Retaining Walls - Hanson QuickBuild

Hanson Precast Products
Retaining Walls
Featuring the unique Hanson QuickLift system
Bespoke mouldage facility
Rigorous quality assurance
About us
The Facility
The QuickBuild range of products
is manufactured at our Somercotes
facility in Derbyshire, which
has been manufacturing heavy
precast products for over 50
years. Continuing investment
means that it has some of the
most modern facilities in the
country. With a production capacity
of over 70,000 tonnes a year,
products of up to 24 tonnes
can be manufactured routinely,
and significantly heavier on
a bespoke basis.
2 | Hanson Retaining Walls
Engineering and Design
With customers ranging from
the nuclear industry through
to waste recycling, product
performance requirements vary
greatly. A dedicated team of
engineers and designers, based
at Somercotes, can advise on all
aspects of a project from outline
design through to final value
engineering. They are supported
by Hanson’s specialist technical
teams in areas such as concrete
mix design and steel fabrication.
No other precast manufacturer
can offer this level of support.
Quality Assurance
From initial design through to
on-site logistics, all aspects of the
Somercotes operation meet the
most exacting quality standards.
These are maintained by Hanson’s
own in-house Quality Inspectors,
and audited by external
certification bodies. Somercotes
meets the requirements of ISO
9001, ISO 14001, ISO 6001
and ISO 18001. All precast
engineering is carried out in
accordance with British
Standards or EC 2 as required.
Mouldage and Cage Facility
As well as standard products, a
wide range of bespoke products
are designed and manufactured at
Somercotes. This is achieved quickly
and cost-effectively by maintaining a
highly skilled in-house mould joinery
team, and a steel reinforcement
bending and fabrication facility.
Fixing Services
Hanson provides a variety of
fixing services for precast products.
Installation teams operate in line with
all current Health and Safety regulations,
and can supply all required equipment
including craneage.
Purpose-built, high quality mouldage
Customer Service and Support
We are committed to providing
an excellent product and service to
our customers. Support and advice is
available at every stage in the project
cycle from engineering design through
to on-site logistics.
Bespoke cage making facilities
Hanson Retaining Walls | 3
Technical Information
Retaining Walls
We are proud to introduce our new range of QuickBuild
retaining wall products, which have been specifically
engineered using our 50 years of experience within
the precast and contracting sectors.
We understand that as a client you are looking for the
most efficient fixing solution for your project, hence our
design utilises a number of key features which focus on
saving time and resource by up to 20%.
The
Range
1.00m wall
1.50m wall
1.75m wall
2.00m wall
2.50m wall
3.00m wall
3.75m wall
Height: 1000mm
Height: 1500mm
Height: 1750mm
Height: 2000mm
Height: 2500mm
Height: 3000mm
Height: 3750mm
Width: 1000mm
Width: 1000mm
Width: 1000mm
Width: 1000mm
Width: 1000mm
Width: 1000mm
Width: 1000mm
Depth: 500mm
Depth: 750mm
Depth: 875mm
Depth: 1000mm
Depth: 1250mm
Depth: 1500mm
Depth: 1875mm
Weight: 450kg
Weight: 650kg
Weight: 1013kg
Weight: 1138kg
Weight: 1370kg
Weight: 1800kg
Weight: 2700kg
Embedment: 150mm
Embedment: 150mm
Embedment: 220mm
Embedment: 250mm
Embedment: 250mm
Embedment: 250mm
STORAGE CAPACITY
The unit will be designed to be
loaded from either side with the
following conditions: retained
material level with the top of the
wall and with an applied surcharge
of 10kN/m2 or a sloping backfill with
a maximum angle of 35º without an
imposed surcharge. The retained
material will be assumed to be
granular and drained with a specific
maximum moist density of 18kN/m3.
For more information on specific
material densities see table 1. When
installed with a suitable joint sealant
the wall becomes waterproof.
Unlike many other systems we have
no hidden costs for expensive lifting gear.
In addition to the overturning and
sliding resistance of the supporting
insitu base, the overall ground
bearing pressure must be checked
by others and considered when
designing the insitu support base.
Finishes
Corner Unit
Embedment: 375mm
Medium
dense
sand
Loose
sand /
gravel
Grain
Woodchip
Sewage
waste
Rolled Silage
Paper
waste
Composted
green
waste
PFA
18
16
8
8
11
4+72z
(see note 1)
6
5
10
To further enhance efficiencies
on-site we also offer cast-in
finishes. Using state-of-the-art
form liner technology the
QuickBuild retaining wall unit can
be cast with a preformed finish to
provide an aesthetically pleasing
appearance to the end user.
