Materials Specifications · Resource Hub
Materials & specifications.
Practical materials reference for Malaysian geotechnical works. Steel reinforcement (Grade 460 Y-bar, T-bar, GEWI threadbar Grade 500/670/950, mild steel mesh A6/A8/A10/A12, BRC). Sheet pile steel (Grade S270GP/S320GP/S355GP/S390GP/S430GP). Prestressing strand (7-wire 15.2/15.7 mm low-relaxation, Grade Y1860, BS 5896 / EN 10138). Grout mixes (cement-water ratio, plasticiser, target cube strength). Concrete grades and shotcrete (wet-mix, dry-mix, ACI 506). Geosynthetics (geogrid, geotextile, geomembrane, geocell, geocomposite). Drainage materials. Aligned with BS / EN, MS standards, AASHTO, JKR/SPJ. By Infraconcrete - CIDB G7 specialist geotechnical contractor.
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Engineer's note
We hold supply relationships with the major Malaysian stockists for GEWI threadbar (Grade 670 standard), prestressing strand (15.7 mm Y1860), sheet pile (S355GP local stock), and HDPE/PET geogrid (Tensar, Strata, Miragrid). The lead-time bottleneck on most projects is non-stock European sheet pile sections (8-16 weeks) or specialty Macalloy/Williams threadbar (6-12 weeks). Where material lead time is on the critical path, we plan procurement at design stage - send the spec for a stock vs. lead-time advisory.
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01 / Reinforcement Steel
Rebar grades for Malaysian geotechnical works.
| Grade | Yield (N/mm^2) | UTS (N/mm^2) | Standard | Use |
|---|---|---|---|---|
| R6 / R10 mild steel | 250 | ~350 | BS 4449 / MS 145 | Stirrups, links, low-stress reinforcement (rare in modern work) |
| Y-bar Grade 460 / 500 | 460 / 500 | ~600 | BS 4449 / MS 146 | Standard structural rebar, RC walls, footings, capping beams |
| T-bar (deformed) Grade 460 / 500 | 460 / 500 | ~600 | BS 4449 (B500B / B500C) | Modern Malaysian standard - higher ductility, higher yield |
| High-tensile rebar Grade 600+ | 600+ | 700+ | BS 4449, AS/NZS 4671 | Special high-stress applications, megaprojects |
Common diameters in Malaysia: 6, 8, 10, 12, 16, 20, 25, 32, 40 mm. Stock sizes vary; specify pairs in design (e.g. T16 + T20 + T25 for capping beam). Bend schedule per BS 8666.
JKR specification. JKR/SPJ / SPJ-AS specifies B500B (or B500C for high seismic / heavy gauge) rebar for federal works. Hot-dip galvanised optional for chloride-exposed elements. Epoxy-coated alternative permitted on a case-by-case basis. Mill certificates for every batch. Site QA: random tensile test 1 in 50 ton, bending and rebending test 1 in 100 ton.
02 / GEWI Threadbar (Soil Nail / Tieback)
Continuous-thread high-tensile steel.
GEWI is a continuous coarse-pitch thread on a hot-rolled steel bar - patented by DSI (Dywidag Systems International) and produced by DSI, Williams Form Engineering, Macalloy, and licensed manufacturers. The continuous thread allows in-situ coupling and mechanical end fittings without thread cutting. Used worldwide for soil nails, tiebacks, micropiles, ground anchors (where threadbar is preferred over strand).
| Grade | Yield (N/mm^2) | UTS (N/mm^2) | Common dia (mm) | Use |
|---|---|---|---|---|
| Grade 500 (B500B equivalent) | 500 | 550-600 | 16, 20, 25, 32, 40, 50 | Soil nails, micropiles, lower stress applications |
| Grade 670 (most common Malaysia) | 670 | 800 | 25, 28, 32, 36, 40, 50, 57, 63, 75 | Standard soil nail / tieback / threadbar anchor |
| Grade 835 / 950 | 835 / 950 | 1030 / 1050 | 25, 32, 36, 40, 47, 57, 63, 75 | High-load anchors / micropiles |
| Grade 1050 / 1080 / 1230 | 1050+ | 1230+ | 25, 32, 47, 65, 75 | Permanent prestressed anchors (alternative to strand) |
Common Malaysian soil nail bar
32 mm GEWI Grade 670 - working load 280-330 kN, ultimate ~530 kN. Use for permanent and temporary soil nails. Hot-dip galvanised (HDG) or epoxy-coated for permanent works.
