installation booklet 1

7/27/2019 Installation Booklet 1

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Tel: (02) 4631 1383

Fax: (02) 4631 [email protected]

900 Wilton Road

(P.O. Box 89)Appin NSW 2560

Tasman and Norolk

Retaining WallEvaluation and Installation Guide

Tasman and Norolk are registered trade marks o Baines Masonary Blocks Pty Ltd and are used under licence.


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Norolk and Tasman block retaining wall systemsare proven Segmental Retaining Wall Systems (SRWS)designed and manuactured in Australia or Australianconditions.

The unique characteristics o the Norolk and Tasmansystems ensure construction o any wall will be durableand strong or both residential and commercial projects.

The aesthetic value o the split ace (rock ace) nishedtexture coupled with natural Australian colour tonesmeans the Norolk and Tasman systems when installed,enhance any landscaped environment - which means,to you, a sensational looking space that blends to thenatural surroundings adding value and usability to yourproperty.

Both the Norolk and Tasman SRW systems haveundergone extensive testing (eld and lab) in the moststate o art testing acility by the most experienced stain Australia. The results both systems achieved, at worse,were equal to but in most cases, bettered the majority o

segmental retaining wall products produced worldwide .Skilled Architects, Engineers and Designers time and timeagain preer the qualities both systems oer:

Positive connection, no pins or plastic connectors thatmay not be used.

Snug tting connections, very little movement onceblocks are correctly installed.

A proessionally designed user riendly sotwarepackage that is a guide or your engineer to conrmAustralian Standard (AS/NZ 4678) verication.

Imitation is the highest form of compliment - Not a truerword has been spoken in regards to the Norolk andTasman Segmental Retaining Wall Systems. Many o ourcompetitors will oer you products o similar shape andcolour, but due to legal reasons they cannot duplicate thesuperior locking connection o both systems.

Our product quality and our superior, unique, systemdesign is your piece o mind that you are investing in thebest segmental retaining wall system in Australia.

It is the original and the best!

Tasman and Norolk are registered trade marks oBaines Masonary Blocks Pty Ltd and are used underlicence.


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Tasman and Norolk Retaining WallEvaluation and Installation Guide

This installation guide demonstrates the basics on how toconstruct

A. Segmental Concrete Gravity Retaining Walls up to900mm high (Gravity)

B. Segmental Concrete Reinorced Soil Retaining Wallsover 1 metre high (Reinorced)

C. Segmental Concrete Gravity Retaining Walls with No-nes Concrete over 1 metre high (No-nes Concrete)

This is a guide only, to help determine whether a gravity, soilreinorced or no-nes concrete retaining wall is the mostappropriate or your situation, and the preparation necessary toachieve the end result.

This guide is not a design manual or soil reinorced or no-nesconcrete retaining walls.

The inormation provided in no way replaces the services oproessional consultants on a particular project. No liability canthereore be accepted by Baines Masonry.

STEP 1. Wall Height:Determine the maximum wall height. (see gure 1)

WallHeight

Figure 1. Maximum Wall Height

STEP 2. Decide on

A. Gravity retaining wall

B. Soil reinorced retaining wall

C. No-nes concrete retaining wall

A. Segmental Concrete Gravity Retaining Wall.

There are two types o gravity retaining walls:Type A1 Norolk which can be constructed up to 900mm highand Type A2 Tasmanwhich can be constructed up to 660mmhigh or straight walls and 860mm or serpentine walls.

Tasman and Norolk Retaining Wall

Evaluation and Installation Guide


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The maximum permissible height or both straight and serpentineNorolk retaining walls is 900mm (4 blocks at 180mm plus onecapping block at 180mm).

Norolk retaining walls supporting up to 800 mm o soil, shouldcomply with the ollowing specication. Norolk walls intended tosupport higher embankments must comply with AS 4678 EarthRetaining Structures and the advice o a competent civil engineershould be sought.

