Professional Documents
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Geotechnical
ESC 410
Engineering Standard
EARTHWORKS AND FORMATION
Version 2.0
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Document control
Revision Date of Approval Summary of change
2.0 July, 2010 Changes detailed in Summary table below
1.2 December, 2009 Change of format for front page, change history and table of
contents; Minor editing and formatting throughout
1.1 October, 2007 New section 11 on ground anchors to be consistent with ESC 350.
1.0 September, 2006 First issue as a RailCorp document. Replaces C 1100, TS 3421, TS
3422
Contents
1 Purpose, Scope and Application ............................................................................................................ 4
2 References ................................................................................................................................................ 4
2.1 Australian and International Standards ......................................................................................... 4
2.2 RailCorp Documents ..................................................................................................................... 4
2.3 Other References .......................................................................................................................... 4
3 Definitions ................................................................................................................................................. 4
4 Design Requirements .............................................................................................................................. 6
4.1 General .......................................................................................................................................... 6
4.2 Design investigation ...................................................................................................................... 6
4.3 Design flood level .......................................................................................................................... 6
4.4 Formation....................................................................................................................................... 7
4.5 Documentation .............................................................................................................................. 7
5 Cuttings ..................................................................................................................................................... 7
5.1 Excavation ..................................................................................................................................... 7
5.2 Batter Slopes ................................................................................................................................. 8
6 Embankments ........................................................................................................................................... 8
6.1 Embankment Material.................................................................................................................... 8
6.2 Compaction Standards .................................................................................................................. 9
6.3 Sampling and Testing.................................................................................................................... 9
6.4 Drainage Blanket ........................................................................................................................... 9
6.5 Embankment Profile ...................................................................................................................... 9
6.6 Rock Facing of Embankments....................................................................................................... 9
7 Capping Layer........................................................................................................................................... 9
8 Earthworks near Structures .................................................................................................................. 10
8.1 General ........................................................................................................................................ 10
8.2 Construction................................................................................................................................. 10
8.3 Excavation ................................................................................................................................... 11
9 Tolerances for Earthworks .................................................................................................................... 11
9.1 Vertical Tolerances...................................................................................................................... 11
9.2 Horizontal Tolerances.................................................................................................................. 12
10 Drainage .................................................................................................................................................. 12
11 Ground Anchors ..................................................................................................................................... 12
12 Train Examination Areas ....................................................................................................................... 12
13 Walkways ................................................................................................................................................ 13
14 Rehabilitation of Formation................................................................................................................... 13
Appendix 1 Single Track Cross Section ...................................................................................................... 14
Appendix 2 Double Track Cross Section..................................................................................................... 15
Appendix 3 Shoulder Distance ..................................................................................................................... 16
2 References
2.1 Australian and International Standards
AS 1289 Methods of testing soils for engineering purposes
3 Definitions
Borrow Pit: Excavation made for the procurement of material
Capping Layer: Layer of compacted material that provides a sealing layer to the
earthworks.
CBR: Soaked California Bearing Ratio, determined on a compacted sample.
Cohesionless Soil: Material consisting mostly of sand and gravel mixture, generally with
less than 5% fines (i.e., particles finer than 75 m diameter).
Cohesive Soil: Material consisting mostly of silt and clay and has a well-defined
moisture-density relationship when tested in accordance with AS
1289.5.1.1 or AS 1289.5.2.1.
Collapsible Soil: Soil that may suffer a significant decrease in volume under load or
when it becomes nearly saturated, which may have existed in this
metastable state for a long time
Compaction: The process whereby the density of soil is increased by mechanical
means. This typically involves, rolling, impact or vibration, or a
combination of these processes.
Contaminated Material: Material that may contain toxic substances or soluble compounds
harmful to environment, water supply or agriculture.
Cutting: An earth or rock excavation within the works site that is made below an
existing surface to create the railway formation.
Dispersive soil: Soil that has the ability to pass rapidly into suspension in the presence
of water
Earthworks: The activities covered by this specification
Earthworks Level: Level at the centre of the earthworks prior to placing of the capping
layer.
Embankment: An earth or rock fill structure above an existing and/or excavated
surface to create the rail track formation.
Expansive Soil: Soil that will suffer a high volume change when in contact with
water. Any increase or decrease in the moisture content of such soil,
would cause swelling or shrinkage, respectively. This type of soil is also
called Reactive Soil and Swelling Soil.
