Maccaferri Railway November 2021 Eng

EFFICIENT SOLUTIONS FOR
RAILWAY INFRASTRUCTURE
Date November, 2021
Author Officine Maccaferri S.p.A.
All rights reserved. Reproduction in whole or in part is prohibited without the prior written consent of Officine Maccaferri S.p.A.
TABLE OF CONTENTS
MACCAFERRI AT A GLANCE
THE UNIQUENESS OF MACCAFERRI
SOLUTIONS FOR THE RAILWAY WORLD
2
MACCAFERRI AT A GLANCE
“140 years ago, we invented modern gabions

and dramatically changed the civil engineering
Founded in 1879, Officine Maccaferri landscape. We are still changing it today”
is based upon long-held values of
innovation, integrity, excellent service
and respect for the environment.
We are a leading international

provider of advanced solutions to the
civil, geotechnical and environmental
construction markets.
We deliver solutions from retaining

walls to hydraulic works and from
rockfall mitigation systems to soil
reinforcement.
3
THE UNIQUENESS OF MACCAFERRI
“140 years
As manufacturer as well as designer, we can combine products, creating
ago,
tailor-made
we invented
solutions
modern gabions
M More than 140 years of technical experience landscape. We are still changing it today”
M Global presence and local mindset
M Internal R&D centre, experimental labs and testing facilities
M World’s widest portfolio of products and solutions
M Proprietary software developed with leading universities
4
MACCAFERRI AROUND THE GLOBE
Sales in 100+ countries
Revenues ~ 500 M€
2,500+ employees
25+ factories
60+ subsidiaries
5
OUR CENTRE OF KNOWLEDGE
Maccaferri has a centre of excellence entirely dedicated to research and development, concentrating
in a single place the capital of knowledge and know-how: in Bolzano (Italy) the Maccaferri Innovation
Center (M.I.C.) is constantly working to innovate our products and solutions
MIC in NoiPark research centre Quality Control Tests Testing Facility
6
RAILWAY SECTOR APPLICATIONS
We cover a number of applications within the railway sector, assisting our clients through all the different
project stages. Our solutions start from the design of the project, with the simple aim of solving a
problem. Then, we proceed through all the stages of development, in close synergy with our clients;
landscape. We are still changing it today”
manufacturing, designing and installing solutions throughout the world.
Basal Retaining Walls & Drainage of

Soil Reinforcement Structures Erosion Control Rockfall Protection
Reinforcement & Snow Barriers
Hydraulic Works Safety & Noise Soil Stabilisation Fencing & Wire
Tunnelling
Barriers & Pavements
7
EROSION CONTROL
EROSION CONTROL SOLUTIONS
Typical Applications for Railway Embankments
EROSION
CONTROL
Protection of vulnerable soils slopes,
reducing erosion through stabilization.
Maccaferri geosynthetics solution
prevent erosion phenomena due to
wetting and drying, forces from wind,
rain and gravity.
9
DESIGN CHALLENGES IN THE RAILWAY INDUSTRY
Erosion control of embankment slopes
COMMON PROBELMS SOLUTIONS

Embankment slope failure
Water seepage into embankment Reinforced geomat capable to avoid

washout and top soil erosion
Superficial erosion due to weather
elements
10
Geosynthetics product for avoiding slope surface erosion
TECHNICAL ENVIRONMENTAL
Superficial erosion protection from impact Natural revegetation process
of rain drops and strong wind facilitated by the sunrays that pass
Surface stabilization and liquid conveying trough the geomat
OUTSTANDING
LIGHT
PENETRATOIN
11
WHAT ARE THE KEY REVEGETATION FACTORS?
KEY INDICATORS
Light Penetration
Thickness
Color
Water absorption
Weight
Roughness and run-off
Uniformity
12
GEOSYNTHETIC APPLICATION FOR SURFACE EROSION
Geomat – MacMat® are made of synthetic material filaments, tangled together to form a highly deformable
layer 10-20 mm thick, featured by a very high porosity (greater than 90% on average).
They can be used on slopes, along the banks of canals and river courses, or to convey liquids (drainage) in
association with geotextiles and/or geomembranes.
13
OUR EXPERIENCE
Securing the way to Russia’s key economic venture
640.000,00 m2 of
MacMat-R were used
Slope erosion
protection
Frosting/defrosting
cycle resistant
material
14
EROSION CONTROL & SLOPE STABILIZATION
A graded range of products to addressany level of

erosion risk in a project
- Biomac® biodegradable geomats

- MacMat® reinforced and unreinforcedgeomats
- MacTex® geotextile for Erosion Control
- Traditional double twist steel wire-based
products
MacMat® used in conjunction with soil nails, United Kingdom MacMat® R, New Zealand
15
Strength points
• Superficial erosion prevention

