Boral MASONRY

Build something great™

Masonry Design Guide

segmental block retaining walls south australia BOOK 4

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

Contents Fast Find Guide

4 A2 4 A3

PAGE

PAGE
BOOK

BOOK
South Australia Book 4 A South Australia Book 4 A

The quickest way to find a Boral Masonry Segmental Block Retaining Wall Solution.
A

PAGE

PAGE
Introduction Simply follow the FAST FIND guide on the right hand side of the table.

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2 Products @ a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4

Fast Find Product and Application Guide . . . . . . . . . . . . . . . A3 About This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6 BORAL
MASONRY
B Planning and Design SEGMENTAL

k
oc
Bl
BLOCK

e
l
al
CT

d
on

lle
ne
nw
RETAINING

el
An Introduction to Site Investigation — Preliminary Design . . . . . . . . . . . . . . . . B6
Fast Find

st

on

Fi
to

te
D

de

th
Segmental Block Retaining Walls . . . . . . . . . . . . . . . . . . . . . B2

rm
O

ys

ys

re
WALLS

ea
ar
PR

Co
Ke

Ke
Py
G

H
C Gardenwall® Surcharge
Loading
Wall Height
(mm)
Wall
Type
a Boral
Gardenwall Product Information . . . . . . . . . . . . . . . . . . . . . . C2 Curved Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
Nil ≤ 1125
Vertical D E E  Solution
Selection and Construction Guidelines . . . . . . . . . . . . . . . . . C3
Set Back C E  1 Select your application
criteria from the left
D E E 
D Heathstone ®
≤ 5kPa ≤ 1600
Vertical


hand columns

Heathstone Product Information . . . . . . . . . . . . . . . . . . . . . . D2 Step Tread and Cap Unit Installation. . . . . . . . . . . . . . . . . . . D5

Set Back E 2 Go straight to the book
≤ 5kPa Property section indicated by the
Gravel Fill Construction Guidelines . . . . . . . . . . . . . . . . . . . . D3 Corner Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6
or Boundary  letter at the intersection of
Curved Wall Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . D4 No-Fines Concrete Wall Construction . . . . . . . . . . . . . . . . . . D7 ≤ 1:4 ≤ 3000 application rows and
Step Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D4 Sloped Not product columns (e.g.
Backfill Boundary E E  Section E in this example)

E Keystone® and Pyrmont® ≤ 25kPa > 3000

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

Keystone Product Information . . . . . . . . . . . . . . . . . . . . . . . E4 No-Fines Concrete Wall Selection Set Back E  Requiring ‘Geogrid’ systems
Construction Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . E11
Pyrmont Product Information . . . . . . . . . . . . . . . . . . . . . . . . E5 Vertical F Please refer to Book 1, Boral
Geogrid Soil-Reinforced > 25kPa > 6000  Masonry Design Guide and Book 2,
Gravity Wall Selection and Construction Guidelines . . . . . . . E6 Wall Selection Construction Guidelines . . . . . . . . . . . . . . . E13 Set Back F Boral Masonry Blocks & Bricks Guide
Typical Installation Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . E8 Typical Specification for
Keystone/Pyrmont Block Retaining Walls . . . . . . . . . . . . . . E15
For technical support and sales office details please refer to the outside back cover

F Custom Engineered Wall Systems

Engineered Retaining Walls . . . . . . . . . . . . . . . . . . . . . . . . . F2 Typical Terraced Wall Application . . . . . . . . . . . . . . . . . . . . . F9

Keysteel Product Information . . . . . . . . . . . . . . . . . . . . . . . . F4 Typical Fencing Application . . . . . . . . . . . . . . . . . . . . . . . . . F10

Typical Soil-Anchor Application . . . . . . . . . . . . . . . . . . . . . . . F6 Typical Railing and Barrier Application. . . . . . . . . . . . . . . . . F11

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

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

Max. wall heights disclaimer:

The gravity wall heights are maximum heights calculated in accordance with CMAA MA-53 Appendix D guidelines and a qualified engineer should confirm the suitability of the product
for each intended application. As such, due consideration must be given to but not limited to:
• Cohesion,
The information presented herein is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. No responsibility can be accepted by
• Dry backfill: no ingress of any water into the soil behind the retaining wall,
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 • All retaining walls are designed for zero surcharge.
for any loss or damage caused by any person acting or refraining from action as a result of this information. These walls are intended for structure Classification A walls only as defined in AS4678 Earth Retaining Structures as being where failure would result in minimal damage and loss of access.

A2 September 2007 | BORAL MASONRY DESIGN GUIDE BORAL MASONRY DESIGN GUIDE | September 2007 A3
Products @ a Glance Products @ a Glance

4 A4 4 A5

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PAGE
BOOK

BOOK
South Australia Book 4 A South Australia Book 4 A

Landscape • Gardenwall® Engineered • Pyrmont®

Retaining Wall Systems Boral Gardenwall is ideal for gravity wall installations Retaining Wall Systems Boral Pyrmont retaining walls are a modern-day link
to our pioneer heritage. Pyrmont combines modern
of less than 1125mm wall height. The blocks are laid
for low-height domestic and commercial for domestic and commercial landscaping, roadside engineering versatility with the elegance of a vertical
with a slight set-back, and are located by a lug along
garden beds and retaining wall applications and custom engineered retaining wall applications
the back edge. Gardenwall can also be used curved wall and the style of hand-finished natural stone.
wall applications. Pyrmont gravity or soil reinforced retaining wall
systems can be engineered for applications up to 6m
• Keystone® height and can accommodate gentle curves and step
Boral Keystone walls have been proven time-and- installations.
• Heathstone® and Heathstone® Grande
time-again, by engineers, architects, councils, road
Boral Heathstone retaining wall systems combine • Keysteel™ Custom Engineered Retaining
authorities and landscapers throughout Australia.
the attractive impression of natural hewn stone, Wall Systems
Keystone walls can cater for a wide range of
the elegance of a vertical wall and the simplicity of Boral Keysteel is a high performance engineered
applications from low height gravity walls to geogrid
mortarless installation. Various installation formats retaining wall system for applications requiring wall
soil reinforced applications up to 12m wall height.
cater for walls up to 0.97m height. Heathstone Grande heights in excess of 6m and/or where critical surcharge
Keystone walls can be constructed as near vertical
double-length blocks are particularly effective in larger loadings are present. Boral Keysteel is an internationally
with curves as tight as 1m radius, or set-back. Blocks
installations. proven system that integrates the superior strength
are available in a wide selection of colours.
and durability of Keysteel blocks with steel-ladder soil-
reinforcement to provide engineered solutions for the
most demanding retaining structures.

A4 September 2007 | BORAL MASONRY DESIGN GUIDE BORAL MASONRY DESIGN GUIDE | September 2007 A5
About This Guide

4 A6

PAGE
BOOK
South Australia Book 4 A Boral MASONRY
Build something great™

Boral Masonry Product Range Please note that this guide is based on products available at
the time of publication from the Boral Masonry South Australia
Boral Masonry offers a comprehensive range of proven products
sales region. Different products and specifications may apply
and systems including Segmental Block Retaining Wall
to Boral products sourced from other regions.
Systems, Segmental Paving Products, Masonry Blocks, Masonry

Masonry Design Guide

Bricks, Masonry Fire and Acoustic Wall Systems. Additional Assistance and Information
What’s in this Guide • Contact Details: Please refer to the outside back cover
of this publication for Boral Masonry contact details.
The Boral Masonry Segmental Block Retaining Walls Guide,
(this book), details a comprehensive selection of retaining wall • Colour and Texture Variation: The supply of raw
options ranging from low height gravity landscaping walls to materials can vary over time. In addition, variation can
critically loaded reinforced-soil retaining structures. occur between product types and production batches. segmental block retaining walls south australia BOOK 4
Also please recognise that the printed colours in this
This guide has been prepared as a comprehensive Boral
brochure are only a guide. Please, always ask to see a B planning and DESIGN
Product Reference Guide. It does not attempt to cover all the
sample of your colour/texture choice before specifying
requirements of the Codes and Standards which apply to
or ordering.

4
retaining wall construction. All structural detailing should
be checked and approved by a structural engineer before • Terms and Conditions of Sale: For a full set of Terms
construction. Boral reserves the right to change the contents and Conditions of Sale please contact your nearest Boral
of this guide without notice. Masonry sales office.

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.
Product Range, Book and
Page Identification Keystone® & Pyrmont®

South Australia Book 4 E

4 E4
PAGE
BOOK

315
315 315
315 Product Name and other
Keystone®®
200
200 200
200
Systems
Retaining Wall Systems
identifying features
455 455
455 455 INTRODUCTION
INTRODUCTION the tail
the tail to
to 300mm
300mm width.
width.
Standard
Standard Unit
Unit Flushface
Flushface Unit
Unit Boral Keystone
Boral Keystone is is an
an advanced,
advanced,
(Made
(Made to
to order) •• Can
Canbebeinstalled
installedasasnear
nearvertical,
vertical,

Product Icons
order) highly versatile
highly versatile and
and thoroughly
thoroughly
or for
or for straight
straight walls
walls without
without
proven high
proven high performance
performance segmental
segmental
275 275 curves or
curves or corners
corners itit can
can bebe
block retaining
retaining wall
wall system
system which
which
with dimensions
275 275
block
installed with
installed with aa 1-in-8
1-in-8 setback.
setback.
100
100 100
100
can be
can be used
used as
as aa gravity
gravity structure
structure
or it
it can
can incorporate
incorporate geogrid
geogrid soil-
soil- COLOURS
for products Product information
or COLOURS
455
455 reinforcement to to cater
cater for
for greater
greater Keystone is is offered
offered inin aa range
range of
of
455
455 reinforcement Keystone
surcharge loading
loading colours to to suit
suit decorative
decorative and and
available in your relating to features,
Standard Flushface
Flushface Straight heights and surcharge colours
Standard Cap
Cap Straight
(made
(made to order) Sided Cap situations. engineering applications.
engineering applications. Please
Please
(made to order) refer to
to colour
colour swatch
swatch information
information
applications, and
refer
region/state 275
275
CONSIDERATIONS
DESIGN CONSIDERATIONS
straight and
• Suitable for straight and curved
curved
for an
for an indication
indication of
of current
current colours.
colours.

installations with
withaaminimum
minimum To reduce
reduce the
the possibility
possibility of
of staining
staining
accessories
300
300 wall installations To
100
50 radius of
convex curve radius of 1800mm
1800mm and to
and to enable
enable easier
easier cleaning,
cleaning, aa
300 trimming the
without trimming the tail
tail width,
width, masonry sealer
masonry sealer can
can be
be applied
appliedtotoall
all
455
455
radius by
or 970mm radius by trimming
trimming visible surfaces
visible surfaces after
after installation.
installation.
Straight
Straight Sided Cap Standard
D-Cap Cap
(made
(made to order)

