BORAL MASONRY
Build something great™
Masonry Design Guide PAVING NEW SOUTH WALES BOOK 3
www.boral.com.au/masonry
Updated August 2009
PAGE
PAGE
New South Wales Book 3 A
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
Products at a Glance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A4
Fast Find Product and Application Guide . . . . . . . . . . . . . . . A3
About This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6
A B
Introduction
Planning and Design
Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
Installation Guidelines Flexible Laying System for pavers laid on Pods . . . . . . . . . B10
Design Assistance and Additional Information . . . . . . . . . . B2 Cutting Pavers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B11 Application Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12 Choosing an Appropriate Boral Paving System . . . . . . . . . . . . B3
Cleaning and Sealing of Pavers . . . . . . . . . . . . . . . . . . . . . . B13 About Laying Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3 Colour and finish variation . . . . . . . . . . . . . . . . . . . . . . . . . . B13 Installation Guidelines Flexible Laying System with Unbound Sand . . . . . . . . . . . . B4
C
Small Format Paving Systems
Pavestone™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
D
Large Format Paving Systems
Promenade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5
Stoneworks Travertine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D9
Precinct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6
Aspenstone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D10
Stoneworks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8
Bradstone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D11
E
Stylestone Paving Systems
Stylestone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E2
Stylestone — Honed and Shot-Blast. . . . . . . . . . . . . . . . . . . E5
Colours and Textures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4
Stylestone — Quarry and Sand . . . . . . . . . . . . . . . . . . . . . . E6
F
Hydrapave Permeable Paving
Hydrapave Permeable Paving System . . . . . . . . . . . . . . . . . F2
Design Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F5
Typical System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F3
Construction Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . F7
Alternative Hydrapave Systems . . . . . . . . . . . . . . . . . . . . . . F4
Material Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F8
G
Industrial Traffic Paving Systems
Industrial Traffic Paving Systems . . . . . . . . . . . . . . . . . . . . . G2
H
Interpave and Pavestone 80 . . . . . . . . . . . . . . . . . . . . . . . . G3
Accessories
Geofix™ Paving Joint Mortar . . . . . . . . . . . . . . . . . . . . . . . . . H1
The information presented herein is supplied in good faith and to the best of our knowledge was accurate at the time of preparation. No responsibility can be accepted by Boral or its staff for any errors or omissions. Users are advised to make their own determination as to the suitability of this information in relation to their particular purpose and specific circumstances. Since the information contained in this document may be applied under conditions beyond our control, no responsibility can be accepted by us for any loss or damage caused by any person acting or refraining from action as a result of this information.
A2
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 A
Stylestone
Large Format
Small Format
LA
Y
BORAL SEGMENTAL PAVING PRODUCTS
IN Fl G ex ib S Y Sl le + S T ab Sa E M + S nd Sl ab and + Pe Po rm ds e Sa ab le lt Te Pr ste od d uc To t P AS ag 445 e 6
The quickest way to find a Boral Masonry Paving Solution. Simply follow the FAST FIND GUIDE on the right hand side of the table.
C4
D5
LT
D5
P
P
Stoneworks
P
P
D6
Stoneworks Travertine
P
P
D7
Aspenstone
P
P
D7
Pavestone 50
LT
LT
Promenade 400 x 50
P
P
Promenade 300 x 50
LT
Precinct
Bradstone
P
P
400 x 400 x 40
P
P
Beach/Quarry
P
P
1
Laying systems are indicated in the top row, while products are listed in the far left column.
2
Maximum allowable application for the combination of product and laying system is indicated at the intersection of the row and column. P
Pedestrian only
D8
P1 Private Pedestrian to 1.8kN (per AS1170)
P1
E6
P2 Public Pedestrian to 4.5kN (per AS1170)
P1
E7
LT Light Vehicle Traffic IT
Hydrapave Permeable Industrial
P1
Fast Find a Boral Solution
LT
F2
Interpave 80
IT
IT
G3
Pavestone 80
IT
IT
G3
3
Industrial Vehicle Traffic
You will find appropriate product information by turning to the section and page number indicated in the far right column. eg. Section E, Page G3 in this example
For technical support and sales office details please refer to the outside back cover
BORAL MASONRY DESIGN GUIDE
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A3
New Ne N eew wS South oouuutth W Wales allees BBook oookk 3 A
Small Format Pavers For domestic and commercial pedestrian and light vehicular applications
• Pavestone™ 50 Moulded rectangular concrete pavers are ideal for pedestrian, pool and light vehicular access applications.
