Masonry Wall BOR11999 VIC Manual Bk4

BORAL MASONRY
Build something great
Masonry Design Guide

SEGMENTAL BLOCK RETAINING WALLS VICTORIA BOOK 4
www.boral.com.au/masonry
Updated July 2005
Victoria Book 4 A
PAGE
A B C D
Introduction
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2 Fast Find Product & Application Guide . . . . . . . . . . . . . . . . . A3
Products @ a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4 About This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6
Planning & Design

Site Investigation Preliminary Design . . . . . . . . . . . . . . . . . B6
An Introduction to Segmental Block Retaining Walls . . . . . . . . . . . . . . . . . . . . . B2
Gardenwall
Curved Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
Gardenwall Product Information . . . . . . . . . . . . . . . . . . . . . . C2 Selection & Construction Guidelines . . . . . . . . . . . . . . . . . . . C3
Heathstone
Step Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4 Step Tread and Cap Unit Installation . . . . . . . . . . . . . . . . . . . D5
Heathstone Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2 Gravel-Fill Construction Guidelines . . . . . . . . . . . . . . . . . . . . D3
Corner Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6 Curved Wall Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . D4 No-Fines Concrete Wall Construction . . . . . . . . . . . . . . . . . . D7
Keystone & Pyrmont

No-Fines Concrete Wall Construction Guidelines . . . . . . . . . . . . . . . . . . . . . . . . E11 Geogrid Soil-Reinforced Wall Construction Guidelines . . . . . . . . . . . . . . . . . . . . . . . . E13 Typical Specification for Keystone/Pyrmont Retaining Walls . . . . . . . . . . . . . . . . . . . E15
Keystone Product Information . . . . . . . . . . . . . . . . . . . . . . . . E4 Pyrmont Product Information. . . . . . . . . . . . . . . . . . . . . . . . . E5 Gravel-Fill Wall Selection & Construction Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E6 Typical Installation Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . E8
Custom Engineered Walls

Typical Seawall Application. . . . . . . . . . . . . . . . . . . . . . . . . . . F8 Typical Terraced Wall Application . . . . . . . . . . . . . . . . . . . . . . F9 Typical Fencing Application. . . . . . . . . . . . . . . . . . . . . . . . . . F10 Typical Railing & Barrier Application . . . . . . . . . . . . . . . . . . . F11
Engineered Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . . F2 Keysteel Product Information. . . . . . . . . . . . . . . . . . . . . . . . . F4 Typical Soil-Anchor Application . . . . . . . . . . . . . . . . . . . . . . . . F6 Typical Rock-Anchor Application . . . . . . . . . . . . . . . . . . . . . . . F7
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.
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PAGE
Victoria Book 4 A
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
BORAL MASONRY SEGMENTAL BLOCK RETAINING WALLS

Surcharge Loading Nil Wall Height (mm) 1125 Wall Type Vertical Set Back 5kPa 5kPa or 1:4 Sloped Backfill 25kPa 1600 Vertical Set Back
D C
D E
E E E E
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)
Requires No-fines Concrete Backfill or Geogrid systems Requiring Geogrid systems Please refer to Book 1, Boral Masonry Design Guide and Book 2, Boral Masonry Blocks & Bricks Guide
3000
Property Boundary Not Boundary
E E E E E F F

> 3000
Vertical Set Back
> 25kPa
> 6000
Vertical Set Back
For technical support and sales office details please refer to the outside back cover
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 unless noted otherwise. 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/or loss of access.
BORAL MASONRY DESIGN GUIDE
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Fast Find a Boral Solution
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Victoria Vi V ic ct tor t ori ia a B Book oo o ok 4 A
Landscape Retaining Wall Systems

for low-height domestic and commercial garden beds and retaining wall applications
Gardenwall
Boral Gardenwall is ideal for gravity wall installations of less than 1.125m 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 for curved wall applications.
Heathstone & Heathstone Grand

Boral 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 Grand double-length blocks are particularly effective in larger installations.
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Victoria V Vic ict tor oria ia B Bo Boo Book ok k4 A
Engineered Retaining Wall Systems

for 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 cur ves and step installations.
Keystone
Boral Keystone walls have been proven time-andtime-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 and in splitface or flushface formats.
Keysteel Custom Engineered Retaining Wall Systems

