Bor11999 Sa Manual Bk4

Masonry Design Guide

www.boral.com.au/masonry Updated September 2007

Boral MaSoNrYBuild something great™

segmental block retaining walls south australia BooK 4

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A IntroductionContents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

Fast Find Product and Application Guide . . . . . . . . . . . . . . . A3

Products @ a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

About This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6

B Planning and Design

C Gardenwall®

Gardenwall Product Information . . . . . . . . . . . . . . . . . . . . . . C2

Selection and Construction Guidelines . . . . . . . . . . . . . . . . . C3

Curved Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4

D Heathstone®

Heathstone Product Information . . . . . . . . . . . . . . . . . . . . . . D2

Gravel Fill Construction Guidelines . . . . . . . . . . . . . . . . . . . . D3

Curved Wall Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . D4

Step Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4

Step Tread and Cap Unit Installation . . . . . . . . . . . . . . . . . . . D5

Corner Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6

No-Fines Concrete Wall Construction . . . . . . . . . . . . . . . . . . D7

E Keystone® and Pyrmont®

Keystone Product Information . . . . . . . . . . . . . . . . . . . . . . . E4

Pyrmont Product Information . . . . . . . . . . . . . . . . . . . . . . . . E5

Gravity Wall Selection and Construction Guidelines . . . . . . . E6

Typical Installation Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . E8

No-Fines Concrete Wall SelectionConstruction Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . E11

Geogrid Soil-Reinforced Wall Selection Construction Guidelines . . . . . . . . . . . . . . . E13

Typical Specification for Keystone/Pyrmont Block Retaining Walls . . . . . . . . . . . . . . E15

F Custom Engineered Wall SystemsEngineered Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . F2

Keysteel Product Information . . . . . . . . . . . . . . . . . . . . . . . . F4

Typical Soil-Anchor Application . . . . . . . . . . . . . . . . . . . . . . . F6

Typical Rock-Anchor Application . . . . . . . . . . . . . . . . . . . . . . F7

Typical Seawall Application . . . . . . . . . . . . . . . . . . . . . . . . . . F8

Typical Terraced Wall Application . . . . . . . . . . . . . . . . . . . . . F9

Typical Fencing Application . . . . . . . . . . . . . . . . . . . . . . . . . F10

Typical Railing and Barrier Application. . . . . . . . . . . . . . . . . F11

The information presented herein is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. No responsibility can be accepted by Boral or its staff for any errors or omissions. Users are advised to make their own determination as to the suitability of this information in relation to their particular purpose and specific circumstances. Since the information contained in this document may be applied under conditions beyond our control, no responsibility can be accepted by us for any loss or damage caused by any person acting or refraining from action as a result of this information.

An Introduction to Segmental Block Retaining Walls . . . . . . . . . . . . . . . . . . . . . B2

Site Investigation — Preliminary Design . . . . . . . . . . . . . . . . B6

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Vertical

SurchargeLoading

Nil

≤ 5kPa

≤ 5kPa or≤ 1:4SlopedBackfill

≤ 25kPa

> 25kPa

Wall Height (mm)

≤ 1125

≤ 1600

≤ 3000

> 3000

> 6000

Wall Type

Set Back

Vertical

Set Back

Property Boundary

NotBoundary

Vertical

Set Back

Vertical

Set Back

Garden

wall

Heath

stone

Pyrm

ont

Keyst

one

Keyst

eel

Core Fi

lled B

lock

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E� E� �

E�E�

E�

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Select your application criteria from the left hand columns

Go straight to the book section indicated by the letter at the intersection of application rows and product columns (e.g. Section E in this example)

Please refer to Book 1, Boral Masonry Design Guide and Book 2, Boral Masonry Blocks & Bricks Guide

Requires ‘No-fines Concrete Backfill ’ or ‘Geogrid’ systems

Requiring ‘Geogrid’ systems

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�

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BORALMASONRYSEGMENTAL BLOCKRETAINING WALLS PRODUCT

Fast Finda BoralSolution

1

2

For technical support and sales office details please refer to the outside back cover

The quickest way to find a Boral Masonry Segmental Block Retaining Wall Solution.Simply follow the FAST FIND guide on the right hand side of the table.

Max. wall heights disclaimer:

The gravity wall heights are maximum heights calculated in accordance with CMAA MA-53 Appendix D guidelines and a qualified engineer should confirm the suitability of the product for each intended application. As such, due consideration must be given to but not limited to:

• Cohesion,

• Dry backfill: no ingress of any water into the soil behind the retaining wall,

• All retaining walls are designed for zero surcharge.

These walls are intended for structure Classification A walls only as defined in AS4678 Earth Retaining Structures as being where failure would result in minimal damage and loss of access.

Fast Find Guide

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Landscape Retaining Wall Systemsfor low-height domestic and commercial garden beds and retaining wall applications

• Gardenwall®

Boral Gardenwall is ideal for gravity wall installations of less than 1125mm wall height. The blocks are laid with a slight set-back, and are located by a lug along the back edge. Gardenwall can also be used curved wall applications.

• Heathstone® and Heathstone® GrandeBoral Heathstone retaining wall systems combine the attractive impression of natural hewn stone, the elegance of a vertical wall and the simplicity of mortarless installation. Various installation formats cater for walls up to 0.97m height. Heathstone Grande double-length blocks are particularly effective in larger installations.

Products @ a Glance

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Engineered Retaining Wall Systemsfor domestic and commercial landscaping, roadside and custom engineered retaining wall applications

• Pyrmont®

Boral Pyrmont retaining walls are a modern-day link to our pioneer heritage. Pyrmont combines modern engineering versatility with the elegance of a vertical wall and the style of hand-finished natural stone. Pyrmont gravity or soil reinforced retaining wall systems can be engineered for applications up to 6m height and can accommodate gentle curves and step installations.

• Keysteel™ Custom Engineered Retaining Wall SystemsBoral Keysteel is a high performance engineered retaining wall system for applications requiring wall heights in excess of 6m and/or where critical surcharge loadings are present. Boral Keysteel is an internationally proven system that integrates the superior strength and durability of Keysteel blocks with steel-ladder soil-reinforcement to provide engineered solutions for the most demanding retaining structures.

• Keystone®

Boral Keystone walls have been proven time-and-time-again, by engineers, architects, councils, road authorities and landscapers throughout Australia. Keystone walls can cater for a wide range of applications from low height gravity walls to geogrid soil reinforced applications up to 12m wall height. Keystone walls can be constructed as near vertical with curves as tight as 1m radius, or set-back. Blocks are available in a wide selection of colours.

Products @ a Glance



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4Keystone® & Pyrmont®

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INTRODUCTIONBoral Keystone is an advanced, highly versatile and thoroughly proven high performance segmental block retaining wall system which can be used as a gravity structure or it can incorporate geogrid soil-reinforcement to cater for greater heights and surcharge loading situations.

DESIGN CONSIDERATIONS• Suitable for straight and curved

wall installations with a minimum convex curve radius of 1800mm without trimming the tail width, or 970mm radius by trimming

the tail to 300mm width.

• Can be installed as near vertical, or for straight walls without curves or corners it can be installed with a 1-in-8 setback.

COLOURSKeystone is offered in a range of colours to suit decorative and engineering applications. Please refer to colour swatch information for an indication of current colours.

To reduce the possibility of staining and to enable easier cleaning, a masonry sealer can be applied to all visible surfaces after installation.

Keystone®

Retaining Wall Systems

Standard Cap(made to order)

275

100

455

Flushface Straight Sided Cap(made to order)

275

100

455

Lifting Bars

Description HxLxDmm Wt kg N°/m2

Standard Unit 200x455x315 41 11

Straight Sided Cap 100x455x275 25 2.2/lin mtr

Standard Half High Unit 100x455x275 20 22

Standard Cap 100x455x275 20 2.2/lin mtr

Flushface Unit 200x455x315 41 11

Flushface Straight Sided Cap 100x455x275 26.3 2.2/lin mtr

Pins 2 pins per full unit (high strength pultruded fibreglass)

Lifting Bars (Keystone units should be lifted by two people using the Keystone lifting bars)

Specifications

315

200

455

Standard Unit

315

200

455

Flushface Unit(Made to order)

Availability & Colours• No minimum order quantities apply.• Lead time 0-4 weeks.

Tuscan

Keygrid Geogrid Soil Reinforcement

Straight Sided Cap(made to order)

275

100

455

Pins

Almond

Paperbark

300

50

300

D-Cap

About This Guide

A Guided Tour of a Typical Product Information PageProduct pages are laid out in a consistent manner to assist with easy selection and specification

of Boral Masonry products.

Product Range, Book and Page Identification

Product Name and other identifying features

Product information relating to features, applications, and accessories

ProductSpecifications

Product Icons with dimensions for products available in your region/state

Colour and Availabilityinformationfor products distributedin your region/state

Boral Masonry Product RangeBoral Masonry offers a comprehensive range of proven products and systems including Segmental Block Retaining Wall Systems, Segmental Paving Products, Masonry Blocks, Masonry Bricks, Masonry Fire and Acoustic Wall Systems.

What’s in this GuideThe Boral Masonry Segmental Block Retaining Walls Guide, (this book), details a comprehensive selection of retaining wall options ranging from low height gravity landscaping walls to critically loaded reinforced-soil retaining structures.

This guide has been prepared as a comprehensive Boral Product Reference Guide. It does not attempt to cover all the requirements of the Codes and Standards which apply to retaining wall construction. All structural detailing should be checked and approved by a structural engineer before construction. Boral reserves the right to change the contents of this guide without notice.

Please note that this guide is based on products available at the time of publication from the Boral Masonry South Australia sales region. Different products and specifications may apply to Boral products sourced from other regions.

Additional Assistance and Information• Contact Details: Please refer to the outside back cover

of this publication for Boral Masonry contact details.

• Colour and Texture Variation: The supply of raw materials can vary over time. In addition, variation can occur between product types and production batches. Also please recognise that the printed colours in this brochure are only a guide. Please, always ask to see a sample of your colour/texture choice before specifying or ordering.

• Terms and Conditions of Sale: For a full set of Terms and Conditions of Sale please contact your nearest Boral Masonry sales office.

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Keystone®



275

100

455


275

100

455

Lifting Bars










Specifications

315

200

455

Standard Unit

315

200

455


Availability and Colours• No minimum order quantities apply.• Lead time 0-4 weeks.

