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www.boral.com.au/masonry
Contents
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BOOK
A B C D
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Introduction
PAGE
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.
PR O D U G CT ar de nw H al ea l th st on Py e rm on t Ke ys to ne Ke ys te el Co re Fi lle d Bl
BOOK
D C
Heathstone
Step Tread and Cap Unit Installation. . . . . . . . . . . . . . . . . . . D5 Corner Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6 No-Fines Concrete Wall Construction . . . . . . . . . . . . . . . . . . D7
1600
D E
Heathstone Product Information . . . . . . . . . . . . . . . . . . . . . . D2 Gravel Fill Construction Guidelines . . . . . . . . . . . . . . . . . . . . D3 Curved Wall Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . D4 Step Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4
E E E E
, , , , ,
3000
Property Boundary Not Boundary Vertical Set Back Vertical Set Back
E# E# E# E# E# F F
,
#
> 3000
Keystone Product Information . . . . . . . . . . . . . . . . . . . . . . . E4 Pyrmont Product Information . . . . . . . . . . . . . . . . . . . . . . . . E5 Gravity Wall Selection and Construction Guidelines . . . . . . . E6 Typical Installation Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . E8
> 25kPa
> 6000
For technical support and sales office details please refer to the outside back cover
Engineered Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . F2 Keysteel Product Information . . . . . . . . . . . . . . . . . . . . . . . . F4 Typical Soil-Anchor Application . . . . . . . . . . . . . . . . . . . . . . . F6 Typical Rock-Anchor Application . . . . . . . . . . . . . . . . . . . . . . F7 Typical Seawall Application . . . . . . . . . . . . . . . . . . . . . . . . . . F8
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, 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. 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.
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Products @ a Glance
Products @ a Glance
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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.
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.
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Boral MASONRY
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455 455
INTRODUCTION INTRODUCTION Boral Keystone Keystone is is an an advanced, advanced, Boral highly versatile versatile and and thoroughly thoroughly highly proven high high performance performance segmental segmental proven block retaining retaining wall wall system system which which block can be be used used as as a a gravity gravity structure structure can or it it can can incorporate incorporate geogrid geogrid soilsoilor reinforcement to to cater cater for for greater greater reinforcement surcharge loading loading heights and surcharge situations. CONSIDERATIONS DESIGN CONSIDERATIONS straight and and curved curved Suitable for straight installations with witha aminimum minimum wall installations radius of of 1800mm 1800mm convex curve radius trimming the the tail tail width, width, without trimming radius by by trimming trimming or 970mm radius
the tail tail to to 300mm 300mm width. width. the Canbe beinstalled installedas asnear nearvertical, vertical, Can or for for straight straight walls walls without without or curves or or corners corners it it can can be be curves installed with with a a 1-in-8 1-in-8 setback. setback. installed COLOURS COLOURS Keystone is is offered offered in in a a range range of of Keystone colours to to suit suit decorative decorative and and colours engineering applications. applications. Please Please engineering refer to to colour colour swatch swatch information information refer for an an indication indication of of current current colours. colours. for
To reduce reduce the the possibility possibility of of staining staining To and to to enable enable easier easier cleaning, cleaning, aa and masonry sealer sealer can can be be applied appliedto toall all masonry visible surfaces surfaces after after installation. installation. visible
455 455
Pins
Specifications
Description Standard Unit Straight Sided Cap Cap Standard Half High High Unit Unit Standard Cap Flushface Unit HxLxDmm HxLxDmm 200x455x315 200x455x315 100x455x275 100x455x275 100x455x275 100x455x275 100x455x275 100x455x275 200x455x315 200x455x315 100x455x275 100x455x275 Wt Wt kg kg 41 41 25 25 20 20 20 20 41 41 26.3 26.3
22 N/m N/m
No minimum minimum order order quantities apply. No Lead time time 0-4 0-4 weeks. weeks. Lead
Almond Almond
Tuscan
Flushface Straight Straight Sided Sided Cap Cap Pins Lifting Lifting Bars Bars
2 2 pins pins per per full full unit unit (high (high strength strength pultruded pultruded fibreglass) fibreglass) (Keystone (Keystone units units should should be be lifted lifted by by two two people people using using the the Keystone Keystone lifting lifting bars) bars)
Paperbark Paperbark
Product Specifications
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Adequate connection to the facing to provide local stability; A drainage system that will relieve hydro static pressures for the life of the structure.