Formation: The earthworks structure including all Foundation, Structural Treatment
and Capping Layer, on which ballast is laid
Formation Level: Finished level at the centre of the formation preparatory to laying
ballast. It includes the required capping layer.
Formation Width: Width at formation level
Foundation Treatment: A special layer or treated zone at the base of a formation for the
purpose of reinforcing, strengthening or drainage.
General Fill: The zone below the structural zone of the embankment.
Geosynthetics: Prefabricated sheet made of polymeric materials which may be
permeable or non-permeable. This material may be used as filter-
drainage (if permeable) or foundation reinforcement. It includes
geotextile, geonet, geogrid and geocell.
Geotechnical Engineer: RailCorps Principal Geotechnical Engineer or a competent person with
delegated engineering authority for geotechnical design activities
relating to earthworks.
Rail Level: Theoretical level of the running surface of the rails. In the case of
superelevated track, it is the low rail.
Relative Compaction: For cohesive soils, the dry density ratio determined in accordance with
AS 1289.5.4.1, or the Hilf density ratio determined in accordance with
AS 1289.5.7.1.
For cohesionless soils, the density index determined in accordance
with AS 1289.5.6.1.
Relative Density: The field dry density expressed in terms of maximum/minimum
densities established by laboratory test (used for cohesionless soils).
The specific minimum value should be determined with the Earthworks
Specifications.
Right of Way: The strip of land over which railroads are built.
Rockfill: Fill compacted almost exclusively of fragments of broken rock. It
generally consists of a large portion of gravel, cobble, and larger sized
fragments, and may contain large open voids.
Shoulder Distance: Distance from the track centreline to the edge of the formation.
Soluble Soil: Soil containing perishable particles such as gypsum or rock salt.
Stockpile: Placement of material that has been selected, loaded, transported and
unloaded in a heap outside the confines of a borrow pit or of an
excavation that forms part of the works.
Structural Zone: The upper zone of the embankment. Its thickness varies from 500 mm
to 1000 mm, depending on the CBR of the general fill.
Tolerance: Range between the limits within which a dimension or position lies.
Top Soil: A natural surface soil that may contain organic matter.
Unsuitable Material: The material that occurs in the borrow site or below the foundation level
of embankment and is not considered as suitable due to its adverse
4 Design Requirements
4.1 General
Earthworks and formation design includes:
cuttings
embankments
capping layer.
New lines shall be constructed on a corridor wide enough to accommodate earthworks and
formation designed and constructed in accordance with the requirements in this document. The
corridor shall also accommodate associated drainage and access roads as detailed in relevant
RailCorp engineering standards.
In the preliminary assessment, planning and design of earthworks, the following items shall be
considered:
Site investigation
Adjoining property
Preservation items
Rehabilitation
Drainage
Erosion and siltation
Sloping ground
Slope stability
Cuttings and trenches
Retaining walls
Problematic soils requiring special consideration including reactive (expansive) soils,
dispersive soils, collapsible soils, soluble soils, soft-compressible soils, and potential acid or
sulfate soils.
Compaction moisture content
Surcharging of slopes
Calculation of quantities
Geosynthetics (Geotextile, Geogrid, etc.)
Construction vibrations
Non-potable water to be used for soil compaction
Contamination
4.4 Formation
Formation is the earthworks structure including all foundation, structural treatment and capping
layer on which ballast is laid.
The formation for single track mainlines and single track sidings shall comply with the appropriate
dimensions shown in Appendix 1.
The formation for double track mainlines and double track sidings shall comply with the appropriate
dimensions shown in Appendix 2.
The formation for multiple track mainlines and multiple track sidings shall comply with the
appropriate dimensions shown in Appendix 2, subject to the requirement that the water from one
track shall not cross another track to get away. For example, if there are three tracks, there shall be
at least one subsurface centre drain.
Where reduced shoulder distances exist due to physical constraints, an assessment is to be made
of the need for safety refuges, handhold devices and limited clearance signs. The requirements are
specified in ESC 350 Retaining Walls and Platforms.
4.5 Documentation
All activities of earthworks shall be documented. Appropriate documents should be prepared in the
following stages:
5 Cuttings
Design of cuttings shall provide for excavation of material within the limits of the batters including
benching and terracing of cut batters; cleaning of batter surfaces; treatment of cutting floors; and
foundation treatment below the embankment. Cuttings in both soil and rock should provide a
stable, safe foundation for the structure.
5.1 Excavation
Excavation shall be carried out to the lines, levels, dimensions and slopes shown on the Drawings.