Tuscan



275

100

455

Pins

Almond

Paperbark

300

50

300

Standard Cap

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An Introduction to Segmental Block Retaining WallsBackgroundFor many years cantilever retaining walls have been constructed with reinforced concrete masonry stems (steel reinforcement grouted into hollow concrete block work) and reinforced concrete footings. (Refer to Fig B1).

Segmental block gravity retaining structures, consisting of dry-stacked concrete units which resist overturning by virtue of their own weight and setback, were introduced into Australia in the early 1990’s, and rapidly became popular. This system provides an attractive and cost effective solution, but its stability is limited by the geometry of the units and wall heights. (Refer to Fig B2).

In order to achieve greater heights, reinforced-soil walls (such as Boral Keystone) were introduced. These walls typically consist of geosynthetic materials, which are placed in horizontal layers in the compacted backfill and mechanically connected to the blocks. Such systems can be constructed several metres high, and accommodate significant loads.

A further development of this system is the Boral Keysteel system which utilises steel-ladder reinforcement. Here the steel-ladder reinforcement is placed in horizontal layers in the compacted backfill and mechanically connected to the blocks. These systems are individually engineer designed, and are suitable for walls in excess of 6m high and for critical surcharge loadings. (Refer to Fig B3).

Steel reinforced and concrete grout filled hollow concrete block wall

Reinforcedconcretefootings

Fig B1 — Typical Reinforced Concrete MasonryCantilever Retaining Wall

Segmental block gravity retaining structure, dry-stacked against a soil slope

Fig B2 — Typical Segmental Block Gravity Retaining Wall

Segmentalconcretegravityretainingstructure, with reinforced soil

Fig B3 — Typical Reinforced-Soil Segmental Block Retaining Wall

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Behaviour of Segmental Block Reinforced-Soil Retaining WallsIf unrestrained, a soil embankment will slump to its angle of repose. Some soils, such as clays, have cohesion that enables vertical and near-vertical faces to remain partially intact, but even these may slump under the softening influence of ground water. When an earth retaining structure is constructed, it restricts this slumping. The soil exerts an active pressure on the structure, which deflects a little and is then restrained by the friction and adhesion between the base and soil beneath, passive soil pressures in front of the structure and bearing capacity of the soil beneath the toe of the structure.

If water is trapped behind the retaining structure, it exerts an additional hydraulic pressure. This ground water also reduces the adhesion and bearing resistance.

If massive rock formations are present immediately behind the structure, these will restrict the volume of soil which can be mobilised and thus reduce the pressure.

Reinforced-soil systems consist of a series of horizontal geogrids that have been positioned and pulled tight within a compacted soil mass, thus strengthening it and restricting its slump. The geogrids are strategically placed to intersect potential failure planes that are inclined from near the base of the wall, up at an angle (depending on the soil properties), to the top of the fill. The function of the geogrids is to ‘strengthen’ the soil mass and they are ‘anchored’ by compacted backfill beyond the potential failure planes.

Local collapse and erosion of the front face is eliminated by fixing concrete segmental facing units to the exposed ends of the geogrids. However, the segmental concrete facing is not designed to ‘retain’ the strengthened soil mass, which should be able to stand independently of the facing except for local effects. The connection spacing (and the geogrid spacing) must account for the local stability of the facing, including bulging and rotation above the top geogrid. The top capping course is normally bonded to the course below using a concrete to concrete adhesive.

A surface sealing layer and surface drainage system minimise the quantity of rainwater entering the soil mass. A sub-surface drainage system behind the segmental concrete facing and (sometimes) beneath the wall reduce pore water pressures and thus reduce the tendency for local or global slip.

Thus, the essential features of a properly designed and constructed segmental block reinforced soil retaining wall are:

• Geogrids with adequate length and strength;

• Adequate connection to the facing to provide local stability;

• A drainage system that will relieve hydro static pressures for the life of the structure.

Importance of a Geotechnical ReportThe design of a reinforced soil retaining wall includes two essential parts:

• Analysis of the proposed reinforced soil structure and the adjacent ground for global slip, settlement, drainage and similar global considerations; and

• Analysis and design of the reinforced soil structure itself.

These analyses must be based on an accurate and complete knowledge of the soil properties, slope stability, potential slip problems and ground water.

Except in the case of simple structures, a geotechnical report by a qualified and experienced geotechnical engineer should be obtained.

Such a report must address the following considerations, as well as any other pertinent points not listed.

• Soil properties;

• Extent and quality of any rock, including floaters and bedrock;

• Global slip and other stability problems;

• Bedding plane slope, particularly if they slope towards the cut;

• Effect of prolonged wet weather and the consequence of the excavation remaining open for extended periods;

• Effect of ground water;

• Steep back slopes and the effect of terracing;

• Effect of any structures founded within zone of influence.

Safety and Protection of Existing StructuresWhenever soil is excavated or embankments are constructed, there is a danger of collapse. This may occur through movement of the soil and any associated structures by:

• Rotation around an external failure plane that encompasses the structure;

• Slipping down an inclined plane;

• Sliding forward, or

• Local bearing failure or settlement.

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These problems may be exacerbated by the intrusion of surface water or disruption of the water table, which increase pore water pressures and thus diminish the soil’s ability to stand without collapse.

The safety of workers and protection of existing structures during construction must be of prime concern and should be considered by both designers and installers. All excavations should be carried out in a safe manner and in accordance with the relevant regulations, to prevent collapse that may endanger life or property. Adjacent structures must be founded either beyond or below the zone of influence of the excavation. Where there is risk of global slip, for example around a slip plane encompassing the proposed retaining wall or other structures, or where there is risk of inundation by ground water or surface water, construction should not proceed until the advice of a qualified and experienced Geotechnical Engineer has been obtained and remedial action has been carried out.

Global slip failureSoil retaining structures must be checked for global slip failure around all potential slip surfaces or circles.

Designers often reduce the heights of retaining walls by splitting a single wall into two (or more) walls, thus terracing the site. Whilst this may assist in the design of the individual walls, it will not necessarily reduce the tendency for global slip failure around surfaces encompassing all or some of the retaining walls.

Analysis for global slip is not included in this guide, but it is recommended that designers carry out a separate check using commercially available software.

Differential SettlementThe Concrete Masonry Association of Australia (CMAA) recommends that for dry stacked mortarless retaining walls employing masonry units (i.e. units with an area less than 0.2m2) on an aggregate levelling pad, the differential settlement should be limited to 1% of the length. Whilst it is permissible for the retaining wall to undergo differential settlement up to 1% of the length, it may be preferable to limit settlement to a lower figure giving consideration to aesthetics (i.e. keeping the bedding planes level), in addition to the structural considerations.

Techniques to reduce or control the effects of differential settlement include:

• Articulation of the wall (in discontinuing the normal stretcher bond) at convenient intervals along the length,

• Excavating, replacing and compacting areas of soft soil,

• Limiting the stepping of the foundation and bottom course to a maximum of 200mm.

Unit Cracking/Gapping — Settlement Keystone modular retaining wall structures can tolerate a certain amount of settlement due to the flexible nature of the system and small individual unit size.

Observation of a number of completed structures that have undergone settlement indicates that the wall’s tolerance for settlement without cracking is inversely proportional to the wall height. Lower height walls (H<5m) appear to have considerably more facial flexibility than taller walls (H>5m). This increased flexibility is due to lower confining forces and load transfer taking place on each block, which permits small individual movements to occur, accommodating the settlement experienced without facial distress. Taller walls place the lower wall units under considerable confining pressure, restricting unit movement and permitting shear and flexural stresses to build up to the point where a block cracks as a means of stress relief.

Low wall settlement problems are typically observed in residential projects where soils adjacent to houses are uncompacted and the walls settle differentially over a short distance. Usually gapping or offset joints are visually noted and the settlement is obvious.

Gapping and offset joints

Downwardmovement

Fig B4 — Typical Low WallSettlement

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Tall wall settlement is not as obvious but occasional facial cracks can be observed in areas of flexural stress concentration, typically in small groupings in the bottom 1/3 of the wall. Settlement induced cracks are usually not structurally significant and are just a means of facial stress relief for the unreinforced dry-stack facing system. However, cracked units can be a symptom of other types of problems, so a review by an engineer is always recommended.

Importance of DrainageThis guide assumes that a properly functioning drainage system is effective in removing hydraulic pressure. If this is not the case, the designer will be required to design for an appropriate hydraulic load.

Based on an effective drainage system, it is common to use drained soil properties. For other situations, the designer must determine whether drained or undrained properties are appropriate. In particular, sea walls that may be subject to rapid drawdown (not covered in this guide) require design using undrained soil properties.

High confining pressure

Flexural stress

Facial cracks

Downwardmovement

Fig B5 — Typical Tall WallSettlement



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Site Investigation: Preliminary Design Date: _______________________

Report prepared by: _______________________

Client: __________________________________________________________________________

Project: _________________________________________________________________________

Location: ________________________________________________________________________

Use for which retaining wall is intended: _____________________________________________

Proximity of other structures to the face of the retaining wall:Structure or load Distance (m)

Distance of live loads from top of wall (Dqi) _______________________

Distance of dead loads from top of wall (Dqd) _______________________

Distance of point loads from top of wall (Di) _______________________

Distance of other structures from base of wall (Ds) _______________________

Structure classification: _________________________________________________

For guidance refer AS4678, Table 1.1

Structure Classification Examples

2. Where failure would result in significant damage or risk to life3. Where failure would result in moderate damage and loss of services4. Where failure would result in minimal damage and loss of access

Required design life: _____________________________________________________

For guidance refer AS4678, Table 3.1

Type of Structure Design life (years) Type of Structure Design life (years)

Temporary site works 5 Residential dwellings 60Mine structures 10 Minor public works 90Industrial structures 30 Major public works 120River and marine structures 60

Wall geometry:Wall height above GL (H’) ___________ m

Embedment depth (Hemb)H/20 or 200mm ___________ m

Wall slope (v) ___________ °

Angle of backfill slope (b) ___________ °

Height of backfill (h) ___________ m

Foundation material:

Allowable bearing pressureUnder reinforced soil block ___________ kPa

Water profile:Water table depth within wall fill ___________ m

Retained soil data:Soil density (gr) ___________ kN/m3

Internal friction angle (fr) peak ___________ °

Cohesion (C*i) ___________ kPa

Loading data:Dead load surcharge (qd) ___________ kPa

Live load surcharge (ql) ___________ kPa

Horizontal line load (F) ___________ kN/m

Vertical line load (P) ___________ m

Width of bearing (b) ___________ m

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4Gardenwall®

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INTRODUCTIONBoral Gardenwall is ideal for low landscaping walls and edgings in garden and communal areas. Gardenwall’s rockface texture, multi-faceted face and setback construction produces an aesthetically pleasing feature for landscaped areas. Gardenwall is often used for garden edges and raised beds, terraces and to create decorative features such as around pools.

