Primary Crusher Wall, Dyer Quarry, Birdsboro, PA

CASE HISTORY
Ref: USA-149, Rev: 00, Date: 10.14.2014
DYER QUARRY, CRUSHER (DUMP) MSE WALL

BIRDSBORO, PA
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MSEW QUARRY CRUSHER , PENNSYLVANIA

Wall Type: Parawall System; Reinforcement ParaGrid & MacDrain
The MSEW Crusher in operation
Crusher Walls (Mine Dump Walls)
Crusher walls (Mine Dump Walls) are used to support vertical or

near vertical grade changes to minimize the footprint of the facility.
Hoppers or crushers can be installed within these walls. Mined
material is hauled to the upper terrace and unloaded into the
hopper/crusher.
Often MSE walls are used in this application. Reinforced soil is

ideally suited to accommodate the high loads applied by the dump
trucks.
MSEW Crusher location
Dyer Quarry, Inc.
Dyer Quarry, Inc. is located in Robeson Township, Berks County,

Owner:
DYER QUARRY INC.

Contractor:
GOLDER ASSOCIATES
Engineer:
TITAN ENGINEERS PC / MACCAFERRI INC

Product Used:
PARAWALL SYSTEM; REINFORCEMENT PARAGRID

Date of construction:
MARCH-SEPTEMEBER 2014
Maccaferri, Inc.
10303 Governor Lane Blvd., Williamsport, MD 21795
Tel. (800) 638-7744 - Fax (301) 223-4590
E-mail: [email protected] - Web site: www.maccaferri-usa.com
The finished MSEW Crusher

Area Offices:
Phoenix, Arizona
Sacramento, California
Miami, Florida
St. Louis, Missouri
Trenton, New Jersey

Albuquregue, New Mexico
Caguas, Puerto Rico
Dallas/Ft. Worth, Texas
2014 Maccaferri. All rights reserved. Maccaferri will pursue any infringement.
These large structures are part of the concentration facilities

within the mine and crush the mined material to predetermined
dimensions for further processing. The large haul trucks deposit
the mined ores into the top of the crusher. Access to the top of the
crusher and the maneuvering yard is provided by ramps and tall
retaining walls.
Pennsylvania.
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The facility is strategically located and serviced by Norfolk

Southern Rail lines. Dyer also produces a wide variety of
aggregate sizes meeting PA, NJ, DE, MD DOT's and AASHTO
requirements. Such aggregates are mostly used in railway
applications for their hardness.
Need for a Crusher Wall
A new primary crusher unit was being added to the Dyer Quarry
in Birdsboro, PA in year 2014. The terrain at the design location
for the new crusher was extremely challenging, a retaining wall
was necessary to create a safe platform for unloading trucks.
Solution
The Maccaferri MSE wall system, "Parawall" was the superior

choice offering best value for its cost effectiveness and ease of
installation. Parawall is welded wire fascia wall designed for this
application which has following components:
Fascia: Welded wire panels
HDPE Net: Fascia stone retainer material
MSE Wall Reinforcement: Paragrid 65, 100, 120, 150 and
200.
Drainage Composite: MacDrain W1051
Geotextile Fabric: MacTex N35.1.
Crusher Wall Alignment Detail
Maccaferri Inc. working with Titan Engineering PC provided

engineering services for the design of these walls and Golder
Associates built these walls in record time. Additionally,
Maccaferri coordinated the engineering services and material
supply.
Construction and Materials
The wall shows several peculiarities and required special

attention during the construction. Any field design changes
(FDC) to the original submittal were documented and duly
reported to the owner. As build construction drawings were also
issued on the projects completion.
Typical Section
It is interesting to note that the reinforced soil in bottom courses

1-16 was #57 stone while PADOT Modified 2A was used from
course 16 to 28. The geosynthetic drainage composite MacDrain
W 1051 was installed between the modified 2A and the retained
soil starting at the bottom of course 12
Maccaferri, Inc.
Tel. (800) 638-7744 - Fax (301) 223-4590
Area Offices:
Phoenix, Arizona
Miami, Florida
St. Louis, Missouri
Trenton, New Jersey

Caguas, Puerto Rico
The maximum exposed height of the Parawall is 70.0ft with

approximate wall fascia area of 20,000 sq. ft. The drawing (top
right) shows the wall alignment with respect to crusher. The
Parawall is built around the crusher to minimize the lateral earth
pressure on the crusher. The wall is designed to support the live
load of the haul truck CAT D773 used in this facility, which has
a payload of 219,007 lbs. The Parawall provides stabilized
access platform for the haul truck.
The bonded geogrid (Paragrid) with tensile strength varying from

65 to 200kN/m was used as an MSE wall reinforcement.
Intermediate courses of Paragrid with tensile strength of 100,
120 and 150kN/m, were used to optimize the installed cost of the
structure.
Paragrid
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Paragrid consists of aligned arrays of high tenacity polyester

yarns encased in a thick protective sheath of Linear Low Density
Polyethylene (LLDPE). The LLDPE coating is more robust and
durable against biological and chemical degradation which leads
to unique performance in terms of long term tensile strength and
durability.
The project was completed in a record time. Each phase of the
12950 sq./ft. project was completed ahead of schedule. Despite
heavy rainfall throughout the construction phase of Courses 1 to
16, there were no recorded weather delays due to the selection
of free-draining AASHTO #57 stone as the structural backfill.
MacDrain W1051
Back Fill over the ParaGrid Early in the Construction Process
Aerial View of Construction Site
Close up of Paragrid 150 Installation
Close up of the MacDrain Drainage Material

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Maccaferri, Inc.
Tel. (800) 638-7744 - Fax (301) 223-4590
Area Offices:
Phoenix, Arizona
Miami, Florida
St. Louis, Missouri
Trenton, New Jersey

Caguas, Puerto Rico
(Above and Below) Detailed view of the finished MSEW Crusher

Primary Crusher Wall, Dyer Quarry, Birdsboro, PA

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CASE HISTORY

Ref: USA-149, Rev: 00, Date: 10.14.2014

DYER QUARRY, CRUSHER (DUMP) MSE WALL

MSEW QUARRY CRUSHER , PENNSYLVANIA

The MSEW Crusher in operation

Crusher Walls (Mine Dump Walls)

Crusher walls (Mine Dump Walls) are used to support vertical or

Often MSE walls are used in this application. Reinforced soil is

MSEW Crusher location

Dyer Quarry, Inc.

Dyer Quarry, Inc. is located in Robeson Township, Berks County,

DYER QUARRY INC.

TITAN ENGINEERS PC / MACCAFERRI INC

PARAWALL SYSTEM; REINFORCEMENT PARAGRID

The finished MSEW Crusher

Trenton, New Jersey

These large structures are part of the concentration facilities

The facility is strategically located and serviced by Norfolk

Need for a Crusher Wall

The Maccaferri MSE wall system, "Parawall" was the superior

Crusher Wall Alignment Detail

Maccaferri Inc. working with Titan Engineering PC provided

Construction and Materials

The wall shows several peculiarities and required special

It is interesting to note that the reinforced soil in bottom courses

Trenton, New Jersey

The maximum exposed height of the Parawall is 70.0ft with

The bonded geogrid (Paragrid) with tensile strength varying from

Paragrid consists of aligned arrays of high tenacity polyester

Back Fill over the ParaGrid Early in the Construction Process

Aerial View of Construction Site

Close up of Paragrid 150 Installation

Close up of the MacDrain Drainage Material

Trenton, New Jersey

(Above and Below) Detailed view of the finished MSEW Crusher

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