ISSUE IX OCTOBER 2017

CONTENTS
T U N N E L S
A case study of tunnels T40-41 in
Sangaldan area / 11
Rock fall mitigation measures above and
near tunnel portals / 24
SISO (An internet based real time data
management system) in T-48 / 38
Comprehensive geotechnical
investigation required in Himalayas / 57

BRIDGES
Pressure grouting
for stabilization of FINANCE
rock mass / 82 Economic rationale
behind USBRL,
Use of Drone a national
survey on USBRL project / 95
Project / 93

EDITORIAL EDITORIAL BOARD ASSOCIATE EDITORS CREATIVE EDITORS

A.K. SACHAN G.S. HIRA B.B.S. TOMAR R.K. HEGDE HUSSAIN KHAN
Chief Administrative Financial Advisor & Chief Chief Engineer/North Chief Engineer/Co/KRCL Dy.CE/Design/USBRL
Officer Accounts Officer/USBRL
and SANDEEP GUPTA A.K. GOYAL MATIN AHMED
Editor in Chief RANDHAWA SUHAG Chief Engineer/South Executive Director /IRCON Secy. to
Chief Electrical Engineer/USBRL CAO/USBRL/JAT
 TUNNELS

A CASE STUDY ON CONSTRUCTION OF ROCKFALL

MITIGATION MEASURES ABOVE AND NEAR TUNNEL
PORTALS ALONG HILL ROAD

Roshan.R.S.V Keywords: Rockfall Mitigation,

Manager, Mumbai-Pune Expressway, Slope
Maccaferri Environmental Solutions Pvt. Ltd., India, Stabilisation, Secured Drapery, Dynamic
Email: roshan@maccaferri-india.com Rockfall Barrier, Tunnel Portal

ABSTRACT
Rockfall mitigation measures are prescribed with the goal of lessening the effect of Rockfall events
and can never be completely eliminating the eminent risk. While exact forensics is not possible,
efforts to establish possible causes would help selecting appropriate measures for stabilization.
There have been several events of rock slide/rockfall near tunnel portal locations of Khandala
and Adoshi on Mumbai Pune Expressway which have been life threatening to the dense traffic on
Mumbai Pune Expressway. This article intends to discuss the construction of various rockslide cum
rockfall mitigation measures executed along the above said expressway.

Figure 1: Location Map showing Mumbai -Pune Expressway SOURCE: WIKIPEDIA

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1. Introduction
The Yashwantrao Chavan Mumbai Pune Expressway
(popularly known as the Mumbai Pune Expressway)
(Figure 1), connecting Mumbai with Pune is India's first
six-lane concrete, high-speed, access controlled express-
way. The location is shown in Figure 1. During monsoon
season, there are problems of rockfall/landslide/ subsi-
dence which have been reported in few locations, along
the Mumbai - Pune express way, which affects the traffic.
These frequent incidences cause disruption of traffic,
property loss and loss of life.
During the period of June to August 2015, there have
been several events of rock slide/ rockfall near Khandala
tunnel portal and Adoshi tunnel portal, which are two of
the many tunnels along the expressway. In July 2015, a
rockslide/rockfall has occurred near the Adoshi tunnel por-
tal on Pune side. In June and August 2015, multiple rock-
slide/rockfall events have occured near Khandala Tunnel
Portal on Pune side. These events have been life threaten-
ing to the dense traffic on Mumbai Pune Expressway and
the immediate requirement of installation of rockfall/ rock-
slide measures have been identiifed (Refer Figure 2).
SOURCE: THE TIMES OF INDIA
2. Scope
2.1 Khandala tunnel location
In this paper, only two main stretches near Khandala tun-
nel portal are considered (Refer Figure 3, Figure 4 and
Figure 5), which are as follows:
n Stretch-K-A: Rockslide area at distance of 130m
away from Khandala tunnel Pune side portal
n Stretch-K-B: Between the rockslide location and
Khandala tunnel Pune side portal (including slope
above tunnel portal)
2.2 Adoshi tunnel location
In this paper, only two main stretches near Adoshi tunnel
portal are considered (Refer Figure 6, Figure 7 and Figure
8), which are as follows:
n Stretch-A-A: Between Adoshi tunnel Pune
side portal and Valley (adjacent Mumbai Corridor)
n Stretch-A-B: Slope above the Adoshi tunnel
(adjacent to Pune Corridor)