DESIGN CONSIDERATIONSDepending on the foundation and retained soil characteristics, Gardenwall is effective as a gravity retaining wall structure up to 1125mm (maximum 9 courses). Never install where loads (e.g. buildings, driveways) will be located within 1125mm of the wall. For engineered walls (to AS4678) higher than 1125mm, or where a surcharge is present, Boral Keystone or Pyrmont walls should be considered.

ADVANTAGES• Gardenwall does not require

concrete foundations.

• Easy installation of straight walls and curved walls.

• Durable, low maintenance, long-term landscaping.

• Solid units — eliminates the need for capping and corner units.

COLOURSGardenwall is offered in a range of colours to suit traditional and contemporary settings. Please refer to colour swatch information for an indication of current colours.


Product Description Finish HxLxDmm Approx Wt kg No. per m2

Standard Unit Rockfaced 125x300x228 15.5 26.7

Straight Sided Unit Rockfaced 125x300x228 15.5 26.7

Specifications

Gardenwall®

Retaining Wall System


228

125

300

Standard Unit

228

125

300

Straight Sided Unit

Hawkesbury YellowPaperbark

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IMPORTANT: Please consult with the regulating council for local design requirements prior to the design and construction of a retaining wall. Councils in general require that retaining walls be designed and certified by a suitably qualified engineer where the wall is over 0.5m in height and/or where there is surcharge loading such as a roadway, house, or other structure near the wall.

• Boral Gardenwall is only suitable for walls up to 1125mm in height and where no loads or surcharge exists within 1125mm behind the wall.

Installation• Remove the retaining lug on the base of the unit on

those Gardenwall blocks being used on the base course only (this makes levelling the first course much easier). To remove the lip, place at an angle on the ground and strike the lug firmly with a hammer (safety glasses should be worn).

• As a safety precaution to avoid lifting or movement of the top units, it is recommended that the top course units are secured using a construction adhesive. This is also recommended in areas of possible vandalism.

• Standard units can also be used to construct convex curves.

Gardenwall Unit

1 in 5 set-back

150mm width of 12-20mmØ free draining granular material eg. blue metal

Backfill placed and compacted in 250mm layers

Compacted road base levelling pad on undisturbed inorganic soil

First course to be buried below final ground level (to engineer's specification - 100mm min.)

Drainage pipe (if required)

350mmmin.

100mm min.

Native soil

Dish drain to direct surface run-off (if required)

H

No loads to be located within 1125mm behind wall

Backfill should be no higher than the top of the wall

Filter fabric to stop siltclogging drainage material

Fig C1 — Typical Gravity Wall Construction Detail — Gardenwall

Selection and Construction Guidelines

Note: Refer to max. wall heights disclaimer on page A3 of this guide.The gravity wall heights are maximum heights calculated in accordance with CMAA MA-53 Appendix D guidelines and a qualified engineer should confirm the suitability of the product for each intended application.



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for 1st course

Radius = 1000mm

Minimum

Fig C2 — Construction of Curved Walls

• When designing Gardenwall for convex curves to the maximum height of 8 courses, it is necessary to begin with a minimum radius of 1000mm. It may also be necessary to remove the outer portions of the retaining lug from each unit to maintain a consistent setback. It is important that the entire lug is not removed.

• When building curves, some blocks may also require trimming of the length to maintain a half bond pattern.

Curved Walls

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4Heathstone®

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INTRODUCTIONBoral Heathstone is ideal for low, vertical landscaping walls in garden and communal areas. The rockface texture and bevelled edges add a formal and elegant element to a landscaped area. Heathstone is often used to separate and highlight entertaining areas, BBQ areas, paths, garden beds, hedges, or to create and differentiate levels. Heathstone is also suitable for constructing steps, planter boxes and for curved walls.

DESIGN CONSIDERATIONSDepending on the foundation and retained soil characteristics, Heathstone is effective as a gravity structure up to 972mm, or up to 1600mm when installed with no-fines concrete backfill. Heathstone should not be used where the base soil or backfill is not firm, or is of expansive clay. Never install where loads (e.g. buildings, driveways) will be located within 1000mm of the wall. For walls higher than this, or where a surcharge is present, Boral Keystone or Pyrmont walls should be considered.

The range of Heathstone components is designed to optimise space, and includes a ready-to-install corner unit and a series of caps to accommodate single or double sided applications and curved installations.

Convex curves as tight as 900mm radius can be constructed using the standard unit. The Curved Cap can be used to form curves of 1800mm outside radius and 1500mm inside radius.

COLOURSHeathstone is offered in colours which emulate natural hewn stone, and which contrast beautifully with soil, mulch, shrubbery and grassed areas. Please refer to colour swatch information for an indication of current colours.


Heathstone®

Retaining Wall System

Grand Unit

280

162

440

300

50

300

Stoneworks® Cap

Product Description Finish HxLxDmm Approx Wt kg No. per m2

Standard Unit Rockfaced/Smoothfaced 162x220x280 11.9 28.1 units/m2

Standard Corner Unit Rockfaced x 2 Faces 162x380x270 23 1/course/corner

Grand Unit Rockfaced 162x440x280 26.2 14.05 units/m2

Bullnose Cap Smooth 50x300x300 9.4 3.3/linear metre

Stoneworks Cap Rockfaced 50x300x300 22 3.3/linear metre

Specifications


LimestoneStoneworks Cap ONLY(made to order)

SandstoneStoneworks Cap ONLY(made to order)

300

50

300

280

162

220380

162

270

Standard Corner Unit Standard Unit

Bullnose Cap

Charcoal

Tuscan

Note: Refer to max. wall heights disclaimer on page A3 of this guide.

Paperbark

Almond

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Blocks to be embedded a minimum of 100mm

Native soil

No loads to be located within 1.0m of the wall

150mm min. of 12-20mmØ free draining granular material eg. blue metal

Dish drain to direct surface water or filter fabric to stop silt filling drainage layer

Voids in and around Heathstone blocks to be filled (if required) with 12-20mmØ free draining granular material eg. blue metal

Backfill (eg. excavated soil) to be placed and compacted as each course of blocks is laid

Agricultural drainage line 100mmØ

100mm min.

350mmmin.

Compactedroadbase

Refer to Heathstone Gravel-Fill Selection Table for maximum number of courses


Fig D1 — Typical Construction Detail — Heathstone Gravel-Fill


Heathstone® Gravel-Fill Construction

Maximum Courses Maximum Courses For walls without gravel fills For walls with gravel fills to all voids and cores to all voids and cores

Poor soils — including sands, gravelly

clays, sandy clays and silt clays 2 (324mm) 4 (648mm)

Average soils — including well graded

sands and gravelly sands 3 (486mm) 5 (810mm)

Good soils — including gravels, sandy

gravels and crushed sandstone 4 (648mm) 5 (810mm)

NOTES: Backfill retained by a retaining wall should be no higher than the top of the retaining wall.

For engineered retaining walls to AS4678, refer to the Heathstone No-Fines Concrete Wall Guidelines.

Refer to max. wall heights disclaimer on page A3 of this guide.

The gravity wall heights are maximum heights calculated in accordance with CMAA MA-53 Appendix D guidelines

and a qualified engineer should confirm the suitability of the product for each intended application.

Table D1 - Maximum Wall Height — Heathstone Gravel-Fill

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Curved Wall Construction Curves as small as 900mm in radius can be constructed with Heathstone Standard Units.

Bolster back of blocks to form convex curves

NOTE: Premium Curved Caps have an outside radius of 1800mm

Fig D2 — Forming Convex Curve

Concave (Internal) Curves

• For concave curves use Standard Units spaced evenly to a scribed arc.

Concave Curve Radius

Minim

um radius 900m

m

HeathstoneStandard Unit

Fig D3 — Forming Concave Curve

Convex (External) Curves

• For convex curves, the tails of the blocks must be trimmed to suit the desired radius. Use a hammer and bolster on the back, top and bottom of the tail. Use light hammer blows first to trace the area to be removed, then a heavier blow on top. Repeat the tracing and final blow if necessary.

1:10 Cement : Sand

Native soil

255

162

45

25

HeathstoneUnits

Remove locating lugs before laying

Fix cap units with construction adhesive

Bullnose Cap

Fig D4 — Construction of Heathstone Steps

Step Construction

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Step Treads and Cap Unit Installation• Splitface Cap (225mm long) has a recess in the underside

to allow for the lug on the Heathstone Unit. Removal of the lug is not required in this case

• To allow for installation of the Double-sided Rockface Cap units and step treads, it is necessary to bolster locating lugs from the blocks.

• Push the Heathstone split-face into sand for support. Trace along the back of the lug with a bolster and hammer, increasing the force of hammer blows until the lug splits off. All blows must be from the back of the block, with the bolster blade nearly parallel to the top of the Heathstone unit. Refer to the illustration. Any remaining high spots should be removed with a scutch hammer or an old screwdriver and hammer.

Fig D5 — Bolstering Lug from Heathstone Units

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Corner UnitCorner Unit

Fig D6 — Heathstone Standard External Corner (270°)

Corner Unit

Standard Unit

Corner Unit

110mm

Fig D7 — Heathstone Standard Internal Corner (90°)

Standard Corner Unit

Standard Corner Unit

Grand Unit

330mm

Grand Unit

Grand Unit cutto 330mm on site

Grand Unit cutto 330mm on site

Fig D8 — Heathstone Grand External Corner (270°)

Grand Unit

Grand Unit

Bolster lug tofit next course

Bolster lug tofit next course

220mm

NOTE: Internal 90º corners using Grand Units do not require corner units

Fig D9 — Heathstone Grand Internal Corner (90°)

Corner Construction Constructing Internal and External Corners

• Corners are constructed using Corner Units and Standard Units or Grand Units and Corner Units.