Boral 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 soilreinforcement to provide engineered solutions for the most demanding retaining structures.
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Victoria Book 4 A
Boral Masonry Product Range

Boral 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.
Please note that this guide is based on products available at the time of publication from Boral Masonry Victorian sales region. Different products and specifications may apply to Boral products sourced from other regions.
Additional Assistance & 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.
Whats in this Guide

The 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.
A Guided Tour of a Typical Product Information Page

Product pages are laid out in a consistent manner to assist with easy selection and specification of Boral Masonry products.
Victoria Book 4 E
Product Range, Book and Page Identification

305
305 200
200
Keystone Retaining Wall Systems

INTRODUCTION Boral 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 soilreinforcement 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. 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.
Product Name and other identifying features
455
455
Standard Unit
Flushface Unit
Product Icons with dimensions for products available in your region/state
275 275 100 100 455 455
Standard Straight Sided Cap
Flushface Straight Sided Cap
Product information relating to features, applications, and accessories
Lifting Bars
Pins
Availability & Colours

No minimum order quantities apply. Lead time 0-4 weeks.
Colour and Availability information for products distributed in your region/state
Specifications
Natural Parchment Description Standard Unit Standard Straight Sided Cap Sunset Terracotta Flushface Unit Flushface Straight Sided Cap Pins Lifting Bars Charcoal Bluestone Brown Wt kg 35 25 38 26.3 N/m2 11 2.2/lin mtr 11 2.2/lin mtr
2 pins per full unit (high strength pultruded fibreglass) (Keystone units should be lifted by two people using the Keystone lifting bars)
Product Specifications
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BORAL MASONRY

SEGMENTAL BLOCK RETAINING WALLS VICTORIA BOOK 4 B PLANNING AND DESIGN
Victoria Book 4 B
An Introduction to Segmental Block Retaining Walls

Background
For 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 byvirtue of their own weight and setback, were introduced into Australia in the early 1990s, 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).
Segmental block gravity retaining structure, drystacked against a soil slope
Fig B2 Typical Segmental Block Gravity Retaining Wall
Segmental concrete gravity retaining structure, with reinforced soil
Steel reinforced and concrete grout filled hollow concrete block wall
Reinforced concrete footings
Fig B3 Typical Reinforced-Soil Segmental Block Retaining Wall
Fig B1 Typical Reinforced Concrete Masonry Cantilever Retaining Wall
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Victoria Book 4 B
Behaviour of Segmental Block Reinforced-Soil Retaining Walls

If 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 Report

The 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 Structures

Whenever 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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Victoria Book 4 B
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.
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, or 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 walls 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
Global slip failure

Soil 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 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 0.2m 2 ) 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.
Downward movement
Fig B4 Typical Low Wall Settlement
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Victoria Book 4 B
Tall wall settlement is not as obvious but occasional facial cracks can be obser ved in areas of f lexural 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 High confining pressure Flexural stress
Facial cracks
Fig B5 Typical Tall Wall Settlement
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, seawalls that may be subject to rapid drawdown (not covered in this guide) require design using undrained soil properties.
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Victoria V Vic cto tor oria a Bo B Book ook ok k4 B
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 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) Distance (m) ____________________ ____________________ ____________________ ____________________
Structure classification: __________________________________________________

For guidance refer AS4678, Table 1.1 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
Required design life:______________________________________________________

For guidance refer AS4678, Table 3.1 Type of Structure Temporary site works Mine structures Industrial structures River and marine structures Design life (years) 5 10 30 60 Type of Structure Residential dwellings Minor public works Major public works Design life (years) 60 90 120
Wall geometry:
Wall height above GL (H) Embedment depth (Hemb) H/20 or 200mm Wall slope () Angle of backfill slope () Height of backfill (h) Foundation material: Allowable bearing pressure Under reinforced soil block __________ kPa __________ m __________ m __________ __________ __________ m
Retained soil data:

Soil density (r) Internal friction angle (r) peak Cohesion (C*i) __________ kN/m3 __________ __________ kPa
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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BORAL MASONRY