• Precinct® Moulded smooth faced bevelled edge concrete pavers, made up of a collection of square and rectangular shaped pavers to form a french pattern.
Large Format Pavers For domestic and commercial pedestrian and light vehicular applications
• Promenade® 300 and 400 Moulded smooth faced, bevelled edge concrete pavers in 300 x 300 x 50mm or 400 x 400 x 50mm formats, offering design flexibility for cost competitive pedestrian applications. The 300 x 300 x 50mm size is also available for light vehicular applications.
• Stoneworks™, Stoneworks™ Travertine, Abode®, Aspenstone™ and Bradstone Premium quality concrete pavers for pedestrian and poolside applications. These pavers emulate the naturally-aged appearance of stone cut by master stonemasons from generations past.
A4
August 2009 | BORAL MASONRY DESIGN GUIDE
Neew New wS So South out uth hW Wa Wal Wales ales es BBoo Bo Book okk 3 A
Stylestone® Paving Systems With infinite design possibilities for architectural landscaping and commercial traffic applications
Permeable Paving System For cost effective and environmentally friendly control of stormwater run-off
Industrial Paving System
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Stylestone high density concrete pavers are available in 40mm and 53mm thicknesses. These pavers are suitable for pedestrian applications.
• Hydrapave™ LT Permeable Paving Systems Innovative and effective paving system for the control, detention, on-site treatment, infiltration or recycling of stormwater run-off. Engineered for pedestrian and light vehicular traffic access, used along malls, carparks and driveways.
• Interpave™ Industrial Paving System High performance, flexible concrete paving system with unparalleled performance from the innovative interlocking shape, plus proven durability.
For heavy haulage and container terminals, airports, service stations and industrial sites
BORAL MASONRY DESIGN GUIDE
• Stylestone®
August 2009
A5
New South Wales Book 3 A
Boral reserves the right to change the contents of this guide without notice.
Boral Masonry Construction Solutions Boral Masonry offers a comprehensive range of proven products and systems including Segmental Paving Products, Masonry Blocks, Masonry Bricks, Masonry Fire and Acoustic Wall Systems and Segmental Block Retaining Wall systems.
Please note that this guide is based on products available in New South Wales at the time of publication from Boral Masonry.
What’s in this Guide
• Colour and Texture Variation: The supply of raw materials can vary over time. In addition, variation can occur between product types and production batches. Also please recognise that the printed colours in this brochure are only a guide. Always ask to see a sample of your colour/texture choice before specifying or ordering.
The Boral Masonry Paving guide details a comprehensive range of concrete paving products appropriate for pedestrian, light traffic, commercial traffic, and industrial applications. Boral Masonry is at the forefront in design and manufacture of paving systems developed specifically for commercial, architectural and public area landscaping.
• Terms and Conditions of Sale: For a full set of Terms and Conditions of Sale, please contact your nearest Boral Masonry sales office.
Boral Masonry is paving the way with the innovative use of materials and technology to create pavers that have the design flair and engineering qualities to exceed the expectations of the most challenging paving projects. This guide has been prepared as a comprehensive Boral Product Reference Guide. It does not attempt to cover all the requirements of the Codes and Standards which apply to paving construction. All detailing should be checked and approved by an appropriate engineer before construction.
A Guided Tour of a Typical Product Information Page in Book 3: Paving Product pages are laid out in a consistent manner to assist with easy selection and specification of Boral pavers.
Book, Page and Section Identification
Large Format Paving Systems
3
PAGE
BOOK
New South Wales Book 3 D
D11
Bradstone®® Classic Style Pavers Flagstone and and cobblestones cobblestones have have enhanced enhanced patios patios and Flagstone gardens in in Europe Europe for for centuries. centuries. Now Now it is possible to gardens
Product Product
recreate this warm, character-filled look in Australia with internationally renowned Bradstone from Boral.