• Re-establishment of vegetation
• Full-scale test executed by SKZ (Germany)
MacMat® R, France BioMac®, Philippines
16
Beaver-netting, Germany
17
18
19
Our goal is to deliver safe solutions that integrates into in the environment, in a way
that considers wildlife already living around it.
20
MACCAFERRI SOLUTIONS
Solution to prevent burrows
We offer a wide portfolio of solutions that dissuade animals from burrowing, inducing those animals to dig
their lodges non-critical areas
RENOMESH RENOMESH BIO RENOMESH GREEN
ANTI-BURROWING ANTI-BURROWING ANTI-BURROWING

SOLUTION SOLUTION SOLUTION
EROSION CONTROL LONG TERM

EROSION CONTROL
21
22
23
24
25
26
27
28
29
SAFETY & NOISE BARRIERS
Solutions to mitigate noise pollution and to enhance safety EN 14388:2015 & EN 1973-6: 2013
• Simple to construct reinforced soil bunds and gabion

walls can provide acoustic and visual screening
• New technology safety barriers can prevent hostile
vehicle intrusion into restricted areas
• Aesthetically pleasing and unobtrusive solutions for
urban landscape
• Tested systems in accordance with international
standards Green SoniMac Noise Barrier, Spain
Barrier to prevent
vehicles from
accidentally leaving
motorway or railway
Safety Barrier along the high speed rail, Italy Safety Barrier against vehicle intrusion, Principality of Monaco
18
High Speed Rail, Italy
VISTA ASSONOMETRICA
VISTA DI INSIEME DUNE E TERMINALI

TERMINALE 1
BIFACCIALE INCLINATO 60/60 SEZIONE TIPO
5.11
4.35
GABBIONE DI CHIUSURA
TERMINALE MI 3.59
2.82
VISTA ASSONOMETRICA 2.06
1.30
GABBIONE DI CHIUSURA GABBIONE CHIUSURA
GEOGRIGLIE
3.00
0.66
°
60
60
°
2.00
0.30
4.76
TERMINALE 2
0.55
TERMINALE BO
DUNA 90/60
4.00
Double sided berm – Duna System

18
High Speed Rail, Italy
VISTA ASSONOMETRICA
TERMINALE 1
GABBIONE DI CHIUSURA
2.00
TERMINALE 2
0.55
DUNA 90/60
4.00
18 Double sided berm – Duna System

DB Schenker, Leipzig, Germany, 2016
Double sided berm with Green Terramesh®

18
Wasserburg, Bavaria, Germany, 2014
Wasserburg, Green Terramesh®
18
18

18
RETAINING WALLS & SOIL REINFORCEMENT
RAILWAY INFRASTRUCTURE
RETAINING WALLS &

SOIL REINFORCEMENT
Soil mechanical proprieties improvement
thanks to geogrids which allow to design and
build a safer embankment reducing its footprint
Soil Mechanical Properties Enhancement

Embankment slope failure
Geosynthetics embankment slope
Differential settlements reinforcement
Interaction with urban environment Vertical concrete faced soil reinforcement