B
Pins
Lifting
Lifting Bars

Keygrid Geogrid Soil Reinforcement

Keygrid
Specifications
Colour and Description HxLxDmm
HxLxDmm Wt
Wt kg
kg N°/m
N°/m22

Availability Availability and

Availability
•• No
No minimum
& Colours
Colours
minimum order
•• Lead
Lead time
time 0-4
order quantities apply.
0-4 weeks.
weeks.
Standard Unit 200x455x315
200x455x315 41
41 11
11

information
Straight Sided Cap
Cap 100x455x275
100x455x275 25
25 2.2/lin
2.2/linmtr
mtr
Standard Half High
High Unit
Unit 100x455x275
100x455x275 20
20 22
22

for products
Standard Cap 100x455x275
100x455x275 20
20 2.2/lin
2.2/linmtr
mtr
Flushface Unit 200x455x315
200x455x315 41
41 11
11

distributed Almond
Almond Tuscan Flushface Straight
Pins
Straight Sided
Sided Cap
Cap
22 pins
pins per
per full
100x455x275
100x455x275
full unit
26.3
26.3 2.2/lin
2.2/linmtr
mtr

Product
unit

in your Lifting
Lifting Bars
(high
(high strength
strength pultruded
(Keystone
(Keystone units
pultruded fibreglass)
units should
should be
fibreglass)
be lifted
lifted by
Specifications
Bars by

region/state Paperbark
Paperbark
two
two people
people using
using the
the Keystone
Keystone lifting
lifting bars)
bars)

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Planning and Design Planning and Design

4 B2 4 B3

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BOOK

BOOK
South Australia Book 4 B South Australia Book 4 B

An Introduction to Segmental Behaviour of Segmental Block • Adequate connection to the facing to provide local stability;
Reinforced-Soil Retaining Walls
Block Retaining Walls Segmental block gravity
• A drainage system that will relieve hydro static pressures
retaining structure, dry-
stacked against a soil If unrestrained, a soil embankment will slump to its angle of for the life of the structure.
Background slope
repose. Some soils, such as clays, have cohesion that enables
vertical and near-vertical faces to remain partially intact, but
Importance of a Geotechnical Report
For many years cantilever retaining walls have been constructed
with reinforced concrete masonry stems (steel reinforcement even these may slump under the softening influence of ground The design of a reinforced soil retaining wall includes two
grouted into hollow concrete block work) and reinforced water. When an earth retaining structure is constructed, it essential parts:
concrete footings. (Refer to Fig B1). restricts this slumping. The soil exerts an active pressure on • Analysis of the proposed reinforced soil structure and
the structure, which deflects a little and is then restrained by the adjacent ground for global slip, settlement, drainage
Segmental block gravity retaining structures, consisting
the friction and adhesion between the base and soil beneath, and similar global considerations; and
of dry-stacked concrete units which resist overturning by
passive soil pressures in front of the structure and bearing
virtue of their own weight and setback, were introduced into • Analysis and design of the reinforced soil structure itself.
Fig B2 — Typical Segmental Block capacity of the soil beneath the toe of the structure.
Australia in the early 1990’s, and rapidly became popular. This Gravity Retaining Wall
system provides an attractive and cost effective solution, but If water is trapped behind the retaining structure, it exerts an These analyses must be based on an accurate and complete
additional hydraulic pressure. This ground water also reduces knowledge of the soil properties, slope stability, potential slip
its stability is limited by the geometry of the units and wall
the adhesion and bearing resistance. problems and ground water.
heights. (Refer to Fig B2).

If massive rock formations are present immediately behind the Except in the case of simple structures, a geotechnical report
In order to achieve greater heights, reinforced-soil walls
structure, these will restrict the volume of soil which can be by a qualified and experienced geotechnical engineer should
(such as Boral Keystone) were introduced. These walls
mobilised and thus reduce the pressure. be obtained.
typically consist of geosynthetic materials, which are
placed in horizontal layers in the compacted backfill and Such a report must address the following considerations, as
Reinforced-soil systems consist of a series of horizontal
mechanically connected to the blocks. Such systems can well as any other pertinent points not listed.
geogrids that have been positioned and pulled tight within
be constructed several metres high, and accommodate Segmental
a compacted soil mass, thus strengthening it and restricting
concrete • Soil properties;
significant loads. gravity
its slump. The geogrids are strategically placed to intersect
retaining
structure, with
potential failure planes that are inclined from near the base of • Extent and quality of any rock, including floaters and
A further development of this system is the Boral Keysteel reinforced soil
the wall, up at an angle (depending on the soil properties), to bedrock;
system which utilises steel-ladder reinforcement. Here the
steel-ladder reinforcement is placed in horizontal layers in the top of the fill. The function of the geogrids is to ‘strengthen’ • Global slip and other stability problems;
the compacted backfill and mechanically connected to the the soil mass and they are ‘anchored’ by compacted backfill
beyond the potential failure planes. • Bedding plane slope, particularly if they slope towards
blocks. These systems are individually engineer designed,
the cut;
and are suitable for walls in excess of 6m high and for critical Local collapse and erosion of the front face is eliminated by
surcharge loadings. (Refer to Fig B3). fixing concrete segmental facing units to the exposed ends of • Effect of prolonged wet weather and the consequence of
the geogrids. However, the segmental concrete facing is not the excavation remaining open for extended periods;
designed to ‘retain’ the strengthened soil mass, which should • Effect of ground water;
be able to stand independently of the facing except for local
Steel reinforced
and concrete effects. The connection spacing (and the geogrid spacing) must • Steep back slopes and the effect of terracing;
grout filled
account for the local stability of the facing, including bulging
hollow concrete
block wall
• Effect of any structures founded within zone of influence.
and rotation above the top geogrid. The top capping course
is normally bonded to the course below using a concrete to Safety and Protection of Existing
Fig B3 — Typical Reinforced-Soil
Segmental Block Retaining Wall
concrete adhesive. Structures
Reinforced
concrete A surface sealing layer and surface drainage system minimise Whenever soil is excavated or embankments are constructed,
footings
the quantity of rainwater entering the soil mass. A sub-surface there is a danger of collapse. This may occur through movement
drainage system behind the segmental concrete facing and of the soil and any associated structures by:
(sometimes) beneath the wall reduce pore water pressures and
• Rotation around an external failure plane that encompasses
thus reduce the tendency for local or global slip.
the structure;
Thus, the essential features of a properly designed and
• Slipping down an inclined plane;
constructed segmental block reinforced soil retaining wall
are: • Sliding forward, or
Fig B1 — Typical Reinforced Concrete Masonry
Cantilever Retaining Wall • Geogrids with adequate length and strength; • Local bearing failure or settlement.

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Planning and Design Planning and Design

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South Australia Book 4 B South Australia Book 4 B

These problems may be exacerbated by the intrusion of surface Techniques to reduce or control the effects of differential Tall wall settlement is not as obvious but occasional facial
water or disruption of the water table, which increase pore settlement include: cracks can be observed in areas of flexural stress concentration,
water pressures and thus diminish the soil’s ability to stand typically in small groupings in the bottom 1/3 of the wall.
• Articulation of the wall (in discontinuing the normal
without collapse. Settlement induced cracks are usually not structurally
stretcher bond) at convenient intervals along the length,
significant and are just a means of facial stress relief for the
The safety of workers and protection of existing structures
• Excavating, replacing and compacting areas of soft soil, unreinforced dry-stack facing system. However, cracked units
during construction must be of prime concern and should be
can be a symptom of other types of problems, so a review by
considered by both designers and installers. All excavations • Limiting the stepping of the foundation and bottom course
an engineer is always recommended.
should be carried out in a safe manner and in accordance with to a maximum of 200mm.
the relevant regulations, to prevent collapse that may endanger
life or property. Adjacent structures must be founded either
Unit Cracking/Gapping — Settlement
beyond or below the zone of influence of the excavation. Where Keystone modular retaining wall structures can tolerate a
there is risk of global slip, for example around a slip plane certain amount of settlement due to the flexible nature of the
encompassing the proposed retaining wall or other structures, system and small individual unit size.
or where there is risk of inundation by ground water or surface
Observation of a number of completed structures that have
water, construction should not proceed until the advice of a
undergone settlement indicates that the wall’s tolerance
qualified and experienced Geotechnical Engineer has been
for settlement without cracking is inversely proportional to Downward
obtained and remedial action has been carried out. movement
the wall height. Lower height walls (H<5m) appear to have High confining
pressure
Global slip failure considerably more facial flexibility than taller walls (H>5m). Flexural stress
This increased flexibility is due to lower confining forces and
Soil retaining structures must be checked for global slip failure
load transfer taking place on each block, which permits small
around all potential slip surfaces or circles.
individual movements to occur, accommodating the settlement
Designers often reduce the heights of retaining walls by experienced without facial distress. Taller walls place the lower
splitting a single wall into two (or more) walls, thus terracing wall units under considerable confining pressure, restricting Facial cracks
the site. Whilst this may assist in the design of the individual unit movement and permitting shear and flexural stresses
walls, it will not necessarily reduce the tendency for global to build up to the point where a block cracks as a means of
slip failure around surfaces encompassing all or some of the stress relief.
retaining walls.
Low wall settlement problems are typically observed in
Fig B5 — Typical Tall Wall
Analysis for global slip is not included in this guide, but it is residential projects where soils adjacent to houses are Settlement
recommended that designers carry out a separate check using uncompacted and the walls settle differentially over a short
commercially available software. distance. Usually gapping or offset joints are visually noted
and the settlement is obvious. Importance of Drainage
Differential Settlement
This guide assumes that a properly functioning drainage
The Concrete Masonry Association of Australia (CMAA)
system is effective in removing hydraulic pressure. If this is
recommends that for dry stacked mortarless retaining
Gapping and offset joints not the case, the designer will be required to design for an
walls employing masonry units (i.e. units with an area
appropriate hydraulic load.
less than 0.2m2) on an aggregate levelling pad, the
differential settlement should be limited to 1% of the Based on an effective drainage system, it is common to use
length. Whilst it is permissible for the retaining wall to drained soil properties. For other situations, the designer
Downward
undergo differential settlement up to 1% of the length, movement must determine whether drained or undrained properties are
it may be preferable to limit settlement to a lower appropriate. In particular, sea walls that may be subject to
figure giving consideration to aesthetics (i.e. keeping rapid drawdown (not covered in this guide) require design
the bedding planes level), in addition to the structural using undrained soil properties.
considerations.