Application and and usage usage Application
40 40 300 300
450 450
Product Information relating to features, applications, colours available by region
Unit Unit weight (kg) (kg) weight
7.4 units units per sq metre 7.4 per sq metre
12.1 12.1
2.22 units per lineal metre 2.22 units per lineal metre
12.1 12.1
7.4 units per sq metre 7.4 units per sq metre
15.5 15.5
7.5 units per sq metre 7.5 units per sq metre
A) 8.3 A) 8.3 B) 12.1 B) 12.1 C) 16.5 C) 16.5
Old Town Old Town
Product Icons with dimensions for products available in your region/state
40 40 300 450 300 450 Old Town Bullnose Old Town Bullnose
50 50 300 450 300 450 Cobblestone Cobblestone *A
*A
*B *B
300 300
40 40 300 300 40 40
450 *C 450 *C
300 300
40 40 600 300 600 Old Town Random300 Old Town Random
Suitable application legend Suitable application legend
grey green grey green
Colour Swatch
Pedestrian Pedestrian
Pools Pools
Specifications and and additional additional information information Specifications
BORAL MASONRY DESIGN GUIDE
A6
Application Icons Legend. These products are recommended for the indicated applications (subject to appropriate laying systems and site conditions and to region available)
gironde gironde
Content Content Dimensional Category Dimensional Category Characteristic Breaking Load (kN) Characteristic Breaking Load (kN) Abrasion Resistance Class Abrasion Resistance Slip Resistance ClassClass Slip Class Salt Resistance Tested to AS/NZS4456.10 Salt Tested to AS/NZS4456.10 Manufacturing and Test Standard Manufacturing and Test Ordering Requirements Standard Ordering Lead TimeRequirements Lead Bulk Time Ordering Bulk Ordering Application Application
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Product Name or other identifying feature, such as texture finish
Cement, sand, aggregate, colour oxide Cement, DPB1 sand, aggregate, colour oxide DPB1 5 53,5 3,5 V V Yes Yes AS/NZS4455, 4456 and 4586 AS/NZS4455, 4456 quantity and 4586applies No minimum order No 0-2minimum weeks order quantity applies 0-2 weeksextended lead times Requires Requires extended lead times Refer to product/laying system selection table on pageA3 in this guide to Random patternsystem on D10selection table on pageA3 in this Refer product/laying guide Random pattern on D10
Product Specifications
D11
August 2009 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide PAVING NEW SOUTH WALES BOOK 3 B PLANNING AND DESIGN
3
B
New South Wales Book 3 B
Design Considerations Boral Masonry has amassed extensive nationwide experience in the design and manufacture of segmental pavers, and in the development and use of appropriate laying systems. The long-term success and performance of segmental paving systems is reliant on the selection of a paving product suitable for the application; the selection of the most appropriate laying system compatible with the chosen paver, the application and the location; and adherence to correct installation procedures and recommended tolerances. The following section outlines a range of design considerations, installation methods and materials specifications which must be addressed during the selection and design of a suitable paving system. Detailed product information is provided within the product specific sections of this guide.
Design Assistance and Additional Information Appropriate design and installation for pavers is dependant on many factors including the location, soil characteristics, drainage requirements, intended laying system, application and paver choice. A suitably qualified engineer or experienced specialist should be consulted before design and site preparation is undertaken. The following information is intended as an introductory guide for the selection and installation of Boral Paving Systems. More detailed design information is available from the Concrete Masonry Association of Australia (CMAA) on their Website: www.cmaa.com.au.
Application Definitions Pedestrian Only Paving (P) Throughout this guide, Boral Pavers that are suitable for Pedestrian Applications are indicated by the icon shown here. Segmental paving for footpaths not subject to vehicle overrun or parking, pedestrian precincts which are completely closed to vehicle access, residential paths and patios and hard landscaping. NOTE: The following sub categories are used only with ‘Pod’ laying systems. Refer to Stylestone Pavers Page B10.
B2
Private Pedestrian Areas (P1) Pavements within a building to which the general public does not have access. Public Pedestrian Areas (P2) Pavements within a building to which the general public has access. This includes communal areas within residential buildings, office and institutional buildings.