40
Soil Mechanical Properties Enhancement
Tensile strength Lateral confinement Load distribution Superior behavior

enhancement increase angle increase under seismic loads
41
Benefit for the railway industry
TECHNICAL ENVIRONMENTAL ECONOMICAL
Smaller embankment Re-use in situ soil as
print structural backfill Cost effective
Shorter ballast height Lower CO2 emission Fast installation
Higher SF static and Low environmental impact Low maintenance
dynamic condition EPD certified products
42
Our wide range of products and extensive experience enable us

to meet client’s needs
• We can offer a wide variety of face finishes including

vegetation, rock, concrete block and panel. If requested we
can enhance or, alternatively, prevent vegetation growth
• The use of our products maximises the opportunity to reuse

site-won materials as structural backfill, embrace
sustainability and reduce polluting truck movements
• Our solutions accommodate differential settlements and

seismic loads better than rigid solutions MacRes® Concrete Panel Wall, United Kingdom
Gabion Wall, United Kingdom Reinforced Soil Wall, Indonesia
43
Maccaferri can offer
• Products and solutions that enable the construction of

super-tall hybrid structures such as the world tallest
retaining wall (74-m high structure at the SikkimAirport,
India)
• ParaDrain®, a unique and new generation geogrid,

combining reinforcement and drainage in one product
• MacSTARS software, a renowned suite to assist

engineers in the design of retaining walls and reinforced
soil applications, optimizing solutions to balance
technical performance, environmental compatibility and
architectural harmony
MacRes® Concrete Panel Wall, Belgium
ParaDrain® close up, Italy
44
Hàjek – Dalovice, Czech Republic
Cross Section at km 181,625 direction Cheb Cross Section at km 181,625 direction Cheb
Reinforced earth structure with Green Terramesh®
45
Cross Section at km 181,625 direction Cheb, Cross Section at km 181,625 direction Cheb,
Sept 2020 Sept 2020
46
47
Sept 2020
48
49
Completed, Sept 2020
50 Completed, Sept 2020

Copenhagen, Denmark
The challenge
Construction of a new Metro line connecting
Airport area with central Copenhagen
The Solution
Due to the location (urban area) the solution
was adopted for its high environmental
friendliness (visual barrier) in relationship
with the cost effectiveness, and the need to
have a vegetated wall face. The high fire
self-estinguishing ability of the steel made it
prefer to other alternative soil reinforcement
systems.
Beginning of works: 06/2004

End of works: 12/2005
51
Copenhagen, Denmark
52
Copenhagen, Denmark
53
Copenhagen, Denmark
54
Copenhagen, Denmark
TYPICAL SECTION H=2.80 m
METRO PHASE 3
Contractor: Hoffmann-Arkil Novejfa (H.A.N.)
Engineer : E&G & Maccaferri
System Used: Green Terramesh® & Duna Walls
18
Copenhagen, Denmark
18
Copenhagen, Denmark
18
WATER MANAGEMENT
WATER MANAGEMENT
With thousands of projects carried out around the world, we support

clients by selecting the most appropriate solutions
- Railway bridge scour protection (piers and abutments)

- Longitudinal structures to protect river banks
- Channeling works
- Waterproofing of lakes and channels
Bridge abutment scour protection, Brazil
Channeling works, South Africa Reno Mattress® underwater installation, France Bridge piers scour protection, USA
59
WATER MANAGEMENT
Reno Mattress Plus

with X-Ties
The PoliMac® coating

Vertical standing double gives outstanding
diaphragm make filling protection against
operation easier. mechanical loads and
chemical aggressions
X-Tie is the experimentally

developed and patented tie to
maximise the structural
resistance of the mattress
60
WATER MANAGEMENT
0,9 Rip Rap

Standard Mattress
0,8
Reno Mattress Plus
Thickness of the revetment [m]
0,7 with X-Ties

0,6 - 73%
0,5
0,4
0,3
- 54%
0,2
0,1 Reno Mattress Plus
0,0 Flume testing

200 250 300 350 400 campaign executed
between 2019 and
Shear Stress [N/m2] 2020
61
In application with high
values of shear stress,
Reno Mattress Plus is
over 73% more efficent

than rip-rap
62
WATER MANAGEMENT
30 Rip Rap
Standard Mattress
kgCO2 eq per m2 of bank protection*
25 Reno Mattress Plus

with X-Ties
20
15 - 82%
10
- 28%
5
Reno Mattress Plus
0 Flume testing
200 250 300 350 400 campaign executed
between 2019 and
Shear Stress [N/m2] 2020
*Data are based on Environmental Product Declarations (EPD)