25 mm GEWI Grade 670 - working load 170-200 kN. Use for shorter / lighter nails.
40 mm GEWI Grade 670 - working load 430-510 kN. Use for high-load nails / temporary tiebacks.
Accessories
- Couplers - mechanical, 1.5-2x bar diameter outside, screw-on engagement
- End plates - 200 x 200 x 25 mm steel plate or 300 x 300 x 30 mm for high load
- Hex nuts - galvanised, matching grade
- Centralisers - plastic, every 1.5-2 m, ensures 25 mm minimum grout cover
- Spacers / chairs in dual-corrosion-protected systems
Macalloy / Williams alternative. Macalloy 1030 (1030 N/mm^2 yield) and Williams All-Thread bars (Grade 75/97/100/150) are alternative threadbar systems used in Malaysia. Functionally interchangeable with GEWI in design - select based on project specification, lead time, supplier preference. All to BS EN 14199 (micropiles), BS 8081 / EAD 160004 (anchors), or BS EN 14490 (soil nails) execution standards.
03 / Prestressing Strand (Ground Anchor)
7-wire low-relaxation strand for high-load anchors.
| Property | 15.2 mm strand | 15.7 mm strand |
|---|---|---|
| Nominal diameter | 15.2 mm | 15.7 mm |
| Cross-sectional area | 140 mm^2 | 150 mm^2 |
| Tensile strength (Y1860) | 1860 N/mm^2 | 1860 N/mm^2 |
| Yield (0.1 percent proof) | 1670 N/mm^2 | 1670 N/mm^2 |
| Breaking load (per strand) | 260 kN | 279 kN |
| Working load (typical 60% UTS) | 156 kN | 167 kN |
| Standard | BS 5896, EN 10138-3 | BS 5896, EN 10138-3 |
Strand configuration
- 4-strand: 600-700 kN typical working - residential / commercial walls
- 6-strand: 900-1000 kN - highway / commercial walls
- 8-strand: 1300-1400 kN - large commercial / federal works
- 12-strand: 1900-2000 kN - tall walls, dam tieback, mega-projects
- 15-strand and above: special applications (dam, bridge tieback, megaprojects)
Corrosion protection class
- Class 1 (most common): single PE / HDPE sheath in free length, bare strand bonded in cement grout in fixed length
- Class 1A: sheath plus grease in free length
- Class 2 (double corrosion): additional outer corrugated duct around bond zone, double-corrosion-protected
Class 2 mandatory for: aggressive ground (sulphate / chloride / acid), critical permanent works, very long design life (100+ years), restrike / re-stress anchors.
04 / Sheet Pile Steel
Hot-rolled and cold-formed sheet pile sections.
| Grade | Yield (N/mm^2) | UTS (N/mm^2) | Standard | Use |
|---|---|---|---|---|
| S240GP | 240 | 340 | BS EN 10248-1 | Light / temporary works |
| S270GP | 270 | 410 | BS EN 10248-1 | Standard temporary works, low-load permanent |
| S320GP | 320 | 440 | BS EN 10248-1 | Standard permanent works |
| S355GP | 355 | 480 | BS EN 10248-1 | Standard permanent works (most common Malaysia) |
| S390GP | 390 | 490 | BS EN 10248-1 | Higher-load applications |
| S430GP | 430 | 510 | BS EN 10248-1 | High-load / heavy commercial / industrial |
| S460GP | 460 | 550 | BS EN 10248-1 | Specialist high-load works |
Common Malaysian sheet pile sections: U-section (Larssen, Frodingham, FSP series Japanese, AU/PU European). Z-section (AZ, ZZ series). Most jobs use Grade S355GP as default, with S270GP or S320GP for very low-stress applications.
Local supply. ArcelorMittal (Luxembourg / Europe), JFE / Nippon Steel (Japan), Tata Steel (Europe). Local stockists in Malaysia (Klang Valley, Penang, Johor Bahru port-side) hold AU16, AU18, AU20, FSP-IIIA, FSP-IVw sections. Lead time for non-stock sections: 8-16 weeks ex-mill plus shipping. Always check stock availability at design stage to avoid programme issues.