• Lay the Corner Units’ largest splitface in alternate directions in adjacent courses (see illustrations).

• Continue this step until the desired height of the wall is achieved.

• Use a construction adhesive to secure corner blocks and caps.

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No-Fines Concrete shall consist of cement, water and coarse aggregate. Cement will comply with the definitions for cement per AS3972-1991 — ‘Portland and Blended Cements’. The quantity of cement is specified as 210kg/m3 with a total water/cement ratio of between 0.45 and 0.55.

The particle size distribution of the aggregate shall comply with the limitations for the nominal single sized 20mm aggregate specified in AS2758.1.

NOTES:

• Table D2 is based on AS4678 : 2002, Earth Retaining Structures. The code assumes a surcharge of 5kPa is

H(Refer to Heathstone

No-Fines Concrete Selection Table)

Blocks to be embedded to engineer‘s detail (1 course min.)

Retained soil

No loads above 5kPa to be located within 1.0m of the wall

T

15MPa ‘No Fines’ concrete. All voids within and around units to be completely filled.

Filter fabric or dish drain

Cap unit

Pour no-fines concrete directly onto prepared foundation material

Sub-soil drain connected to stormwater system or flood pit. Place loose aggregate around subsoil drain before pouring no-fines concrete.

150mm min.

600mm min.

Filter fabric to stop siltclogging drainage of‘no-fines’ material

25MPa concrete footing on 150kPa allowable bearing capacity material

Fig D10 — Typical Construction Detail — Heathstone No-Fines Concrete Wall

Heathstone® No-Fines Concrete Wall Construction

Wall Height Retained Soil Retained Soil Retained Soil

‘H’ (mm) CLAY φ = 26° (POOR) SAND φ = 30° (AVERAGE) GRAVEL φ = 34° (GOOD)

‘T’ (mm) ‘T’ (mm) ‘T’ (mm)

972 670 570 570

1296 730 770 670

1620 1170 970 770

φ Denotes the internal angle of friction of the retained material

Table D2 — Heathstone Maximum Wall Heights — No-Fines Concrete Construction

applied to all retaining wall structures.

• Global stability and all design considerations should be checked by an engineer in poor clay conditions.

• Design assumes a dry excavation (i.e. water table is below bottom of footing level). If ground water exists in the excavation the wall is to be re-designed by a suitably qualified engineer.

• These tables are supplied free of charge and do not form any part of any contract with the user.

• 15MPa No-Fines concrete with a 6:1 ratio (Gravel : Cement).

• Remove tail fins to allow “no fines” to connect block fill to back fill.



e KEYstoNE® aND pYrMoNt®

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south australia Book 4 D


Boral MaSoNrYBuild something great™B

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• The density of this product will vary with the density of the aggregate used. The density range may be from 1650kg/m3 to 2100kg/m3.

• The void ratio of the mix is expected to be between 20% and 30% and should be free draining.

• The compressive strength should generally exceed 10MPa for design purposes.

• This product has no slump and exerts similar pressures on the soil and formwork, as does loosely poured aggregate.

No-Fines Construction StepsSpecial purpose construction such as waterside walls, post fixing, earthquake zones, and terraces will require additional engineer’s design.

STEP 1: Excavation/Preparation of Levelling Pad

Excavate a trench 600mm wide and sufficiently deep to allow a 150mm levelling base plus 1 course below ground.

STEP 2: Installing the First Course

Lay the first course of Heathstone units side by side over the prepared base. Bolster off the tails so that ‘No-Fines’ concrete connects backfill to core-fill areas.

STEP 3:No-Fines Concrete Backfill

Backfill the first 21Ú2 courses of the wall with ‘No Fines’ concrete. All voids inside and between the units must also be filled. The vertical height of any pour of ‘No Fines’ concrete is limited to 400mm. For walls greater in height, each pour must be allowed to harden prior to pouring the next lift. Alternatively the wall may be propped to support the lateral load from the wet concrete.

STEP 4:

Installing Capping Units

Install capping units and fix with construction adhesive.

e2 e3Boral MasoNrY DEsiGN GuiDE | september 2007september 2007 | Boral MasoNrY DEsiGN GuiDE

south australia Book 4 E south australia Book 4 EB

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4Keystone® and Pyrmont®

E2

Keystone® and Pyrmont Retaining Wall SystemsThe Keystone Retaining Wall System is a world-wide success story, and since its introduction by Boral into Australia in 1992, hundreds of thousands of square metres have been installed along our highways, roads and transport corridors, and around our sports facilities, buildings, foreshores and open spaces.

Boral Keystone retaining wall systems combine proven engineering capabilities with design versatility, cost effectiveness, lasting durability and an attractive dynamic appearance to provide total solutions for retained earth structures.

Keystone®

Boral Keystone systems provide infinite flexibility for design variation and individuality. The range of components and installation methods cater for straight, curved and terraced walls, level or stepped foundations

and capping, and a near vertical or set-back face. Then there is a choice of standard or flushface, and a selection of popular standard colours or custom colours can be ordered for larger projects.

Pyrmont®

Boral Pyrmont retaining wall system retains all of the engineering characteristics of the Keystone system and combines them with a more traditional appeal of a bevelled-edge splitface block, and vertical construction to emulate walls built during Australia’s pioneering era.

The range of components and installation methods cater for straight and gently curved walls as well as crisp 90º corners, while the rock-faced caps provide a finishing touch that completes the transformation into a masterpiece from the colonial era.

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Ease of ConstructionBoral Keystone and Pyrmont systems are designed to reduce construction time and cater for all locations. The modular blocks can be moved and installed without the need for heavy lifting machinery, and the dry stacked, mortarless installation provides less complex, more rapid construction.

Proven EngineeringVarious installation methods cater for simple gravity walls through to geogrid soil-reinforced retaining structures. Boral Keystone and Pyrmont systems can also cater for critical surcharge loads, enabling the construction of buildings or roadways close to the wall to optimise land usage.

For high performance retaining walls, please refer to the section on Boral Keysteel Custom Engineered Retaining Wall Systems later in this guide.

DurabilityBoral Keystone and Pyrmont systems combine the durability of concrete units and interlocking fibreglass pins to produce maintenance free walls with life expectancies of up to 120 years.



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Keystone®



275

100

455


275

100

455

Lifting Bars










Specifications

315

200

455

Standard Unit

315

200

455



Tuscan



275

100

455

Pins

Almond

Paperbark

300

50

300

Standard Cap

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Lifting Bars

INTRODUCTIONBoral Pyrmont retaining wall systems integrate the engineering capabilities of the Keystone system with the versatility and pleasing aesthetics of a vertical wall. The Pyrmont unit is a split-face block with four chamfered edges, emulating the care, skill and determination of stone masons from Australia’s early settler period.

Boral Pyrmont retaining wall system is also suitable for constructing steps, planter boxes, gently curved walls and crisp 90° corners.

DESIGN CONSIDERATIONSSuitable for curved wall installations with a suggested minimum convex curve radius of 5m (resulting in a 5mm lip).

COLOURSPlease refer to colour swatch information for an indication of current colours.


Pyrmont Cap(made to order)

275

100

455



Pyrmont™ Cap 100x455x275 20 2.2/lin mtr



Lifting Bars (Pyrmont units should be lifted by two people using the Keystone lifting bars)

Specifications

Pyrmont®

Vertical Retaining Wall System

305

20 0

455

Standard Unit

275

100

455



Pins


TuscanAlmond

Paperbark



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Fig E1 — Installation of Pins


Refer to Keystone and Pyrmont ‘No-Fines Concrete’ Guidelines for engineered retaining walls to AS4678.

• Two sets of pin holes are provided in Keystone units.

• For near vertical construction, install pins in the front holes.

• For 1 in 8 setback construction, install pins in the back holes.

• Near vertical installation must be used when designing walls with curves or corners.

Wall Height H(mm) Surcharge Loading

Backfill Near 1 in 8

Type

Vertical Setback

SETBACK Poor 800 900

Average 900 1000

Good 1000 1200

Poor 600 900

Average 700 900

Good 800 1100

Poor 400 500

Average 500 600

Good 600 800

No S

urch

arge

Loa

ding

15° S

lope

d Ba

ckfil

lDr

ivewa

y/Ca

rpar

k Loa

ding

(5kPa

)

Table E1 — Maximum Wall Height for Gravel-Fill WallsGravel-Fill Wall Selection

Gravel-Fill Wall Construction Guidelines

For low, non-critical walls, (i.e.. walls covered in the adjacent table) the Keystone and Pyrmont Retaining Wall Systems are effective as a gravity wall structure, utilising their weight and interaction of the units to resist earth pressures.

Retained Soil Descriptions

Poor Soils Include fine sands, gravelly clays, sandy clays, silty sands. Angle of internal friction ≥ 25°

Average Soils Include well graded sands, gravelly sands. Angle of internal friction ≥ 30°

Good Soils Include gravels, sandy gravels, crushed sandstone Angle of internal friction ≥ 35°

NOTES: Pyrmont walls can only be constructed in near vertical format, and must be selected on the basis of data in the near vertical column from Table E1.Table E1: Refer to max. wall heights disclaimer on page A3 of this guide. The gravity wall heights are maximum heights calculated in accordance with CMAA MA-53 Appendix D guidelines and a qualified engineer should confirm the suitability of the product for each intended application.

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• For curved installations, leave a small gap between units for convex curves. Concave curves will require a small overlap of adjacent units. Refer to curve installation details on Page E9 of this guide.

• If backfill is required behind the drainage zone, place and compact existing site soils in 200mm maximum lifts. Heavy clays and organic soils are not recommended due to water holding problems.

• Provide a filter fabric between the drainage layer and the

backfill if the type of backfill is likely to wash into the drainage layer and clog it.

• Use only walk-behind compaction equipment within 1000mm of the wall face to prevent movement of the Keystone units.

• In areas of possible vandalism, it is recommended that capping units be secured using a masonry adhesive.