63
WATER MANAGEMENT
64
WATER MANAGEMENT
65
WATER MANAGEMENT
66
WATER MANAGEMENT
67
ROCKFALL PROTECTION
ROCKFALL PROTECTION
Our wide variety of rockfall and natural hazard mitigation systems

offers the highest level of performance in the industry, allowing
designers to select the optimum solution for their specificapplication
Developed in conjunction with engineers and international
contractors, our Rockfall Systems are durable, effective and
simple to install
- Simple Drapery Systems
- Dynamic Rockfall Barriers (from 100 kJ to 8,600 kJ impactenergy)
- Embankments (above 8,600 kJ impact energy)
- Debris Flow Barriers
- Soil Nailing
Soil Nailing, Australia Drapery System, United Kingdom
69
ROCKFALL BARRIERS
• Tested and certified in accordance with the

European Test and Approval Guideline 27
(ETAG 27) of the European Organisation for
Technical Approvals (EOTA)
• Patented energy dissipation systems to absorb
the kinetic energy efficiently with industry leading
after-impact residual height and deflection limit
• Ease of installation in the most severe
conditions
Rockfall Barrier and Drapery System, Ireland Rockfall Barrier Testing Facility, Italy
70
SOIL NAILING
Soil nailing is a technique used to stabilize slopes with low cohesion or

purely frictional behavior.
It is recommended for soil with no groundwater presence, partially saturated,

with a miscellaneous granular matrix (from sandy gravel to clayey silt) and
with a low to medium cementation grade, or for altered rocks (Cola et al.,
2011)
Nails increasing the

stability of the
slope
Soil Nailing
Facing contains the soil

movement
between nails
71
SOIL NAILING
The Facing in the British Standard
“Facing: covering to the exposed face of the reinforced ground that may provide a
stabilizing function to retain the ground between soil nails, provide erosion protection
and have an aesthetic function.”
BS EN 14490:2010
THE
FACING
72
DEFINITION OF THE SOLUTION: MAC S-DESIGN
Maccaferri has a centre of excellence entirely

dedicated to research and development,
concentrating in a single place the capital of
knowledge and know-how: in Bolzano (Italy)
the Maccaferri Innovation Center (M.I.C.) is
constantly working to innovate our products
andsolutions
developed in collaboration with Politecnico di Milano
73
DEFINITION OF THE SOLUTION: MAC S-DESIGN
Mac S-Design has been developed

is a web-based tool accessible via edesign.maccaferri.com with a modular approach:
Mac S-Design
Pre-Analysis
Design Phase
Phase
Mesh Anchor
Design Design
74
ROCKFALL PROTECTION
EBA Certified – Maccaferri SteelGrid HR30
75
ROCKFALL PROTECTION
Frauenberg, Germany
76
ROCKFALL PROTECTION
Frauenberg, Germany
77
SOIL STABILIZATION / GROUND IMPROVEMENT
SOIL STABILIZATION
The base of the embankment

Optimization of the dynamic load transfer
High dynamic loads
Infrastructure permanent damages Long term permanent strength gains
79
SOIL STABILIZATION
Bearing Capacity
“Effective load distribution over

the widest area possible
is the key principle to limit
settlement
also on poor quality soils…
..but due to technical constraints
embankment footprint is often
limited”
TECHNICAL CONSTRAINTS
Limited Space / Existing Infrastructure

Ground Geomorphology
80
SOIL STABILIZATION
WITH
GEOGRID REINFORCEMENT
WHITOUT
REINFORCEMENTS
81
OUR EXPERIENCE
Railway line Plovdiv-Burgas, Bulgaria
Construction over soft soil