Light Vehicle Traffic Paving (LT) Throughout this guide, Boral Pavers that are suitable for Light Vehicle Applications are indicated by the icon shown here. Segmental paving for areas generally subject to pedestrian and light vehicle traffic. A small percentage of commercial vehicle traffic is permissible provided the foundations are appropriately designed. These areas would generally include footpaths, domestic driveways and mall type situations. Light Vehicle Definition Light vehicles are those which when fully-loaded have a gross weight less than 3 tonnes. This category includes cars, utilities, delivery vans and some light 2-axle trucks.
Commercial Vehicle Traffic Paving (CT) Throughout this guide, Boral Pavers that are suitable for Commercial Vehicle Applications are indicated by the icon shown here. Segmental paving for pedestrian, light vehicle and commercial vehicle traffic. Commercial Vehicle Definition Commercial vehicles are on-road vehicles having a gross weight of 3 tonnes or more and which comply with state or commonwealth legislation for the axle loads, tyre pressures and dimensions of normal on-road vehicles.
Industrial/Heavy Vehicle Traffic Paving (IT) Throughout this guide, Boral Pavers that are suitable for Industrial/Heavy Traffic Applications are indicated by the icon shown here. These paving products are designed for the most arduous situations such as high volume and heavy vehicle traffic, high point loadings, and sites with poor foundation characteristics. These products can be engineered to suit virtually any situation including industrial, transport and container terminals, light and heavy aircraft service areas, public roadways etc. These systems are individually designed, and require specialist knowledge.
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 B
About Flexible Laying Systems
Saline Environments Throughout this guide, Boral Pavers suitable for Pool Surround and Saline Applications are indicated by the icon shown here. Boral Pavers tested to AS/NZS4456.10 Determining Resistance to Salt Attack can be used in saline environments. However, consideration should be given to applying an appropriate penetrative sealer to further safeguard against saline effects in salt pool surround applications and other areas subject to constant saline environments.
Choosing an Appropriate Boral Paving System The selection of the most suitable paving system depends on many factors, and the decision ultimately lies with the project architect/engineer and client. The principal factors in this process are: • Selecting a paving product with appropriate characteristics and durability to suit the application and the expected traffic type and volume. • Selecting a paving product which meets the aesthetic and cost requirements of the client and the design. • Selecting an appropriate laying system to suit the site sub-base characteristics, load carrying capacity and intended traffic conditions, and which is compatible with the chosen pavers. NOTE: Please refer to the following summary of ‘Laying Systems’, together with the ‘Fast Find’ table and ‘Products at a Glance’ on Pages A3, A4 and A5 in this guide.
About Laying Systems Segmental Pavement Laying Systems can be divided into two main categories, ‘Flexible’ and ‘Rigid’. This guide provides introductory information for laying Boral Pavers with the following flexible laying systems.
Flexible Laying Systems • Flexible Base Course (Roadbase) plus pavers laid with Unbound Sand
Probably the most common laying method is a flexible system employing either a roadbase or concrete base course and unbound bedding sand. This method has been employed with great success since the inception of segmental pavers. It caters for numerous applications, and the flexible nature of these systems enables greater tolerance during installation. These systems can be used with many Boral Pavers in pedestrian and light vehicle applications. Installation procedures and specifications are provided later in this section. About Flexible Laying Systems using Pods In some pedestrian applications, pavers can be laid on pods over a concrete base course. These pods support the pavers at all four corners, and also provide gaps between the pavers allowing drainage to the cavity below. Boral recommends the use of adjustable height pods in these applications. Refer to Section B10 of this guide for additional information. Boral Hydrapave™ LT Permeable Paving System The Boral Hydrapave LT Permeable Paving System can be used to absorb and direct stormwater to specially prepared subsurface layers to reduce run-off, and to provide on-site detention, treatment and various end-use options. This system employs a special sub-base allowing for tanked and infiltration systems. Boral Hydrapave LT is suitable for pedestrian and light traffic applications. Product and installation information is provided in Section F of this guide. A design software - Permpave can assist in designing your pavement. This program can be purchases by contacting the CMAA on their website: www.cmaa.com.au. Industrial and Heavy Vehicle Applications Boral Interpave 80 and Pavestone 80 form have a long history of success utilising flexible paving systems. These industrial and heavy traffic pavers can be engineered to cater for the most difficult and arduous applications providing the advantages of a flexible system, including elimination of shrinkage, cracking and joint stepping, while maintaining ready access to underground services. These products are detailed in Section G of this guide. Extensive design and installation information (including the ‘Lockpave’ program) has been developed by the Concrete Masonry Association of Australia. This information can be obtained by contacting the CMAA on their website www.cmaa.com.au
• Concrete Slab plus pavers laid with Unbound Sand • Concrete Slab plus pavers laid with Pods • Permeable Pavement Systems BORAL MASONRY DESIGN GUIDE
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B3
New South Wales Book 3 B
Flexible Laying System (Unbound Sand) Installation Guidelines for Flexible Laying System with Unbound Sand
In large areas of flexible paving where expansion and contraction is to be expected, control joints should be considered.