SEGMENTAL BLOCK RETAINING WALLS VICTORIA BOOK 4 C GARDENWALL
Victoria Book 4 C
228 125
Gardenwall Retaining Wall System

INTRODUCTION Boral Gardenwall is ideal for low landscaping walls and edgings in garden and communal areas. Gardenwalls rockface texture, multifaceted 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 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. 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.
305
Standard Unit

Light Sands
Terrain
Kota Green
Portstone
Paperbark
Hawkesbury Yellow
Specifications
Product Description Standard Unit Finish Rockfaced HxLxDmm 125x305x228 Approx Wt kg 16.5 N/m2 26.3 units/m2
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Victoria Book 4 C
Selection & Construction Guidelines

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.
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 H 150mm width of 12-20mm free draining granular material eg. blue metal 1 in 5 set-back Native soil Drainage pipe (if required) First course to be buried below final ground level (to engineer's specification - 100mm min.)
100mm min.
350mm min.
Compacted road base levelling pad on undisturbed inorganic soil
Fig C1 Typical Gravity Wall Construction Detail Gardenwall

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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Victoria Book 4 C
Curved Walls
m 0m um 10 0 e m s = i in s ur M diu t co Ra 1s r fo
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.
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BORAL MASONRY

SEGMENTAL BLOCK RETAINING WALLS VICTORIA BOOK 4 D HEATHSTONE
Victoria Book 4 D
280 162 380 220 270 162
Heathstone Retaining Wall System

INTRODUCTION Boral 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 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. 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. 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.
Standard Unit
280 162
Standard Corner Unit
162 380 160
440
Grand Unit
340 60 225
Grand Corner Unit

300 50 600
Splitface Cap
300 50 300
Double Sided Rockface Cap

470 300
50
392
Rockface Corner Cap
1800 radius
Double Sided Rockface Curved Cap

Portstone
Hawkesbury Yellow
Charcoal
Specifications
Product Description Standard Unit Standard Corner Unit Grand Unit Grand Corner Unit Splitface Cap Double Sided Rockface Cap Rockface Corner Cap Double Sided Rockface Curved Cap Finish Rockfaced Rockfaced x 2 Faces Rockfaced Rockfaced x 2 Faces Rockfaced x 1 Edge (225mm) Rockfaced x 2 Long Edges Rockfaced x 2 Adjacent Edges Rockfaced x 2 Long Edges HxLxDmm 162x220x280 162x380x270 162x440x280 162x380x160 60x225x340 50x600x300 50x300x300 50x392/470x300 Approx Wt kg 11.0 15.6 26.3 10.5 11.3 22.0 10.7 15.6 N/m2 28.1 units/m2 1/course/corner 14.05 units/m2 1/course/corner 4.5/linear metre 1.6/linear metre 1/corner 24 per Full Circle (15 each) 6 per Quarter Circle
Note: Refer to max. wall heights disclaimer on page A3 of this guide.
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Victoria Book 4 D
Heathstone Gravel-Fill Construction

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.
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 Native soil Refer to Heathstone Gravel-Fill Selection Table for maximum number of courses
Compacted roadbase 350mm min.
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 Maximum Courses For walls with gravel fills to all voids and cores
2 (324mm)
4 (648mm)
3 (486mm)
5 (810mm)
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.
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Victoria Book 4 D
Curved Wall Construction

Curves as small as 900mm in radius can be constructed with Heathstone Standard Units. NOTE: Double Sided Rockface Curved Cap radius is 1500mm to the inside face and 1800mm to the outside face.
Concave (Internal) Curves For concave curves use Standard Units spaced evenly to a scribed arc in conjunction with Double Sided Rockface Curved Caps butted together to form a 1500mm radius wall face.
Heathstone Standard Unit
m 150 0
Heathstone Curved Cap
1800mm
NOTE: Premium Curved Caps have an inside radius of 1500mm
Co n ca
ve
Fig D2 Heathstone Curved Cap Radius
Cu rv e
Ra di u
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.
Fig D4 Forming Concave Curve
Step Construction
Bolster back of blocks to form convex curves
Double Sided Rockface Cap Fix cap units with construction adhesive Remove locating lugs before laying 255
162 25
NOTE: Premium Curved Caps have an outside radius of 1800mm
45 Heathstone Units 1:10 Cement : Sand
Fig D3 Forming Convex Curve