Figure 2: Newspaper
excerpt showing
various rockfall
events happened
along Mumbai Pune
Expressway from
June to August 2015
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Figure 3: Google imagery showing details of main stretches near Khandala tunnel (Pune side) Earth

Figure 3: Photographs showing Stretch-K-A (Rockslide area)

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Figure 5: Photographs showing Stretch-K-B

Figure 6: Google Earth imagery showing details of stretches near Adoshi tunnel side)

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Figure 7: Photograph showing Stretch-A-A

Figure 8: Photograph showing part of Stretch-A-A and Stretch-A-B

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3 Mitigation Measures
3.1 Khandala tunnel location
n Stretch-K-A: scaling, rock slope Stabilisation sys-
tem, sub-surface drainage system
n Stretch-K-B: scaling, rockfall mitigation system
(secured drapery system with mesh system, top,
bottom and surface anchors), sub-surface drainage
system
3.1.1 Scaling
As per IRC-HRB-Special Report-23, loose Scaling is one
of the 'Rockfall Prevention Measures'. 'Rockfall
Prevention Measures' are defined as 'measures which
increase the resisting forces or reduce the forces causing
the rockfall and thus prevent any detachment and move-
ment of rocks'.
This measure is one of the basic rockfall mitigation
measure employed to improve rock slope stability and
reduce surface instability by removing the unstable rock
mass. This activity shall be carried out before carrying out
other mitigation measures proposed over the slope.
3.1.2 Secured Drapery system
As per IRC-HRB-Special Report-23, Surficial
Strengthening/Cortical strengthening System (also known
as 'Secured Drapery system') is one of the 'Rockfall
Retention Measures'. 'Rockfall Retention Measures' are
'measures are taken to contain or retain the rock masses
which are on the verge of movement'.
Surficial reinforcing system/ secured drapery/ cortical
strengthening system is aimed at the stabilisation of
the rock, with depth of unstable rock mass less than
or equal to 2m. In this system, the weathered rock
slope surface is draped with one or combination of
meshes with the help of surface, top and bottom
anchors. Any loosened rock mass sliding down the
slope, towards the toe, shall be contained between the
surface anchors.
However, this sliding of rock mass happens in a
controlled way between the anchors and can be removed
for in a systematic way from within the draped system.
In this type of system, surface anchors are installed
along the slope of the rock at specified intervals along with
mesh systems.
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In this system, revetments are provided along the slope
of the rock at specified intervals along with one or combi-
nation of the meshes- Mono oriented Reinforced Steel
Wire Mesh (steelgrid MO) and /or High Strength
Rhomboidal cable Wire Rope Panel (High Energy
Absorption (HEA) Panel). When steelgrid MO alone is
used as mesh system in secured drapery system, diagonal
cable wire ropes are installed over the same.
3.1.3 Sub-surface Drainage system
Drainage measures also are one of the 'Rockfall Prevention
Measures' (Refer section 3.1.1 for definition) as per
IRC-HRB-Special Report-23. As water ('force causing
rockfall' as per aforesaid definition) is one of the main trig-
gering causes of a rockfall/rockslide, it has to be effective-
ly drained and channelised to reduce the impact.
Drainage pipes (Perforated PVC pipes wrapped in non
-woven geotextile) are placed in inclined upward drilled
holes and/or inclined short drainage holes are drilled
upward in near the toe of rock slopes. This facilitates dip-
ping the phreatic surface and helps decreasing the pore
water pressure in rock / soil slopes. In general, it enables
controlled drainage in such cases.
3.1.4 Rock slope Stabilisation system
As rockslide was the problem identified in stretch-K-A,
slope stabilization measures are proposed in this location.
Unlike in stretch K-B where secured drapery system was
employed, for depth of unstable Rock mass more than 2m
from surface or where deep seated failure of rock mass
anticipated, rock slope stabilization methods are consid-
ered. These issues are primarily treated using long nails of
varying depth, spacing and yield strength as per the design
requirements and using appropriate mesh facia system-
Steelgrid MO and HEA Panel.
This also can be considered one of the 'Rockfall
Prevention Measures' (Refer section 3.1.1 for definition)
as per IRC-HRB-Special Report-23.
3.2 Adoshi tunnel location
n Stretch-A-A and Stretch-A-B: scaling, rockfall mit-
igation system (secured drapery system with mesh
system, top, bottom and surface anchors and
dynamic rockfall bar-riers), sub-surface drainage
system
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3.2.1 Scaling
Refer section 3.1.1.