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.
Steel reinforced and concrete grout filled hollow concrete block wall
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 soils 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.
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.
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.
Downward movement
Facial cracks
Differential Settlement
The 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.
Importance of Drainage
This 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.
Downward movement
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c gardenwall
Structure Classification
2. 3. 4.
Examples
Where failure would result in significant damage or risk to life Where failure would result in moderate damage and loss of services Where failure would result in minimal damage and loss of access
Type of Structure
Temporary site works Mine structures Industrial structures River and marine structures
Type of Structure
Residential dwellings Minor public works Major public works
Wall geometry:
Wall height above GL (H) Embedment depth (Hemb) H/20 or 200mm Wall slope (v) Angle of backfill slope (b) Height of backfill (h) Foundation material: Allowable bearing pressure Under reinforced soil block ___________ kPa ___________ m ___________ m ___________ ___________ ___________ m
Loading data:
Dead load surcharge (qd) Live load surcharge (ql) Horizontal line load (F) Vertical line load (P) Width of bearing (b) ___________ kPa ___________ kPa ___________ kN/m ___________ m ___________ m
Water profile:
Water table depth within wall fill
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___________ m
Gardenwall
Gardenwall
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228 125
228 125
300
300
Standard Unit
ADVANTAGES Gardenwall does not require concrete foundations. Easy installation of straight walls and curved walls. Durable, low maintenance, longterm landscaping. Solid units eliminates the need for capping and corner units. COLOURS
Gardenwall 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. To reduce the possibility of staining and to enable easier cleaning, a masonry sealer can be applied to all visible surfaces after installation.
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.
DESIGN CONSIDERATIONS
Depending 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.
No loads to be located within 1125mm behind wall Backfill should be no higher than the top of the wall
Dish drain to direct surface run-off (if required) Gardenwall Unit Backfill placed and compacted in 250mm layers
Light Sands
Tuscan
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150mm width of 12-20mm free draining granular material eg. blue metal Drainage pipe (if required) First course to be buried below final ground level (to engineer's specification - 100mm min.) H
Paperbark
Hawkesbury Yellow
Native soil
Specifications
Product Description Standard Unit Straight Sided Unit Finish Rockfaced Rockfaced HxLxDmm 125x300x228 125x300x228 Approx Wt kg 15.5 15.5 No. per m2 26.7 26.7
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Boral MASONRY
Curved Walls
m 0m um 10 0 e m s = i in s ur M diu t co Ra 1s r fo
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.
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Heathstone
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Standard Unit
280 162
440
Grand Unit
300 50 300 300 300 50
Bullnose Cap
Stoneworks Cap
DESIGN CONSIDERATIONS
Depending on the foundation and retained soil characteristics, Heathstone is effective as a gravity structure up to 972mm, or up to 1600mm when installed with nofines 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.
COLOURS
Heathstone 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. To reduce the possibility of staining and to enable easier cleaning, a masonry sealer can be applied to all visible surfaces after installation.
No loads to be located within 1.0m of the wall Dish drain to direct surface water or filter fabric to stop silt filling drainage layer
150mm min. of 12-20mm free draining granular material eg. blue metal
Voids in and around Heathstone blocks to be filled (if required) with 12-20mm 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 100mm Blocks to be embedded a minimum of 100mm Refer to Heathstone Gravel-Fill Selection Table for maximum number of courses
Tuscan
Almond
Charcoal
Paperbark
100mm min.
Fig D1 Typical Construction Detail Heathstone Gravel-Fill Table D1 - Maximum Wall Height Heathstone Gravel-Fill Maximum Courses For walls without gravel fills to all voids and cores Poor soils including sands, gravelly clays, sandy clays and silt clays Average soils including well graded sands and gravelly sands Good soils including gravels, sandy gravels and crushed sandstone 2 (324mm) 3 (486mm) 4 (648mm) Maximum Courses For walls with gravel fills to all voids and cores 4 (648mm) 5 (810mm) 5 (810mm)
Specifications
Product Description Standard Unit Standard Corner Unit Grand Unit Bullnose Cap Stoneworks Cap Finish Rockfaced/Smoothfaced Rockfaced x 2 Faces Rockfaced Smooth Rockfaced HxLxDmm 162x220x280 162x380x270 162x440x280 50x300x300 50x300x300 Approx Wt kg 11.9 23 26.2 9.4 22 No. per m2 28.1 units/m2 1/course/corner 14.05 units/m2 3.3/linear metre 3.3/linear metre
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.