Native soil
Fig D5 Construction of Heathstone Steps

Note: For alternative step detail, see page E10.
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Victoria Book 4 D
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 D6 Bolstering Lug from Heathstone Units
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Victoria Book 4 D
Corner Construction
Constructing Internal and External Corners Corners are constructed using Corner Units and Standard Units or Grand Units and Grand 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.
Bolster lug to fit next course
Grand Corner Unit
Grand Unit
Grand Unit Corner Unit Corner Unit
Fig D7 Heathstone External Corner (270)
Fig D9 Heathstone Grand External Corner (270)
110mm Corner Unit
Grand Unit
220mm Bolster lug to fit next course
Standard Unit
Bolster lug to fit next course
Corner Unit Grand Unit NOTE: Internal 90 corners using Grand Units do not require corner units
Fig D8 Heathstone Internal Corner (90)
Fig D10 Heathstone Grand Internal Corner (90)
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Victoria Book 4 D
Heathstone No-Fines Concrete Wall Construction

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
No loads above 5kPa to be located within 1.0m of the wall T Cap unit
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).
Filter fabric or dish drain 15MPa No Fines concrete. All voids within and around units to be completely filled. 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.)
H (Refer to Heathstone No-Fines Concrete Selection Table)
25MPa concrete footing on 150kPa allowable bearing capacity material 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) Retained Soil CLAY = 26 (POOR) T (mm) 670 730 1170 Retained Soil = 30 (AVERAGE) T (mm) 570 770 970 Retained Soil GRAVEL = 34 (GOOD) T (mm) 570 670 770
SAND
972 1296 1620
Denotes the internal angle of friction of the retained material
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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 15MPa for design purposes. This product has no slump and exerts similar pressures on the soil and formwork, as does loosely poured aggregate.
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 212 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:
No-Fines Construction Steps

Special purpose construction such as waterside walls, post fixing, earthquake zones, and terraces will require additional engineers 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.
Installing Capping Units Install capping units and fix with construction adhesive.
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BORAL MASONRY

SEGMENTAL BLOCK RETAINING WALLS VICTORIA BOOK 4 E KEYSTONE AND PYRMONT
Victoria Book 4 E
Keystone & Pyrmont Retaining Wall Systems

The 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. 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 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
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,
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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.
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.
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305 200
305
200
Keystone Retaining Wall Systems

INTRODUCTION Boral 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 soilreinforcement 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. 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
455
Standard Unit
Flushface Unit
275 275 100 100 455 455
Lifting Bars
Pins

Specifications
Natural Parchment Description Standard Unit Standard Straight Sided Cap Sunset Terracotta Flushface Unit Flushface Straight Sided Cap Pins Lifting Bars Charcoal Bluestone Brown Wt kg 35 25 38 26.3 N/m2 11 2.2/lin mtr 11 2.2/lin mtr
2 pins per full unit (high strength pultruded fibreglass) (Keystone units should be lifted by two people using the Keystone lifting bars)
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Victoria Book 4 E
305
200
340 60
Pyrmont Vertical Retaining Wall System

INTRODUCTION Boral 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 Australias early settler period. Boral Pyrmont retaining wall system is also suitable for constructing steps, planter boxes, gently curved walls and crisp 90 corners. 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.
455
225
Standard Unit
Standard Cap
355 65 455 355
355 65
Premium Cap Rockfaced

(Hawkesbury Yellow only)
Premium Corner Cap Rockfaced

(Hawkesbury Yellow only)
200
222
450
450
222
90 Corner Unit Right or Left Hand
Lifting Bars
Pins