The ollowing limitations comply with the requirements o Concrete

Masonry Association o Australia Manual MA53 Segmental ConcreteGravity Retaining Walls Appendix E. This design may be used todetermine the permissible height o retaining walls satisying theollowing criteria. For retaining walls outside these criteria, the designshall be determined using engineering analysis similar to that shownin the worked example, Appendix A, by qualied and experiencedcivil or structural engineers with a comprehensive workingknowledge o soil mechanics and structural analysis and design.

Details o the Norolk System

Block height

Block lengthBlock depth (into the embankment)

Block weight

Capping block weight

Setback distance per block

Wall slope

Inll behind and withinthe acing blocks

Bearing pad

Drainage pipe

180 mm (plus 10mm tab height)

390 mm190 mm

18.5 kg

21.5 kg

55 mm

17 degrees (55 in 180)

Compacted 10 to 20 mmcrushed rock aggregate

Compacted 10 to 20 mmcrushed rock aggregate

100 mm diameter PVCagricultural pipe with sock

Bearing Pad

Compacted Foundation

Retained Soil

100mm Slotted PVC Pipe

Free Draining Layer

Top Soil

Optional Capping Unit

Norfolk Blocks

1

Level or

1 in 8 MAX200mm(MIN.)

The limits o application are as ollows:

All retaining walls shall comply with AS 4678 StructureClassication A (Available rom SAI Global Publishingwww.sai-global.com)

Permissible height or both straight and serpentinewalls is 900 mm (4 blocks at 180 mm plus one cappingblock at 180 mm)

All retaining walls are designed or level backll. I thebackll has a slope greater than 1 in 8, engineeringadvice should be sought. This design does not apply to

terraced retaining walls

This design is not suitable or imposed loads. Iimposed loads are expected, the retaining wall shouldbe designed by engineering analysis similar to that inthe worked example, in CMAA Manual MA53 AppendixA (Available rom The Concrete Masonry Association oAustralia. www.cmaa.com.au )

This design is not suitable or situations o excessivewater run-o

This design applies to retaining walls with acompacted crushed rock levelling pad, 600 mm widex 150 mm deep. (The addition o portland cement isrecommended to avoid erosion over the long term

Notes

Structure Classication A retaining structures under 800 mm highare outside the scope o AS 4678.

The criteria or Norolk gravity retaining walls under 800mm isbased on MA53 o the Concrete Masonry Association o Australia.

For all retaining walls it is the owners responsibility to

determine i council approval is required, irrespective o height

or site conditions.

Figure 2. Norolk Straight and Curved or Serpentine Garvity

Walls up to 900mm

A1 - Norolk

Norolk Blocks

Norolk Block Norolk Cap


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Step 1 Check Compliance

Check with your local council to ensure all local Building Codes arecomplied with.

Step 2 Foundation

The oundation material, (the natural soilor rock material under retaining walls)shall be compacted by several passes o amechanical plate vibrator. Where there are

signicant variations o oundationmaterial or compaction, sot spots, orwhere there is ponding o ground water,the material shall be removed, replaced

and compacted in layers not exceeding 150 mm. Trenches shall bedewatered and cleaned prior to construction, such that no sotenedor loosened material remains.

Step 3Bearing Pad

The acing shall be built on a bearing pad,not less than 150 mm thick, consisting oone o the ollowing options:

Compacted crushed rock, well-graded and o low plasticity (withoutclay content), compacted by a platevibrator;

Cement-stabilized crushed rock,with an additional 5% by mass o GPPortland cement thoroughly mixed,

moistened and compacted by a plate vibrator; or

Lean-mix concrete with a compressive strength o not lessthan 15 MPa.

Step 4 First Course

Spread 25mm o metal dust with an

additional 5% by mass o GP Portlandcement over the compacted base.