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Heathstone
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Concave (Internal) Curves For concave curves use Standard Units spaced evenly to a scribed arc.
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.
Bolster back of blocks to form convex curves
Step Construction
Bullnose Cap Fix cap units with construction adhesive Remove locating lugs before laying 255
45
Heathstone Units
Native soil
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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.
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.
Cap unit
NOTES:
Grand Unit Standard Corner Unit No loads above 5kPa to be located within 1.0m of the wall
Table D2 is based on AS4678 : 2002, Earth Retaining Structures. The code assumes a surcharge of 5kPa is
T
330mm
Filter fabric or dish drain 15MPa No Fines concrete. All voids within and around units to be completely filled. Grand Unit cut to 330mm on site Retained soil Sub-soil drain connected to stormwater system or flood pit. Place loose aggregate around subsoil drain before pouring no-fines concrete. Pour no-fines concrete directly onto prepared foundation material Blocks to be embedded to engineers detail (1 course min.)
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Grand Unit
25MPa concrete footing on 150kPa allowable bearing capacity material Standard Unit Bolster lug to fit next course 600mm min.
150mm min.
Fig D10 Typical Construction Detail Heathstone No-Fines Concrete Wall Table D2 Heathstone Maximum Wall Heights No-Fines Concrete Construction Wall Height H (mm) 972
Corner Unit Grand Unit NOTE: Internal 90 corners using Grand Units do not require corner units
SAND
1296 1620
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Boral MASONRY
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.
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Proven Engineering
Various 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.
Ease of Construction
Boral 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.
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 Australias pioneering era. The range of components and installation methods cater for straight and gently curved walls as well as crisp 90 corners, while the rock-faced caps provide a finishing touch that completes the transformation into a masterpiece from the colonial era.
Keystone
Durability
Boral 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.
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
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315 200
315
200
305
20 0
455
455
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. COLOURS
Keystone 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.
455
Standard Unit
Standard Unit
275 100 455
455
455
Standard Cap
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
Lifting Bars
Specifications
Description Standard Unit Straight Sided Cap Standard Half High Unit Standard Cap Flushface Unit HxLxDmm 200x455x315 100x455x275 100x455x275 100x455x275 200x455x315 100x455x275 Wt kg 41 25 20 20 41 26.3 N/m2 11 2.2/lin mtr 22 2.2/lin mtr 11 2.2/lin mtr Paperbark Almond Tuscan
Specifications
Description Standard Unit Pyrmont Cap Straight Sided Cap Pins Lifting Bars HxLxDmm 200x455x305 100x455x275 100x455x275 Wt kg 42 20 21 N/m2 11 2.2/lin mtr 2.2/lin mtr
Almond
Tuscan
2 pins per full unit (high strength pultruded fibreglass) (Pyrmont units should be lifted by two people using the Keystone lifting bars)
2 pins per full unit (high strength pultruded fibreglass) (Keystone units should be lifted by two people using the Keystone lifting bars)
Paperbark
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DESIGN CONSIDERATIONS Suitable for curved wall installations with a suggested minimum convex curve radius of 5m (resulting in a 5mm lip). COLOURS
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.
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Table E1 Maximum Wall Height for Gravel-Fill Walls Surcharge Loading Backfill Type Poor Wall Height H(mm) Near 1 in 8 Vertical Setback 800 900
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.
No Surcharge Loading
SETBACK
Average
900
1000
Good
1000
1200
15 Sloped Backfill
Average Soils
Poor
600
900
Average
700
900
Good Soils
Good
800
1100
Poor
400
500
Compacted backfill soil (if required) Drainage pipe
Average
500
600
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.
Good
600
800
Compacted footing
Native soil
Near vertical installation must be used when designing walls with curves or corners.
Keystone or Pyrmont units Backfill Optional 1:8 wall setback with Keystone units 12-20mm free draining granular material, fill all voids in and around units Drainage pipe (if required) First course to be buried below final ground level (to engineer's specification - 100mm min.) H
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.