without differential settlement
Important reduction of ballast

height
Project cost and time

reduction
82
BASAL REINFORCEMENT
BASAL REINFORCEMENT
In case of piled embankements, the use of ParaLink® and “140 years ago, we invented modern gabions
ParaGrid® enables an increase in the pile spacings and dramatically changed the civil engineering
reducing construction cost and time
Reliability: our geogrids are amongst the most tried
and tested in the world, offering 120 year design life
Design optimisation: the use of Maccaferri software
allows to design the most suitable solution to solve
weak ground problems
Easy to install systems: ParaLink® and ParaGrid®
installation requires 1 excavator and 4 workers only
ParaLink® offers up to1600 kN/m resistance and the
industry best installation damage performance
84
BASAL REINFORCEMENT
Our geogrids are widely used
• As basal reinforcement of the embankments tracks based on cohesive soils in order to improve the stability of theembankment
and to limit the differential settlements; often in combination with Prefabricated Vertical drains
• As basal reinforcement of the embankments tracks based on cohesive soils in order to avoid any settlements especiallywhen
embankments were connected to rigid structures (e.g. bridgeabutments)
In case of enlargement of the existing embankment: very severe applications where no settlement in the new portion of the
embankment is acceptable
BASAL REINFORCEMENT APPLICATIONS ALONG THE ITALIAN HIGH SPEED RAIL
Embankement Location Product
RI 01 Rome ParaLink+ParaGrid
RI 83 Parma ParaLink ParaGrid®

Tensile Strength from 30 to 200 kN/m
RI 84 Parma ParaLink
RI 108 Bologna ParaLink+ParaGrid

ParaLink®
RI 107 Bologna ParaLink+ParaGrid Tensile Strength up to 1600 kN/m
RI 161 Reggio Emilia ParaLink+ParaGrid

85
BASAL REINFORCEMENT
Italian High-Speed Rail
86
BASAL REINFORCEMENT
Jutland, Denmark
87
BASAL REINFORCEMENT
Jutland, Denmark
88
DRAINAGE SOLUTIONS
89 STRICTLY CONFIDENTIAL
DRAINAGE
DRAINAGE
Geosynthetic solutions for
draining out water from
embankment, avoiding soil
/retaining wall failure due
to water table raise.
90
DRAINAGE
Drainage of water away from railway infrastructure
rainfall
Water seepage
Capillary water raise

Water level rise behind containment Geosynthetic drain layers between the
structures different elements (foundation soil,
Capillary rise embankment, ballast)
Slopes erosion due to heavy rainfall Draining geogrid inside the embankment
91
DRAINAGE
Water: a major risk for infrastructure integrity
Embankment failure
Heavy intense rainfall Increase in water table level Retaining wall overturning
Drain clogging by fine deposit
92
GEOSYNTHETICS FOR WATER DRAINAGE
Ensuring drainage effectiveness with Maccaferri products
Maccaferri offers tailor made solutions able to absolve drainage
and reinforcement functions
ParaDrain offer excellent drainage function in addition to
reinforcement one
Long-term drainage effectiveness guarantee by combination of
geotextile layer, avoiding drain occlusion due to fine deposit.
93
GEOSYNTHETICS FOR WATER DRAINAGE
Ensuring drainage effectiveness with Maccaferri products
94
OUR EXPERIENCE
Proof of excellence certified by Italian High Speed Railway Company
ITALFERR, part of the RFI

group, has installed our drainage
products for new high-speed
tracks.
150.000 m2 of MacDrain
installed
Installation started in 2000
High-speed track are in service

since 2007 without any
problem related to the use of
MacDrain.
95
TUNNELLING SOLUTIONS
Maccaferri offers solutions for all stages of both

conventional and TBM excavated tunnels, that enable the
safe and rapid advance including large diameter tunnels
• Portal works and support systems

• Support and pre-consolidation of the tunnel
• Primary lining
• Soft-eye breakthrough
• Final lining
INNOVATIVE PROPRIETARY SYSTEM

B.Zero TondoTM Tunnel Support System is our patented
mechanized steel arch system for the first stage support:
• Efficiency: 65% reduction of the installation time
• Safety: only one worker needed / 10 m away from the
excavation front
• Cost-reduction
B.Zero TondoTM Steel Arch, Italy
96
SPECIAL SOLUTIONS FOR SPECIAL NEEDS
ParaFence for Protection from Wind & Sand Drifting:
It is Maccaferri's solution for

Ultimate Windbreak Fencing
Systems.
ParaFence® effectively destroys or

reduces wind velocities, it can also
be used to control the drifting of
sand.
Its light weight, ease of installation,

durability and the fact that it is rot
proof and unaffected by Sunlight,
rain or salt water, makes it the ideal
choice for this type of application.
97
OTHER APPLICATIONS
PARAFIL® - The ultimate synthetic rope