Specifications
Description Standard Unit Standard Cap (Rockfaced 1 side) Premium Cap (Rockfaced 1 side) Premium Corner Cap (Rockfaced 2 sides) Wt kg 37.3 11.3 24 18.8 31 N/m2 11 4.44/lin mtr 2.2/lin mtr 1/90 corner 5/vertical metre
Portstone
Hawkesbury Yellow
90 Corner Unit (Right or Left Hand) Pins Lifting Bars
2 pins per full unit (high strength pultruded fibreglass) (Pyrmont units should be lifted by two people using the Keystone lifting bars)
Charcoal
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Victoria Book 4 E
Gravel-Fill Wall Selection

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.
Table E1 Maximum Wall Height for Gravel-Fill Walls Backfill Type Poor Wall Height H (mm) Near 1 in 8 Vertical Setback 800 900
Surcharge Loading
Retained Soil Descriptions

Poor Soils Include fine sands, gravelly clays, sandy clays, silty sands. Angle of internal friction 25 Include well graded sands, gravelly sands. Angle of internal friction 30 Include gravels, sandy gravels, crushed sandstone Angle of internal friction 35
No Surcharge Loading
SETBACK
Average
900
1000
Good
1000
1200
15 Sloped Backfill
Average Soils
Poor
600
900
Average
700
900
Good Soils
Good Driveway/Carpark Loading (5kPa)
800
1100
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.
Poor
400
500
Average
500
600
Good
600
800
Gravel-Fill Wall Construction Guidelines

IMPORTANT: Please consultwith the regulating council forlocal 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 engineerwhere the wall is over0.5m in height and/orwhere there is surcharge loading such as a roadway, house, or other structure near the wall. 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, and maintain a distance of 226mm between pin hole centres of adjacent units.
226mm pin cts 226mm pin cts
For 1 in 8 setback construction, install pins in the back holes, and maintain a distance of 226mm between pin hole centres of adjacent units. Near vertical installation must be used when designing walls with curves or corners.
Fig E1 Installation of Pins
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Victoria Book 4 E
For curved installations, maintain 226mm between pin hole centres of adjacent units. This will leave a small gap between units for convex curves, and will require a small overlap of adjacent units with concave curves. 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 drainage layer and backfill if the type of backfill is likely to wash into 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.
Compacted backfill soil (if required) Drainage pipe Free draining granular material
Compacted footing
Native soil
Fig E2 Typical Installation Detail Keystone Gravity Wall

Granular material for drainage 300mm Cap Unit
Backfill
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 Drainage pipe (if required) First course to be buried below final ground level (to engineer's specification - 100mm min.)
150mm min
600mm min.
Compacted roadbase, crushed stone or gravel levelling pad
Fig E3 Typical Construction Detail Keystone Gravity Wall
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Victoria Book 4 E
Typical Installation Details
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
FIRST COURSE
SECOND COURSE
Align face of unit with the centre line of adjacent unit Cut to suit on site
Cut to suit on site
Omit one pin only
Omit one pin only
Align face of unit with the centre line of adjacent unit
Fig E5 90 Internal Corner Flushface Keystone/Pyrmont Units
305mm
455mm
455mm
77mm Omit one pin only 455mm Use Flushface unit and bolster face to suit
455mm FIRST COURSE
90 corner unit cut from face of Flushface unit and fixed in place with epoxy adhesive
SECOND COURSE
Fig E6 90 External Corner with Standard Keystone Units
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Victoria Book 4 E
450mm
455mm
455mm
222mm
455mm Pyrmont corner unit Pyrmont corner unit
FIRST COURSE 455mm
SECOND COURSE
Fig E7 90 External Corner Pyrmont Units
226mm centres Use front pin holes for curves. Maintain a centre-to-centre distance of 226mm between pins in adjacent units (small overlaps between units will be required)
Fig E8 Concave Curve
226m
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 centre-to-centre distance of 226mm between pins in adjacent units (small gaps between units will be required)
Bolster backs as required
Fig E9 Convex Curve
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Radius r
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Victoria Book 4 E
Keystone cap unit
Keystone unit
Fig E10 Stepped Capping Units
Bolster backs as required
290mm Treads
Fig E11 Plan view of step through Keystone
Tread approx. 290mm for 40mm pavers (30)
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
Fig E12 Keystone section through steps
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Victoria Book 4 E
No-Fines Concrete Wall Construction Guidelines