Filter fabric to stop silt from clogging drainage material
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FIRST COURSE
SECOND COURSE
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FIRST COURSE
SECOND COURSE
Use front pin holes for curves. Maintain a small overlap between units.
Align face of unit with the centre line of adjacent unit Cut to suit on site
3 unit 90 corner : r = 900mm 4 unit 90 corner : r = 1250mm 5 unit 90 corner : r = 1540mm 6 unit 90 corner : r = 1830mm 7 unit 90 corner : r = 2120mm
Use front pin holes for curves. Maintain a small gap between units.
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Radius r
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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.
Cap unit
225 corner unit to be cut and bolstered on site from Keystone/Pyrmont Unit Next course is a mirror image.
Keystone unit
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.
T
Filter Fabric to stop clogging No Fines material 15MPa No-Fines concrete. All voids within and around units to be completely filled. Bolster backs as required Retained soil Keystone or Pyrmont unit
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290mm Treads
Pour no-fines concrete directly onto prepared foundation material Blocks embedded to engineer's detail (10 0mm min)
25MPa concrete footing on 150kPa allowable bearing capacity material (see note below Table E2) 60 0mm min.
150mm min
Fig E13 Typical Construction Detail Keystone No-Fines Concrete Mass Gravity Wall
Compacted bedding sand 40mm Boral Pavers 160mm riser 40mm 10mm 100mm 10mm 10mm mortar joint Keystone Flushface Caps Sand : cement = 6 : 1 Bedding sand compact before laying treads
Table E2 Maximum Wall Heights for No-Fines Concrete Wall Construction Wall Height H (mm) 1000 1400 1800 Retained Soil CLAY = 26 (POOR) T (mm) 550 750 NA NA NA SAND Retained Soil = 30 (AVERAGE) T (mm) 500 700 1000 1250 1350 Retained Soil GRAVEL = 34 (GOOD) T (mm) 450 650 850 1000 1200
2200 2600
Denotes the internal angle of friction of the retained material Non-shaded Area = Compacted Roadbase Footing Shaded Area = Concrete Footing as per Fig E12 If material below no fines concrete is of poor quality, then the material must be replaced with a 150mm thick layer of crushed sandstone.
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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.
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.
NOTES: Table E3 is prepared as per AS4678 : 2002. Suitability of the information contained in the table must be referred
Table E3 Maximum Wall Heights for Geogrid Soil-Reinforced Walls Surcharge Wall Height H (m) 1 15 Degree Backfill Slope 1.1 1.5 1.9 2.3 2.7 3.1 5kPa Driveway 1.1 1.5 1.9 2.3 2.7 3.1 *Geogrid with Tul=55kN/m2 2 3 4 5 6 7 2 3 4 4 5 6 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 2 0.8 0.6 0.6 0.6 0.6 0.6 0.8 0.6 0.6 0.8 0.6 0.6 3 1.2 1.0 1.0 1.0 1.0 1.2 1.0 1.4 1.2 1.0 Geogrid Layers Geogrid Height Above Levelling Pad Layers 4 1.6 1.4 1.4 1.4 1.6 2.0 1.8 1.6 5 2.0 1.8 1.8 2.4 2.2 6 2.4 2.2 2.6 7 2.8 25 2.2 2.5 2.4 2.8 3.6 4.3 2.4 2.7 3.0 3.3 3.6 4.0 Geogrid Length L (m) Soil Type (phi) 30 2.0 2.0 2.0 2.4 2.7 3.0 2.0 2.1 2.4 2.7 3.0 3.3 35 2.0 2.0 2.0 2.0 2.4 2.7 2.0 2.0 2.0 2.3 2.5 2.8
Construction Steps
Special purpose construction such as waterside walls, post fixing, earthquake zones, and terraces will require additional engineers design.
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Native soil
3. General Requirements
3.1 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.
Geogrid sections are located over pins at the front, pulled taught and staked at the back Compacted backfill soil Drainage pipe Free draining granular material
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.
Native soil
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.
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.
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.
3.3 Certification
The Contractors 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.
2. Standard Specification
Wherever 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 AS4456 AS3600 AS4456.4 AS4678 AS1289 Methods of Testing Concrete Concrete Masonry Units Concrete Structures Masonry Units Compressive Strength Earth Retaining Structures Methods of Testing Soils
12-20mm free draining granular material, fill all voids in and around units
4. Materials
4.1 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.