Fig B4 — Typical Low Wall

Settlement

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Planning and Design

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BOOK
South Australia Book 4 B Boral MASONRY
Boral MASONRY
Build
Build something
something great
™
great™

Site Investigation: Preliminary Design

Date: _______________________

Report prepared by: _______________________

Client: __________________________________________________________________________

Project: _________________________________________________________________________

Location: ________________________________________________________________________
Masonry Design Guide
Use for which retaining wall is intended: _____________________________________________
segmental block retaining walls south australia BOOK 4
Proximity of other structures to the face of the retaining wall:
Structure or load Distance (m) c gardenwall®
Distance of live loads from top of wall (Dqi) _______________________

4
Distance of dead loads from top of wall (Dqd) _______________________

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

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

Structure classification: _________________________________________________

For guidance refer AS4678, Table 1.1
Structure Classification Examples
2. Where failure would result in significant damage or risk to life
3. Where failure would result in moderate damage and loss of services
4. Where failure would result in minimal damage and loss of access

Required design life: _____________________________________________________

For guidance refer AS4678, Table 3.1

Type of Structure Design life (years) Type of Structure Design life (years)
Temporary site works 5 Residential dwellings 60
Mine structures 10 Minor public works 90
Industrial structures 30 Major public works 120
River and marine structures 60

Wall geometry: Retained soil data:

Wall height above GL (H’) ___________ m Soil density (gr) ___________ kN/m3
Embedment depth (Hemb) Internal friction angle (fr) peak ___________ °
H/20 or 200mm ___________ m Cohesion (C*i) ___________ kPa
Wall slope (v) ___________ °
Loading data:

C
Angle of backfill slope (b) ___________ °
Dead load surcharge (qd) ___________ kPa
Height of backfill (h) ___________ m
Live load surcharge (ql) ___________ kPa
Foundation material:
Horizontal line load (F) ___________ kN/m
Allowable bearing pressure
Vertical line load (P) ___________ m
Under reinforced soil block ___________ kPa
Width of bearing (b) ___________ m
Water profile:
Water table depth within wall fill ___________ m

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Gardenwall® Gardenwall®

4 C2 4 C3

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South Australia Book 4 C South Australia Book 4 C

228 228

125 125 Gardenwall® Selection and Construction Guidelines

300 300
Retaining Wall System IMPORTANT: Please consult with the regulating council for
local design requirements prior to the design and construction
INTRODUCTION ADVANTAGES
Standard Unit Straight Sided Unit of a retaining wall. Councils in general require that retaining
Boral Gardenwall is ideal for low • Gardenwall does not require
walls be designed and certified by a suitably qualified engineer
landscaping walls and edgings concrete foundations.
where the wall is over 0.5m in height and/or where there is
in garden and communal areas.
• Easy installation of straight walls surcharge loading such as a roadway, house, or other structure
Gardenwall’s rockface texture, multi-
and curved walls. near the wall.
faceted face and setback construction
produces an aesthetically pleasing • Durable, low maintenance, long- • Boral Gardenwall is only suitable for walls up to 1125mm
feature for landscaped areas. term landscaping. in height and where no loads or surcharge exists within
Gardenwall is often used for garden 1125mm behind the wall.
• Solid units — eliminates the need
edges and raised beds, terraces and
for capping and corner units. Installation
to create decorative features such as
around pools. COLOURS • Remove the retaining lug on the base of the unit on
Gardenwall is offered in a range those Gardenwall blocks being used on the base course
DESIGN CONSIDERATIONS
of colours to suit traditional and only (this makes levelling the first course much easier).
Depending on the foundation
contemporary settings. Please refer To remove the lip, place at an angle on the ground and
and retained soil characteristics,
to colour swatch information for an strike the lug firmly with a hammer (safety glasses should
Gardenwall is effective as a gravity
indication of current colours. be worn).
retaining wall structure up to
1125mm (maximum 9 courses). To reduce the possibility of staining • As a safety precaution to avoid lifting or movement of the
Never install where loads (e.g. and to enable easier cleaning, a top units, it is recommended that the top course units
buildings, driveways) will be located masonry sealer can be applied to all are secured using a construction adhesive. This is also
within 1125mm of the wall. For visible surfaces after installation. recommended in areas of possible vandalism.
engineered walls (to AS4678) higher
• Standard units can also be used to construct convex curves.
than 1125mm, or where a surcharge
is present, Boral Keystone or Pyrmont
Availability and Colours walls should be considered.
• No minimum order quantities apply. Dish drain to direct surface
• Lead time 0-2 weeks. No loads to be located within 1125mm behind wall run-off (if required)
Gardenwall Unit
Backfill should be no higher than the top of the wall
Backfill placed and
compacted in 250mm layers

Light Sands Tuscan Filter fabric to stop silt 150mm width of 12-20mmØ
clogging drainage material free draining granular
material eg. blue metal
1 in 5 set-back H
Drainage pipe (if required)

Native soil First course to be buried below

Paperbark Hawkesbury Yellow final ground level (to engineer's
specification - 100mm min.)

100mm min.

350mm

Specifications min. Compacted road base levelling

pad on undisturbed inorganic soil

Product Description Finish HxLxDmm Approx Wt kg No. per m2

Fig C1 — Typical Gravity Wall Construction Detail — Gardenwall
Standard Unit Rockfaced 125x300x228 15.5 26.7 Note: Refer to max. wall heights disclaimer on page A3 of this guide.
Straight Sided Unit Rockfaced 125x300x228 15.5 26.7 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.

C2 September 2007 | BORAL MASONRY DESIGN GUIDE BORAL MASONRY DESIGN GUIDE | September 2007 C3
Gardenwall®

4 C4

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BOOK
South Australia Book 4 C Boral MASONRY
Build something great™

Curved Walls

i
in s
m =
M diu t co
ur
0m
um 10 0 e
s
m
Masonry Design Guide
Ra 1s
r
fo

segmental block retaining walls south australia BOOK 4

d heathstone®

4
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.

D
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South Australia Book 4 D South Australia Book 4 D

280
Heathstone® Heathstone® Gravel-Fill Construction
Retaining Wall System
162 162
IMPORTANT: Please consult with
380
220 270 the regulating council for local design
INTRODUCTION The range of Heathstone components
Standard Unit Standard Corner Unit requirements prior to the design and
Boral Heathstone is ideal for low, is designed to optimise space, and
construction of a retaining wall. Councils
vertical landscaping walls in garden includes a ready-to-install corner unit
280 in general require that retaining walls
and communal areas. The rockface and a series of caps to accommodate
be designed and certified by a suitably
162 texture and bevelled edges add a single or double sided applications
qualified engineer where the wall is over
formal and elegant element to and curved installations.
440
0.5m in height and/or where there is
a landscaped area. Heathstone is
Convex curves as tight as 900mm surcharge loading such as a roadway,
Grand Unit often used to separate and highlight
radius can be constructed using the house, or other structure near the wall.
entertaining areas, BBQ areas, paths,
standard unit. The Curved Cap can
300 300 garden beds, hedges, or to create and
be used to form curves of 1800mm
50 50 differentiate levels. Heathstone is
outside radius and 1500mm inside
300 300 also suitable for constructing steps,
radius.
Stoneworks® Cap planter boxes and for curved walls.
Bullnose Cap COLOURS
DESIGN CONSIDERATIONS No loads to be located Dish drain to direct surface water
Heathstone is offered in colours within 1.0m of the wall or filter fabric to stop silt filling
Availability and Colours Depending on the foundation drainage layer
• No minimum order quantities apply. which emulate natural hewn stone,
and retained soil characteristics,
• Lead time 0-2 weeks. and which contrast beautifully with
Heathstone is effective as a gravity 150mm min. of 12-20mmØ Voids in and around Heathstone
soil, mulch, shrubbery and grassed free draining granular blocks to be filled (if required)
structure up to 972mm, or up to material eg. blue metal with 12-20mmØ free draining
areas. Please refer to colour swatch granular material eg. blue metal
1600mm when installed with no-
information for an indication of Backfill (eg. excavated soil) Refer to Heathstone
fines concrete backfill. Heathstone to be placed and Gravel-Fill Selection
Filter fabric to stop silt
Tuscan Almond current colours. clogging drainage material compacted as each course Table for maximum
should not be used where the base of blocks is laid number of courses

soil or backfill is not firm, or is of To reduce the possibility of staining Agricultural drainage line 100mmØ
expansive clay. Never install where and to enable easier cleaning, a
Blocks to be embedded
loads (e.g. buildings, driveways) will masonry sealer can be applied to all a minimum of 100mm
Native soil
Charcoal Paperbark be located within 1000mm of the visible surfaces after installation.
wall. For walls higher than this, or Compacted
roadbase 100mm min.
where a surcharge is present, Boral
Keystone or Pyrmont walls should 350mm
min.
be considered.
Limestone Sandstone
Stoneworks Cap ONLY Stoneworks Cap ONLY
(made to order) (made to order)
Fig D1 — Typical Construction Detail — Heathstone Gravel-Fill

Table D1 - Maximum Wall Height — Heathstone Gravel-Fill

Specifications Maximum Courses Maximum Courses
For walls without gravel fills For walls with gravel fills
Product Description Finish HxLxDmm Approx Wt kg No. per m2
to all voids and cores to all voids and cores
Standard Unit Rockfaced/Smoothfaced 162x220x280 11.9 28.1 units/m2
Poor soils — including sands, gravelly
Standard Corner Unit Rockfaced x 2 Faces 162x380x270 23 1/course/corner clays, sandy clays and silt clays 2 (324mm) 4 (648mm)
Grand Unit Rockfaced 162x440x280 26.2 14.05 units/m2
Average soils — including well graded
Bullnose Cap Smooth 50x300x300 9.4 3.3/linear metre sands and gravelly sands 3 (486mm) 5 (810mm)
Stoneworks Cap Rockfaced 50x300x300 22 3.3/linear metre Good soils — including gravels, sandy
gravels and crushed sandstone 4 (648mm) 5 (810mm)
Note: Refer to max. wall heights disclaimer on page A3 of this guide.
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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South Australia Book 4 D South Australia Book 4 D

Curved Wall Construction Concave (Internal) Curves Step Treads and Cap Unit Installation
• For concave curves use Standard Units spaced evenly to
Curves as small as 900mm in radius can be constructed with • Splitface Cap (225mm long) has a recess in the underside
a scribed arc.
Heathstone Standard Units. to allow for the lug on the Heathstone Unit. Removal of
the lug is not required in this case

Heathstone
• To allow for installation of the Double-sided Rockface Cap
Convex (External) Curves Standard Unit units and step treads, it is necessary to bolster locating
• For convex curves, the tails of the blocks must be lugs from the blocks.
trimmed to suit the desired radius. Use a hammer and • Push the Heathstone split-face into sand for support.
bolster on the back, top and bottom of the tail. Use light Trace along the back of the lug with a bolster and
hammer blows first to trace the area to be removed, then hammer, increasing the force of hammer blows until
a heavier blow on top. Repeat the tracing and final blow the lug splits off. All blows must be from the back of
if necessary. the block, with the bolster blade nearly parallel to the
C
M onc
in
im ve
a top of the Heathstone unit. Refer to the illustration. Any
um Cu
Bolster back ra rve remaining high spots should be removed with a scutch
of blocks to di
form convex us Rad hammer or an old screwdriver and hammer.
90 ius
curves 0m
m