3.2.2 Secured Drapery system

Refer section 3.1.2

3.2.3 Dynamic Rockfall Barrier

As per IRC-HRB-Special Report-23, Rockfall barrier is
one of the 'Rockfall Protection Measures'.'Rockfall
Protection Measures' are 'measures which don't affect or
prevent the process of rock detachment and guide the
falling rock and control the distance and direction in
which the falling rock travels this protection the area
prone to hazards'.
The rolling down of boulders from upslope is antici-
pated along stretch-A-B and some part of stretch-A-A.
This is because of the presence of some continuous slopes
with weathered surfaces or containing boulders either veg-
etated or clean, are prone to loosening of rock masses and
roll down of it. Anticipated sizes of rockmass along with
slope angles were modeled to see the impact energy gener-
ated by such masses at rockfall barriers placed at best suit- Figure 9: Photographs: Left-Temporary Gabion wall, which is
able locations and of a height to resist the impacts and used for lane protection on road. right-sand layer of approx.
200mm thick is placed between the Gabion wall and the slope
rockfall barrier of 1500 kJ capacity and 4m high was pro-
toe for dampen the impact of fallen rock, before hitting the
posed in these stretches. Gabion

3.2.4 Sub-surface Drainage system
Refer section 3.1.3 for definition of drainage measure.
Short drainage holes (in upward direction) are drilled near
the toe of rock slopes. This facilitates dipping the phreatic
surface and helps decreasing the pore water pressure in
rock / soil slopes. In general, it enables controlled drainage
in such cases.
4.0 Construction of Mitigation Measures
4.1. Khandala tunnel location
Rockfall mitigation measures propsoed for Stretch-K-A
and Stretch-K-B of Khandala stretch primarily comprised
of nailing operation and installation of mesh (Steelgrid
MO and/or HEA panel). The first operation for imple-
mentation of mitigation measures was to remove vegeta-
tion, from the area where mitigation measures are to be
installed. Shotcrete had been removed in certain stretches
where the shotcrete has already developed cracks or where
there was a need to inspect the rock mass behind the shot-
crete. Loose scaling of the area was done to remove any
loose boulders which can be dislodged manually using
crow bar. For these expert climbers had climbed the verti-
cal cut and checked the individual blocks, which can be
removed from the cut face or steep slope area. Traffic block
was required during the loose scaling operation and which
were carried out in coordination with concerned authori-
ties.
The next operation was to install the mesh and rock
bolts as per the approved drawings, which is explained in
following paragraph. Some modification to the scheme
proposed in the drawing was done giving due considera-
tion to the site situation post loose scaling operation or
development during installation. Such modifications were
brought to the notice of Engineer and recorded.
Nailing was done on the sloping surface above the crest
of the vertical cut, followed by installation of nails on ver-
tical face (Refer Figure 10 for drilling activities). After
placement of the bolts into the drill hole, the hole was air
flushed and then grouted with neat cement grout and

HIM PRABHAT 30 OCTOBER 2017

Figure 10: (Left) Photographs showing drilling activities
Figure 11: Photographs- left-mesh installation in stretch-K-A right
Photograph showing mesh installation above tunnel portal location
Figure 12: Photograph drainage pipes working effectively during
monsoon of 2016

non-shrink admixture. After the installation of nails,

Steelgrid MO and /or HEA panel were installed along the
rock surface (Refer Figure 11). The meshes shall be
wrapped around the longitudinal wire rope (top support
rope) passing through the topmost row of nails on the
sloping surface. The meshes shall also be wrapped around
bottom support cable (bottom support rope) passing
through bottom row of anchors. In stretch-K-A, belting
(using cable wire rope spaced vertically at specified dis-
tances) was provided in the top portion of the cut consist-
ing of vertical and sub-horizontal joints. In portion of
stretch-K-B, where Steelgrid MO alone was installed, diag-
onal wire ropes were installed above the same.