The excavated faces shall be neatly trimmed and the top edges of the cuttings neatly rounded.
Under cutting of the slopes shall not be permitted under any circumstances.
Excavation shall be carried out in such a manner as to prevent erosion or slip; working faces shall
be limited to safe height and slopes, and surfaces shall be drained to avoid ponding and erosion.
Batters will generally require fattening at the ends of cuttings owing to the presence of less stable
material. In all cuttings, undulations in the general plane of the batter shall not be permitted.
Overhanging and loose or unstable materials likely to slip shall be cut back, removed or stabilised.
Rock cuttings and exposed surfaces shall be excavated so as to obtain smooth, uniformly trimmed
surface.
Excavation at the base of cutting shall be finished at a level to suit the capping thickness, with
cross falls and cess drains provided.
Prior to placing formation materials and carrying any designed foundation treatment, the cutting
floor shall be tested and inspected by the Geotechnical Engineer.
Slopes shown on the Drawings represent the estimated requirements for the expected types of
material and will be subject to re-determination on the basis of site inspection and investigation
during excavation. Where necessary, advice shall be obtained from the Geotechnical Engineer.
6 Embankments
6.1 Embankment Material
Embankment materials shall comply with Engineering Specification SPC 411 Earthworks Materials.
Embankments are earthfill or rockfill structures above an existing and/or excavated surface to
create the rail track formation.
Structural Zone.
General fill is the embankment below the structural zone.
The thickness of the structural zone (H) is determined by the following relationship with the general
fill in the embankment:
for general fill with CBR* of 3 to 8%, H = 500 mm
for general fill with CBR* of 1 to 3%, H = 1000 mm.
* (Soaked California Bearing Ratio, Standard Compaction).
Material for use in the structural zone shall comply with SPC 411.
Field (in-situ) density and laboratory tests shall be carried out in accordance with Australian
Standards. The test results must be representative of the tested layer at its full depth, width and
length.
Proof rolling shall be carried out on all layers to detect any possible soft or unstable pocket.
The completed batter must be free of rills running down the face of batter. Any loose material on
the batter shall be promptly removed as the work progresses.
7 Capping Layer
Capping is a compacted layer from selected materials that provides seal to the earthwork
underneath. The capping layer shall be constructed in a single layer having a compacted thickness
of minimum 150 millimetres.
The material shall be spread in uniform horizontal layer so as to achieve the specified compacted
thickness for the full width of the capping layer. Capping is to be laid on subgrade with a minimum
CBR of 8%.
Capping material shall comply with Engineering Specification SPC 411 Earthworks Materials.
Compaction shall achieve a minimum dry density of 95 per cent Maximum Dry Density as
determined by AS 1289, Test 5.2.1.
The capping material shall be well mixed throughout the layer so that all voids are filled. The top of
the final layer shall be graded and trimmed, and material shall be added as necessary to produce
an even sealing layer.
8.2 Construction
Care shall be exercised in constructing earthworks within 5m of structures to avoid damage to the
structures.
Non-vibratory compaction equipment shall be used within this distance and adjacent to the
structure as defined in the following table:
Selected backfill shall be placed adjacent to structures in accordance to the following table. The
selected backfill shall consist of a granular material having a maximum dimension not exceeding 50
mm and a plasticity index, determined in accordance with AS 1289.3.3.1, neither less than 2 nor
more than 12. In the table, H = overall height of the structure.
Selected Backfill
Structure Type
Width Height
Bridge Abutments 2m H
Box Culverts, Precast Culverts H/3 H + 300 mm
Corrugated Steel Pipes and Arches 0.5 m H + 500 mm
Retaining Walls H/3 H
Select fill adjacent to structures
The fill shall be placed in horizontal layers with a compacted thickness between 100 mm and 150
mm.
Layers shall be placed simultaneously on both sides of box culverts to avoid differential loading.
Compaction shall start at the wall and proceed away from it.
The existing slope behind the structures shall be cut in the form of successive horizontal terraces,
each terrace being at least 1 meter in width and 600 mm in height.
In case of spill-through abutments, rocks shall not be dumped against the columns or retaining
walls but shall be built up evenly by hand placing around or against such structures.
In the case of framed structures, embankments at both ends of the structure shall be brought up
simultaneously and the difference between the levels of the embankments at the respective
abutments shall not exceed 500 mm unless otherwise specified in the Drawings or within the
specifications.
