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Making Better Communities Through Contextual Infrastructure Planning
March 2001 • Issue No. 49 • Volume XVI • Number 1
Contextual Infrastructure Planning and Design
Engineering and Aesthetics for the A5 Glyn Bends Improvement in Wales
By Jeff Rowlands, Cardiff, Wales, 0144 2920 396045, rowlandsj@pbworld.com
Construction of major highways in environmentally sensitive upland areas requires very sensitive design because the deep cuttings and high embankments that are required have a major impact on the landscape. The Glyn Bends scheme presented such a challenge, which was met by innovative techniques, particularly in the rock cutting to mitigate the effects.

The Glyn Bends Improvement lies on the A5 London-Holyhead Trunk Road in Wales, some 25 km (15 miles) west of Llangollen. It passes through high quality landscape of exceptional scenic beauty between Ty Nant and Dinmael and is of particular engineering and landscaping interest because of the dramatic topography created by the adjacent Ceirw Gorge.

In the 1970s, this portion of A5 was identified as a priority for improvement because of its higher-than-national-average accident rate. Our firm was commissioned by the National Assembly for Wales to carry out a route study for 50 km (32 miles) of the A5 trunk road through mainland North Wales. We were to identify the operational characteristics of the route in terms of road width, visibility, accident rate, etc., and produce a ranking to prioritise sectional improvements.


Figure 1: Aerial view showing original road and new road under construction

Figure 2: Masonry arch bridge over Ceirw Gorge

Figure 3: Rock cut showing anticline
New Bypass of Ceirw Gorge Recommended

The original trunk road area meandered around the very tight bends of the gorge, having been constructed on a ledge cut into the rock face and supported by high masonry retaining walls built by Thomas Telford in the 1800s. Through the gorge, the road passed some 35 m (115 feet) above the bed level of the River Ceirw (Figure 1).

In the area of the project, the trunk road was narrow with no verges (a soft, grassed strip outside the carriageway, typically 2 m (6 feet) wide) and it had a horizontal alignment that was severely substandard with limited forward visibility. In addition, up-slope rock falls had occurred and there was a history of movement at the base of the supporting retaining walls. These walls offered no guarantee of long-term serviceability. The constraints imposed by the gorge precluded an on-line improvement of the existing A5 route, so the decision was taken to bypass the gorge to the north.

The bypass required a deep cutting through the adjacent hillside, some 640 m (2,100 feet) long and 31 m (102 feet) wide at its deepest point. The design and construction of the cutting, together with the contiguous length of embankment of up to 18 m (59 feet) in height, presented a considerable challenge to our team and TACP, our landscape subconsultant.

The new road, which opened to traffic in mid-1996, generally consists of s 7.3-m (24-foot) -wide single carriageway with 0.5-m (1.7-foot) hard strips (shoulders) reducing to 0.3 m (1 foot) in the cutting. The carriageway widens to 10 m (33 feet) where a climbing lane or right turn lane is provided.

As lead design consultant on the bypass project, we were responsible for carrying out all detailed design of the scheme, preparing contract documents and supervising the construction. The construction contract for the 2.4-km (1.4-mile) -long A5 Glyn Bends Improvement was awarded to Miller Civil Engineering Ltd. by the National Assembly for Wales in May 1994 at a tender value of £4.2m.

Engineering Details

The engineered cut was formed by pre-split and bulk blasting techniques removing 255 000 m3 (more than 9 million cubic feet) of rock, which was then deposited into a new embankment that runs parallel to and south of the existing road. A sophisticated array of vibrograph and electro-level measuring equipment was installed to monitor the blasting operations because of possible effects on the walls supporting the existing trunk road above the Ceirw Gorge and on a high single-span masonry arch bridge that carries a minor road over the gorge. Figure 2 shows the bridge and provides a good indication of the dramatic topography of the gorge.

In addition, visual inspection of the retaining walls and arch bridge were considered necessary and access platforms were specified at three levels on the retaining wall and the masonry arch bridge to facilitate inspection during the 20 minute closure of the trunk road.

The cutting was excavated in the Upper Ordovician deposits, which consist predominantly of fine grained siltstone. Low-grade metamorphism has produced a rock of high strength and has imposed a spaced cleavage. Faulting was widespread over the length of the cutting and both anticlinal (a fold in which layered strata are inclined down) and synclinal (concave upward) structures were present (Figure 3). The bedding dips into the cut from the north 30º - 60º typically and the presence of weak/soft volcanic ash on these bedding planes has had a significant effect on slope stability.

In the light of these characteristics, we recommended the cross section indicated in Figure 4 in our Interpretative Report. The scale of the cutting in relationship with the gorge (Figure 5) clearly demonstrates the engineering challenge of this unique scheme. Due to a very high water table and the presence of ash bands, dewatering was specified to improve short term stability until permanent measures were installed. These consisted of horizontal drainage in the rock face with stability measures such as rock anchoring, bolting, rock netting and masonry facing. Rock dowels were also subsequently specified during construction.