05 / Mesh & Wire
BRC, soft mesh, hex mesh, double-twist mesh.
| Mesh type | Wire / spacing | Standard | Use |
|---|---|---|---|
| BRC A6 | 6 mm @ 200 mm c/c both ways | BS 4483 / MS 145 | Shotcrete reinforcement (light) |
| BRC A8 | 8 mm @ 200 mm c/c | BS 4483 / MS 145 | Shotcrete reinforcement (standard) |
| BRC A10 | 10 mm @ 200 mm c/c | BS 4483 / MS 145 | Heavy shotcrete / RC slab |
| BRC A12 / B / C series | 12 mm and bigger | BS 4483 / MS 145 | RC slab reinforcement |
| Hex mesh (chicken wire) | 1.5-2.5 mm wire, 25-50 mm aperture | BS 1485 | Light surface / vegetation backing |
| Double-twist hex mesh (gabion) | 2.7-3.0 mm wire, 60 x 80 / 80 x 100 mm aperture | BS EN 10223-3, ASTM A975 | Gabion / Reno mattress / soft revetment |
| Steel chain link | 2.0-3.5 mm wire, 50-100 mm aperture | BS 1722 | Rock fall mesh, slope drape |
| High-tensile steel rope net | 8-12 mm rope, 250-500 mm rhombic | ETAG 027, EAD 230025 | Rockfall barrier, rockfall netting (Maccaferri Steelgrid HR / SPIDER) |
Galvanising. All wire mesh for slope / soil / ground works should be hot-dip galvanised to BS EN 10244-2 (Class A or Class W coating). Polymer over-coated (PVC, polyamide) for aggressive environments or extended life. Galvanised + PVC double-coat: 50+ years design life typical.
06 / Grout Mixes
The cement glue that bonds steel to ground.
| Application | w/c ratio | Cement | Admixture | Target 28-day strength |
|---|---|---|---|---|
| Soil nail bond zone | 0.40 - 0.45 | OPC CEM I 42.5N | Plasticiser 0.5-1% (optional) | 30-35 N/mm^2 |
| Permanent ground anchor bond zone | 0.40 - 0.42 | OPC CEM I 42.5N or CEM II | Plasticiser 0.5-1% | 40-50 N/mm^2 |
| Anchor free length (sheath / tube grout) | 0.40 - 0.45 | OPC | Plasticiser, expansion (optional) | 25-30 N/mm^2 |
| Micropile | 0.40 - 0.45 | OPC CEM I or sulphate-resisting | Plasticiser | 30-40 N/mm^2 |
| Compaction / void grouting | 0.50 - 0.70 | OPC + bentonite (3-5%) or fly ash | Stabiliser, retarder | 5-15 N/mm^2 (low strength) |
| Jet grouting | 1.0 - 1.5 (cement-water-soil) | OPC CEM I, high cement content | Plasticiser | 3-8 N/mm^2 (soil-cement) |
Quality control
- Mill certificate for every cement batch
- Pre-construction trial mix - confirm flowability, bleed, set time, strength
- Cube tests: 7-day and 28-day, minimum 3 cubes per batch
- Density check by mud balance during pumping (target density 1.85-1.95 g/cm^3)
- Bleed test: less than 2 percent at 3 hours per BS EN 445
Pumping & placement
- Mixer: high-shear colloidal mixer for stable, low-bleed grout
- Pumping pressure: 5-10 bar typical at the borehole collar
- Tremie placement: bottom-up, displace air / drilling fluid
- Grout return at collar - confirms full bond zone fill
- Re-grouting (post-grouting / regrouting) for high-load anchors / nails in weak soil - 12-48 hours after primary, tube-a-manchette technique
07 / Concrete & Shotcrete
Cast and sprayed concrete in geotechnical works.