For details on the materials specified in these guidelines, please refer to the ‘Materials Specification’ later in section B.
Edge restraints should be provided around the periphery of pavements to the full depth of the paver and bedding sand. Edge restraints should be capable of preventing the loss of bedding sand and preventing the sideways movement of the pavers. The edge restraints must also be capable of accepting the design traffic loads. Edge restraints should be in place prior to installing the bedding sand where possible.
Drainage Surface Run-Off Paving should be installed so that water will not pond within the paved area. Adequate falls toward designated water channels and/or stormwater drains should be provided in the base course and/or levelling screed. Bedding Sand Drainage After extended rainfall, water can penetrate the joints and enter the bedding sand, particularly when the pavement is new. This can result in movement of the bedding sand and rocking of the pavers under traffic. The water captured bedding sand layer should be drained into the drainage system. Refer to Fig B1 and Fig B2 for recommended drainage methods. The use of geofabrics is recommended in this application to ensure there is no erosion of the bedding or jointing sand via the drainage of water from the bedding sand.
Expansion Joints Expansion joints are generally not required when pavers are laid over unbound bedding sand and 3-5mm joints are incorporated between adjacent pavers. This system allows flexible movement of the pavers for expansion and contraction.
Boral Pavers
Bituminous seal Bedding sand
Geofabric filter covering pipe inlet PVC pipe (min 20mm dia.on three sides of pit
Edge Restraint
Some important detailing requirements for edge restraints include: • Following compaction, the top of pavers should finish 2-3mm above the abutting top surface of the edge restraint to which they are draining so that water will not pond on the pavement. • The edge restraint should have a vertical or near-vertical side on the face that abuts the pavers. • The base course should extend below the edge restraint for its full width (to minimise the likelihood of the edge restraint itself being disturbed) except in situations such as walls or pits. • Where the edge restraint is in the form of a standard road-authority kerb, gutter/channel or dish drain, the requirements of that authority in relation to concrete quality should be followed. Elsewhere the use of a Grade N32 concrete is recommended. Geofabric filter covering pipe inlet Boral Pavers Bituminous seal Bedding sand
PVC pipe (min 20mm dia. at 5m centres) surrounded with concrete backfill
Kerb and gutter
Pit grate
Base course Drainage pit Natural soil
Base course Subsurface drain Agricultural drainage pipe (100mm dia. typical) Natural soil
Fig B1 — Drainage of Bedding Sand into Drainage Pit
B4
Fig B2 — Drainage of Bedding Sand into Sub-surface Drain
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 B
Types of Edge Restraint Suitable edge restraints include: • Adjacent Structures (such as buildings and/or foundation slabs).
Compaction of Roadbase: If a plate compactor is used, compaction of roadbase should be carried out on layers of 50mm maximum thickness. For compaction of layers greater than 50mm thickness, heavier compaction machinery will be required.
• Concrete Kerbs or Channels (site-formed). • Mortar formed into an on-site edge restraint. • Timber (suitable for in-ground use).