Fig D3 — Forming Concave Curve

NOTE: Premium Curved

Caps have an outside
radius of 1800mm

Step Construction
Fig D2 — Forming Convex Curve

Bullnose Cap
Fix cap units with
construction adhesive

Remove locating
lugs before laying

255

Fig D5 — Bolstering Lug from Heathstone Units

162
25

45
Heathstone 1:10
Units Cement : Sand

Native soil

Fig D4 — Construction of Heathstone Steps

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South Australia Book 4 D South Australia Book 4 D

Corner Construction • Continue this step until the desired height of the wall is
Heathstone® No-Fines Concrete Wall Construction
achieved.
Constructing Internal and External Corners
No-Fines Concrete shall consist of cement, water and coarse applied to all retaining wall structures.
• Corners are constructed using Corner Units and Standard • Use a construction adhesive to secure corner blocks and
aggregate. Cement will comply with the definitions for cement
Units or Grand Units and Corner Units. caps. • Global stability and all design considerations should be
per AS3972-1991 — ‘Portland and Blended Cements’. The
checked by an engineer in poor clay conditions.
• Lay the Corner Units’ largest splitface in alternate quantity of cement is specified as 210kg/m3 with a total
directions in adjacent courses (see illustrations). water/cement ratio of between 0.45 and 0.55. • Design assumes a dry excavation (i.e. water table is
Grand Unit cut below bottom of footing level). If ground water exists in
to 330mm on site The particle size distribution of the aggregate shall comply with the excavation the wall is to be re-designed by a suitably
the limitations for the nominal single sized 20mm aggregate qualified engineer.
specified in AS2758.1.
• These tables are supplied free of charge and do not form
NOTES: any part of any contract with the user.

• Table D2 is based on AS4678 : 2002, Earth Retaining • 15MPa No-Fines concrete with a 6:1 ratio (Gravel : Cement).
Grand Unit Structures. The code assumes a surcharge of 5kPa is
• Remove tail fins to allow “no fines” to connect block fill
Standard Corner Unit to back fill.
T
No loads above 5kPa to be
located within 1.0m of the wall
330mm Cap unit

Filter fabric or dish drain

15MPa ‘No Fines’ concrete.

Grand Unit All voids within and around
units to be completely filled.

Retained soil
Corner Unit Grand Unit cut Sub-soil drain
Corner Unit to 330mm on site connected to
Standard Corner Unit stormwater system
or flood pit. Place H
loose aggregate (Refer to Heathstone
Fig D6 — Heathstone Standard External Corner (270°) Fig D8 — Heathstone Grand External Corner (270°) around subsoil drain No-Fines Concrete
before pouring Selection Table)
no-fines concrete.

Filter fabric to stop silt Pour no-fines concrete

110mm Grand Unit 220mm clogging drainage of directly onto prepared
Corner Unit ‘no-fines’ material foundation material
Bolster lug to
fit next course
Blocks to be embedded to
engineer‘s detail (1 course min.)

25MPa concrete
footing on 150kPa 150mm min.
allowable bearing
capacity material
Standard Unit Bolster lug to 600mm min.
fit next course

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

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

Wall Height Retained Soil Retained Soil Retained Soil
‘H’ (mm) CLAY φ = 26° (POOR) SAND φ = 30° (AVERAGE) GRAVEL φ = 34° (GOOD)
‘T’ (mm) ‘T’ (mm) ‘T’ (mm)

972 670 570 570

Corner Unit
1296 730 770 670
Grand Unit
1620 1170 970 770
NOTE: Internal 90º corners using Grand
Units do not require corner units

Fig D7 — Heathstone Standard Internal Corner (90°) Fig D9 — Heathstone Grand Internal Corner (90°) φ Denotes the internal angle of friction of the retained material

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Build something great™

• The density of this product will vary with the density STEP 2:
of the aggregate used. The density range may be from Installing the First Course
1650kg/m3 to 2100kg/m3. Lay the first course of Heathstone units side by side over the
prepared base. Bolster off the tails so that ‘No-Fines’ concrete
• The void ratio of the mix is expected to be between 20%
connects backfill to core-fill areas.

Masonry Design Guide

and 30% and should be free draining.
STEP 3:
• The compressive strength should generally exceed
No-Fines Concrete Backfill
10MPa for design purposes.
Backfill the first 21Ú2 courses of the wall with ‘No Fines’
• This product has no slump and exerts similar pressures concrete. All voids inside and between the units must also be
on the soil and formwork, as does loosely poured filled. The vertical height of any pour of ‘No Fines’ concrete is
aggregate. limited to 400mm. For walls greater in height, each pour must
segmental block retaining walls south australia BOOK 4
be allowed to harden prior to pouring the next lift. Alternatively
No-Fines Construction Steps the wall may be propped to support the lateral load from the
e keystone® and pyrmont®
Special purpose construction such as waterside walls, post wet concrete.
fixing, earthquake zones, and terraces will require additional

4
engineer’s design. STEP 4:
Installing Capping Units
STEP 1:
Install capping units and fix with construction adhesive.
Excavation/Preparation of Levelling Pad
Excavate a trench 600mm wide and sufficiently deep to allow
a 150mm levelling base plus 1 course below ground.

E
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South Australia Book 4 E South Australia Book 4 E

Keystone® and Pyrmont Retaining Wall Systems

The Keystone Retaining Wall System is a world-wide and capping, and a near vertical or set-back face. Then Proven Engineering Ease of Construction
success story, and since its introduction by Boral into there is a choice of standard or flushface, and a selection Various installation methods cater for simple gravity walls Boral Keystone and Pyrmont systems are designed to
Australia in 1992, hundreds of thousands of square of popular standard colours or custom colours can be through to geogrid soil-reinforced retaining structures. reduce construction time and cater for all locations. The
metres have been installed along our highways, roads ordered for larger projects. Boral Keystone and Pyrmont systems can also cater modular blocks can be moved and installed without the
and transport corridors, and around our sports facilities, for critical surcharge loads, enabling the construction of need for heavy lifting machinery, and the dry stacked,
Pyrmont®
buildings, foreshores and open spaces. buildings or roadways close to the wall to optimise land mortarless installation provides less complex, more rapid
Boral Pyrmont retaining wall system retains all of the
usage. construction.
Boral Keystone retaining wall systems combine proven engineering characteristics of the Keystone system
engineering capabilities with design versatility, cost and combines them with a more traditional appeal of a For high performance retaining walls, please refer to the
effectiveness, lasting durability and an attractive dynamic bevelled-edge splitface block, and vertical construction to section on Boral Keysteel Custom Engineered Retaining
appearance to provide total solutions for retained earth emulate walls built during Australia’s pioneering era. Wall Systems later in this guide.
structures.
The range of components and installation methods Durability
Keystone ®
cater for straight and gently curved walls as well as Boral Keystone and Pyrmont systems combine the
Boral Keystone systems provide infinite flexibility crisp 90º corners, while the rock-faced caps provide a durability of concrete units and interlocking fibreglass pins
for design variation and individuality. The range of finishing touch that completes the transformation into a to produce maintenance free walls with life expectancies
components and installation methods cater for straight, masterpiece from the colonial era. of up to 120 years.
curved and terraced walls, level or stepped foundations

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315 315 305 275

200 Keystone® 100

Pyrmont®
200 20 0

Retaining Wall Systems 455 Vertical Retaining Wall System

455 455 455
INTRODUCTION the tail to 300mm width. INTRODUCTION DESIGN CONSIDERATIONS
Standard Unit Flushface Unit Boral Keystone is an advanced, Standard Unit Straight Sided Cap Boral Pyrmont retaining wall systems Suitable for curved wall installations
(Made to order) • Can be installed as near vertical, (made to order)
highly versatile and thoroughly integrate the engineering capabilities with a suggested minimum convex
or for straight walls without 275
proven high performance segmental of the Keystone system with the curve radius of 5m (resulting in
275 curves or corners it can be
275 block retaining wall system which 100 versatility and pleasing aesthetics of a 5mm lip).
installed with a 1-in-8 setback.
100 100 can be used as a gravity structure a vertical wall. The Pyrmont unit is a
455 COLOURS
or it can incorporate geogrid soil- COLOURS split-face block with four chamfered
455
Please refer to colour swatch
455 reinforcement to cater for greater Keystone is offered in a range of edges, emulating the care, skill and
Pyrmont Cap information for an indication of
Flushface Straight heights and surcharge loading colours to suit decorative and (made to order) determination of stone masons from
Standard Cap current colours.
(made to order) Sided Cap situations. engineering applications. Please Australia’s early settler period.
(made to order) refer to colour swatch information To reduce the possibility of staining
DESIGN CONSIDERATIONS Boral Pyrmont retaining wall system
for an indication of current colours. and to enable easier cleaning, a
275 • Suitable for straight and curved is also suitable for constructing steps,
masonry sealer can be applied to all
300 wall installations with a minimum To reduce the possibility of staining planter boxes, gently curved walls
100 visible surfaces after installation.
50 convex curve radius of 1800mm and to enable easier cleaning, a and crisp 90° corners.
300 without trimming the tail width, masonry sealer can be applied to all
455 Lifting Bars
or 970mm radius by trimming visible surfaces after installation.
Straight Sided Cap Standard Cap Pins
(made to order)

Pins
Lifting Bars
Keygrid Geogrid Soil Reinforcement

Availability and Colours

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

Keygrid Geogrid Soil Reinforcement

Specifications
Availability and Colours
Description HxLxDmm Wt kg N°/m2
Almond Tuscan
Specifications
• No minimum order quantities apply. Standard Unit 200x455x315 41 11
Description HxLxDmm Wt kg N°/m2
• Lead time 0-4 weeks.
Straight Sided Cap 100x455x275 25 2.2/lin mtr
Standard Unit 200x455x305 42 11
Standard Half High Unit 100x455x275 20 22
Pyrmont™ Cap 100x455x275 20 2.2/lin mtr
Standard Cap 100x455x275 20 2.2/lin mtr
Straight Sided Cap 100x455x275 21 2.2/lin mtr
Flushface Unit 200x455x315 41 11 Paperbark
Pins 2 pins per full unit
Almond Tuscan Flushface Straight Sided Cap 100x455x275 26.3 2.2/lin mtr (high strength pultruded fibreglass)
Pins 2 pins per full unit Lifting Bars (Pyrmont units should be lifted by
(high strength pultruded fibreglass) two people using the Keystone lifting bars)
Lifting Bars (Keystone units should be lifted by
two people using the Keystone lifting bars)
Paperbark

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Table E1 — Maximum Wall Height for Gravel-Fill Walls • For curved installations, leave a small gap between units backfill if the type of backfill is likely to wash into the
Gravel-Fill Wall Selection for convex curves. Concave curves will require a small drainage layer and clog it.
Wall Height H(mm)
Backfill
For low, non-critical walls, (i.e.. walls covered in the adjacent Surcharge Loading Near 1 in 8 overlap of adjacent units. Refer to curve installation
Type • Use only walk-behind compaction equipment within
table) the Keystone and Pyrmont Retaining Wall Systems are Vertical Setback details on Page E9 of this guide.
1000mm of the wall face to prevent movement of the
effective as a gravity wall structure, utilising their weight and
SETBACK Poor 800 900 • If backfill is required behind the drainage zone, place Keystone units.