Fill slopes were generally 1 in 2 but steepened locally to 1 in 1-1/2 at one location and flattened to a 1 in 3 profile where possible to mould the embankment into the existing side long ground below the old road. Where masonry revetment had been used, considerable care was taken to produce a face that blends with the rock cut. It was for this reason that the use of shotcrete was discouraged in the contract.


Figure 4: Typical cross section in rock cut

Figure 5: Cross section showing relationship with gorge

Figure 6: Rock cutting

Figure 7: Design perspective of rock cut showing ledges and buttresses

Figure 8: Example of masonry around slope drainage outfall and ledge
Particular Attention Given to Aesthetic Considerations

In view of the sensitivity of the area, we paid particular attention to the impact of the scheme on the environment and to the methods by which environmental impacts could be avoided or mitigated as far as possible. We closely followed the philosophy and principles adopted in the Welsh Office Highway Directorate document entitled Roads in Upland Areas: A Design Guide to achieve the desired objective of producing a good quality safe trunk road designed in sympathy with the landscape through which it passes.

One such important area has been identified as a refinement of the pre-splitting of the rock face to ensure a more natural-looking profile rather than the "hot knife through butter" effect that commonly results from this process. This profile has been achieved by varying the cut slope angle at designated locations in order to produce an irregular face and to form buttresses. In addition, ledges have been incorporated in the cut at appropriate locations and where possible, natural geological features have been exposed and emphasised (Figure 6).

The final refinement and incorporation of all these features at the design stage was an iterative process. Having decided how the natural effect could best be achieved and having checked the stability of the steeper faces, TACP provided sketch proposals for the locations of ledges and variations in cut slopes. These were checked from an engineering viewpoint before computer perspectives were produced (Figure 7).

Our design team discussed the results and, if necessary, other options were prepared, including further perspectives, until the final design was acceptable. A fundamental principle of the process was to attempt to expose the natural rock features and emphasise them. For instance, small wedge failures were anticipated at the berm level during construction but as long as the berm width was not reduced significantly, it was not proposed to carry out any remedial work, thus avoiding long lengths of masonry infilling seen on most rock cuts at berm edges.

In constructing the rock cutting, recesses have been formed into the face at rock anchor locations to reduce the visual impact of the anchor heads. In addition, horizontal seepage pipes, which normally emerge from the rock face in a regular grid of 5 m (16 feet), have been installed in a fan arrangement and collected at single specific locations on the rock face that have subsequently been masked by masonry facing won from the cutting (Figure 8). TACP and the National Assembly for Wales' Landscape Advisor have worked closely with us in the development of integrated engineering and landscape details, both during the design and in the construction stages.

Other areas of interest include mounding at the back of verges to the embankment to reduce the visual impact of the road from long-range views across the valley. This mounding together with an indigenous planting scheme ensured successful integration into the existing landscape. The proposed masonry walls, boundary fences and gates have also been detailed and specified to reflect existing conditions. Three reinforced concrete retaining walls and a concrete box culvert were constructed in the fill area and clad with masonry produced from rock in the cutting.

Key features were:
  • The degree to which the irregularities of the geology were used to create (as far as practicable) a natural looking rock face
  • Wildflower and tree planting mixtures, which have all been tailored to help re-establish the original site flora
  • Special measures that were incorporated with help from the Countryside Council for Wales to enrich the ecological interest of the scheme.
Looking ahead, ongoing management of the new landscape ensures that the measures taken will mature effectively and will help to minimise the long-term visual impact of the road in this scenic area.

Conclusions

Both the original and the new trunk road routes are of particular engineering and landscaping interest because of the dramatic topography created by the adjacent Ceirw Gorge, which was designated a "Site of Special Scientific Interest." The final outcome is considered to be a testimony to all those involved, all of whom have been extremely proud to have been involved in the scheme. The key success is the degree that the rock face has been varied and the irregularity of the geology used to create a natural looking rock face.

A dangerous section of road has been improved and the twin objectives of building a safe modern road in sympathy with the environment have been achieved. At the same time, a very attractive part of the countryside has been given back to people to enjoy once again.

Jeff Rowlands is a Technical Director with PB's U.K. Infrastructure operation and the senior line manager for Civils 2 Infrastructure in the UK and Europe and is based in Cardiff, Wales. After graduation, he spent a period in local government followed by three years in consultancy in South Africa before joining PB in 1973. Jeff has been the recipient of a number of design awards.

This article was based on a paper co-authored by Jeff Rowlands and Ray Hooper, of the National Assembly for Wales and published in the Institution of Highways & Transportation Magazine June 1995.
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