Fig E2 — Typical Installation Detail — Keystone Gravity Wall

Native soilCompacted footing

Free draining granular material

Drainage pipe

Compacted backfill soil (if required)

Cap Unit

Keystone or Pyrmont units

Optional 1:8 wall setback with Keystone units

12-20mm free draining granular material, fill all voids in and around units

Compacted roadbase, crushed stone or gravel levelling pad

First course to be buried below final ground level (to engineer's specification - 100mm min.)

Drainage pipe (if required)

300mm

Granular material for drainage

600mm min.

150mm min

H

Backfill

Filter fabric to stop siltfrom clogging drainage material

Fig E3 — Typical Construction Detail — Keystone Gravity Wall



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FIRST COURSE SECOND COURSE

Align centre of unit with face of adjoining wall

No pin in overlapping unit

No pin in overlapping unit

Fig E4 — 90° Internal Corner — Standard Keystone Units

Align face of unit with thecentre line of adjacent unit


Align face of unit with thecentre line of adjacent unit

Omit one pin only

Cut to suit on site

Omit one pin only

Cut to suit on site

Fig E5 — 90° Internal Corner — Pyrmont Units

Typical Installation Details

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Use front pin holes for curves. Maintain a small overlapbetween units.

Fig E7 — Concave Curve

Full mitre-cut Pyrmont unit


Adhesive fix corner units. Liquid Nails or similar

Half mitre-cut Pyrmont unit

Half mitre-cut Pyrmont unit

Full mitre-cut Pyrmont unit

Rad

ius

‘r’

3 unit 90 corner : r = 900mm





Use front pin holes for curves. Maintain asmall gap between units.

Bolsterbacks as required

Fig E8 — Convex Curve

Fig E6 — 270° External Corner Detail— Pyrmont Units



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225˚ corner unit – to be cut and bolstered on site fromKeystone/Pyrmont UnitNext course is a mirror image.

Drill and install fixing pin

Keystone cap unit

Keystone unit

Bedding sand –compact before laying treads

290mm Treads

Bolster backs as required

Compacted bedding sand

Sand : cement = 6 : 1

40mm Boral Pavers

10mm mortar joint

Keystone Flushface Caps

Tread approx. 290mm for 40mm pavers (30˚)

10mm

10mm100mm

40mm

160mm riser

Fig E12 — Keystone section through steps

Fig E11 — Plan view of step through Keystone

Fig E9 — 225° External Corner Flushface Keystone/Pyrmont Units

Fig E10 — Stepped Capping Units

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Fig E13 — Typical Construction Detail — Keystone No-Fines Concrete Mass Gravity Wall

‘No-Fines Concrete’ Wall Construction GuidelinesThe ‘No-Fines Concrete’ backfill system increases the mass of Keystone/Pyrmont allowing the maximum heights in Table E1 to be exceeded without using geogrids.

This is ideal for boundary walls where the geogrids would otherwise cross the boundary line.

No-Fines Concrete shall consist of cement, water and coarse aggregate. Cement will comply with the definitions for cement per AS3972 : 1991 — ‘Portland and Blended Cements’. The quantity of cement is specified as 210kg/m3 with a total water/cement ratio of between 0.45 and 0.55.

The particle size distribution of the aggregate shall comply with the limitations for the nominal single sized 20mm aggregate specified in AS2758.1.

NOTES:

• 15MPa No-Fines concrete with a 6:1 ratio (Gravel : Cement).

• The density of this product will vary with the density of the aggregate used. The density range may be from 1650kg/m3 to 2100kg/m3. Table based on density of 2100kg/m3.

• The void ratio of the mix is expected to be between 20% and 30% and should be free draining.

Wall Height Retained Soil Retained Soil Retained Soil

CLAY φ = 26° (POOR) SAND φ = 30° (AVERAGE) GRAVEL φ = 34° (GOOD)

‘H’ (mm) ‘T’ (mm) ‘T’ (mm) ‘T’ (mm)

1000 550 500 450

1400 750 700 650

1800 NA 1000 850

2200 NA 1250 1000

2600 NA 1350 1200

φ Denotes the internal angle of friction of the retained materialNon-shaded Area = Compacted Roadbase Footing Shaded Area = Concrete Footing as per Fig E12If material below no fines concrete is of poor quality, then the material must be replaced with a 150mm thick layer of crushed sandstone.

Table E2 — Maximum Wall Heights for No-Fines Concrete Wall Construction

H

Blocks embedded toengineer's detail(10 0mm min )

Retained soi l

T

25MPa concretefooting on 150kPaallowable bearingcapacity material(see note belowTable E2 )

15MPa ‘No-Fine s’ concrete .All voids within and aroundunits to be completely filled.

Filter Fabric to stopclogging ‘No Fines’ material

Cap unit

Keystone or Pyrmont uni t

Pour no-fines concretedirectly onto preparedfoundation material

Sub-soil drainconnected tostormwater systemor flood pit

150mm min

60 0mm min .



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E12

• The compressive strength should generally exceed 15MPa for design purposes.

• This product has no slump and exerts similar pressures on the soil and formwork, as does loosely poured aggregate.

Table E2 is prepared as per AS4678 : 2002, and is based on a 5kPa surcharge loading at the top of the wall. This table is supplied as a guide, and does not form any part of any contract with the user.

• The maximum slope of the backfill behind the wall is to be 5% (1 vertical to 20 horizontal).

• The vertical height of any pour of ‘No Fines’ concrete is limited to 600mm. Each pour must be allowed to harden prior to pouring the next lift. Alternatively the wall may be propped to support the lateral load from the wet concrete.

• For higher walls or walls with a greater surcharge loading, Geogrid soil reinforced construction is required.

• For walls founded on clay with a height greater than 2.0m, Geogrid reinforcement is required.

• Global stability considerations should be checked by an engineer in poor clay conditions.

• Design assumes a dry excavation (i.e. water table is below bottom of footing level). If ground water appears in the excavation, the wall is to be re-designed by a suitably qualified engineer.

Construction StepsSpecial purpose construction such as waterside walls, post fixing, earthquake zones, and terraces will require additional engineer’s design.

STEP 1:Excavation/Preparation of Levelling Pad

For walls less than 900mm high, excavate a trench 600mm wide and sufficiently deep to allow a levelling base of 150mm +25mm height for each course. Spread coarse sand or 12-20mm gravel for the levelling base and compact.

For higher walls or in poor foundation material, a footing as shown in Fig E12 may be necessary. Refer to Table E2.

STEP 2: Installing the First Course

Lay the first course of units side to side over the prepared base, with the 12mm pinholes on top and kidney holes on the underside. Maintain the required distance between pinhole centres of adjacent units. In straight walls, units will touch. In concave or convex curves, the units will overlap or require spacing respectively. Refer to Figs E7 and E8 for curve installation details.

STEP 3: Installing the Pins

Place the high strength fibreglass connecting pins into each unit. Use the front holes for a near vertical setback (corners and curved walls). Use the rear holes for a 1 in 8 setback (i.e. for every course the wall will set back 25mm for straight walls only).

STEP 4: Additional Courses

Sweep the top of the previous course of units clean of any loose gravel. Place the next course of units so that the kidney holes fit over the pins of the two units below. Pull the unit towards the face of the wall until it locks with the pins on both sides. Repeat steps 3 and 4.

STEP 5: No-Fines Concrete Backfill

Backfill the wall with ‘No Fines’ concrete. All voids inside and between the units must also be filled. The vertical height of any pour of ‘No Fines’ concrete is limited to 600mm. Each pour must be allowed to harden prior to pouring the next lift. Alternatively the wall may be propped.

STEP 6: Installing Capping Units

Lay capping units, backfill and compact to required grade. In areas accessible to public vandalism, it is recommended that the capping units be secured using masonry construction adhesive or epoxy cement.

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E13

Geogrid Soil-Reinforced Wall Construction Guidelines

Surcharge Wall Geogrid Geogrid Height Above Geogrid Length

Height Layers Levelling Pad L (m)

H (m) Layers Soil Type (phi)

1 2 3 4 5 6 7 25 30 35

15 Degree 1.1 2 0.2 0.8 — — — — — 2.2 2.0 2.0

Backfill Slope 1.5 3 0.2 0.6 1.2 — — — — 2.5 2.0 2.0

1.9 4 0.2 0.6 1.0 1.6 — — — 2.4 2.0 2.0

2.3 5 0.2 0.6 1.0 1.4 2.0 — — 2.8 2.4 2.0

2.7 6 0.2 0.6 1.0 1.4 1.8 2.4 — 3.6 2.7 2.4

3.1 7 0.2 0.6 1.0 1.4 1.8 2.2 2.8 4.3 3.0 2.7

5kPa 1.1 2 0.2 0.8 — — — — — 2.4 2.0 2.0

Driveway 1.5 3 0.2 0.6 1.2 — — — — 2.7 2.1 2.0

1.9 4 0.2 0.6 1.0 1.6 — — — 3.0 2.4 2.0

2.3 4 0.2 0.8 1.4 2.0 — — — 3.3 2.7 2.3

2.7 5 0.2 0.6 1.2 1.8 2.4 — — 3.6 3.0 2.5

3.1 6 0.2 0.6 1.0 1.6 2.2 2.6 — 4.0 3.3 2.8

Table E3 — Maximum Wall Heights for Geogrid Soil-Reinforced Walls

For taller, more critical walls, the combination of Keystone units with geogrid soil reinforcement allows walls to be built to heights of 12m and greater, without costly structural footings. When placed between layers of compacted soil, geogrids create a reinforced soil mass, which essentially acts as a larger gravity wall structure.

Geogrids can be used with most existing site-soils and are not affected by water, micro organisms, alkali or acidic soils. Consult your engineer for design requirements of Keystone walls using geogrid soil reinforcement.

NOTES:

• Table E3 is prepared as per AS4678 : 2002. Suitability of the information contained in the table must be referred

to a qualified professional engineer. These tables are supplied as a guide, and do not form any part of any contract with the user.

• Table E3 is based on foundation material with minimum 200kPa bearing capacity.

• Where site conditions and loadings vary from those in the table, professional engineering advice should be obtained.

• The minimum embedment of wall below ground level is assumed to be H/20, or 100mm, whichever is greater.

• The length of the 15° backfill slope is assumed to be equal to the height of wall, H.

