DOCUMENT REF :

TRANS RESOURCES COORPORATION

SDN BHD REVISION NO :

EFFECTIVE DATE :
CONSTRUCTION METHOD STATEMENT MANUAL
PAGE : 1 of 7
SOIL NAILS, ROCK BOLTS & GUNITING

11¦111111–µ1µ11111111ü111111111111111111111A) DRILLING &

GROUNTING

1. Introduction

This method statement is based generally on standard British practice, where

the project specification is not definitive.

2. Preparatory Work

The careful consideration and execution of preparation are essential to the

smooth flow and operation o the slope stabilization works. The following
items are predominantly important.

2.1 Transportation And Delivery Of Machinery And Materials

Installation machinery and equipment will be transported by truck and

pick-up to the project site where it will be of-loaded by cranes and placed
at the assigned location within the construction site.

2.2 Water supply And Drainage Facilities

The water supply for drilling of borehole and mixing of cement grout shall
be secured so as to produce adequate volume for the above works.
Attention should be given to the water supply to ensure the purity of water
as oil or other contaminant will effect the bonding of soil nails, rock bolt
and Gunite.

2.3 Electrical Supply Facilities

Location and positioning of electrical supply facilities such as Generator

and other related equipment at the site shall be determined.

2.4 Facilities For Assembling Of Nails, Rock Bolts And Mixing Plant

One or two areas are generally required for the assembly of nails, rock bolt
sand mixing of cement grout. Suitable location shall be determined upon
consultation with relevant parties.

3. Drilling Plant And Equipment

3.1 Rotary Percussive Drilling

 DOCUMENT REF :
TRANS RESOURCES COORPORATION
SDN BHD REVISION NO :

EFFECTIVE DATE :
CONSTRUCTION METHOD STATEMENT MANUAL
PAGE : 2 of 7
SOIL NAILS, ROCK BOLTS & GUNITING

Rotary percussive drilling in overburden and rock will be carried out by

tact mounted drilling rigs type HongDrill HD90, Koken RPD-130C or
similar with rotary percussive top hammerstype Kruup HBS28A, Arrow
Drills or similar (Refer Appendix A). The drill hole will normally be
drilled using 38mm45mm extension steels and 65mm76mm diameter
tungsten carbide insert. Handrills may be used for drilling shallow holes
for rock bolts.

3.2 Flushing

Either Air flush or water flush for all soil nail, rock bolt and rock dowel
hole drilling will be provided from a high pressure compressor and water
pump respectively.

4) Grouting Plant And Equipment

4.1 Grout Mixing

Grout mixing will be carried out by an air or diesel driven impeller mixer,
type 100A ELE with one stand-by mixer or similar.

Calibrated tank o water meter will measure mixer water, cement will be
measured by bag.

4.2 Grout Pumping

Grout from the mixer will be transferred to paddle type agitating tanks
from which it will be delivered direct to the suction of a positive
displacement diesel driven hydraulic grout pump, type craelius ZBE,
Koken MG10 or similar. 1 No service pump and one stand-by will be
provided.

4.3 Grouting Ancillaries

Grout delivery to holes will be by high pressures flexible line.

Connections to tremie pipes will be by screwed coupling or quick
coupling. In either case a grouting manifold will be used having provision
for control cock to hole, blow-off cock with return line to permit re-
circulation where required.

4.4 Grout Mix

The grout is to comprise of neat non-shrink (with additive) cement grout

with water/cement ratio of 0.4 to 0.50. The grout is to be mixed for
 DOCUMENT REF :
TRANS RESOURCES COORPORATION
SDN BHD REVISION NO :

EFFECTIVE DATE :
CONSTRUCTION METHOD STATEMENT MANUAL
PAGE : 3 of 7
SOIL NAILS, ROCK BOLTS & GUNITING

approximately 2 minutes in a high-speed mixer before pumping into the

drilled hole. A plastic or steel grout pipe of 1” in diameter is inserted to
within 0.5 m from the bottom of the hole and the grouting is perform under
tremie condition until the drilled hole is full. The overflow grout will have
a similar consistency to that of the mixing plant. Once the neat grout
flows out from the top of the drilled hole, the drilling casing may be
removed by either jacking or rotating out the rotary casing via the drilling
machine. During and after the removal of casing the grouting the grout
column is to be topped up with additional grout as when it is necessary.
Six (6) number of grout cubes for testing will be taken at each grouting
day.

For stable ground conditions where the hole is not lied, the process of
extract casing is omitted.

B) Soil Nailing

1. General

The basic concept of soil nailing is to reinforce and strengthen the existing
ground by installing closely spaced steel bars “Nails” into a slope or
excavation as construction proceeds from the “Top down”. This
process creates a reinforced section that it itself stable and able to retain
the ground behind it. The reinforcements are passive and develop their
reinforcing action through nail-ground interactions as the ground deforms
both during and following construction. Nails work predominantly in
tension, but are considered by some to also wok in bending/shear under
certain circumstances. Generally, the soil nails significantly increase the
apparent cohesion of the soil through their ability to carry tensile loads. A
construction facing I also usually required, and is typically shotcrete
reinforced by welded wire mesh. The sequence of soil nail installation is
as per schematic plan presented in Appendix B.

2. Nail Hole

The required nail hole diameter and length is achieved via method of
drilling as describe on item A (3).

3. Nail Bars

The nail bar is of high tension steel bar of size Y32. The Y32bars is
encased in Corrugated Plastic pipe for corrosion protection. The full
details of the components of the corrosion protection system,
 DOCUMENT REF :
TRANS RESOURCES COORPORATION
SDN BHD REVISION NO :

EFFECTIVE DATE :
CONSTRUCTION METHOD STATEMENT MANUAL
PAGE : 4 of 7
SOIL NAILS, ROCK BOLTS & GUNITING

manufacturing arrangement, spacer, centralises, is as shown on figures

appended in Appendix C.