Compacted backfill material Reinforced Soil Zone Geogrid soil reinforcement to engineer's specification H
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.
First course to be embedded below final ground level to engineer's detail (10 0mm min.)
Materials or operations not covered by the above standard codes shall conform to the appropriate Australian Standard.
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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.
Sieve Size
75mm 26.5mm 4.75mm 0.425mm 0.075mm
% Passing by Weight
100 50 - 100 25 - 75 10 - 50 0 - 20
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.
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.
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.
4.1.4 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.
4.5 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.
4.3 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.
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;
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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.
Surface drainage during and after construction of the wall shall be provided to minimise water infiltration in the reinforced soil zone.
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 Testing
6.1 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:
Geogrid
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.
Vibrating rollers with a mass < 1000kg Vibrating plate compacters with a mass < 1000kg
Wall Face
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Boral MASONRY
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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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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305
305
200
200
455
455
Standard Unit
Flushface Unit
275 100
COLOURS
Boral 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.
Pylon
455
DESIGN CONSIDERATIONS
Boral 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
Lifting Bars
Tuscan
Desert Sand
Specifications
Description Standard Unit Standard Straight Sided Cap Flushface Unit Flushface Straight Sided Cap Pins (steel) Lifting Bars HxLxDmm 200x455x305 100x455x275 200x455x305 100x455x275 2 pins per full unit hot-dip galvanised steel (Keysteel units should be lifted by two people using the Keysteel lifting bars)
Fig F2 Typical Curved Wall Detail Keysteel Fig F3 Typical Straight Wall Detail Keysteel
Wt kg 36 25 39 26.3
Antique Copper
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Reinforcing bar to project specifications Geogrid (if required) Galvanised steel pipe
Drainage net
Granular backfill
Expansion joint material to design details TYPICAL PLAN VIEW Keystone unit Top of wall stepped (optional)
Reinforcing bar to design details Galvanised pipe Geogrid Galvanised pipe, loop connector and soil anchors (staggered installation) Soil Anchor to design details
Finished grade Footing step (optional) TYPICAL WALL ELEVATION 300mm nominal Stiff firm soil Cap unit Temporary concrete and mesh facing support system with drainage to design details 300mm nominal Drainage net to design details
Footing step
Finished grade
Keystone cap
See anchorage detail Keystone unit Horizontal reinforcing bar to design details Vertical reinforcing bar to design details Concrete backfill to design detail 1 8 Rock anchor system to design details 1500mm typical Geogrid at 600mm vertical centres extended to wall face between reinforcing bar Drainage pipe Levelling pad Soil anchor to design details TYPICAL CONNECTION DETAIL Granular material wrapped in geotextile TYPICAL SIDE ELEVATION TYPICAL ANCHORAGE DETAIL Finished grade Steel plate and securing nuts to design detail Concrete backfill Rock anchor to design detail
See connection detail Keystone units Keystone unit Geogrid 8 Galvanised steel pipe Loop connector Drainage pipe Leveling pad to engineer's detail Finished grade Granular fill
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Keystone unit Geogrid Reinforcing bar to design detail Thread bar to design details
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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.
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.
Question:
How far apart do the terrace walls have to be to perform as individual gravity walls?
Question:
What if there isnt enough room to space the terraces according to this rule (1.5 x H1 minimum)?
Test Reports
Tests have been carried out on the high velocity flow effects, wave action and sudden draw down and Mannings n determination. These test results are available on request.
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.
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.
300mm
Free draining granular material (less than 10% passing the #200 sieve, no organic material)
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Load Typical 900mm 150mm Additional Geogrid layer turned upwards and wrapped around void former at 400mm below ground level 900mm min.
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1824mm max.
900mm
Railing offset
Railing offset
Guardrail
Traffic Barrier
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Technical Enquires
Queensland 62 Industrial Ave, Wacol, 4076 North Queensland: Cairns 8 Palmer Street, Portsmith, 4870 Townsville 360 Bayswater Road, Garbutt, 4814 Mackay David Muir Street, Slade Point, 4740
T: (07) 4035 1888 F: (07) 4035 1208 T: (07) 4725 6285 F: (07) 4725 6043 T: (07) 4955 1155 F: (07) 4955 4130
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.