The 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 2100 kg/m3.) The void ratio of the mix is expected to be between 20% and 30% and should be free draining.
T Cap unit
Filter Fabric 15MPa No-Fines concrete. All voids within and around units to be completely filled. Retained soil Keystone or Pyrmont unit
Sub-soil drain connected to stormwater system or flood pit
Pour no-fines concrete directly onto prepared foundation material Blocks embedded to engineer's detail (100mm min) 25MPa concrete footing on 150kPa allowable bearing capacity material (see note below Table E2) 600mm min.
150mm min
Fig E13 Typical Construction Detail Keystone No-Fines Concrete Mass Gravity Wall
Table E2 Maximum Wall Heights for No-Fines Concrete Wall Construction Wall Height H (mm) 1000 1400 1800 2200 2600 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
Denotes the internal angle of friction of the retained material Non-shaded Area = Compacted Roadbase Footing Shaded Area = Concrete Footing as per Fig E13 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.
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 to maintain the 226mm pin distance. Refer to Figs E8 and E9 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.
Construction Steps
Special purpose construction such as waterside walls, post fixing, earthquake zones, and terraces will require additional engineers 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 1220mm gravel for the levelling base and compact. For higher walls or in poor foundation material, a footing as shown in Fig E13 may be necessary. Refer to Table E2.
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Victoria Book 4 E
Geogrid Soil-Reinforced Wall Construction Guidelines

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 costlystructural 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.
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
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Victoria Book 4 E
Native soil
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
Native soil
Compacted roadbase footing
Fig E14 Typical Installation Detail Keystone/Pyrmont Geogrid Reinforced-Soil Wall
L Granular material 300mm Cap Unit
Keystone or Pyrmont unit
12-20mm free draining granular material, fill all voids in and around units
Compacted backfill material Reinforced Soil Zone Geogrid soil reinforcement to engineer's specification
Drainage pipe (as required)
First course to be embedded below final ground level to engineer's detail (100mm min.)
Compacted roadbase or concrete footing
150mm min.
600mm min.
Fig E15 Typical Construction Detail Keystone/Pyrmont Geogrid Reinforced-Soil Wall
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Typical Specification for Keystone or Pyrmont Retaining Walls

1. Scope of Work
1.1 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.
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. 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 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
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. 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.
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. 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 75mm 26.5mm 4.75mm 0.425mm 0.075mm
% Passing by Weight 100 50 - 100 25 - 75 10 - 50 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 densityvalues 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.
E16
Victoria Book 4 E
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 subgrade 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 Contractors 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 Contractors 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.
July 2005
E17
Victoria Book 4 E
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
Geogrid
Wall Face
Vibro tampers having a mass < 75kg
Fig 5.4 Typical Geogrid Layout
E18
Victoria Book 4 E
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.
6.2 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.
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: 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.
July 2005
E19
Victoria Book 4 E
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.
E20
BORAL MASONRY

SEGMENTAL BLOCK RETAINING WALLS VICTORIA BOOK 4 F CUSTOM ENGINEERED WALLS
Victoria Book 4 F
Engineered Retaining Wall Systems

for 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.
F2
Victoria Book 4 F

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 & Rock-Anchor Walls Fencing, Railings & Barriers

Boral 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 soilreinforcement to provide engineered solutions for the most demanding retaining structures.
July 2005
F3
Victoria Book 4 F
305
305
200
200
455
455
Keysteel High Performance Engineered Retaining Wall Systems

INTRODUCTION Boral 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 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 Keysteel retaining structures. Please contact Boral Masonry Technical Services in your region for assistance with Keysteel projects. 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.
Standard Unit
Flushface Unit
275 100
275 100 455
455
Steel Pins (hot-dip galvanised)
Lifting Bars

All Keysteel products are made-to-order. Lead times apply Please consult with the Boral Masonry sales office in your region.
Specifications
Natural Parchment Description Standard Unit Standard Straight Sided Cap Flushface Unit Sunset Terracotta Flushface Straight Sided Cap Pins (steel) Lifting Bars Charcoal Bluestone Brown 2 pins per full unit hot-dip galvanised steel (Keysteel units should be lifted by two people using the Keysteel lifting bars) Wt kg 36 25 39 26.3 N/m2 11 2.2/lin mtr 11 2.2/lin mtr
F4
Victoria Book 4 F
Typical Keysteel Application Layout