4. Grouting

After completion of drilling for nail hole, Nail bar is inserted into the flush
clean drilled hole. Tremie grout pipe I inserted together with nail bars.
The grouting is proceeded as described on item A (4).

5. Nail Heads And Bearing Plates

All anti-corrosion measure is in accordance with S 80881.1989

The entire head assembly is encased in gunite.

6. Stressing

The soil nail is stressed by means of torque wrenches. Stressing is carried

out only after the grout has attained crushing strength of at least 20Mpa.
The nail is stressed to 10% of the working load.

7. Testing

All trial soil nails for the pullout test is tested to destruction.
Permanent soil nail is subjected to Proving Tests. The test loads for the
proving test is determined by the Engineer.

8. Records

The proposed soil nail record is appended in Appendix D.

C) Guniting (Sprayed Concrete)

1. General

The plant used for sprayed concrete will be of the dry mix delivery type
with water added at the nozzle. Only skilled operators experienced in the
use of sprayed concrete will be employed as nozzlemen.

2. Mix Design

Before sprayed concrete is used, the Contractor will submit his mix design
for approval and will demonstrate the process that he is use by spraying
 DOCUMENT REF :
TRANS RESOURCES COORPORATION
SDN BHD REVISION NO :

EFFECTIVE DATE :
CONSTRUCTION METHOD STATEMENT MANUAL
PAGE : 5 of 7
SOIL NAILS, ROCK BOLTS & GUNITING

trial panels to establish the suitability of the plant, the materials and the
operators t be used. The trial panels should consist of :

a. A 100mm x 1000mm x 100mm thick test panel sprayed at the same

time and cured in accordance with sub-clauses 9 of his section.

3. Sprayed Concrete

Sprayed concrete will apply in layers not exceeding 100mm thick.

4. Materials

All materials used will comply with and will be stored, tested and used in
accordance with the provisions of the relevant Clauses in the specification.

5. Control Of Water

The moisture content of the mix before use will not exceed 10%, the
remaining water being added at the instant of application. The air and
water supply, the rate of application and all other factors affecting the
quality of the work will adjust by the operator so as to produce dense
concrete with no sloughing. No mix will be used more than two hours
after any water has been added to it. Rebound material will not be reused
and, when so required by the S.O. will remove within 8 hours of spraying.

6. Preparation Before Guniting

The slope face or any previously sprayed concrete surfaces, will be

cleaned down with an air jet before sprayed with concrete. Surplus water
will be removed by air jet and if any water is flowing from across the rock
or existing sprayed concrete and is liable to reduce the adhesion of the
concrete it will be diverted by the pipes, hoses or other approved means
before spraying starts. Where ordered or approved by the S.O, weep holes
will be formed, or pipes and hoses built in to relieve water pressure behind
the concrete and to divert the water from the face.

7. Weepholes

50mm diameter weepholes will be formed with PVC pipes at 1.5 m centres
in each direction or otherwise as directed by the S.O.

8. Records
 DOCUMENT REF :
TRANS RESOURCES COORPORATION
SDN BHD REVISION NO :

EFFECTIVE DATE :
CONSTRUCTION METHOD STATEMENT MANUAL
PAGE : 6 of 7
SOIL NAILS, ROCK BOLTS & GUNITING

A record will be kept of the quantities of all material used at each slope
and submitted daily to the S.O

9. Strength Of Concrete

The strength of the applied concrete will determined by crushing 100mm

diameter cores cut from 100mm thick test panels prayed at the same time
and cured in the same manner as the in-situ concrete. Moulds for
unreinforced test panels will be 1000mm x 1000mm 250mm thick rigidly
fixed alongside the works to the approval of the S.O.
Six cored will be cut from each panel, three of which will be crushed at 7
days and three at 28 days. Cores will not be taken within 125mm of the
edges of the panel. Prior to crushing the density of each core will be
measured. The minimum equivalent cube strength of the core will be:

At 7 days 10Mpa
At 28 days 20Mpa

D) Permanent Rock Bolt (Single Protection)

1. Drilling Works :

As item A (3)

2. Assembling Of Rock Bolt

The deformed bar of rock bolt will be of Grade 410 as specified. The bar
is to be cleaned and greased and covered with poly-Ethylene (PE) tube
over the free length. The bar will be fixed with centralized before inserts
into the drilling hole. Extra care will be observed to prevent the damage to
the PE tube.

3. Injection Of Cement Grout

The deformed bar will be inserted into the cased drilling hole immediately
after drilling and cleaning of borehole. Grouting will be carried out
without delay. The grouting is proceeded as described on item A (4).

E) Permanent Rock Bolt (Double Protection)

1. Drilling Works:

As item A (3)
 DOCUMENT REF :
TRANS RESOURCES COORPORATION
SDN BHD REVISION NO :

EFFECTIVE DATE :
CONSTRUCTION METHOD STATEMENT MANUAL
PAGE : 7 of 7
SOIL NAILS, ROCK BOLTS & GUNITING

2. Assembling Of Rock Bolt

The rock bolt will be consisted of high tensile steel bar Grade 410 encased
in corrugated PVC sheathing. The size used will be as specified in
specification by Engineer. The high tensile deformed bar will be fixed
with internal plastic spacer and inserted into corrugated PVC sheathing
and pregrouted corrugated PVC sheathing with deformed bar will be fixed
with external plastic spacer before inserted into the drilling hole.

3. Injection Of Cement Grout

The deformed bar pregrouted in corrugated PVC sheathing will be inserted

into the cased drilling hole immediately after drilling and cleaning of
borehole. The grouting is proceeded as described on item A (4).