Adjacent to weep holes, free draining filter material encapsulated in a suitable geotextile fabric
should be placed, horizontally for at least 300 mm from, and vertically for 450 mm above the weep
- hole. Free draining material must be provided by broken stone or river gravel consisting of clean,
hard, durable particles graded from 50 mm to 10 mm such that:
8.3 Excavation
Care should also be exercised when excavating within 5m of structures (for example near
overhead wiring structures when benching into slopes for embankment widening or when
excavating for track reconditioning).
When excavating adjacent to structures, there is a risk that the footings may be undermined or the
structure destabilized, resulting in structural failure and potential collapse.
Excavations in the vicinity of structure footings are therefore not permitted unless documented
engineering advice and approval are obtained.
No excavation should be made within this 5m distance without prior analysis of structure stability
with respect to the effects of the excavation.
No excavation shall be made below the base of the footings of any structure (for example bridges,
retaining walls and station platform walls) without prior analysis of structure stability with respect to
the effects of the excavation.
9.1.2 In cuttings
Floor of cut (top of common earthworks): other than rock + 40 mm to 40 mm
Floor of cut (top of common earthworks): rock + 0 mm to 80 mm
Top of Structural Zone: other than rock + 0 mm to 50 mm
The width of the capping layer from the design centreline to the finished top of embankment slopes
or toe of batters in cuttings shall be not less than the dimensions required by Appendix 3.
When the capping layer is tested with a three (3) metre straight edge laid perpendicular to the
centre line the deviation from design profile shall not exceed 10mm concavity.
10 Drainage
Cess drains; sub-surface drains, top drains and interceptor drains shall be provided for cuttings and
are to comply with the requirements in ESC 420 Track Drainage.
11 Ground Anchors
Ground anchors shall have a design life of 100 years.
Ground anchors shall comply with the requirements of AS 4678 Earth-retaining structures and
Technical Specification S38 Permanent Rock Anchors in RailCorp Engineering Specification SPC
301 Structures Construction.
The design of ground anchors shall include mitigation against the effects of stray currents.
The designer shall specify requirements for testing. Test procedures shall comply with Technical
Specification S38.
The designer shall specify requirements for long term monitoring, if any.
Ground anchors shall not extend under private property without the approval of the Chief Engineer
Civil.
The train examination area is not to be assumed as available for road access purposes.
13 Walkways
Where nominated, walkways are to be provided for staff to walk along the track cess. The
minimum requirement is to cover walkways with a 50mm layer of 10mm single sized aggregate as
in Appendices 1 and 2.
14 Rehabilitation of Formation
In rehabilitating the formation, the following shall be taken into account when preparing the work
plan and design:
CL
Shoulder Distance Shoulder Distance
Rail Level
1.5 :1 1.5 :1
1000 min. Ballast Formation Level
1 in 30 1 in 30 Earthworks Level
1 in 10
Capping Layer
Batter Slope
Natural
Surface
EMBANKMENT
Where space permits,
increase this distance to
allow for mechanized
maintenance equipment.
1000 min
CL
Batter Slope
Batter Slope
Top drain
1.5 :1 1.5 :1
1 in 30 Ballast 1 in 30
Capping Layer
Cess drain
ROCK Additional area to be used
EARTH
for drainage where grade in
cutting is less than 1 in 200
CUTTING or where additional drainage
is required.
CL
1250
50 min.
Rail Level
1.5 :1 1 in 30
1.5 :1
1 in 30 Formation Level
Earthwork Level
1 in 30 1 in 30
Capping Layer
Batter Slope
1.5 1.5 :1
:1 Ballast 1 in 30 Top Drain
EARTH
ROCK Capping Layer
Cess Drain Additional area to be used
for drainage where grade in
CUTTING cutting is less than 1 in 200
or where additional drainage
is required.
Shoulder Distance
3 :1 3 :1
1.5 :1 1.5 :1
1 in 1 in 30 1 in 30
1 in 30
Capping Subsurface Drain
Surface Drain
CENTRE DRAIN
Shoulder
50 min.
1.5 :1
1 in 30
1 in 30
Capping
Shoulder distance
Plain track mm
Main line (Electrified or non-electrified) 4250
Siding (Electrified) 4250
Siding (non-electrified) 3000
Main line or siding with parallel access road (Electrified) 6200
Main line or siding with parallel access road (Non-electrified) 5500
Special Requirements
Shunters and guards parallel walkways 4250
Train Examination areas 5500
Train Examination areas with parallel access road 7750
Clear width of road from back of any structure 3000