We offer a range of economical
corner details. For further
information call or email:
Please see our Finishes and
Textures section on page 10
for further information.
Tel: 01773 600 211
Email: retainingwalls@hanson.com
EXPOSURE CONDITIONS
Due to a nominal cover of 45mm
(including ∆c of 5mm) and C50/60
concrete used in the manufacture
of the retaining wall units they are
suitable for the following exposure
conditions XC3/XC4, XD3, XS3,
XF4 as defined in BS8500-1:2006.
These cover severe conditions such
as tidal splash / spray zones and
de-icing salts. The limiting crack
width will be taken as 0.3mm
and the design life span will
be at least 50 years.
QuickBuild
Joint Profile
All our standard units are provided
with a unique interlocking detail
which further enhances installation
times through accurate and fast
alignment. The added benefits of
this detail also ensure a strong
and reliable connection detail
which can be made waterproof
with an appropriate sealant.
STEEL GRADES
All steel to be grade S275 UNO
All Anchor Bolts to be grade 8.8
UNO See detailed bolt calculations.
CONCRETE SPECIFICATION
The concrete shall be produced
in accordance with BS8500-2.
Compressive strength class
Maximum water/cement ratio
Minimum cement/
combination content
C50/60
0.35
380 kg/m3
Allowable cement/combinations types
IIB-V IIIA IIIA+SR IIIB IIIB+SR (DC-4m)
Maximum aggregate size
Aggregates
20mm
Freeze thaw resisting
Chloride content class
Cl 0,40
S3
Material
Note 2 – For other material bulk densities please refer to Table 7 within BS 5502-22: 2003
The QuickLift System has
been developed to minimise
lifting times, as well as eliminate
working at height issues. Unlike
many other systems we have
no hidden costs for expensive
lifting gear, or the requirement
to fit lifting attachments.
Using a standard lifting hook,
a telehandler can complete a
lift from delivery vehicle to final
position with minimal secondary
operations, increasing efficiency
against alternative solutions by
some 20%.
FOUNDATION TYPE
Assumed to be uncracked,
mass / reinforced concrete base
of minimum strength 25N/mm2.
This can be designed by Hanson
Concrete or other manufacturers
to resist the overturning and sliding
forces exerted by the retaining wall
unit and to consider the allowable
ground bearing pressure to the
relevant site.
Consistence class
Note 1 – z = depth below rolled surface of grass silage or the compacted surface of bedding (in m).
Silage loading is in accordance with BS 5502-22: 2003
In addition all lifting positions
are located within working height
zones eliminating the need to
work at height.
4 | Hanson Retaining Walls
The grouted anchor bolts will be
post fixed into the suitable base
below and secured with a washer
plate on top of the unit to increase
the bearing capacity onto the base
slab and prevent punching shear of
the bolt head through the unit. The
resistance of the anchors into the
base must be checked by others.
Table 1 – Storage material densities
Density
(kN/m3)
The Hanson QuickLift System
OVERALL STABILITY
The primary job of the unit is to
retain the material behind and to
do this the stem and the base have
been designed to withstand the
applied forces. However, to resist
overturning and sliding with a factor
of safety of 2 for overturning and
1.5 for sliding respectively the
units require anchoring into a mass
or reinforced insitu concrete base
which can be designed by Hanson
Concrete or other manufacturers
to give enough resistance to the
overturning and sliding forces.
DESIGN SCOPE /
PHILOSOPHY
The reinforced concrete
precast retaining wall unit has
been designed in accordance
with the latest set of Eurocodes
in particular BS EN 1997-1:2004 Eurocode 7 - Geotechnical Design
with the UK National Annex and BS
EN 1992-1-:2004 - Eurocode 2 Design of concrete structures
with the UK National Annex have
been used.
HOLDING DOWN BOLTS
M20 (grade 8.8) Anchor with
200mm minimum embedment
into the insitu foundation with
100x100x10mm washer plate with
22mm diameter hole. Hole to be
grouted up using non-shrink grout
with minimum strength of 40N/mm2.
For more detailed downloadable section drawings please see our website
hanson-precast.co.uk/range
REINFORCEMENT NOTES
All reinforcement to be high yield
with a yield strength of 500N/mm2.
All reinforcement to be Type 2
deformed bars including any
specified mesh.
Minimum lap length to be 40 x
smallest lapped bar diameter.