The rst course is now bedded into themetal dust. The use o a level and stringline is recommended to ensure the rstcourse is laid correctly. Ensure eachblock is also well lled with ree-drainingmaterial. (eg crushed rock aggregate /blue metal).

Step 5Drainage and Backfll

Place 100 mm diameter PVCagricultural pipe with sock behind thewall, with a 1 in 100 all. Backll behindthe courses o blocks to a width oapprox. 200mm - 300mm using 10 - 20mm ree draining material (eg crushedrock aggregate / blue metal). Ensureeach block is also well lled with

ree-draining material.

Step 6Laying Additional Courses

Lay the next course and subsequentcourses to a string line ollowing thesame procedure, as outlined in step 4,cleaning the top o the blocks, llingthe block cores and backlling behindthe blocks to a maximum o one blockhigh, at a time. (As per step 5)

Step 7 Capping Units

When a Norolk capping block is laidas the nal course no adhesive xing isnecessary.

I using a Tasman cap on either Norolkor Tasman walls the capping blockshall be xed by Mason Bond adhesive

Note: The criteria or Norolk and Tasman Gravity Retaining

walls are based on MA53 o the Concrete Masonry Association

o Australia

Installing Segmental Concrete

Gravity Retaining Walls A1 and A2

Tasman Block Tasman Cap

Tasman Blocks


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Step 6 Laying Geogrid

Clean any debris rom the top o the blockwall to ensure the next block and or thegeogrid layer sits perectly. Roll thegeogrid perpendicular to the wall, pulltight, stake in place and cut to therequired length. Ensure that the geogridsits within 15mm o the ace o the block,so that the purpose made connecting lugs

can interlock. Butt join the geogrid alongthe length o the wall. Place the next course on top o the geogrid.

Baines Masonry recommends and supplies Fortrac Geogrid

Manuactured by Huesker Inc

Step 7 Laying Additional Courses

Lay the next course and subsequent

courses to a string line ollowing theprocedures outlined previously i.e. Cleanany debris rom the top o the block wallto ensure the next block and or thegeogrid layer sits perectly. Backll behindthe course o blocks to a width o not lessthan 300mm using 10-20 mm ree

draining material (eg crushed rock aggregate / blue metal). Ensureeach block is also well lled with ree-draining material.

Back ll behind the drainage layer with the specied backll in amaximum o 200mm layers.

Compaction rate o 95% must be achieved (use only hand operatedplate compactors close to the wall). Sot or wet clay must not be usedto backll.

Step 8 Capping

The capping block shall be xed byMason Bond adhesive

Step 9Surace Drainage

The whole o the disturbed ll suraceshould be sealed by at least 150mm o

compacted clay and properly drained.Alternative means, such as bentonitelayers or PVC membranes may beemployed, provided they do notintroduce potential slip planes into thesurace material.

Build your walls with MASON BOND masonry adhesiveinstead o mortar and youll save TIME & MONEY.

WHY ?

Simple to applySets quicklyComplete your masonry project in HALFthe time - thats a 50% labour reduction!No trowelling, no premixing no waiting!3.5 times stronger than mortar80% less water penetrationEconomical

MASON BOND is a moisture cure, polyurethaneadhesive ormulated to permanently bond concretemasonry block structures. MASON BOND meets therequirements o the International Code Council (ICC)A362 and is recognised as an alternative to mortar inICCs Evaluation Services Report 1968


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Step 1Check Compliance

Check with your local council to ensure all local Building Codes arecomplied with.

Step 2 For walls up to 3m high

Engage a qualied civil engineer with a comprehensive workingknowledge o soil mechanics and structural analysis and design.The design should comply with AS 4678 Earth Retaining Structures(A detailed engineering sotware design and specication disc is

available rom Baines Masonry)

Walls over 3m high must be designed by a qualied and experiencedcivil or structural engineer with a comprehensive working knowledgeo soil mechanics and structural analysis and design, using thedesign sotware available rom Baines Masonry. It may be a councilrequirement to have the retaining wall certied and supervised by acivil or structural engineer.