*Geogrid with Tul=55kN/m2



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E14

Cap Unit

Keystone or Pyrmont uni t

Geogrid soil reinforcementto engineer's specification

Compacted ba ckfill materia l

Compacted roadbase orconcrete footing

First cou rse to be embeddedbelow final ground level toengineer's detail ( 10 0mm min. )

Drainage pipe (as required)

Reinforced Soil Zon e

30 0m m

Granularmaterial

60 0mm min .

150mm min .

H

L

12-20mm free draining granular material, fill all voids in and around units


Fig E15 — Typical Construction Detail — Keystone/Pyrmont Geogrid Reinforced-Soil Wall

Native soil

Native soil

Geogrid sections are located over pins at the front, pulled taught and staked at the back

Compactedroadbase footing

Free draining granular material

Drainage pipe

Compactedbackfill soil

Fig E14 — Typical Installation Detail — Keystone/Pyrmont Geogrid Reinforced-Soil Wall

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E15

Typical Specification for Keystone or Pyrmont Retaining Walls1. Scope of Work1.1 Extent

This specification covers the works for construction of segmental, reinforced-soil retaining structures. The works include footing excavation, foundation preparation, drainage, backfill and compaction and related items necessary to complete the work indicated on drawings and as further specified.

All retaining wall construction is to be carried out in accordance with the levels, distances and details as shown on the drawings and in accordance with this specification.

The Keystone reinforced retaining wall system shall also be constructed in accordance with the manufacturers installation guidelines by a suitably qualified and experienced contractor.

1.2 Responsibilities

The Contractor shall be responsible for carrying out the installation of all retaining walls in accordance with this specification and the associated contract documents.

2. Standard SpecificationWherever reference is made to Standards Association of Australia (SAA) the requirements of the editions and amendments, shall apply to the relevant materials or operations and be deemed to be incorporated in this specification.

In the case of a conflict between the referenced standard specification and code and this specification, the more stringent provisions shall apply.

The following is a summary of standard specifications applicable to this subsection of the work:

AS1012 Methods of Testing ConcreteAS4456 Concrete Masonry UnitsAS3600 Concrete StructuresAS4456.4 Masonry Units — Compressive StrengthAS4678 Earth Retaining StructuresAS1289 Methods of Testing Soils

Materials or operations not covered by the above standard codes shall conform to the appropriate Australian Standard.

3. General Requirements3.1 General

Terms used in this specification shall have the meanings assigned to them as follows:

‘Approved’ shall mean approved in writing by the Engineer.

‘Or equal approved’ shall mean equivalent in performance, quality and price to that specified and approved by the Engineer.

Where limits to the properties of soils are defined elsewhere herein these properties shall be determined by the methods laid down in AS1289.

The term ‘construction area’ in this Part shall be defined as an area to be excavated or an area to be cleared and filled.

3.2 Regulations

The Contractor shall comply with all relevant Acts, Regulations and By-Laws in respect of all work specified herein, including temporary timbering, strutting, guard rails and all safety measures to be adopted.

3.3 Certification

The Contractor’s Geotechnical Engineer shall certify that the bearing capacity of the foundation is as per the foundation requirements specified on the drawings. The Geotechnical Engineer shall also inspect and certify that the Reinforced Soil Block material is as specified on drawings with regard to friction angle, and bulk density.

4. Materials4.1 Masonry Units

The retaining wall units shall be manufactured in accordance with AS4456 Concrete Masonry Units. Block types and sizes for Keystone retaining walls shall be as shown on the drawings or specified herein.

4.1.1 Tolerance

Permissible tolerance in the manufacture of retaining wall units shall comply with AS4456.3 - 1997. In the case of Keystone units, the tolerance of ± 2mm shall not apply to profiled or textured faces. Non conforming concave distortions shall be rejected.



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4.1.2 Strength

Retaining wall units shall be manufactured with a minimum compressive strength of 10MPa. A minimum of ten (10) samples must be tested to obtain a mean compressive strength, tested to failure as per AS4456.4 — 1997 under normal compressive and laboratory conditions.

4.1.3 Colour

The colour and texture of masonry units shall be as specified and shall remain consistent with the ‘sample range’ approved by the project Superintendent.

4.1.4 Handling/Storage/Delivery

Keystone units shall be delivered on pallets to minimise damage during transportation. The Contractor shall store and handle units so as to prevent units from damage, which may affect the aesthetic quality or structural integrity of the finished wall.

4.2 Connecting Pins

High strength pultruded fibreglass pins shall be used to interlock and align all Keystone units in a running bond pattern. Pins shall also provide an integral connection between the Keystone units and the geogrid.

4.3 Geogrids

The reinforcing elements for the reinforced soil structure shall be as shown on the drawings.

If required, each consignment of geogrids delivered to site shall be accompanied by a Quality Control Tensile Test Certificate from the manufacturer.

4.4 Approved Reinforced Soil Block Backfill

Material for backfilling between geogrids for the Keystone retaining wall shall be ‘Approved Backfill’ defined as sand, crushed sandstone or broken rock obtained from excavations or approved borrow areas. Such material shall be

• Free of rock fragments greater than 75mm in size.• Free of clay lumps retained on a 75mm sieve.• Free of organic matter.• Within the following grading requirements;

Sieve Size % Passing by Weight 75mm 100 26.5mm 50 - 100 4.75mm 25 - 75 0.425mm 10 - 50 0.075mm 0 - 20

• Non-plastic in that the fraction passing 0.425mm has a Plasticity Index of not greater than 15.

• Capable of being brought to a moisture content suitable for compaction as specified elsewhere herein, under the weather conditions prevailing on site.

The ‘Approved Backfill’ shall be stockpiled on site, and inspected and approved by the Geotechnical Engineer that the material satisfies the specification above the design friction angle and dry density values as specified on drawings. Testing for dry density and friction angle shall be in accordance with section 6 herein.

4.5 Drainage

All retaining walls are to contain drainage systems that prevent the build up of hydrostatic pressure behind walls. This is to include a 12-20mm free draining clean hard aggregate, used to fill all voids within the retaining wall units and to extend 300mm behind the units.

Drainage is to be installed as per the drawings and as per the manufacturers recommendations.

4.6 Concrete Works

All concrete for use in footings for retaining walls shall have a compressive strength after 28 days of 25MPa unless specified otherwise.

The supply, placement, finishing and curing of reinforcement and insitu concrete shall comply in every respect with AS3600.

4.7 Hold and Witness Points

The following shall be deemed a Hold Point:

• Submission of test results and samples of all retaining wall components.

The following shall be deemed a Witness Point:

• On-site slump and strength testing of concrete.

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5. Construction of Keystone/Pyrmont Retaining Walls 5.1 Foundations

Excavation is to be to the lines and grades shown on the drawings. The reinforced soil block foundation size shall be constructed as per drawings unless alterations are made by the Geotechnical Engineer, who may require tests on the sub-grade material, to be carried out by a registered N.A.T.A. Testing Laboratory.

The reinforced soil block foundation subgrade shall be proof rolled with a heavy steel drum roller (minimum applied intensity of 4t/m width of drum with at least 8 passes) without vibration. Any material which is soft, visibly deformed, unstable or deemed unsuitable by the Contractor’s geotechnical consultant shall be excavated and replaced with approved fill and compacted to achieve dry densities of between 98% and 103% of Standard Maximum Dry Density at moisture content of ±2% of Standard Optimum Moisture Content.

The foundation shall be inspected and approved by the Geotechnical Engineer, who shall verify that the foundation bearing capacity exceeds the required bearing capacity as specified on drawings. The approval of the reinforced soil block foundation shall be deemed a HOLD POINT.

Detailed excavation for the mass concrete footing shall proceed following acceptance of the foundation. The footing subgrade shall be inspected by the Contractor’s Geotechnical Engineer and any areas deemed soft, unstable or unsuitable by the Geotechnical Engineer shall be excavated and replaced as described above.

The footing shall be constructed as shown on the drawings. It could be shown as compacted roadbase or concrete. For concrete, the footing shall be poured to the correct level using formwork edge boards, or other methods which ensure the correct level of the footing. The concrete footing shall be screeded flat. The level of the footing or first course of blocks shall be verified by survey methods, and approved by the Contractors QA representative. This shall be deemed a WITNESS POINT.

5.2 Unit Installation

Foundations and all courses are laid level. Batters are achieved by inserting the fibreglass connecting pins into the appropriate holes. The Keystone retaining walls shall be constructed with batters as shown on the drawings.

First course of units shall be placed side by side on the base levelling pad. Units shall be levelled side to side and front to back and checked for alignment. The accurate placement

of the first course is most important, to ensure acceptable horizontal and vertical tolerances. Two fibreglass connecting pins shall be inserted into the appropriate holes to interlock and align units.

The front set of pin holes shall be used for near vertical setback.

The rear pair of holes shall be used for 25mm (1:8) setback.

All voids in units and between units shall be filled with drainage fill as specified in section 4.5. Drainage fill shall extend to 300mm behind units.

Units shall be placed in a running bond pattern. Top of units shall be swept clean of excess material. Kidney holes of units above shall be positioned over pins in units below. Units shall be pulled toward the face of the wall to interlock the pins with units on either side. Levels and alignment of each course shall be checked. Each course shall be filled, backfilled and compacted prior to placement of the next course. The Keystone wall shall be surveyed for vertical level tolerance every 3 courses. This shall be deemed a HOLD POINT.

5.3 Drainage Installation

The drainage measures shall be installed as shown on drawings. 100mm diameter agricultural pipe shall be used for subsoil drainage behind the first course of Keystone units. The subsoil drain shall be placed with a minimum 1% fall as shown on drawings.

‘T’ piece connection fittings shall be used at all outflow points to connect the subsoil drainage to a 100mm diameter pipe stub which extends 300mm past the face of the Keystone wall. The pipe stub material shall be UPVC or HDPE and shall be approved by the project Superintendent.

The outflow points shall be at a maximum of 60m centres. The locations of the outflow points shall be determined by the Superintendent. The outflow pipe stub shall be supported on the concrete footing, and shall pass between two Keystone units with 60mm of the facing removed by sawcutting. The gap above the pipe in the first course shall be neatly patched with cement mortar.

The drainage measures shall be inspected by the QA representative after the installation of the first and second course is complete. Inspection and approval of the drainage installation shall be deemed a HOLD POINT.



