Construction of Reinforced Earth® wall and TechRevetment® for Beautification of Nala at Grasim Industries Limited

Project Details

OWNER

GRASIM INDUSTIRES LIMITED (ADITYA BIRLA)

SYSTEM

TerraWall®/GeoStrap5®/ TechRevetment®

DESIGNER

Geoquest India (formerly known as Reinforced Earth India Pvt. Ltd.)

CONTACTOR

SHREE DHIRUBHAI PATEL

CONSTRUCTION

2024

Background

Grasim Industries Limited, the flagship company of the Aditya Birla Group, began as a textile manufacturer in India in 1947. Today, it has evolved into a leading diversified player with a significant presence across various sectors

As part of its Corporate Social Responsibility (CSR) activities, Grasim Industries sought a solution for erosion control measures to protect and beautify the Nala. Terre Armée proposed a solution involving a Reinforced Earth® wall combined with an TechRevetment® Environmental Mattress (EM) fabric-formed concrete mattress.

Using in-house technical expertise, Geoquest designed the Reinforced Earth® wall with TechRevetment® (EM) fabric forms. These forms are used to construct a wide range of concrete-filled systems that provide exceptional performance in erosion control, scour protection and repair, foundation, environmental, and marine construction applications. The fabric forms are constructed from double-layer woven synthetic fabric. The TechRevetment® (EM) linings and mats were installed by positioning the fabric forms over the areas to be protected and then pumping high-strength concrete into the forms.

The system used for the flood protection and Nala beautification works at Grasim Industries included the use of the TechRevetment® (EM) with the Reinforced Earth® wall, making it the first of its kind. The project covered a maximum length of approximately 670 meters and an area of 2006 square meters. Construction of the Reinforced Earth® wall began in April 2023 and was completed in April 2024. The installation of TechRevetment® for this project began in March 2024 and was completed in April 2024.

Challenge

The unprotected banks of the Nala were adversely affected by tidal waters during high and low tides. As part of their Corporate Social Responsibility (CSR) initiatives, Grasim Industries sought a solution to safeguard the Nala banks while also enhancing their aesthetic
appeal. Terre Armée proposed a solution involving the construction of a Reinforced Earth® wall in conjunction with an TechRevetment® (EM)

Solution

TechRevetment® (EM) 400 linings and mats are designed to protect canals, channels, culverts, and other hydraulic and marine structures from the
forces of flowing water and wave action. Given that this application involved a Nala connected to the sea, which experiences rising water levels due to tidal effects, the TechRevetment® (EM) was deemed the ideal solution for this type of environmental challenge. Its robust design effectively mitigates the impact of tidal forces, ensuring the stability and protection of the Nala banks

TechRevetment® (EM) are erosion control linings designed to enhance vegetation growth and protect against periodic high flows. These linings
are installed to safeguard vegetation from the impact of high-water flows. After installation, vegetation can be planted within the open structure of the linings. The TechRevetment® (EM) consists of concrete-filled elements and unfilled areas that facilitate vegetation establishment. Once the concrete sets, the defined unfilled and interwoven areas are opened by cutting the fabric, allowing for planting or filling with topsoil and seeding

The fabric forms can be placed and filled both underwater and in dry conditions. High-strength, aggregate concrete is used instead of conventional concrete due to its pumpability, high strength, impermeability, and resistance to absorption. This makes the TechRevetment® (EM) an effective solution for protecting hydraulic and marine structures, such as canals, channels, and culverts, from the forces of flowing water and wave action.

The Fabric form panels are to be positioned with the designated side folded into the anchor trench provided at the top of the berm. Once the fabric is placed into the trench, it is filled with plain cement concrete grout. This process ensures that the fabric form panels are securely anchored, providing stability and protection against erosion.

Special Features and Advantages

 

The stages of execution were taken up in two stages viz

  • Construction of Reinforced Earth® Wall
  • Installation of TechRevetment® (EM) 400

During the casting of the EM 400, Terre Armée meticulously validated and ensured the bed slopes of the embankment in accordance with the design and drawing specifications. The concrete strength was verified by conducting compressive strength tests on cement mortars to guarantee the strength, quality, and performance of the structure.

The flowability or workability of the cement mortar was ensured by performing the Flow Cone Test as described in ASTM C6449-99. At every stage of the TechRevetment® (EM) 400 installation, experts at the project site closely monitored the placement of fabric forms to ensure the seamless flow of cement mortar into each block.

Ensuring quality and safety throughout all phases of the work was a significant challenge, but it was essential to deliver a high-quality, end-to-end technological solution.