Slotted PVC ag. pipeat min. 1 in 100 fall

Excavation line

B* * See Design Tables 1 and 2 for values

Compactedfoundation material

Bearing pad

Tasman blocks

H*bp

2H*bp

Minimum fall1 in 100

150 min. compacted clayor similar to seal surface

Drain (min. 1 in 100 fall) topermanent stormwater system

1

20No-nes concrete

Retained soil

Optional capping unit

Specifcation o No-fnes Concrete infllNo-nes concrete shall be ree-draining, allowing water to passreadily through it to the drainage system.

No-nes concrete shall have a bulk density not less than 1800kg/m andan aggregate to GP cement ratio not greater than 6:1 (by volume).

Step 3 Foundation

The oundation material shall becompacted by several passes o amechanical plate vibrator. Where thereare signicant variations o oundationmaterial or compaction sot spots, orwhere there is ponding o groundwater, the material shall be removed,replaced and compacted in layers as

per engineers advice. Trenches shallbe dewatered and cleaned prior to construction, such that nosotened or loosened material remains. See example.

Step 4 Bearing Pad

The acing shall be built on a bearingpad, as per engineers advice,consisting o one o the ollowingoptions:

Compacted crushed rock,well-graded and o low plasticity(without clay content), compactedby a plate vibrator;

Cement-stabilized crushed rock,with an additional 5% by mass o GP Portland cementthoroughly mixed, moistened and compacted by aplate vibrator; or

Lean-mix concrete with a compressive strength o notless than 15 MPa.

Step 5Drainage, Backfll and the First Course

Place 100 mm diameter PVCagricultural pipe with sock behind thewall, with a 1 in 100 all.

The agricultural pipe should beconnected to a PVC stormwater pipeand brought through the ront othe wall at intervals not exceeding30m. It should be connected to a PVC

stormwater system at the lower end o each run, where practical,and must drain positively away rom the base o the retaining wall.

Backll behind the course o blocks to a width o not less than300mm using no-nes concrete. Ensure each block is also welllled with no-nes concrete. Back ll behind the drainage layerwith the specied backll in a maximum o 200mm layers.

Compaction rate o 95% must be achieved (use only hand

operated plate compactors close to the wall). Sot or wet claymust not be used to backll. The use o a level and string line isrecommended to ensure the rst course is laid correctly.

Installing Tasman No-fnes Concrete Retaining Walls C


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Step 6 Laying Additional Courses

Lay the next course and subsequentcourses to a string line ollowing theprocedures outlined previously i.e.Clean any debris rom the top o theblock wall to ensure the next block sitsperectly. Backll behind the course oblocks to a width o not less than300mm using no-nes concrete.

Ensure each block is also well lledwith no-nes concrete.

Back ll behind the drainage layer with the specied backll in amaximum o 200mm layers.

Compaction rate o 95% must be achieved (use only handoperated plate compactors close to the wall). Sot or wet claymust not be used to backll.

Step 7 Capping

The capping block shall be xed byMason Bond adhesive

Step 8 Surace Drainage

The whole o the disturbed ll suraceshould be sealed by at least 150mm ocompacted clay and properly drained.Alternative means such as bentonitelayers or PVC membranes may be

employed, provided they do notintroduce potential slip planes into thesurace material.

External Corner CapsInternal Corner Caps

Cut LineCut Line Finished CornerFinished Corner

Internal and External Hal Tasman Caps Cutting Details*

* Not available in all regions


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Curves

Curves and serpentine walls are easy toconstruct and the best guide is to lay outa garden hose and ollow the prole. Beconscious that the length o courses will varyor a concave or convex wall. With ewer blocksper lineal metre o a convex, and more blocksper lineal metre when the wall is concave. Forconvex curved walls knock the back n o the

block with a hammer. For concave walls simplyposition blocks. The minimum radius or thetop course o Tasman hal blocks is 650mmand Tasman blocks is 1300mm. Adjust lowercourses allowing or 10mm step back.

