
or rocks. addition to other PPEs.
 Back and body pains due to  Discuss during Tool Box Meeting the proper
Cutting of stones/rocks to fill Site
5.0 incorrect manual lifting. x x x x x Medium ergonomics for manual lifting and the proper
the Gabion boxes Engineer/Supervisor
 Hand or foot injuries caused by use of tools.
tools used to cut/break rocks.  Always be aware of the work being done, the
 Eye injuries due to flying debris materials and the tools/equipment being used.
from breaking/cutting of rocks
 Assign spotters during Micro Pile installation

 Make eye contact with the Operators before
approaching the equipment
 Struck by equipment
 Restrict work area entry to authorized personnel
 Falling load
Filling up the Gabion boxes only Site
6.0  Hitting or crushing of load to x x x Low
with rocks/stones  Barricade crane swinging radius Engineer/Supervisor
existing structure
 Only the Rigger will provide signal to Operator
 Miscommunication
 Use 2-tag lines for load control
 Man entry under suspended load should be
avoided
 Provide Flagmen on site entry / exit point.
 Driver must drive defensively.
 Regulate vehicle speed, preferably to 30kph,
while driving around the project site and on
 Third Party Vehicle collision
public roads.
Hauling of Excavated while entering/exiting site Site
7.0 x x x x x Medium  Load per truck must be lower than the dump
Materials  Vehicular-Personnel accident e Engineer/Supervisor
box maximum capacity.
 Spillage on public roads
 Conduct water spraying on vehicle tires when
exiting site, as necessary.
 Conduct route surveillance for material spillage
and immediately clean-up if there’s any
P a g e 20 | 21
H : Health, S : Safety, E : Environmental, | P : Person, E : Environment, A : Assets

Low Risk – Site Supervisor, Medium Risk – Construction Manager, High Risk – Project Manager
Site Supervisor Construction Manager Project Manager
P a g e 21 | 21

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KAYSAKAT RAW WATER TRANSMISSION LINE-TUNNEL WORKS

Method Statement for Gabion System of Slope Stabilization

KAYSAKAT RAW WATER TRANSMISSION

REV DATE DESCRIPTION Prepared by Reviewed by Approved by

Rogelio D. Del Rosario

Sec. Item Page No.

Fig. 1-a. Vicinity Plan

Fig. 1-b. Details of Proposed Gabion System Installation

3. PROPOSED TYPE OF GABION SYSTEM

Gabion is a rectangular box made from mechanically woven double-twisted hexagonal

Table 1. Technical Specification of Gabion

Table 2. Minimum Strength Requirements of Mesh and Connections

3.3 Rocks for Filling the Gabion

An un-weathered (sound) naturally occurring angular or crushed hard rock material

Table 4. Properties of Rocks to Fill the Gabion

4. INSTALLATION METHOHOLOGY OF GABION WALLS

Fig. 3. Collapsed Gabion Boxes Delivered in Bundles

4.2 Procedure of Installation

GW-01 is located at coordinates X=311066.0770/Y=1626245.608 with a total length of

GW-02 has two (2) segments. One segment is located at coordinates

Fig. 4. Drawing of Proposed Gabion Wall Installation

4.2.1 Preparation of Base, Formation and Setting Out

4.2.2 Preparation of the Gabion Material

Fig. 5. Opening the Gabion on Flat, Hard Ground (Compacted Soil)

Fig. 6. The Gabion is Formed into a Box

Fig. 7-a. Assembling Details with Lacing Wires

Fig. 7-b. Assembling Details with C-Rings

4.2.3 Filling of Gabion Boxes with Rocks/Stones

Fig. 8. Bracing Wire Details

Fig. 9. Filling Pattern of Gabion Boxes

 If applicable, MS pipe/frame formwork shall be provided at Gabion

4.2.4 Closing and Completing the Gabion Boxes

Fig. 10. Putting in Place, Connecting and Rock-Filling of Gabion Boxes

Fig. 11. Completed Gabion Wall

o Dump Truck 1 o Crane 1

o Palfinger Boom Truck 1 o Payloader 1

6. SUPERVISION AND MANPOWER

o Site Engineer 1 o Crane/Lifting (HE) Operator 2

o QA/QC Engineer 1 o Foreman/Leadman 1

o Safety Officer 1 o Labor/General Workers 10

Heavy Equipment Operator

Please see attached.

HAZCON ASSESSMENT FORM

HAZCON ASSESSMENT FORM

 Assign spotters during Micro Pile installation

HAZCON ASSESSMENT FORM

H : Health, S : Safety, E : Environmental, | P : Person, E : Environment, A : Assets

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