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5.4 Placement of Geogrid

The Geogrid shall be placed between Keystone units as specified on the drawings. Geogrids shall be cut to the required length. Geogrids may be longer than required, but shall not be shorter than the specified length shown on the drawings.

The Geogrids shall be placed with the roll direction perpendicular to the face of the Keystone wall. Correct orientation of the geogrids shall be verified by the Contractor.

After compaction, the layer of select backfill below each geogrid, shall be raked to a depth of 25mm to ensure good interlock between the geogrid and the select backfill. The Geogrid shall be laid horizontally on compacted backfill and connected to the Keystone units by hooking geogrid over the fibreglass pins. The geogrid shall be pulled taut against pins to eliminate slack from connections and loose folds. The back edge shall be staked or secured prior to backfilling to maintain tension in the geogrid. Each block shall be checked for level accuracy, as out of position transverse bars will lead to sloping blocks. If the course above a layer of geogrid is found to be not level, then the blocks shall be removed, and the geogrid repositioned to ensure levelness.

For a straight length of wall, the geogrids shall be laid side by side without joints or overlaps. Where the wall is convex, the geogrids shall not be cut, but shall be overlapped with a minimum of 75mm of compacted fill between them. For a concave wall the position of the layers of grid shall be alternated between consecutive geogrid layers to cover the triangular gaps between strips of geogrid. Refer to Fig 5.4.

The QA Representative shall inspect and keep records of the position of grid and the type of grid placed for each layer of geogrid. The number of courses between each successive layer of geogrid shall be noted. The QA Representative shall also check this. This shall be deemed a WITNESS POINT.

5.5 Placement of Reinforced Soil Backfill

Prior to placement of ‘Approved Backfill’ in the reinforced soil block, the Geotechnical Engineer shall approve the material and confirm that the friction angle and dry density of the material is in accordance with the drawings for that particular section of the project. This shall be deemed a HOLD POINT.

All backfill imported or otherwise shall be as specified on the drawings. Backfill shall be spread in a maximum of 200mm layers, in such a manner that minimises the voids directly underneath the geogrid. Fill should be deposited using suitable plant which causes fill to cascade onto geogrids. Placement of fill on top of the geogrids shall start from the wall face and work back from the wall face in order to minimise slack or loss of pretension from the grid. Care should be taken to not mix the reinforced soil block backfill material with the drainage material. If backfill material mixes with the drainage material, then the drainage material is to be removed and replaced with clean material.

Compaction shall be to 98% of Standard Maximum Dry Density. Compaction shall start at the wall face and work back from the wall face. Compaction testing shall be in accordance with section 6 specified herein. Compaction testing shall be deemed a WITNESS POINT.

Tracked construction equipment shall not be operated directly on the geogrid. A minimum thickness of 150mm of backfill material shall be placed prior to the operation of tracked construction equipment. Rubber tyred equipment may pass over the geogrids at very slow speeds. Sudden braking or sharp turning shall be avoided to prevent displacement of geogrids.

Construction plant and all other vehicles having a mass exceeding 1000kg shall be kept at least 1m from the back of the Keystone units. Compaction of the 1m zone behind the Keystone units shall be restricted to:

• Vibrating rollers with a mass < 1000kg

• Vibrating plate compacters with a mass < 1000kg

• Vibro tampers having a mass < 75kgWall Face

Geogrid

Fig 5.4 — Typical Geogrid Layout

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Surface drainage during and after construction of the wall shall be provided to minimise water infiltration in the reinforced soil zone.

5.6 Hold and Witness Points

The following shall be deemed a HOLD POINT:

• Approval of foundation material by the Geotechnical Engineer.

• Inspection and approval of ‘Approved Backfill’ for use in reinforced soil block by the Geotechnical Engineer.

• Survey of the Keystone Wall every 3 courses.

• Inspection and approval of the drainage installation by the QA Representative.

The following shall be deemed a WITNESS POINT:

• Survey verification that the first course is installed at the correct level, and inspection and approval of footing by the QA Representative.

• Inspection of level and type of geogrid at each layer by the QA Representative.

• Compaction Testing by the Geotechnical Engineer.

6. Material Testing6.1 Testing of ‘Approved Backfill’

Each source of ‘Approved Backfill’ shall be pretreated by 5 cycles of repeated compaction, and then tested for dry density and friction angle. Material for use as ‘approved backfill’ shall be inspected and approved for use by the Geotechnical Engineer. A stockpile at least equivalent to 5 days reinforced soil wall construction shall be maintained on site at all times. This will allow time for friction angle testing of the approved backfill should visual inspection of the material when it is received on site indicate that testing is required.

Notwithstanding the above the following minimum testing shall be carried out:

• Dry Density shall be tested at a frequency of 1 test per 400m3 of approved backfill.

• Friction angle shall be tested at a frequency of 1 test per 2000m3 of approved backfill.

If the dry density results are not within ±5% of the specified design value, then the Engineer shall be notified, and the material not approved for use until the design has been verified.

6.2 Testing for Compaction

Compaction will be checked by standard maximum dry density test and field density test for materials other than sand or by the density index and field density tests for sands as specified on drawings and herein.

Tests will be carried out in groups of at least three, and compaction of the layer concerned will be considered to be satisfactory if no single result falls outside the specified density range. Should the results not reach this standard the Sub-Contractor shall again roll the area, if necessary after scarifying, adding water, blading to reduce the moisture content and/or removing and replacing excessively moist fill as may be required.

Should the Geotechnical Engineer consider that the depth of insufficiently compacted material is greater than can be effectively compacted from the surface, material shall be removed to a depth at which compaction is satisfactory and replaced and compacted in 200mm maximum layers.

The standard maximum dry density referred to herein for materials other than sand shall be maximum standard dry density as determined in accordance with AS1289 - Test numbers 5.1.1.

The modified maximum dry density referred to herein for materials other than sand shall be the maximum modified dry density as determined in accordance with AS1289 - Test 5.2.1.

The field density referred to herein for all materials shall be the dry density of the material in place as determined in accordance with AS1289 - Test 5.3.1.

The percentage of the standard maximum dry density (Dry Density Ratio) elsewhere herein for materials other than sand shall be calculated from the formula given in AS1289.5.4.1.

The maximum and minimum densities of cohesionless materials shall be determined in accordance with AS1289 - Test E5.1.

The Density Index specified elsewhere herein for sands shall be calculated from the formula given in AS1289.E6.1.

6.3 Frequency of Testing

The following testing frequencies relate to acceptance on a ‘not-one-to-fail’ basis. The testing should be carried out in essentially randomly chosen locations and at the frequencies as given below. However, it may be appropriate to undertake testing in specific locations, based on visual appearance or past experience.



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Where a test or group of tests is carried out on an area which has been subjected to essentially the same preparation and compaction procedures, the whole of this area is considered to be represented by this test or group of tests. The uniform area is generally known as a work lot. On this basis, if one or more tests indicate compliance with the specification has not been achieved, the whole of the area which has been submitted for testing is deemed not to comply, unless it can be demonstrated that the area in which the non-complying test result(s) can reasonably be separated from the whole. It should not be assumed a test result applies only to the area immediately surrounding it.

Required frequency of testing, is not less than 1 test per layer of 200 mm thickness per material type per 400m3 which is 1 test per layer per 100 linear metres of wall construction. If different sources of ‘approved backfill’ are used within the 100 linear metre work lot, then 1 test per type of material is required. If the work is staged in sections of less than 100 linear metres, then 1 test per section is required.

The testing frequency may be re-assessed to the approval of the Engineer, if a high degree of uniformity becomes evident during construction.

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4Custom Engineered Wall Systems

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Engineered Retaining Wall Systemsfor domestic and commercial landscaping, roadside and custom engineered retaining wall applications

Boral Keystone, Pyrmont and Keysteel Retaining Wall Systems provide a proven and versatile platform for the development of custom engineered high performance retained earth structures.

Boral has developed alliances with a number of suitably experienced engineering companies that can provide professional assistance with the custom design and installation of Keystone, Pyrmont and Keysteel retaining structures.

Please contact Boral Masonry in your region for assistance with your high performance, engineered retaining wall projects.

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Keysteel Custom EngineeredRetaining Wall Systems

• Keysteel™ Custom Engineered Retaining Wall SystemsBoral Keysteel is a high performance engineered retaining wall system for applications requiring wall heights in excess of 6m and/or where critical surcharge loadings are present. Boral Keysteel is an internationally proven system that integrates the superior strength and durability of Keysteel blocks with steel-ladder soil-reinforcement to provide engineered solutions for the most demanding retaining structures.

• Gravity Retaining Walls

• Mass Gravity Retaining Walls

• Geogrid Reinforced-Soil Retaining Walls

• Steel-Ladder Reinforced-Soil Retaining Structures

• Bridge Abutments

• Stream or Drainage Channels

• Erosion Prevention

• Tunnel Access Walls

• Wing Walls

• Embankment Stabilisation

• Terraced Walls

• Seawall Applications

• Soil-Anchor and Rock-Anchor Walls

• Fencing, Railings and Barriers



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INTRODUCTIONBoral Keysteel is an internationally proven, high performance retaining wall system that integrates the superior strength of Keysteel blocks with steel-ladder soil-reinforcement, and is ideally suited to retaining structures in excess of 6m high and for critical surcharge loadings.

DESIGN CONSIDERATIONSBoral Keysteel installations are individually engineered to match the application criteria.

Boral has developed alliances with a number of suitably experienced engineering companies which can provide professional assistance with the design and installation of

Keysteel retaining structures.

Please contact Boral Masonry Technical Services in your region for assistance with Keysteel projects.

COLOURSBoral Keysteel is made-to-order in the same range of colours as Keystone, allowing integration of the two products within the one project. Please refer to colour swatch information for an indication of current colours.

Keysteel®

High Performance Engineered Retaining Wall Systems



Standard Straight Sided Cap 100x455x275 25 2.2/lin mtr



Pins (steel) 2 pins per full unit hot-dip galvanised steel

Lifting Bars (Keysteel units should be lifted by two people using the Keysteel lifting bars)

Specifications

Standard Straight Sided Cap(made to order)

275

100

455


275

100

455

Steel Pins(hot-dip galvanised)

Lifting Bars

305

200

455

Standard Unit

305

200

455

Flushface Unit

Availability and Colours• All Keysteel products are made-to-order.• Lead times apply Please consult with the Boral Masonry

sales office in your region.