Keystone unit Cut ladder around pylon Where piles prevent installation of ladders refer to engineers detail.
Pylon
Fig F1 Typical Construction Detail Keysteel wall
Wall face
Keysteel unit
Keysteel unit
Soil reinforcing ladder
Soil reinforcement ladder Keysteel unit
Fig F2 Typical Curved Wall Detail Keysteel
Fig F3 Typical Straight Wall Detail Keysteel
July 2005
F5
Victoria Book 4 F
Typical Soil-Anchor Application
Soil anchors
Granular backfill
Geogrid (if required)
Stiff firm soil
Galvanised steel pipe
1200mm cts nominal
Galvanised pipe loop connector
TYPICAL PLAN VIEW
Keystone unit Top of wall stepped (optional)
Galvanised pipe
Galvanised pipe, loop connector and soil anchors (staggered installation)
Finished grade TYPICAL WALL ELEVATION 300mm nominal Stiff firm soil Cap unit
Footing step (optional)
Threaded pipe coupling
See connection detail Keystone units Keystone unit Geogrid 8 Galvanised steel pipe Loop connector Drainage pipe Leveling pad to engineer's detail Finished grade Soil anchor to design details TYPICAL CONNECTION DETAIL Granular fill
Soil failure plane
Soil anchors to site specific design
TYPICAL SIDE ELEVATION
Fig F4 Typical Soil-Anchor Detail
F6
Victoria Book 4 F
Typical Rock-Anchor Application Layout

Rock anchors Temporary face support and drainage system Concrete backfill
Reinforcing bar to project specifications
Geogrid to project specifications
Drainage net
Expansion joint material to design details
Keystone unit TYPICAL PLAN VIEW Top of wall stepped (optional)
Reinforcing bar to design details
Geogrid
Soil Anchor to design details
Finished grade 300mm nominal Drainage net to design details
TYPICAL WALL ELEVATION
Footing step
Keystone cap
See anchorage detail Keystone unit Temporary concrete and mesh facing support system with drainage to design details 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 Finished grade Steel plate and securing nuts to design detail Granular material wrapped in geotextile TYPICAL SIDE ELEVATION TYPICAL ANCHORAGE DETAIL Concrete backfill Rock anchor to design detail
Keystone unit Geogrid Reinforcing bar to design detail Thread bar to design details
Fig F5 Typical Rock-Anchor Detail
July 2005
F7
Victoria Book 4 F
Typical Seawall Application Layout

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. 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 Mannings n determination. These test results are available on request.
Impermeable soil layer
300mm
Filter Fabric Keystone Cap Unit
10-20mm crushed rock, fill cores and voids of Keystone units
Free draining granular material (less than 10% passing the #200 sieve, no organic material)
Keystone block
Typical 1900mm Geogrid as per design Nonwoven filter fabric
Native soil Water level 150 - 200mm rip-rap
Compacted aggregate or crushed rock
150mm min.
600mm min.
Fig F6 Typical Construction Detail Keystone Seawall Application
F8
Victoria Book 4 F
Typical Terraced Wall Application Layout

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. 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 isnt 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.
Keystone or Pyrmont wall H2
Cap unit
L = 1.5 x (H1) L = minimum distance between terraces H1
Keystone or Pyrmont wall
Fig F7 Typical Construction Detail Terraced Wall Application
July 2005
F9
Victoria Book 4 F
Typical Fencing Application Layout

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).
1824mm max.
900mm
700mm
Fig F8 Typical Fencing Detail
F10
Victoria Book 4 F
Typical Railing & Barrier Application Layout

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.
Load Typical 900mm 150mm Additional Geogrid layer turned upwards and wrapped around void former at 400mm below ground level 900mm min.
Load Typical 900mm
Railing offset
Railing offset
Load 1000mm min.
Load Typical 800mm
Guardrail
Traffic Barrier
Fig F9 Railing & Barrier Details
July 2005
F11
July 2005
Customer Support Victoria