| Type | Grade | Slump / consistency | Standard | Use |
|---|---|---|---|---|
| Reinforced concrete (RC walls, capping beam) | C30/37 typical, C25/30 to C40/50 | Slump 75-150 mm | BS 8500, MS 522, JKR/SPJ | RC retaining wall stem, foundation, capping beam, drilled shaft |
| Mass concrete (gravity wall, foundation) | C20/25 to C30/37 | Slump 75-100 mm | BS 8500, MS 522 | Gravity walls, large footings, abutment |
| Wet-mix shotcrete | C30/37 to C40/50 | Slump 75-100 mm at hopper | EN 14487-1, ACI 506R, BS 5328 | Slope facing, soil nail facing, tunnel lining |
| Dry-mix shotcrete (gunite) | C30/37 to C40/50 | Dry pre-mixed; water at nozzle | EN 14487-1, ACI 506R | Slope facing, repair, smaller volumes |
| Steel fibre shotcrete (SFRS) | C30/37 to C50/60 | Wet-mix with steel fibres 30-60 kg/m^3 | EN 14488 series, ACI 506.1R | Tunnel primary lining, high-toughness slope facing |
| Self-compacting concrete (SCC) | C30/37 to C50/60 | Slump-flow 600-800 mm | BS EN 206, EFNARC | Densely-reinforced caisson, capping beam, plug |
Shotcrete vs Gunite. Both are sprayed concrete. "Wet-mix shotcrete" - all ingredients (cement, sand, water, admixtures) pre-mixed; pumped to the nozzle; air added at nozzle. "Dry-mix shotcrete" (also called "gunite") - dry materials pneumatically conveyed; water added at the nozzle. Modern Malaysian practice favours wet-mix for volume work (better quality control, lower rebound, less dust); dry-mix for small-volume / repair / remote site (lower equipment footprint). To EN 14487 and ACI 506.
08 / Geogrid
Polymer reinforcement for MSE walls and reinforced soil.
| Type | Polymer | UTS (kN/m) | T_LTDS (kN/m) | Common products |
|---|---|---|---|---|
| Uniaxial HDPE | HDPE punched and stretched | 50 - 200 | 20 - 80 | Tensar SS / RE / TX, Strata RE series |
| Uniaxial PET (polyester) | PVC-coated PET woven yarn | 40 - 600 | 20 - 250 | Miragrid, Fortrac (Huesker), Geogrid (Tencate) |
| Biaxial | HDPE punched-stretched | 20 - 50 (each direction) | 10 - 25 | Tensar SS series - subgrade / base course stabilisation |
| Triaxial | HDPE patterned | (not directly comparable) | (stiffness-controlled) | Tensar TX series - traffic, working platforms |
Specification checklist
- Polymer (HDPE / PET) - for design life and creep behaviour
- Tensile strength (UTS) - per ASTM D6637 / ISO 10319
- Long-term design strength (T_LTDS) - after partial factors for creep, durability, installation damage, site-specific
- Connection strength to facing block (for SRW / MSE) - 100 percent of design tensile factored
- Junction strength - greater than 90 percent of rib strength
- Aperture geometry for granular interlock
- Roll dimensions and weight for handling
- Long-term creep certified (ASTM D5262)
- Installation damage Type B (ISO 10722)
Partial factors (BS 8006)
From UTS to T_LTDS (long-term design strength):
T_LTDS = UTS / (RF_creep * RF_durability * RF_damage * RF_other)
RF_creep: 1.5 - 2.5 (HDPE), 1.4 - 1.6 (PET)
RF_durability: 1.05 - 1.30 (depends on chemistry / pH / temperature)
RF_damage: 1.05 - 1.40 (depends on fill gradation and angularity)
RF_other: 1.0 - 1.1 (joints, end conditions)
Total RF: typically 2.0 - 4.0 - so T_LTDS is typically 25-50 percent of UTS.
RF_creep: 1.5 - 2.5 (HDPE), 1.4 - 1.6 (PET)
RF_durability: 1.05 - 1.30 (depends on chemistry / pH / temperature)
RF_damage: 1.05 - 1.40 (depends on fill gradation and angularity)
RF_other: 1.0 - 1.1 (joints, end conditions)
Total RF: typically 2.0 - 4.0 - so T_LTDS is typically 25-50 percent of UTS.