LOADING OPTION 1
 BACKFILL POSITIONED
OVER BASE OF UNIT
LOADING
OPTION 1
 LEVEL BACKFILL
 10KN/M2 SURCHARGE
 D
RAINAGE ASSUMED
TO REAR OF WALL STEM
LOADING OPTION 2
 BACKFILL POSITIONED
OVER BASE OF UNIT
 SLOPING BACKFILL - 35º
 NO SURCHARGE
 D
RAINAGE ASSUMED
TO REAR OF WALL STEM
LOADING
OPTION 2
For more information on Hanson ready-mixed concrete visit
hanson.com/uk/concrete
Hanson Retaining Walls | 5
Hanson Retaining Walls | 6
2
20% increase in
efficiency against
alternative lifting
solutions.
4.0
4.1
4.2
4.3
5
3
Retaining Walls
Storage Estimator
1
The quick way to calculate your project.
QuickLift Handling Guide
hanson-precast.co.uk
1
Hanson has developed a unique
online tool that calculates storage
capacity and the number of Hanson
QuickBuild retaining walls you need,
helping you to plan your project
quickly and easily.
The Hanson QuickLift system
has been developed to ensure that no
additional lifting equipment is needed
other than conventional chains and
hooks for the three lifting points. Unlike
many other systems we have no hidden
costs for expensive lifting gear.
Using a standard lifting hook attachment
a handler can complete a lift from wagon
to final position with minimal secondary
operations, increasing efficiency against
alternative solutions by some 20%.
2
The QuickBuild walling system is
delivered on a flat bed wagon, nestled
for maximum efficiency.
3
The QuickBuild walling system
can be lifted off the wagon using
either the three point QuickLift system
or a traditional fork lift methodology.
NB: Ensure that the loader is of an
appropriate capacity to lift the units.
For individual unit weights please
see unit specification.
Lifting units with the three point
QuickLift system allows the units
to be easily manoeuvred and rotated
180 degrees, thus enabling units to be
placed directly adjacent to their final
position. NB: when determining the
appropriate handler the radial dimension
required to rotate the unit must be
considered and chains set to a max
angle of 65 degrees. A banks man
should be used at all times to ensure
units are safely spotted and manoeuvred.
4.0
Once unit is in position adjacent
to its final location the lifter to the toe
should be removed and the chains to
the two main wall lifters are shortened
and secured to equal lengths ensuring
a level and safe lift.
4.1
The unit can then be lifted slowly
balancing the weight on the back of the
heel. NB: if lifting off a hard surface then
a block or mat should be used to protect
from damage.
4.2
As the unit is lifted the vehicle should
move forward slowly ensuring that the
lifting chains are vertical at all times.
4.3
Once the unit is upright the third
lifter can be re-attached to provide
additional stability and maneuverability,
allowing the units to be lifted clear
of the ground into final position.
5 The QuickBuild wall can then
be easily located into its final position.
When positioning adjacent to another
unit the male connection joint of the
suspended unit should be inserted
into the female then lowered slowly
into position ensuring the units
remain interlocked.
Hanson Storage Estimator
Smartphone scan code
Hanson Retaining Walls | 7
8 | Hanson Retaining Walls
Hanson Retaining Walls | 9
Finishes & Textures
Using state-of-the-art form liner technology the QuickBuild retaining walls
or bespoke precast items can be cast with a preformed finish to its outside
face providing an aesthetically pleasing finish to the end user. We have over
200 designs to choose from and are happy to work with bespoke designs.
For further information please call
or email our dedicated sales team.
Tel: 01773 600 211
Email: retainingwalls@hanson.com
In association with
QuickBuild Brick Finishes
The Hanson QuickBuild walling system is an innovative, factory
fabricated brick and block wall panel fascia system. Utilising high
performance bonding mortar a single brick panel is created which
can be used to finish our QuickBuild retaining walls or other bespoke
concrete such as abutments, flood defence systems and parapet
walls. Fixing up to 150m of panel a day makes this an efficient
and labour saving way of finishing structures.
Rough &
textured
finishes
Stone & rock
finishes
Brick &
masonry
Working with our bricks business
we are able to offer a vast selection
of colours layouts and textures.