No Surcharge Loading
interaction of the units to resist earth pressures.
and compact existing site soils in 200mm maximum lifts.
• In areas of possible vandalism, it is recommended that
Retained Soil Descriptions Average 900 1000 Heavy clays and organic soils are not recommended due
capping units be secured using a masonry adhesive.
to water holding problems.
Poor Soils Include fine sands, gravelly
Good 1000 1200
clays, sandy clays, silty sands. • Provide a filter fabric between the drainage layer and the
Angle of internal friction ≥ 25°
Poor 600 900
Average Soils Include well graded sands,

15° Sloped Backfill

gravelly sands.
Average 700 900
Angle of internal friction ≥ 30°

Good Soils Include gravels, sandy gravels, Good 800 1100

crushed sandstone
Driveway/Carpark Loading (5kPa)

Angle of internal friction ≥ 35° Poor 400 500

NOTES: Pyrmont walls can only be constructed in near vertical
format, and must be selected on the basis of data in the near Compacted backfill
Average 500 600 soil (if required)
vertical column from Table E1.
Drainage pipe
Table E1: Refer to max. wall heights disclaimer on page A3
Good 600 800
of this guide. The gravity wall heights are maximum heights Free draining
granular material
calculated in accordance with CMAA MA-53 Appendix D
guidelines and a qualified engineer should confirm the
Compacted footing Native soil
suitability of the product for each intended application.

Gravel-Fill Wall Construction Guidelines

IMPORTANT: Please consult with the regulating council for • Near vertical installation must be used when designing Fig E2 — Typical Installation Detail — Keystone Gravity Wall
local design requirements prior to the design and construction of walls with curves or corners. Granular material
for drainage
a retaining wall. Councils in general require that retaining walls be
300mm
designed and certified by a suitably qualified engineer where the Cap Unit

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.
Keystone or Pyrmont
units
Refer to Keystone and Pyrmont ‘No-Fines Concrete’ Guidelines
Optional 1:8 wall setback
for engineered retaining walls to AS4678. Backfill with Keystone units

• Two sets of pin holes are provided in Keystone units. 12-20mm free draining
granular material, fill all H
Filter fabric to stop silt voids in and around units
• For near vertical construction, install pins in the front holes. from clogging drainage material

Drainage pipe (if required)

• For 1 in 8 setback construction, install pins in the back holes.
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 E1 — Installation of Pins Fig E3 — Typical Construction Detail — Keystone Gravity Wall

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Typical Installation Details

Full mitre-cut Half mitre-cut
Adhesive fix Pyrmont unit Pyrmont unit
corner units.
Liquid Nails or
FIRST COURSE SECOND COURSE similar

Half mitre-cut Full mitre-cut

Pyrmont unit Pyrmont unit

FIRST COURSE SECOND COURSE

Align centre of unit
with face of No pin in
adjoining wall overlapping
unit

Fig E6 — 270° External Corner Detail

No pin in — Pyrmont Units
overlapping
unit

Fig E4 — 90° Internal Corner — Standard Keystone Units

Use front pin holes for curves.

Maintain a small overlap
FIRST COURSE SECOND COURSE between units.

Align face of unit with the

centre line of adjacent unit Cut to suit on site

Cut to suit on site Fig E7 — Concave Curve

Omit one Omit one Align face of unit with the

pin only pin only centre line of adjacent unit Use front pin holes for curves. Maintain a
3 unit 90 corner : r = 900mm small gap between units.
4 unit 90 corner : r = 1250mm
Fig E5 — 90° Internal Corner — Pyrmont Units 5 unit 90 corner : r = 1540mm
6 unit 90 corner : r = 1830mm
7 unit 90 corner : r = 2120mm

Radius ‘r’
Bolster
backs as
required

Fig E8 — Convex Curve

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Drill and
Keystone cap unit
install fixing
pin
‘No-Fines Concrete’ Wall Construction Guidelines
The ‘No-Fines Concrete’ backfill system increases the mass of The particle size distribution of the aggregate shall comply with
Keystone/Pyrmont allowing the maximum heights in Table E1 the limitations for the nominal single sized 20mm aggregate
to be exceeded without using geogrids. specified in AS2758.1.

This is ideal for boundary walls where the geogrids would NOTES:
otherwise cross the boundary line. • 15MPa No-Fines concrete with a 6:1 ratio (Gravel : Cement).
225˚ corner unit – to be cut No-Fines Concrete shall consist of cement, water and coarse
and bolstered on site from • The density of this product will vary with the density
Keystone/Pyrmont Unit aggregate. Cement will comply with the definitions for cement
Next course is a mirror image. of the aggregate used. The density range may be from
Keystone unit
per AS3972 : 1991 — ‘Portland and Blended Cements’. The 1650kg/m3 to 2100kg/m3. Table based on density of
quantity of cement is specified as 210kg/m3 with a total 2100kg/m3.
Fig E9 — 225° External Corner Fig E10 — Stepped Capping Units
Flushface Keystone/Pyrmont Units water/cement ratio of between 0.45 and 0.55.
• The void ratio of the mix is expected to be between 20%
and 30% and should be free draining.
T

Cap unit

Filter Fabric to stop

clogging ‘No Fines’ material

15MPa ‘No-Fines’ concrete.

All voids within and around
units to be completely filled.
Retained soil
Bolster backs as
required Keystone or Pyrmont unit

Sub-soil drain H
connected to
stormwater system
or flood pit

Pour no-fines concrete

290mm Treads directly onto prepared
foundation material

Blocks embedded to
engineer's detail
(10 0mm min)
Fig E11 — Plan view of step through Keystone 25MPa concrete
footing on 150kPa
allowable bearing
capacity material 150mm min
(see note below
Table E2)
Tread approx. 290mm 60 0mm min.
for 40mm pavers (30˚)

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

Compacted bedding sand

Table E2 — Maximum Wall Heights for No-Fines Concrete Wall Construction
40mm Boral Pavers
Wall Height Retained Soil Retained Soil Retained Soil
160mm riser 10mm mortar joint
CLAY φ = 26° (POOR) SAND φ = 30° (AVERAGE) GRAVEL φ = 34° (GOOD)
40mm 10mm Keystone Flushface Caps
‘H’ (mm) ‘T’ (mm) ‘T’ (mm) ‘T’ (mm)
100mm Sand : cement = 6 : 1
10mm 1000 550 500 450
Bedding sand –
compact before laying treads 1400 750 700 650

1800 NA 1000 850

2200 NA 1250 1000

Fig E12 — Keystone section through steps
2600 NA 1350 1200

φ Denotes the internal angle of friction of the retained material

Non-shaded Area = Compacted Roadbase Footing Shaded Area = Concrete Footing as per Fig E12
If material below no fines concrete is of poor quality, then the material must be replaced with a 150mm thick layer of crushed sandstone.

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• The compressive strength should generally exceed STEP 2:

15MPa for design purposes. Installing the First Course
Geogrid Soil-Reinforced Wall Construction Guidelines
Lay the first course of units side to side over the prepared For taller, more critical walls, the combination of Keystone units to a qualified professional engineer. These tables are
• This product has no slump and exerts similar pressures
base, with the 12mm pinholes on top and kidney holes on the with geogrid soil reinforcement allows walls to be built to heights supplied as a guide, and do not form any part of any
on the soil and formwork, as does loosely poured
underside. Maintain the required distance between pinhole of 12m and greater, without costly structural footings. When placed contract with the user.
aggregate.
centres of adjacent units. In straight walls, units will touch. between layers of compacted soil, geogrids create a reinforced soil
• Table E3 is based on foundation material with minimum
Table E2 is prepared as per AS4678 : 2002, and is based In concave or convex curves, the units will overlap or require mass, which essentially acts as a larger gravity wall structure.
200kPa bearing capacity.
on a 5kPa surcharge loading at the top of the wall. This spacing respectively. Refer to Figs E7 and E8 for curve
Geogrids can be used with most existing site-soils and are not
table is supplied as a guide, and does not form any part installation details. • Where site conditions and loadings vary from those in the
affected by water, micro organisms, alkali or acidic soils. Consult
of any contract with the user. table, professional engineering advice should be obtained.
STEP 3: your engineer for design requirements of Keystone walls using
• The maximum slope of the backfill behind the wall is to Installing the Pins geogrid soil reinforcement. • The minimum embedment of wall below ground level is
be 5% (1 vertical to 20 horizontal). Place the high strength fibreglass connecting pins into each assumed to be H/20, or 100mm, whichever is greater.
NOTES:
• The vertical height of any pour of ‘No Fines’ concrete is unit. Use the front holes for a near vertical setback (corners
• Table E3 is prepared as per AS4678 : 2002. Suitability of • The length of the 15° backfill slope is assumed to be equal
limited to 600mm. Each pour must be allowed to harden and curved walls). Use the rear holes for a 1 in 8 setback
the information contained in the table must be referred to the height of wall, H.
prior to pouring the next lift. Alternatively the wall may (i.e. for every course the wall will set back 25mm for straight
be propped to support the lateral load from the wet walls only).
Table E3 — Maximum Wall Heights for Geogrid Soil-Reinforced Walls
concrete. STEP 4: Surcharge Wall Geogrid Geogrid Height Above Geogrid Length