09 / Geotextile
Filtration, separation, drainage, protection.
| Type | Polymer | Mass (g/m^2) | Use |
|---|---|---|---|
| Non-woven needle-punched | PP (polypropylene) | 100 - 400 | Filtration, drainage, separation, protection. Most common for geotech |
| Non-woven heat-bonded | PP / PET | 100 - 200 | Lighter filtration, separation |
| Woven multifilament | PP / PET | 200 - 800 | High strength reinforcement, soft soil basal reinforcement |
| Woven slit film | PP | 100 - 200 | Separation, light reinforcement (tend to clog as filter) |
Filtration design (Christopher-Holtz / FHWA)
- AOS (apparent opening size O95) - per soil gradation
- Permittivity (psi) - greater than 0.5 /sec drained, greater than 0.1 /sec for fines
- Mass per unit area - 200-300 g/m^2 typical for residual soil filter
- Tensile / puncture / burst strength for installation stress
- UV resistance if exposed (otherwise bury within 14-30 days)
Separation / reinforcement design (BS 8006)
- Tensile strength (wide-width per ISO 10319)
- Strain at failure / strain at design load
- Junction efficiency (woven only)
- Long-term creep (PET more stable than PP)
- Durability factors (chemistry, temperature, biology)
10 / Geomembrane
Impermeable barriers - HDPE, LLDPE, PVC, EPDM.
| Type | Thickness (mm) | Permeability | Use |
|---|---|---|---|
| HDPE smooth | 1.0, 1.5, 2.0, 2.5, 3.0 | 1e-13 to 1e-15 m/s | Landfill liner, pond liner, secondary containment |
| HDPE textured (single / double-side) | 1.5, 2.0, 2.5 | same | Slope liner (texture for friction) |
| LLDPE | 0.5, 0.75, 1.0, 1.5, 2.0 | same as HDPE | Steeper / curved geometry, more flexible |
| PVC (polyvinyl chloride) | 0.5, 0.75, 1.0, 1.5 | 1e-12 to 1e-13 m/s | Pond / canal lining, irrigation |
| EPDM (ethylene-propylene-diene) | 1.14, 1.52 | 1e-12 m/s | Pond, roof, repair patches (high flexibility) |
| GCL (geosynthetic clay liner) | 5-10 (with bentonite) | 5e-11 m/s (saturated bentonite) | Self-healing landfill / pond liner |
Welded by hot wedge or extrusion. QA: vacuum box / spark / pressure leak testing on all seams. Long-term performance: HDPE 100+ year design life if installed correctly and protected from UV.
11 / Geocell
3D honeycomb confinement for slope and soil.
Geocell is a 3D cellular confinement system - HDPE strips welded into a honeycomb pattern. Expanded on site, infilled with soil / aggregate / topsoil / concrete. Provides lateral confinement that increases the effective strength of the infill.
| Property | Range |
|---|---|
| Strip thickness | 1.1 - 1.5 mm typical |
| Cell depth | 50, 75, 100, 150, 200 mm |
| Cell size (expanded) | 200 x 200, 300 x 300, 410 x 460 mm typical |
| Polymer | HDPE (most common), NPA (novel polymer alloy - higher creep resistance) |
| Standard | ASTM D7864, GRI-GS5 |
Use cases: slope erosion control with vegetation in cells, working platform on soft soil (75-150 mm cell depth), retaining wall fascia (100-200 mm depth), channel armouring with concrete-filled cells. STRATA Geosystems produces NPA-polymer geocells (Geoweb / equivalent). Tensar Geocell is also available in Malaysia.
12 / Corrosion Protection
Steel embedded in soil - protect for design life.
| Method | Coating thickness / class | Design life addition | Use |
|---|---|---|---|
| Hot-dip galvanising | 85-150 micron typical (Class A or W per BS EN 10244-2) | 20-40 years (depends on environment) | Soil nail bars, mesh, sheet pile |
| Epoxy coating | 250-400 micron | 30-60 years | Permanent rebar, threadbar, structural steel embedded |
| Sacrificial steel thickness | Add-on to design section (e.g. +1.5 mm per face) | BS EN 1993-5: 0.012-0.04 mm/yr fluvial; 0.04-0.10 mm/yr marine | Sheet pile, foundation steel embedded in soil/water |
| Cathodic protection (sacrificial anode or impressed current) | n/a (electrochemical) | Indefinite (with monitoring) | Marine / aggressive environment, critical permanent works |
| Concrete cover | 50-75 mm typical for ground-cast concrete | Per BS 8500 exposure class | Reinforced concrete walls, foundations |
| Plastic / HDPE encapsulation | 3-5 mm corrugated tube | 50-100+ years | Permanent prestressed anchors (Class 2 dual corrosion) |
Design life targets: Federal infrastructure 100-120 years; commercial 60-75 years; temporary 5-10 years. Specify corrosion protection regime to match design life and ground aggressivity (BS EN 14490 for soil nails, BS 8081 / EAD 160004 for anchors).