1. 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 areas 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 1m 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.
Technical Enquires
Specifier Line Internet
1300 360 255 www.boral.com.au/masonry
Orders, Product Samples and Sales Enquires

Victoria Level 1 Port IT, 63-85 Turner Street, Port Melbourne, 3207 T: (03) 9363 1944 F: (03) 9363 6008
Other Regional Sales Offices

NSW ACT South Australia Queensland North Queensland: Cairns Townsville Mackay 8 Palmer Street, Portsmith, 4870 360 Bayswater Road, Garbutt, 4814 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 Clunies Ross Street, Prospect, 2148 16 Whyalla Street, Fyshwick, 2609 Main North Road, Pooraka, 5095 62 Industrial Ave, Wacol, 4076 T: (02) 9840 2333 F: (02) 9840 2344 T: (02) 6239 1029 F: (02) 6280 6262 T: (08) 8262 3529 F: (08) 8260 3011 T: (07) 3271 9292 F: (07) 3271 1581
Heathstone 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 2004.

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BORAL MASONRY

Build something great

Masonry Design Guide

Updated July 2005

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2 Fast Find Product & Application Guide . . . . . . . . . . . . . . . . . A3

Products @ a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4 About This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6

Planning & Design

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

Gardenwall Product Information . . . . . . . . . . . . . . . . . . . . . . C2 Selection & Construction Guidelines . . . . . . . . . . . . . . . . . . . C3

Heathstone Product Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2 Gravel-Fill Construction Guidelines . . . . . . . . . . . . . . . . . . . . D3

Corner Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6 Curved Wall Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . D4 No-Fines Concrete Wall Construction . . . . . . . . . . . . . . . . . . D7

Keystone & Pyrmont

Custom Engineered Walls

July 2005 | BORAL MASONRY DESIGN GUIDE

BORAL MASONRY SEGMENTAL BLOCK RETAINING WALLS

Property Boundary Not Boundary

Vertical Set Back

Vertical Set Back

BORAL MASONRY DESIGN GUIDE

Fast Find a Boral Solution

Victoria Vi V ic ct tor t ori ia a B Book oo o ok 4 A

Landscape Retaining Wall Systems

Heathstone & Heathstone Grand

July 2005 | BORAL MASONRY DESIGN GUIDE

Victoria V Vic ict tor oria ia B Bo Boo Book ok k4 A

Engineered Retaining Wall Systems

Keysteel Custom Engineered Retaining Wall Systems

BORAL MASONRY DESIGN GUIDE

Boral Masonry Product Range

Additional Assistance & Information

Whats in this Guide

A Guided Tour of a Typical Product Information Page

Product Range, Book and Page Identification

Keystone Retaining Wall Systems

Product Name and other identifying features

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

275 275 100 100 455 455

Standard Straight Sided Cap

Flushface Straight Sided Cap

Product information relating to features, applications, and accessories

Availability & Colours

Colour and Availability information for products distributed in your region/state

July 2005 | BORAL MASONRY DESIGN GUIDE

July 2005 | BORAL MASONRY DESIGN GUIDE

Build something great

Masonry Design Guide

An Introduction to Segmental Block Retaining Walls

Fig B2 Typical Segmental Block Gravity Retaining Wall

Segmental concrete gravity retaining structure, with reinforced soil

Reinforced concrete footings

Fig B3 Typical Reinforced-Soil Segmental Block Retaining Wall

Fig B1 Typical Reinforced Concrete Masonry Cantilever Retaining Wall

July 2005 | BORAL MASONRY DESIGN GUIDE

Behaviour of Segmental Block Reinforced-Soil Retaining Walls

Importance of a Geotechnical Report

Safety and Protection of Existing Structures

BORAL MASONRY DESIGN GUIDE

Unit Cracking/Gapping Settlement

Global slip failure

Fig B4 Typical Low Wall Settlement

July 2005 | BORAL MASONRY DESIGN GUIDE

Downward movement High confining pressure Flexural stress

Fig B5 Typical Tall Wall Settlement

BORAL MASONRY DESIGN GUIDE