• For higher walls or walls with a greater surcharge loading, Additional Courses Height Layers Levelling Pad L (m)
Geogrid soil reinforced construction is required. Sweep the top of the previous course of units clean of any loose H (m) Layers Soil Type (phi)
gravel. Place the next course of units so that the kidney holes
1 2 3 4 5 6 7 25 30 35
• For walls founded on clay with a height greater than fit over the pins of the two units below. Pull the unit towards
2.0m, Geogrid reinforcement is required. 15 Degree 1.1 2 0.2 0.8 — — — — — 2.2 2.0 2.0
the face of the wall until it locks with the pins on both sides.
Backfill Slope 1.5 3 0.2 0.6 1.2 — — — — 2.5 2.0 2.0
• Global stability considerations should be checked by an Repeat steps 3 and 4.
1.9 4 0.2 0.6 1.0 1.6 — — — 2.4 2.0 2.0
engineer in poor clay conditions. STEP 5:
2.3 5 0.2 0.6 1.0 1.4 2.0 — — 2.8 2.4 2.0
• Design assumes a dry excavation (i.e. water table is below No-Fines Concrete Backfill
2.7 6 0.2 0.6 1.0 1.4 1.8 2.4 — 3.6 2.7 2.4
bottom of footing level). If ground water appears in the Backfill the wall with ‘No Fines’ concrete. All voids inside
3.1 7 0.2 0.6 1.0 1.4 1.8 2.2 2.8 4.3 3.0 2.7
excavation, the wall is to be re-designed by a suitably and between the units must also be filled. The vertical height
of any pour of ‘No Fines’ concrete is limited to 600mm. Each 5kPa 1.1 2 0.2 0.8 — — — — — 2.4 2.0 2.0
qualified engineer.
pour must be allowed to harden prior to pouring the next lift. Driveway 1.5 3 0.2 0.6 1.2 — — — — 2.7 2.1 2.0
Construction Steps Alternatively the wall may be propped. 1.9 4 0.2 0.6 1.0 1.6 — — — 3.0 2.4 2.0
Special purpose construction such as waterside walls, post 2.3 4 0.2 0.8 1.4 2.0 — — — 3.3 2.7 2.3
STEP 6:
fixing, earthquake zones, and terraces will require additional 2.7 5 0.2 0.6 1.2 1.8 2.4 — — 3.6 3.0 2.5
Installing Capping Units
engineer’s design.
Lay capping units, backfill and compact to required grade. In 3.1 6 0.2 0.6 1.0 1.6 2.2 2.6 — 4.0 3.3 2.8
STEP 1: areas accessible to public vandalism, it is recommended that *Geogrid with Tul=55kN/m2
Excavation/Preparation of Levelling Pad the capping units be secured using masonry construction
For walls less than 900mm high, excavate a trench 600mm adhesive or epoxy cement.
wide and sufficiently deep to allow a levelling base of 150mm
+25mm height for each course. Spread coarse sand or 12-20mm
gravel for the levelling base and compact.

For higher walls or in poor foundation material, a footing as

shown in Fig E12 may be necessary. Refer to Table E2.

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Typical Specification for 3. General Requirements

Native soil Keystone or Pyrmont 3.1 General
Terms used in this specification shall have the meanings
Retaining Walls assigned to them as follows:
1. Scope of Work ‘Approved’ shall mean approved in writing by the Engineer.
1.1 Extent
‘Or equal approved’ shall mean equivalent in performance,
Geogrid sections are This specification covers the works for construction of segmental, quality and price to that specified and approved by the
located over pins at the
front, pulled taught and reinforced-soil retaining structures. The works include footing Engineer.
staked at the back
excavation, foundation preparation, drainage, backfill and
Compacted compaction and related items necessary to complete the work Where limits to the properties of soils are defined elsewhere
backfill soil
indicated on drawings and as further specified. herein these properties shall be determined by the methods
Drainage pipe
laid down in AS1289.
Free draining All retaining wall construction is to be carried out in accordance
granular material
Native soil with the levels, distances and details as shown on the drawings The term ‘construction area’ in this Part shall be defined as an
and in accordance with this specification. area to be excavated or an area to be cleared and filled.

Compacted The Keystone reinforced retaining wall system shall also 3.2 Regulations
roadbase footing
be constructed in accordance with the manufacturers The Contractor shall comply with all relevant Acts, Regulations
installation guidelines by a suitably qualified and experienced and By-Laws in respect of all work specified herein, including
Fig E14 — Typical Installation Detail — Keystone/Pyrmont Geogrid Reinforced-Soil Wall
contractor. temporary timbering, strutting, guard rails and all safety
L measures to be adopted.
1.2 Responsibilities
Granular
material The Contractor shall be responsible for carrying out the 3.3 Certification
30 0mm
installation of all retaining walls in accordance with this The Contractor’s Geotechnical Engineer shall certify that the
Cap Unit specification and the associated contract documents. 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
Keystone or Pyrmont unit Soil Block material is as specified on drawings with regard to
Filter fabric to stop silt
clogging drainage material 2. Standard Specification
friction angle, and bulk density.
Wherever reference is made to Standards Association
12-20mm free draining
granular material, fill all of Australia (SAA) the requirements of the editions and
voids in and around units
amendments, shall apply to the relevant materials or operations
and be deemed to be incorporated in this specification.
4. Materials
Compacted backfill material 4.1 Masonry Units
Reinforced Soil Zone In the case of a conflict between the referenced standard
The retaining wall units shall be manufactured in accordance
specification and code and this specification, the more stringent
Geogrid soil reinforcement with AS4456 Concrete Masonry Units. Block types and sizes
to engineer's specification H provisions shall apply.
for Keystone retaining walls shall be as shown on the drawings
The following is a summary of standard specifications applicable or specified herein.
Drainage pipe (as required)
to this subsection of the work:
4.1.1 Tolerance
First course to be embedded AS1012 Methods of Testing Concrete Permissible tolerance in the manufacture of retaining wall units
below final ground level to
engineer's detail (10 0mm min.) AS4456 Concrete Masonry Units shall comply with AS4456.3 - 1997. In the case of Keystone
AS3600 Concrete Structures units, the tolerance of ± 2mm shall not apply to profiled or
Compacted roadbase or AS4456.4 Masonry Units — Compressive Strength textured faces. Non conforming concave distortions shall be
concrete footing
AS4678 Earth Retaining Structures rejected.
AS1289 Methods of Testing Soils

Materials or operations not covered by the above standard

150mm min.
codes shall conform to the appropriate Australian Standard.
60 0mm min.

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

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4.1.2 Strength Sieve Size % Passing by Weight 5. Construction of Keystone/Pyrmont of the first course is most important, to ensure acceptable
Retaining wall units shall be manufactured with a minimum 75mm 100 Retaining Walls horizontal and vertical tolerances. Two fibreglass connecting
compressive strength of 10MPa. A minimum of ten (10) samples 26.5mm 50 - 100 pins shall be inserted into the appropriate holes to interlock
5.1 Foundations
must be tested to obtain a mean compressive strength, tested 4.75mm 25 - 75 and align units.
Excavation is to be to the lines and grades shown on the
to failure as per AS4456.4 — 1997 under normal compressive 0.425mm 10 - 50
drawings. The reinforced soil block foundation size shall be The front set of pin holes shall be used for near vertical
and laboratory conditions. 0.075mm 0 - 20
constructed as per drawings unless alterations are made by setback.
4.1.3 Colour • Non-plastic in that the fraction passing 0.425mm has a the Geotechnical Engineer, who may require tests on the The rear pair of holes shall be used for 25mm (1:8) setback.
The colour and texture of masonry units shall be as specified Plasticity Index of not greater than 15. sub-grade material, to be carried out by a registered N.A.T.A.
and shall remain consistent with the ‘sample range’ approved Testing Laboratory. All voids in units and between units shall be filled with
• Capable of being brought to a moisture content suitable
by the project Superintendent. drainage fill as specified in section 4.5. Drainage fill shall
for compaction as specified elsewhere herein, under the The reinforced soil block foundation subgrade shall be proof extend to 300mm behind units.
4.1.4 Handling/Storage/Delivery weather conditions prevailing on site. rolled with a heavy steel drum roller (minimum applied
Keystone units shall be delivered on pallets to minimise intensity of 4t/m width of drum with at least 8 passes) Units shall be placed in a running bond pattern. Top of units
The ‘Approved Backfill’ shall be stockpiled on site, and
damage during transportation. The Contractor shall store without vibration. Any material which is soft, visibly deformed, shall be swept clean of excess material. Kidney holes of units
inspected and approved by the Geotechnical Engineer that the
and handle units so as to prevent units from damage, which unstable or deemed unsuitable by the Contractor’s geotechnical above shall be positioned over pins in units below. Units shall
material satisfies the specification above the design friction
may affect the aesthetic quality or structural integrity of the consultant shall be excavated and replaced with approved fill be pulled toward the face of the wall to interlock the pins
angle and dry density values as specified on drawings. Testing
finished wall. and compacted to achieve dry densities of between 98% and with units on either side. Levels and alignment of each course
for dry density and friction angle shall be in accordance with
103% of Standard Maximum Dry Density at moisture content shall be checked. Each course shall be filled, backfilled and
4.2 Connecting Pins section 6 herein.
of ±2% of Standard Optimum Moisture Content. compacted prior to placement of the next course. The Keystone
High strength pultruded fibreglass pins shall be used to 4.5 Drainage wall shall be surveyed for vertical level tolerance every 3
interlock and align all Keystone units in a running bond pattern. The foundation shall be inspected and approved by the courses. This shall be deemed a HOLD POINT.
All retaining walls are to contain drainage systems that prevent
Pins shall also provide an integral connection between the Geotechnical Engineer, who shall verify that the foundation
the build up of hydrostatic pressure behind walls. This is to
bearing capacity exceeds the required bearing capacity as 5.3 Drainage Installation
Keystone units and the geogrid. include a 12-20mm free draining clean hard aggregate, used
specified on drawings. The approval of the reinforced soil block The drainage measures shall be installed as shown on drawings.
4.3 Geogrids to fill all voids within the retaining wall units and to extend
foundation shall be deemed a HOLD POINT. 100mm diameter agricultural pipe shall be used for subsoil
300mm behind the units.
The reinforcing elements for the reinforced soil structure shall drainage behind the first course of Keystone units. The subsoil
be as shown on the drawings. Detailed excavation for the mass concrete footing shall proceed
Drainage is to be installed as per the drawings and as per the drain shall be placed with a minimum 1% fall as shown on
following acceptance of the foundation. The footing subgrade
manufacturers recommendations. drawings.
If required, each consignment of geogrids delivered to site shall shall be inspected by the Contractor’s Geotechnical Engineer
be accompanied by a Quality Control Tensile Test Certificate 4.6 Concrete Works and any areas deemed soft, unstable or unsuitable by the ‘T’ piece connection fittings shall be used at all outflow points
from the manufacturer. All concrete for use in footings for retaining walls shall have a Geotechnical Engineer shall be excavated and replaced as to connect the subsoil drainage to a 100mm diameter pipe
compressive strength after 28 days of 25MPa unless specified described above. stub which extends 300mm past the face of the Keystone wall.
4.4 Approved Reinforced Soil Block Backfill
otherwise. The pipe stub material shall be UPVC or HDPE and shall be
Material for backfilling between geogrids for the Keystone The footing shall be constructed as shown on the drawings.
approved by the project Superintendent.
retaining wall shall be ‘Approved Backfill’ defined as sand, The supply, placement, finishing and curing of reinforcement It could be shown as compacted roadbase or concrete. For
crushed sandstone or broken rock obtained from excavations and insitu concrete shall comply in every respect with concrete, the footing shall be poured to the correct level The outflow points shall be at a maximum of 60m centres.
or approved borrow areas. Such material shall be AS3600. using formwork edge boards, or other methods which ensure The locations of the outflow points shall be determined by the
the correct level of the footing. The concrete footing shall Superintendent. The outflow pipe stub shall be supported on
• Free of rock fragments greater than 75mm in size. 4.7 Hold and Witness Points
be screeded flat. The level of the footing or first course of the concrete footing, and shall pass between two Keystone
• Free of clay lumps retained on a 75mm sieve. The following shall be deemed a Hold Point:
blocks shall be verified by survey methods, and approved by units with 60mm of the facing removed by sawcutting. The
• Free of organic matter.
• Submission of test results and samples of all retaining the Contractors QA representative. This shall be deemed a gap above the pipe in the first course shall be neatly patched
• Within the following grading requirements;
wall components. WITNESS POINT. with cement mortar.