Always keep the ront o the blocks tightlytogether.

Corners

Tasman corners are built by xing thepurpose made corner blocks alternately toeach course using adhesive. Allowancesshould be made or a 10mm step back percourse.

Lugs must be removed rom the TasmanBlocks to ensure that the corner block tsevenly.

A maximum height o one metre isrecommended when using corner blocks.

Curved corners is the preerred method ocorner construction.

Steps

Steps must be built according to the local

building code, so always check with your

local building authority or the minimum

requirements beore commencing.

Tasman

First Course

Additional Courses

Capping

Prepare Surace

Install blocks

Capping

First Course

Additional Courses

Capping


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Corners

Due to the setback o the Norolk, 90corners are difcult to construct, but notimpossible. You may have to remove thelugs and x using a construction adhesive,allowing 55mm or the set back o theblock. Additional cutting o the blocks maybe required. Curved corners are easy toconstruct and the best guide is to lay out

a garden hose and ollow the prole. Beconscious that the length o courses willvary or a concave or convex wall. Withewer blocks per lineal metre o convexwall, and more blocks per lineal metrewhen the wall is concave.

Curves

Curves and serpentine walls are easy toconstruct and the best guide is to lay outa garden hose and ollow the prole. Beconscious that the length o courses willvary or a concave or convex wall.

With ewer blocks per lineal metre o aconvex, and more blocks per lineal metrewhen the wall is

concave. The minimum diameter o thetop course o the Norolk wall is 1900mm(internal dimension). Adjust lower coursesallowing or 55mm step back.

Always keep the ront o the blocks tightlytogether.

Norolk

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First Course

Additional Courses

Capping


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Glossary

Gravity Retaining Walls

Gravity retaining walls depend on the weight o their mass to resistpressures rom behind and will oten have a slight batter set back, toimprove stability by leaning back into the retained soil.

Soil Reinorced Retaining Walls

Soil reinorced retaining walls incorporate geogrids into the soilstructure to create a segmental concrete reinorced soil structure.Such systems can be constructed several metres high andaccommodate signicant loads.

No-Fines Concrete Retaining Wall

No-nes concrete retaining walls use no-nes concrete as a massbehind the concrete acing units to reinorce the soil structure tocreate a segmental concrete reinorced soil structure. Such systemscan be constructed several metres high and accommodate signicantloads.

Serpentine WallThe serpentine wall derives its name rom its curving shape, which isin the orm o a snake.

Geogrids

Layers o metal or plastic material, which when constructed inhorizontal planes in a soil mass, strengthen the soil. The mostcommon geogrids are open mesh consisting o polyester, high-density polyethene, polyproplene or steel.

Inll Material

The soil material, placed behind the retaining wall acing andstrengthened by the geogrids.

Foundation

The natural soil or rock material under a retaining wall.

Bearing Pad

The pad the Tasman or Norolk blocks are built on.

Drainage Fill

The crushed rock, gravel or similar material placed behind a retainingwall to convey groundwater away rom the wall oundations. It iscommonly used in conjunction with other drainage media, such asagricultural pipes.


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Client

Site

Ph Fax

this drawing is indicative only and is not to scale unless otherwise stated

Date


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Supplier:

This manual is intended to be a guide to determine the most appropriate type o segmental concrete retaining walland the procedure or installation.

This is not a design manual or soil reinorced or no-nes concrete retaining walls.Tasman and Norolk are registered trade marks o Baines Masonary Blocks Pty Ltd and are used under licence.

Baines Masonry is a member o the Concrete Masonry Association o Australia. www.cmaa.com.au

The inormation provided in no way replaces the services o proessional consultants on a particular project.No liability can thereore be accepted by Baines Masonry

installation booklet 1

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