Antique Copper

Desert SandTuscan

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Typical Keysteel® Application LayoutKeystone unit

Pylon

Cut ladder around pylon Where piles prevent installation of ladders refer to engineers detail.

Fig F1 — Typical Construction Detail — Keysteel wall

Keysteel unit

Keysteel unit

Soil reinforcementladder

Wall face

Fig F2 — Typical Curved Wall Detail — Keysteel

Keysteel unit Soil reinforcingladder

Fig F3 — Typical Straight Wall Detail — Keysteel



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Finished grade Threaded pipe coupling

Footing step (optional)

Galvanised pipe

Top of wall stepped (optional)

Keystone unit

Granular backfillGeogrid (if required)

Stiff firm soil

Galvanisedsteel pipe

Soil anchors

Galvanised pipe loop connector

Galvanised pipe,loop connector and soil anchors (staggered installation)

1200mm cts nominal

TYPICAL PLAN VIEW

TYPICAL WALL ELEVATION

Keystone unit

Geogrid

Galvanised steel pipe

Loop connector

Granular fill

Soil anchor todesign details

TYPICAL CONNECTION DETAIL

Cap unit

Keystone units

Soil anchors to site specific design

Soil failure plane

5˚

Stiff firm soil

Finished grade

Leveling pad to engineer's detail

Drainage pipe

See connection detail

300mmnominal

TYPICAL SIDE ELEVATION

1

8

Typical Soil-Anchor Application

Fig F4 — Typical Soil-Anchor Detail

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Temporary face support and drainage system

Finished grade Footing step

Reinforcing barto design details

Geogrid Soil Anchor todesign details

Top of wall stepped (optional)

Keystone unit

Reinforcing bar to project specifications Geogrid to project

specifications Concrete backfillDrainage net

Rock anchors

Expansion joint materialto design details TYPICAL PLAN VIEW

TYPICAL WALL ELEVATION

Keystone cap

Keystone unit

Horizontal reinforcing bar to design details

Vertical reinforcing bar to design details

Concrete backfill to design detail

Geogrid at 600mm vertical centres extended to wall face between reinforcing barRock anchor

systemto design details

Granular material wrapped in geotextile

Temporary concrete and mesh facing support system with drainage to design details

Drainage netto design details

Finished grade

Levelling pad

Drainage pipe

1

8

See anchorage detail

1500mmtypical

300mmnominal

TYPICAL SIDE ELEVATION

Keystone unit

Geogrid

Reinforcing barto design detail

Thread bar todesign details

Steel plate and securing nuts to design detail

Concretebackfill

Rock anchorto design detail

TYPICAL ANCHORAGE DETAIL

Typical Rock-Anchor Application Layout

Fig F5 — Typical Rock-Anchor Detail



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Engineering

All water application projects should be designed by a suitably qualified engineer. The Keystone Retaining Wall System has been used in numerous international projects where the blocks are subjected to high velocity flood water, wave action and tidal action.

Spacing of Geogrid

As with all geogrid soil reinforced Keystone walls, the spacing of the geogrid should not exceed 600mm, to prevent bulging between the grid layers.

Suitability of Keystone Blocks in a Seawall Application

It is recommended that if the Keystone units are submerged in salt water, then marine grade Keystone units should be used. Minimum order quantities apply to these units.

NOTE: Product colours will be different due to the use of marine grade cement.

Typical1900mm

Keystone Cap Unit

Filter Fabric

Keystone block

Nonwoven filter fabric

Geogrid as per design

Water level

Free draining granular material (less than 10% passing the #200 sieve, no organic material)

10-20mm crushed rock, fill cores and voids of Keystone units

Native soil

Impermeable soil layer 300mm

Compactedaggregate or crushed rock

150mm min.

600mm min.

150 - 200mmrip-rap

Fig F6 — Typical Construction Detail — Keystone Seawall Application

Undermining of Foundation Wall

Greater embedment of units, concrete footings (piered or otherwise), Keystone units keyed to a concrete foundation are all means of preventing undermining of the wall foundation. Rip-Rap in front of the wall will also help to prevent erosion.

Loss of Material through Wall Face

Filter fabric used behind the 300mm drainage layer will prevent loss of retained soils during fluctuation in water level.

Differential Water Pressures

Fluctuations in water levels and rapid draw down may induce differential water pressures across the face of the wall and need to be addressed.

Test Reports

Tests have been carried out on the high velocity flow effects, wave action and sudden draw down and Manning’s ‘n’ determination. These test results are available on request.

Typical Seawall Application Layout

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When terracing walls, they are effectively being split into sections. This is done for a number of reasons. For example, to level off a sloping front or backyard, to increase the aesthetic appeal of the garden and in some instances to reduce the single wall heights where by they still act as gravity walls and thus minimise the need for geogrid. In such instances, however, the upper terrace wall can put pressure on the lower terrace if the walls are too close together. Multiple terrace walls in close proximity to each other, can have structural stability issues related to the lower walls not having the capacity to carry the loads developed by the upper walls.

Question:

How far apart do the terrace walls have to be to perform as individual gravity walls?

Answer:

As a rule of thumb, the minimum distance between the wall terraces must be at least 1.5 times the height of the lower wall.

Cap unit

Keystone or Pyrmont wall

Keystone or Pyrmont wall

L = 1.5 x (H1)

L = minimum distance between terraces

H 2

H 1

Fig F7 — Typical Construction Detail — Terraced Wall Application

Example:

If the lower gravity wall is 1.2m tall, then the minimum recommended spacing between terraces is 1.8m. This rule also applies to walls with more than two terraces. The distance between any two terraces must be at least twice the height of the lower adjacent terrace wall for multiple terraces.

NOTE: This simple rule of thumb does not address global stability issues where walls are built on steep slopes or over poor soils of low friction strength. If these conditions exist, then contact your engineer.

Question:

What if there isn’t enough room to space the terraces according to this rule (1.5 x H1 minimum)?

Answer:

The wall can still be built, but the effect of the upper terrace on the lower terrace and overall stability must be taken into account when designing the walls. When the terraces are close together, the design analysis may model the structure as a single taller wall to account for the added load from the upper terrace wall on the lower walls.

Typical Terraced Wall Application Layout



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Fences can be incorporated into the Keystone Retaining Wall System by placing fence posts into the Keystone cores or behind the wall.

NOTE: The following recommendations are suitable for fences with no wind loadings.

Fence posts should be embedded through a minimum of three courses (600mm minimum) and then core filled with concrete. Only those units with the fence posts need to be core filled with concrete, the remaining filled with drainage material.

Fence posts positioned behind the wall should be embedded 700mm minimum and encased in concrete.

When constructing a soil reinforced wall, the Geogrid may be cut to allow for placement of fence posts as per the Geogrid manufacturer specifications.

It is important that these walls be designed to accommodate any additional wind loads from fencing (eg. extra embedment).

700mm

900mm

1824mm max.

Fig F8 — Typical Fencing Detail

Typical Fencing Application Layout

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Railing, guard rail, and traffic barrier requirements for retaining walls are not clearly defined in design codes nor are they properly addressed in many site plans. Many times railings and barriers are added as an afterthought which can become a costly and logistical issue when no provisions are made in the original retaining wall layout and site design. Guards and barriers require a common sense approach by the site designer considering the proximity of a wall structure to people and traffic. Sufficient space must be reserved for such installations.

It is important that these walls be designed to accomodate any additional loading these guards and barriers may impose on the Keystone wall.

Typical 800mm

Guardrail Traffic Barrier

Load

1000mm min.

Load

Typical 900mm

150mm

Typical 900mm

Railing – offset Railing – offset

Load Load

900mm min.

Additional Geogrid layer turned upwards and wrapped around void former at 400mm below ground level

Fig F9 — Railing and Barrier Details

Typical Railing and Barrier Application Layout

eBC 03119 september 2007

Other Regional Sales OfficesNSW Clunies Ross Street, Prospect, 2148 T: (02) 9840 2333 F: (02) 9840 2344

231 Wisemans Ferry Road Somersby 2250 T: (02) 4340 1008 F: (02) 4340 1308

ACT 16 Whyalla Street, Fyshwick, 2609 T: (02) 6239 1029 F: (02) 6280 6262

Victoria Level 1 Port IT, 63-85 Turner Street, Port Melbourne, 3207 T: (03) 9363 1944

F: (03) 9363 6008

Queensland 62 Industrial Ave, Wacol, 4076 T: (07) 3271 9292 F: (07) 3271 1581

North Queensland:

Cairns 8 Palmer Street, Portsmith, 4870 T: (07) 4035 1888 F: (07) 4035 1208

Townsville 360 Bayswater Road, Garbutt, 4814 T: (07) 4725 6285 F: (07) 4725 6043

Mackay David Muir Street, Slade Point, 4740 T: (07) 4955 1155 F: (07) 4955 4130

Customer Support New South Wales1. Stock colours Colours other than stock colours are made to order. Not all colours displayed in this brochure are available in all states.

(Contact your nearest Boral Masonry office for your area’s stock colours.) A surcharge applies to orders less than the set minimum quantity.

2. Brochure colours The printed colours in this Masonry Design Guide are only a guide. Please ask to see a sample of your colour/texture before specifying or ordering.

3. Colour and texture variation The supply of raw materials can vary over time. In addition, variation can occur between product types and production batches.

4. We reserve the right to change the details in this publication without notice.

5. For a full set of Terms and Conditions of Sale please contact your nearest Boral Masonry sales office.

6. Important notice Please consult with your local council for design regulations prior to the construction of your wall. Councils in general require those walls over 0.5m in height and/or where there is loading such as a car or house near the wall be designed and certified by a suitably qualified engineer.

Orders, Product Samples and Sales EnquiresSouth Australia Main North Road, Pooraka, 5095 T: (08) 8262 3529 F: (08) 8260 3011

Technical Enquires

Specifier Line 1300 360 255 Internet www.boral.com.au/masonry

® Heathstone, Ravenastone and Pyrmont are registered trademarks of Boral Masonry Limited.

® Keystone and Gardenwall are each registered trademarks of Keystone Retaining Wall Systems, Inc. under licence by Boral Masonry Limited. ABN 13 000 223 718

© Boral Masonry - all rights reserved 2007.

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