OCTOBER 2017 31 HIM PRABHAT

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Figure 13: Photographs showing completed works on stretch-K-A

and stretch-K-B

Drainage pipes (50mm dia PVC pipes wrapped with non-

woven geotextile) were installed in the following configu-
ration:
n Stretch-K-A: 7m long at 4m c/c (in two rows) and
10m long at 4m c/c (in two rows)
n Stretch-K-B: 7m long at 5m c/c (in two rows)
In addition, drainage holes of 40mm diameter, 500mm
long, were made at 3m c/c spacing where shotcrete was pres-
ent, so that water pressure developed in the face of rockmass
due to the presence of shotcreting can be dissipated.
The photographs of completed rockfall mitigation
measures are included in Figure 13.

4.2 Adoshi tunnel location

Rockfall mitigation measures implemented for Stretch-A-
A and Stretch-A-B of Adoshi stretch primarily comprise of
nailing and installation of mesh (Steelgrid MO and/or
HEA panel) and installation of Dynamic Rockfall barrier.
Adequate safety arrangements were provided on/near the
Figure 14: Photograph showing temporary drums (filled with
sand/stone) and signs are used during installation works
Figure 15: Photograph showing temporary Gabions are used for
lane protection on road

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expressway as per the site requirement. (Temporary filled
drums (Figure 14), Temporary Gabion units (Figure 15),
Diversion signs (Figure 16) etc.)
The first operation for implementation of mitigation
measures was to remove vegetation, from the area where
mitigation measures were to be installed. Then the loose
scaling operation (Figure 17) and cleaning off debris/ frag-
ments (Figure 18) were completed. The traffic blocks
required (Figure 16) for the same was carried out in coor-
dination with concerned authorities.
The next operation was to install the mesh and rock
bolts as per the approved drawings, which is explained in
following paragraph. Some modification to the scheme
proposed in the drawing was done giving due considera-
tion to the site situation post loose scaling operation or
development during installation. Such modifications were
brought to the notice of Engineer and recorded.
Nailing was done on the sloping surface above the crest

Figure 16: Photographs showing partial Lane closures during the loose scaling operations. Figure 17: Photographs showing loose scaling
activities. Figure 18: Photographs showing clearing / cleaning of road after loose scaling activities

OCTOBER 2017 33 HIM PRABHAT

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of the vertical cut, followed by installation of nails on ver-
tical face (Refer Figure 19 for drilling activities). After
placement of the bolts into the drill hole, the hole was air
flushed and then grouted with neat cement grout and
non-shrink admixture. After the installation of nails,
Steelgrid MO and /or HEA panel were installed along the
rock surface (Refer Figure 20). The meshes shall be
wrapped around the longitudinal wire rope (top support
rope) passing through the topmost row of nails on the
sloping surface. The meshes shall also be wrapped around
bottom support cable (bottom support rope) passing
through bottom row of anchors. Additional cable wire
ropes were installed above tectonic joints of stretch-A-A.
Figure 19: Photographs showing drilling activities. Figure 20: Photographs showing mesh installation activities
HIM PRABHAT 34 OCTOBER 2017
The location of dynamic rockfall barrier was finlaised
suitable from point of views of capturing maximum
rolling/sliding stones by covering necessary width, anticipat-
ed bounce heights and construction ease and in line with
approved drawings. After finalizing the location, the align-
ment of the rockfall barrier was marked out on site at a spac-
ing of approx. 10m c/c. The material was then shifted to the
crest location, where rockfall barriers were proposed. The
area was then levelled off by construction of plinth to create
level surface for installation of base plate of post. Installation
of posts were then carried out with help of base anchors and
base plates. The location of upslope anchors and lateral
anchors were marked out on site as per installation manual
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Figure 21: Photographs: left- showing shifting of post to crest and erection of the same, right- installation of interception mesh.
Figure 22: Photographs showing installation activities of dynamic rockfall barrier. Figure 23: Photographs showing installed dynamic
rockfall barrier. Figure 24: Photographs showing completed works on stretch-A-A and stretch-A-B