13 / Standards Reference
Codes and references.
| Topic | Reference |
|---|---|
| Reinforcement steel | BS 4449 (B500B / B500C), MS 145, MS 146 |
| Threadbar (GEWI / Macalloy / Williams) | BS EN 14199 (micropile), BS EN 14490 (soil nail), BS 8081 / EAD 160004 (anchor) |
| Prestressing strand | BS 5896, EN 10138-3 |
| Sheet pile steel | BS EN 10248-1 (hot-rolled), BS EN 10249-1 (cold-formed) |
| Wire mesh | BS 4483, BS EN 10223-3 (gabion), BS EN 10244-2 (galvanising) |
| Cement | BS EN 197-1, MS 522 |
| Concrete | BS 8500, BS EN 206, MS 522 |
| Shotcrete | EN 14487-1, EN 14488 series, ACI 506R / 506.1R / 506.2R |
| Geogrid | BS 8006-1 / 8006-2, ASTM D6637, ISO 10319, ASTM D5262 (creep), ISO 10722 (damage) |
| Geotextile | BS 8006-1 / 8006-2, FHWA-IF-99-016, ISO 10319 / 11058 / 12956 / 12958 |
| Geomembrane | GRI-GM13 (HDPE), ASTM D7176, EN 13361 / 13362 |
| Geocell | ASTM D7864, GRI-GS5 |
| Corrosion protection | BS EN 14490 (soil nail), BS 8081 / EAD 160004 (anchor), BS EN 1993-5 (steel pile) |
Frequently asked
Materials questions.
What grade of soil nail bar should I use? +
Standard Malaysian: 32 mm GEWI Grade 670 (working load ~280-330 kN, ultimate ~530 kN). Alternative diameters: 25 mm (170-200 kN) for shorter / lighter nails, 40 mm (430-510 kN) for high-load nails. Hot-dip galvanised or epoxy-coated for permanent works. Centralisers every 1.5-2 m. To BS EN 14490.
What strand for ground anchors? +
7-wire low-relaxation 15.7 mm strand, Grade Y1860 (BS 5896 / EN 10138-3), breaking load 279 kN per strand. Working load typically 60 percent UTS = 167 kN. Multi-strand 4-12 typical. Class 2 dual corrosion protection for permanent / aggressive ground.
What's the standard grout mix? +
OPC CEM I 42.5N, w/c 0.40-0.45, plasticiser 0.5-1 percent (optional), target 30-35 N/mm^2 28-day cube. For permanent anchor bond: w/c 0.40-0.42, target 40-50 N/mm^2. Pre-construction trial mix and 7/28-day cubes. Density 1.85-1.95 g/cm^3 by mud balance during pumping.
What geogrid for MSE walls? +
Uniaxial HDPE (Tensar SS / RE) or PET (Miragrid, Fortrac), UTS 60-200 kN/m typical, T_LTDS 25-90 kN/m after partial factors. Connection strength to facing 100 percent of design tensile. Aperture for granular interlock. Long-term creep certified (ASTM D5262), installation damage Type B (ISO 10722). Design life partial factors per BS 8006-1.
What sheet pile grade is standard? +
S355GP (yield 355 N/mm^2) is the most common Malaysian default for permanent works. S270GP / S320GP for lower-stress / temporary. Higher grades (S430GP, S460GP) for specialist heavy applications. Local stockists hold AU and FSP series. Lead time for non-stock sections: 8-16 weeks ex-mill.
Need materials supply or specification advice?
Send the project specification or design drawings. Same-day response from the engineering team. We supply and install soil nails, anchors, MSE walls, sheet piling, shotcrete, geosynthetics across Peninsular and East Malaysia.