The following shall be deemed a Witness Point: 5.2 Unit Installation The drainage measures shall be inspected by the QA
Foundations and all courses are laid level. Batters are achieved representative after the installation of the first and second
• On-site slump and strength testing of concrete. course is complete. Inspection and approval of the drainage
by inserting the fibreglass connecting pins into the appropriate
holes. The Keystone retaining walls shall be constructed with installation shall be deemed a HOLD POINT.
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

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5.4 Placement of Geogrid The QA Representative shall inspect and keep records of the Surface drainage during and after construction of the wall shall 6.2 Testing for Compaction
The Geogrid shall be placed between Keystone units as position of grid and the type of grid placed for each layer of be provided to minimise water infiltration in the reinforced Compaction will be checked by standard maximum dry density
specified on the drawings. Geogrids shall be cut to the required geogrid. The number of courses between each successive layer soil zone. test and field density test for materials other than sand or by
length. Geogrids may be longer than required, but shall not be of geogrid shall be noted. The QA Representative shall also the density index and field density tests for sands as specified
5.6 Hold and Witness Points
shorter than the specified length shown on the drawings. check this. This shall be deemed a WITNESS POINT. on drawings and herein.
The following shall be deemed a HOLD POINT:
The Geogrids shall be placed with the roll direction perpendicular 5.5 Placement of Reinforced Soil Backfill Tests will be carried out in groups of at least three, and
• Approval of foundation material by the Geotechnical
to the face of the Keystone wall. Correct orientation of the Prior to placement of ‘Approved Backfill’ in the reinforced soil compaction of the layer concerned will be considered to be
Engineer.
geogrids shall be verified by the Contractor. block, the Geotechnical Engineer shall approve the material and satisfactory if no single result falls outside the specified
confirm that the friction angle and dry density of the material • Inspection and approval of ‘Approved Backfill’ for use in density range. Should the results not reach this standard the
After compaction, the layer of select backfill below each
is in accordance with the drawings for that particular section reinforced soil block by the Geotechnical Engineer. Sub-Contractor shall again roll the area, if necessary after
geogrid, shall be raked to a depth of 25mm to ensure good
of the project. This shall be deemed a HOLD POINT. scarifying, adding water, blading to reduce the moisture content
interlock between the geogrid and the select backfill. The • Survey of the Keystone Wall every 3 courses.
and/or removing and replacing excessively moist fill as may
Geogrid shall be laid horizontally on compacted backfill and All backfill imported or otherwise shall be as specified on the
• Inspection and approval of the drainage installation by be required.
connected to the Keystone units by hooking geogrid over the drawings. Backfill shall be spread in a maximum of 200mm
the QA Representative.
fibreglass pins. The geogrid shall be pulled taut against pins layers, in such a manner that minimises the voids directly Should the Geotechnical Engineer consider that the depth
to eliminate slack from connections and loose folds. The back underneath the geogrid. Fill should be deposited using suitable The following shall be deemed a WITNESS POINT: of insufficiently compacted material is greater than can be
edge shall be staked or secured prior to backfilling to maintain plant which causes fill to cascade onto geogrids. Placement of effectively compacted from the surface, material shall be
• Survey verification that the first course is installed at the
tension in the geogrid. Each block shall be checked for level fill on top of the geogrids shall start from the wall face and removed to a depth at which compaction is satisfactory and
correct level, and inspection and approval of footing by
accuracy, as out of position transverse bars will lead to sloping work back from the wall face in order to minimise slack or loss replaced and compacted in 200mm maximum layers.
the QA Representative.
blocks. If the course above a layer of geogrid is found to be of pretension from the grid. Care should be taken to not mix
The standard maximum dry density referred to herein for
not level, then the blocks shall be removed, and the geogrid the reinforced soil block backfill material with the drainage • Inspection of level and type of geogrid at each layer by
materials other than sand shall be maximum standard dry
repositioned to ensure levelness. material. If backfill material mixes with the drainage material, the QA Representative.
density as determined in accordance with AS1289 - Test
then the drainage material is to be removed and replaced with
For a straight length of wall, the geogrids shall be laid side • Compaction Testing by the Geotechnical Engineer. numbers 5.1.1.
clean material.
by side without joints or overlaps. Where the wall is convex,
the geogrids shall not be cut, but shall be overlapped with Compaction shall be to 98% of Standard Maximum Dry Density. 6. Material Testing The modified maximum dry density referred to herein for
materials other than sand shall be the maximum modified dry
a minimum of 75mm of compacted fill between them. For a Compaction shall start at the wall face and work back from 6.1 Testing of ‘Approved Backfill’
density as determined in accordance with AS1289 - Test 5.2.1.
concave wall the position of the layers of grid shall be alternated the wall face. Compaction testing shall be in accordance with Each source of ‘Approved Backfill’ shall be pretreated by 5
between consecutive geogrid layers to cover the triangular gaps section 6 specified herein. Compaction testing shall be deemed cycles of repeated compaction, and then tested for dry density The field density referred to herein for all materials shall be the
between strips of geogrid. Refer to Fig 5.4. a WITNESS POINT. and friction angle. Material for use as ‘approved backfill’ dry density of the material in place as determined in accordance
shall be inspected and approved for use by the Geotechnical with AS1289 - Test 5.3.1.
Tracked construction equipment shall not be operated directly
Engineer. A stockpile at least equivalent to 5 days reinforced
on the geogrid. A minimum thickness of 150mm of backfill The percentage of the standard maximum dry density (Dry
soil wall construction shall be maintained on site at all times.
material shall be placed prior to the operation of tracked Density Ratio) elsewhere herein for materials other than sand
This will allow time for friction angle testing of the approved
construction equipment. Rubber tyred equipment may pass shall be calculated from the formula given in AS1289.5.4.1.
backfill should visual inspection of the material when it is
over the geogrids at very slow speeds. Sudden braking or
received on site indicate that testing is required. The maximum and minimum densities of cohesionless materials
sharp turning shall be avoided to prevent displacement of
shall be determined in accordance with AS1289 - Test E5.1.
Geogrid
geogrids. Notwithstanding the above the following minimum testing
shall be carried out: The Density Index specified elsewhere herein for sands shall
Construction plant and all other vehicles having a mass
be calculated from the formula given in AS1289.E6.1.
exceeding 1000kg shall be kept at least 1m from the back of • Dry Density shall be tested at a frequency of 1 test per
the Keystone units. Compaction of the 1m zone behind the 400m3 of approved backfill. 6.3 Frequency of Testing
Keystone units shall be restricted to: The following testing frequencies relate to acceptance on a
• Friction angle shall be tested at a frequency of 1 test per
‘not-one-to-fail’ basis. The testing should be carried out in
• Vibrating rollers with a mass < 1000kg 2000m3 of approved backfill.
essentially randomly chosen locations and at the frequencies
• Vibrating plate compacters with a mass < 1000kg If the dry density results are not within ±5% of the specified as given below. However, it may be appropriate to undertake
Wall Face design value, then the Engineer shall be notified, and the testing in specific locations, based on visual appearance or
• Vibro tampers having a mass < 75kg
material not approved for use until the design has been past experience.
verified.

Fig 5.4 — Typical Geogrid Layout

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Build something great™

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

Masonry Design Guide

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 segmental block retaining walls south australia BOOK 4
immediately surrounding it.

Required frequency of testing, is not less than 1 test per layer of F custom engineered walls
200 mm thickness per material type per 400m3 which is 1 test
per layer per 100 linear metres of wall construction. If different

4
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.

F
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Engineered Boral Keystone, Pyrmont and Keysteel Retaining Wall Keysteel Custom Engineered • Keysteel™ Custom Engineered Retaining
Retaining Wall Systems Systems provide a proven and versatile platform for the
Retaining Wall Systems Wall Systems
development of custom engineered high performance Boral Keysteel is a high performance engineered
for domestic and commercial landscaping, roadside retained earth structures. • Gravity Retaining Walls retaining wall system for applications requiring wall
and custom engineered retaining wall applications
• Mass Gravity Retaining Walls heights in excess of 6m and/or where critical surcharge
Boral has developed alliances with a number of suitably
• Geogrid Reinforced-Soil Retaining Walls loadings are present. Boral Keysteel is an internationally
experienced engineering companies that can provide
• Steel-Ladder Reinforced-Soil Retaining Structures proven system that integrates the superior strength
professional assistance with the custom design and
and durability of Keysteel blocks with steel-ladder soil-
installation of Keystone, Pyrmont and Keysteel retaining • Bridge Abutments
reinforcement to provide engineered solutions for the
structures. • Stream or Drainage Channels
most demanding retaining structures.
Please contact Boral Masonry in your region for assistance • Erosion Prevention
with your high performance, engineered retaining wall • Tunnel Access Walls
projects. • Wing Walls
• Embankment Stabilisation
• Terraced Walls
• Seawall Applications
• Soil-Anchor and Rock-Anchor Walls
• Fencing, Railings and Barriers

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305
305
Keysteel® Typical Keysteel® Application Layout
200 200
High Performance Engineered Keystone unit Cut ladder around pylon Where piles prevent installation of
ladders refer to engineers detail.

455
Retaining Wall Systems
455
Standard Unit Flushface Unit INTRODUCTION Keysteel retaining structures.
Boral Keysteel is an internationally
Please contact Boral Masonry
proven, high performance retaining
Technical Services in your region for
wall system that integrates the
assistance with Keysteel projects.
superior strength of Keysteel blocks
275 275
with steel-ladder soil-reinforcement, COLOURS
100
100 and is ideally suited to retaining Boral Keysteel is made-to-order
structures in excess of 6m high and in the same range of colours as
455 455 for critical surcharge loadings. Keystone, allowing integration of
the two products within the one
Standard Flushface DESIGN CONSIDERATIONS
Straight Sided Cap Straight Sided Cap project. Please refer to colour swatch
(made to order) (made to order) Boral Keysteel installations are
information for an indication of
individually engineered to match
current colours.
the application criteria.
Pylon
Boral has developed alliances with
a number of suitably experienced
engineering companies which can
provide professional assistance
with the design and installation of
Steel Pins Lifting Bars
(hot-dip galvanised)

Fig F1 — Typical Construction Detail — Keysteel wall

Wall face
Availability and Colours
• All Keysteel products are made-to-order.
• Lead times apply Please consult with the Boral Masonry Keysteel unit
sales office in your region.