For further information call or email:
Tel: 01773 600 211
Email: retainingwalls@hanson.com
Rib & wave
patterns
Sample colours
from the A-Z Guide
To see our A–Z guide visit
hanson.com/uk/bricks
and click on Brick range
 Marne
 Bretagne
 Esterel
 Zyclop
 Nil
 Santa Cruz
 Andulca
 Tigris
 Isar
 Romanche
 Kolcher
 Fulda
10 | Hanson Retaining Walls
Buffs
Browns
Reds
Yellows
Blues & Greys
Hanson Retaining Walls | 11
Bespoke Products
Expertise and capabilities
In addition to our core product
ranges Hanson can provide
a comprehensive design,
manufacturing and fixing service
to meet the requirements of both
building and civil engineering
clients for bespoke precast
concrete products.
Hanson has been designing
precast products and system
solutions for over 50 years using
a dedicated in-house engineering
team who specialise in precast
development. We are committed
to supporting our prospective
clients with this expertise from the
initial outline plan of a project to
full design implementation. We will
ensure that we support and listen
to you our client, providing valued
engineering input throughout
the process to ensure the most
efficient and cost effective solution.
Our precast facility is based at
Somercotes, Alfreton. We have
the capability of manufacturing
units up to 24 tonnes and have
in-house capability for mould
manufacture and cage production.
Recent projects include:
 Ground beams
 Flood defence walls
 Structural building frames
 Parapet units
 Precast floor slabs
 Railway platform units
Specialist
stair flights
Digester
tanks and
other large
bespoke
structures
Walling and
cloaking
Barriers
The Hanson QuickBuild Barrier is
available in two standard sizes of
1500mm and 2500mm, although
we are happy to produce bespoke
lengths if required. The Hanson
QuickBuild Barrier is ideal for
protecting sites that are no longer
in use for a short or long-term
period. The units can be painted
with high visual warning colours,
contact phone numbers to aid
with security or simply company
branding. For details on this,
please contact our sales team.
All concrete security barriers
are manufactured with precast
grooves in the bottom of the
unit to enable easy handling
using a forklift. We can provide
the option to remove these
grooves providing screw out
lifters to the tops of the units
to further aid security if required.
Please note: the QuickBuild
Barrier is not suitable for highway
or structural use.
Omnia Bridge Deck
Barrier weights and dimensions
715mm High x 850mm Wide x 1500mm Long – 1683kg
715mm High x 850mm Wide x 2500mm Long – 2805kg
For further information please call
or email our dedicated sales team.
Tel: 01773 600 211
Email: retainingwalls@hanson.com
Bridge parapets
Escape shafts
Columns and beams
QuickBuild box
culverts and
channel sections
QuickBuild
retaining walls
and flood defence
Should you have a project that you
wish to discuss, please contact our
engineering and sales department
either via email or by calling:
Tel: 01773 602 432
Email: precastuk@hanson.com
12 | Hanson Retaining Walls
Hanson Retaining Walls | 13
Hanson Cement
Our companies and products
Hanson UK is the leading supplier of heavy building materials to the UK construction industry.
We are split into three business lines – Hanson Cement, Hanson Building Products and Hanson
Quarry Products. Hanson UK is owned by the HeidelbergCement Group, which employs over 53,000
people and operates worldwide. Hanson UK employs around 5,000 people across over 300 sites.
For detailed information on all areas of Hanson and our products visit: hanson.com/uk
Hanson UK products and services
Aggregates
•• Sand
•• Gravel
•• Crushed rock
•• Recycled aggregates
Bulk cement products
•• Grey
•• White
•• Blends
•• Regen (GGBS)
Bricks
•• Clay bricks and
brick specials
•• Clay pavers
•• Bespoke clay
products
Contracting
•• Highway maintenance
•• Road surfacing
•• Civil engineering
•• Wind farm construction
•• Waste to energy facilities
•• MOD works
Packed products
•• Cement
•• Ready to use concrete, mortars,
asphalt, aggregate and sand
Blocks
•• Aircrete
•• Aggregate
Precast concrete
•• Retaining walls
•• Culverts
•• Barriers
•• Floors
•• Stairs
•• Structural walls
•• Basements
•• Off-site solutions
Hanson Precast Products
Hanson House, 14 Castle Hill, Maidenhead, Berkshire SL6 4JJ
hanson-precast.co.uk
Asphalt
•• Hot rolled asphalt
•• Stone mastic asphalt
•• Asphalt macadams
Cladding and
render systems
•• Cladding and
render systems
•• External Wall
Insulation (EWI)
•• Structural EWI
•• Fastbrick
Other products
and services
•• SUDS
•• Geothermal
••
•• Roofing
•• Chimneys
••
•• Brick and block
laying contractors
11/2012/2777MICH
Concrete
•• Ready-mixed concrete
•• Ready-mixed mortar
•• Dry silo mortar
•• Screed
•• EcoPlus