PARAFIL® has been used in many locations around the world to support overhead conductive cables for tram
electrification (including Alger, Athens, Bilbao, Brussels, Bucharest, Copenhagen, Dublin, Euro tunnel terminal, Geneva,
Jerusalem, Lisbon, Liverpool, Lyon, Hong Kong, Madrid, Manchester, Marseilles, Melbourne, Milan, Nice, Odessa, Ohio,
Oslo, Porto, Prague, Riga, Rome, Sheffield, Tenerife, Toronto, Turin, Valencia, Zurich and manymore)
Key benefits
Resistant to chemical and biological attack
High strength to weight ratio

High electrical impedance, low creep properties and thermal stability
98
ENVIRONMENTAL AND DIGITAL SAVVY
Not only performance certification but also to

environmental and digital ones.
We provide reliable and comparable information on the Our products are also available as BIM. Our BIM Object have
environmental impacts of the product life cycle reducing been validated by the British Board Agreement (BBA) as
energy and material consumption being a true and fair representation of the physical
product/system. BIM system reduces design time and cost
and facilitates cooperation between project stakeholders
visit maccaferri.com/EPD visit maccaferri.com/BIM
99
Thank You.
linkedin.com/company/maccaferri
instagram.com/maccaferriworld/
twitter.com/MaccaferriWorld
youtube.com/c/maccaferriworld
maccaferri.com
Questions? s.rignanese@maccaferri.com

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EFFICIENT SOLUTIONS FOR

THE UNIQUENESS OF MACCAFERRI

SOLUTIONS FOR THE RAILWAY WORLD

“140 years ago, we invented modern gabions

We are a leading international

We deliver solutions from retaining

Sales in 100+ countries

MIC in NoiPark research centre Quality Control Tests Testing Facility

Basal Retaining Walls & Drainage of

COMMON PROBELMS SOLUTIONS

Water seepage into embankment Reinforced geomat capable to avoid

A graded range of products to addressany level of

- Biomac® biodegradable geomats

• Superficial erosion prevention

MacMat® R, France BioMac®, Philippines

RENOMESH RENOMESH BIO RENOMESH GREEN

ANTI-BURROWING ANTI-BURROWING ANTI-BURROWING

EROSION CONTROL LONG TERM

• Simple to construct reinforced soil bunds and gabion

VISTA DI INSIEME DUNE E TERMINALI

VISTA ASSONOMETRICA 2.06

GABBIONE DI CHIUSURA GABBIONE CHIUSURA

Double sided berm – Duna System

18 Double sided berm – Duna System

Double sided berm with Green Terramesh®

Wasserburg, Green Terramesh®

Wasserburg, Green Terramesh®

Wasserburg, Green Terramesh®

RETAINING WALLS &

COMMON PROBELMS SOLUTIONS

Interaction with urban environment Vertical concrete faced soil reinforcement

Tensile strength Lateral confinement Load distribution Superior behavior

Our wide range of products and extensive experience enable us

• We can offer a wide variety of face finishes including

• The use of our products maximises the opportunity to reuse

• Our solutions accommodate differential settlements and

Gabion Wall, United Kingdom Reinforced Soil Wall, Indonesia

Maccaferri can offer

• Products and solutions that enable the construction of

• ParaDrain®, a unique and new generation geogrid,

• MacSTARS software, a renowned suite to assist

ParaDrain® close up, Italy

Reinforced earth structure with Green Terramesh®

50 Completed, Sept 2020

Beginning of works: 06/2004

With thousands of projects carried out around the world, we support

- Railway bridge scour protection (piers and abutments)

Reno Mattress Plus

The PoliMac® coating

X-Tie is the experimentally

0,9 Rip Rap

0,7 with X-Ties

0,0 Flume testing

over 73% more efficent

25 Reno Mattress Plus

*Data are based on Environmental Product Declarations (EPD)

Our wide variety of rockfall and natural hazard mitigation systems

Soil Nailing, Australia Drapery System, United Kingdom

• Tested and certified in accordance with the

Soil nailing is a technique used to stabilize slopes with low cohesion or

It is recommended for soil with no groundwater presence, partially saturated,

Nails increasing the

Facing contains the soil

Maccaferri has a centre of excellence entirely