Keysteel unit Soil reinforcing

ladder

Specifications
Tuscan Desert Sand
Description HxLxDmm Wt kg N°/m2 Soil
reinforcement
ladder
Standard Unit 200x455x305 36 11
Standard Straight Sided Cap 100x455x275 25 2.2/lin mtr Keysteel unit

Flushface Unit 200x455x305 39 11

Antique Copper
Flushface Straight Sided Cap 100x455x275 26.3 2.2/lin mtr
Pins (steel) 2 pins per full unit
hot-dip galvanised steel
Lifting Bars (Keysteel units should be lifted by
two people using the Keysteel lifting bars) Fig F2 — Typical Curved Wall Detail — Keysteel Fig F3 — Typical Straight Wall Detail — Keysteel

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South Australia Book 4 F South Australia Book 4 F

Typical Soil-Anchor Application Typical Rock-Anchor Application Layout

Rock anchors
Temporary face
Soil anchors support and drainage
Reinforcing bar to system
Geogrid to project Drainage net
project specifications Concrete backfill
specifications

Geogrid (if Galvanised

Granular backfill required) steel pipe
Stiff firm soil 1200mm cts nominal Galvanised pipe
loop connector

Expansion joint material Keystone unit

to design details
TYPICAL PLAN VIEW
Top of wall stepped (optional)
TYPICAL PLAN VIEW Keystone unit

Top of wall stepped (optional)

Reinforcing bar
to design details

Galvanised pipe
Geogrid Soil Anchor to
design details
Galvanised pipe,
loop connector and
soil anchors
(staggered installation)

Finished grade TYPICAL WALL ELEVATION Footing step

300mm
Footing step nominal
Finished grade (optional) Threaded pipe
TYPICAL WALL ELEVATION coupling Drainage net Keystone cap
to design details
300mm
nominal See anchorage detail
Stiff firm soil
Keystone unit Rock anchor
Cap unit
Horizontal reinforcing to design detail
Temporary concrete and bar to design details
mesh facing support
See connection detail system with drainage to Vertical reinforcing bar
5˚ design details to design details Keystone unit
Keystone units Keystone unit
Concrete backfill to Geogrid
Geogrid design detail
Soil failure plane Reinforcing bar
1
1 to design detail
Galvanised steel pipe Geogrid at 600mm
8 Thread bar to
8 vertical centres extended
Soil anchors to site Loop connector to wall face between design details
specific design Rock anchor reinforcing bar
Granular fill system 1500mm
Drainage pipe to design typical
details Drainage pipe
Leveling pad to
engineer's detail Levelling pad Concrete
backfill
Finished grade Soil anchor to Finished grade
design details

Steel plate and securing

TYPICAL CONNECTION DETAIL nuts to design detail

Granular material
wrapped in geotextile
TYPICAL SIDE ELEVATION
TYPICAL SIDE ELEVATION TYPICAL ANCHORAGE DETAIL

Fig F4 — Typical Soil-Anchor Detail Fig F5 — Typical Rock-Anchor Detail

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South Australia Book 4 F South Australia Book 4 F

Typical Seawall Application Layout Typical Terraced Wall Application Layout

Engineering Undermining of Foundation Wall When terracing walls, they are effectively being split into Example:
All water application projects should be designed by a suitably Greater embedment of units, concrete footings (piered or sections. This is done for a number of reasons. For example, to If the lower gravity wall is 1.2m tall, then the minimum
qualified engineer. The Keystone Retaining Wall System has otherwise), Keystone units keyed to a concrete foundation are level off a sloping front or backyard, to increase the aesthetic recommended spacing between terraces is 1.8m. This rule
been used in numerous international projects where the blocks all means of preventing undermining of the wall foundation. appeal of the garden and in some instances to reduce the single also applies to walls with more than two terraces. The
are subjected to high velocity flood water, wave action and Rip-Rap in front of the wall will also help to prevent erosion. wall heights where by they still act as gravity walls and thus distance between any two terraces must be at least twice
tidal action. minimise the need for geogrid. In such instances, however, the height of the lower adjacent terrace wall for multiple
Loss of Material through Wall Face
the upper terrace wall can put pressure on the lower terrace if terraces.
Spacing of Geogrid Filter fabric used behind the 300mm drainage layer will prevent the walls are too close together. Multiple terrace walls in close
As with all geogrid soil reinforced Keystone walls, the spacing loss of retained soils during fluctuation in water level. NOTE: This simple rule of thumb does not address global
proximity to each other, can have structural stability issues
of the geogrid should not exceed 600mm, to prevent bulging stability issues where walls are built on steep slopes or over
Differential Water Pressures related to the lower walls not having the capacity to carry the
between the grid layers. poor soils of low friction strength. If these conditions exist,
Fluctuations in water levels and rapid draw down may induce loads developed by the upper walls.
then contact your engineer.
Suitability of Keystone Blocks in a Seawall differential water pressures across the face of the wall and Question:
Application need to be addressed. Question:
How far apart do the terrace walls have to be to perform as
It is recommended that if the Keystone units are submerged What if there isn’t enough room to space the terraces
Test Reports individual gravity walls?
in salt water, then marine grade Keystone units should be according to this rule (1.5 x H1 minimum)?
Tests have been carried out on the high velocity flow effects, Answer:
used. Minimum order quantities apply to these units.
wave action and sudden draw down and Manning’s ‘n’ Answer:
As a rule of thumb, the minimum distance between the wall
NOTE: Product colours will be different due to the use of determination. These test results are available on request. The wall can still be built, but the effect of the upper terrace
terraces must be at least 1.5 times the height of the lower wall.
marine grade cement. 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
Filter Fabric
Impermeable soil layer 300mm
as a single taller wall to account for the added load from the
Keystone
Cap Unit upper terrace wall on the lower walls.

10-20mm crushed rock,

fill cores and voids of
Keystone units

Free draining granular

material (less than 10%
passing the #200 sieve, Keystone Keystone or Pyrmont wall
no organic material) block
H2
Typical
1900mm
Geogrid as per
design
Cap unit
Nonwoven
filter fabric

Native soil
L = 1.5 x (H1) Keystone or
Water level Pyrmont wall
L = minimum distance between terraces
150 - 200mm
rip-rap H1

150mm min.
Compacted
aggregate or
crushed rock 600mm min.

Fig F6 — Typical Construction Detail — Keystone Seawall Application Fig F7 — Typical Construction Detail — Terraced Wall Application

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South Australia Book 4 F South Australia Book 4 F

Typical Fencing Application Layout Typical Railing and Barrier Application Layout
Fences can be incorporated into the Keystone Retaining Wall Fence posts positioned behind the wall should be embedded Railing, guard rail, and traffic barrier requirements for retaining It is important that these walls be designed to accomodate any
System by placing fence posts into the Keystone cores or 700mm minimum and encased in concrete. walls are not clearly defined in design codes nor are they additional loading these guards and barriers may impose on
behind the wall. properly addressed in many site plans. Many times railings the Keystone wall.
When constructing a soil reinforced wall, the Geogrid may be
and barriers are added as an afterthought which can become
NOTE: The following recommendations are suitable for cut to allow for placement of fence posts as per the Geogrid
a costly and logistical issue when no provisions are made
fences with no wind loadings. manufacturer specifications.
in the original retaining wall layout and site design. Guards
Fence posts should be embedded through a minimum of three It is important that these walls be designed to accommodate any and barriers require a common sense approach by the site
courses (600mm minimum) and then core filled with concrete. additional wind loads from fencing (eg. extra embedment). designer considering the proximity of a wall structure to
Only those units with the fence posts need to be core filled with people and traffic. Sufficient space must be reserved for such
concrete, the remaining filled with drainage material. installations.

Load Load
Typical 900mm min. Typical
900mm 900mm
150mm
Additional Geogrid
layer turned upwards
1824mm max. and wrapped around
void former at 400mm
below ground level

900mm

Railing – offset Railing – offset

Load Load

1000mm min. Typical

700mm 800mm

Guardrail Traffic Barrier

Fig F8 — Typical Fencing Detail Fig F9 — Railing and Barrier Details

F10 September 2007 | BORAL MASONRY DESIGN GUIDE BORAL MASONRY DESIGN GUIDE | September 2007 F11
 eBC 03119 September 2007

Customer Support New South Wales

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 area’s stock colours.) A surcharge applies to orders less than
the set minimum quantity.
2. Brochure colours The printed colours in this Masonry Design Guide are only a guide. Please ask to see a sample of your colour/texture
before specifying or ordering.
3. Colour and texture variation The supply of raw materials can vary over time. In addition, variation can occur between product types and
production batches.
4. We reserve the right to change the details in this publication without notice.
5. For a full set of Terms and Conditions of Sale please contact your nearest Boral Masonry sales office.
6. Important notice Please consult with your local council for design regulations prior to the construction of your wall. Councils in general
require those walls over 0.5m in height and/or where there is loading such as a car or house near the wall be designed and certified by a
suitably qualified engineer.

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

Orders, Product Samples and Sales Enquires

South Australia Main North Road, Pooraka, 5095 T: (08) 8262 3529
F: (08) 8260 3011

Other Regional Sales Offices

NSW Clunies Ross Street, Prospect, 2148 T: (02) 9840 2333
F: (02) 9840 2344
231 Wisemans Ferry Road Somersby 2250 T: (02) 4340 1008
F: (02) 4340 1308
ACT 16 Whyalla Street, Fyshwick, 2609 T: (02) 6239 1029
F: (02) 6280 6262
Victoria Level 1 Port IT, 63-85 Turner Street, Port Melbourne, 3207 T: (03) 9363 1944
F: (03) 9363 6008
Queensland 62 Industrial Ave, Wacol, 4076 T: (07) 3271 9292
F: (07) 3271 1581
North Queensland:
Cairns 8 Palmer Street, Portsmith, 4870 T: (07) 4035 1888
F: (07) 4035 1208
Townsville 360 Bayswater Road, Garbutt, 4814 T: (07) 4725 6285
F: (07) 4725 6043
Mackay David Muir Street, Slade Point, 4740 T: (07) 4955 1155
F: (07) 4955 4130

® Heathstone, Ravenastone and Pyrmont are registered trademarks of Boral Masonry Limited.
® Keystone and Gardenwall are each registered trademarks of Keystone Retaining Wall Systems, Inc.
under licence by Boral Masonry Limited. ABN 13 000 223 718
© Boral Masonry - all rights reserved 2007.