OCTOBER 2017 35 HIM PRABHAT

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and installation of the same were done. After the installation
of upslope anchors and lateral anchors, the posts were con-
nected to the upslope anchors with help of bracing cables.
The upper and lower longitudinal cables were installed on
the posts. The interception mesh consisting of ring net and
DT mesh was then installed with the position of secondary
mesh towards the upslope side. The overall stertch length of
dynamic rockfall barrrier was 610m (Refer Figure 21, Figure
22 and Figure 23).
Drainage holes of 40mm diameter, 500mm long, were
drilled at 3m c/c spacing were sub surface drainage was
observed. The photographs of completed rockfall mitiga-
tion measures are included in Figure 24.
5. Testing
Pull-out tests were carried out on the nails installed to ascer-
tain the nail capacity. Refer Figure 25 for details of pull out
test setup. The tests were carried out in all locations as per
Indian standard- IS: 11309. This was done to ascertain the
pull out strength of nail considered in the design.
Figure 25: Photographs of the setup of the test frame for the Soil
Nail
HIM PRABHAT 36 OCTOBER 2017
6. Maintenance Activities
The effective implementation of maintenance activities
aids in continued effective working of the mitigation
measures.
The maintenance of drapery system primarily com-
prises inspection of any detachments of rocks behind the
drapery system on regular basis and repair/replacement of
affected components as per requirement after any rockfall
event so that the drapery system functions as designed. A
maintenance program must also be undertaken for clean-
ing, repairing and retrofitting the systems, as required,
preferably before the start of monsoon in the area every
year (Refer Figure 26 and Figure 27).
Figure 26: Photographs:-left- Rock mass which are caught
between mesh are being pulled down manually, right- Rock mass
which are caught between mesh are being pulled down by
loosening diagonal cable wire rope
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ance and deposits that are allowed to change the local

slope morphology may affect the trajectory of falling rocks
and therefore the suitability of the installed barrier. A
maintenance program must also be undertaken for clean-
ing, repairing and retrofitting the systems, as required,
preferably before the start of monsoon in the area every
year.

7. Summary and Conclusions

Figure 27: Rock mass removed out of installed mesh during
maintenance activities. Figure 28: Photograph showing cleaning
off the debris from upslope side of rockfall barrier installed
above Adoshi tunnel
The regular monitoring of the various structural and
connecting elements of the dynamic rockfall barrier is
required. It is also necessary to check the interception
nets/panels, which must be kept free of obstacles of signif-
icant size (e.g. larger rocks or trees) that may affect the
dynamic range of the system in the case of a significant
impact. The presence or accumulation of soil etc. behind
or on the barrier may have effects on the system perform-
The rockfall cum rockslide problem along Mumbai - Pune
Expressway have caused accidents the past. The rockslide
cum rockfall mitigation solutions near major stretches of
Khandala - Pune side portal include secured drapery sys-
tem and rock slope stabilization. The rockslide cum rock-
fall mitigation solutions near major stretches of Adoshi
tunnel Pune side portal includes secured drapery system
and dynamic rockfall barrier.
The specifications of meshes installed (Steelgrid MO
and HEA panel) and dynamic rockfall barrier are con-
forming to IRC-HRB-Special Report-23. These solutions
were arrived at based on the inputs derived from the inves-
tigations/studies carried out, and best possible engineering
judgment of the designer taking into account views of
expert Geologists and Geotechnical Engineers. The moni-
toring and maintenance of installed mitigation measures,
during and post construction of the proposed rockfall mit-
igation measure also plays a major role in its performance.
The scope of mitigation works mentioned in the paper
was successfully completed in December 2016 and has
survived monsoon season of 2016 without any reported
rockfall accidents.
The next phase of works covering the slope area on
Mumbai side of the rockslide area has been initiated by
MSRDC (Maharashtra State Road Development
Corporation).

References
1) Gharpure, A. D. (2015): Understanding Risk Assessment and Mitigation of Rockfall
Events Through a Case Study of Ghat Section of Mumbai-Pune Expressway. Pune:
Proccedings of 50th Indian Geotechincal Conference (Pune Chapter).
2) IRC-HRB. (2014). IRC-HRB: Special Report-23. State of the Art: Design and
Construction of Rockfall Mitigation Systems. New Delhi.
3) BIS. (1985/ r. 2001). IS-11309: Method of conducting pull-out test on anchor bars and
rock bolts. New Delhi.

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