Base Course The base course can be either compacted roadbase material, an existing pavement, or a new or existing well-drained concrete slab. The base course must be designed and built in accordance with good engineering practice. If the base is designed using a segmental concrete paving program, the contribution to strength from the pavers shall be ignored. The foundation soil type should be taken into consideration at design stage in all systems, particularly in flexible systems where concrete is not used. Boral recommends that geotechnical soil testing results should be obtained to confirm a visual inspection. Pedestrian Applications: Good construction practice and experience dictates that the minimum requirement is 75mm thickness of granular base course material compacted to 92% of modified maximum dry density. Alternatively, a 60mm thick concrete slab reinforced with fibre mesh can be used to ensure satisfactory performance. Light Traffic Applications: The thickness of the base course will depend on the quality of the existing insitu foundation material. Experience has shown that a granular base course of at least 100mm thickness compacted to 96% of modified maximum dry density, or 75mm reinforced concrete is required to ensure satisfactory performance. Local soil conditions should be taken into account. Commercial Traffic Applications: These systems must be designed by a suitably qualified engineer to suit the location and application. Base Course Levels The finished level of the base course should be within 0-5mm of the required level. If the base is higher, then it must be cut down to the correct level and re-compacted. If the base is too low or excessively uneven, then a levelling screed will be required to bring it to the correct level.
BORAL MASONRY DESIGN GUIDE
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Bedding Course/Bedding Sand It is critical that the base course be checked for level and any deficiencies rectified before spreading of bedding sand commences. Large variations in base level (>5mm) must not be corrected with sand as this will result in variable compaction which can also cause excessive lipping. Stockpiled sand should be protected from excessive changes in moisture content. At the time of spreading and screeding, the sand should have uniform moisture content. The bedding sand should be spread loosely to a uniform depth and screeded to the nominated design profile with sufficient surcharge to allow for compaction to a thickness of 20mm (±2 mm). A small surcharge of sand should be maintained in front of the leading edge of the screeding equipment across its full width during the screeding. Any depressions in the screeding sand exceeding 5mm should be loosened, raked and re-screeded before laying of the paving units. Bedding sand should be screeded slightly ahead of the paving being laid, and maintained in a loose condition at a uniform density and protected from pre-compaction by pedestrian traffic or heavy rain. Any pre-compacted sand or screeded sand left overnight should be removed and replaced with fresh loose sand.
Laying Pavers in Unbound Bedding Sand All full sized paving units should be laid first, prior to cutting of edge pieces. Pavers to be laid on sand should have a joint width of 3-5mm. This nominal joint width is to ensure full filling of the voids. Some pavers have nibs to provide touch alignment of paving units. Pavers without nibs should be placed with the nominal joint so that they do not come into contact with adjoining units. Correct paver alignment must be maintained using a grid of stringlines.
B5
New South Wales Book 3 B
Should it be necessary to manipulate individual paving units to ensure correct joint alignment and spacing, a wide blade instrument should be used. Under no circumstances should screwdrivers or other instruments be used. They are likely to cause damage to the finished edge of the paver.
Do not over compact in an attempt to bring uneven pavers to level. If pavers are proud or depressed by more than 2mm, the paver must be lifted and the sand bed adjusted. The sand bed should be of adequate depth to accommodate variations in thickness of pavers.
Allow for up to 5% of damaged and/or unsuitable pavers. To minimise wastage, damaged paving units should be placed to one side and used for cuts.
Compaction should be undertaken as soon as reasonably practicable after placing paving units. Compaction should not be performed closer than one metre from any unrestrained edge. Compaction and/or correction should continue until lipping has been minimised between adjoining paving units.
Bedding/Compaction of Pavers To ensure complete filling of the joints, both the joint filling sand and paving units should be as dry as practicable. Ideally, joint filling and compaction should be carried out prior to the completion of each days lay. The paving units should be compacted and brought to level using a high frequency, low amplitude, vibrating plate compactor, passing repeatedly over the entire surface until full compaction is achieved. The base plate should be approximately 600mm x 460mm and a suitable resilient material such as carpet or rubber mat should be provided between the vibrating plate and the paving units for a cushioning effect. A thin layer of joint filling sand should be spread evenly over the paving units prior to compaction to aid the movement of the compactor and minimise surface damage.
B6
As noted previously, variation in the thickness of the bedding sand will result in excessive lipping and must be avoided. Any paving units not complying with the acceptance criteria or damaged during compaction, should be immediately removed and replaced. Where possible these pavers can be used for cuts, thereby minimising wastage. Extra care should be taken to ensure that the paving units do not settle below the level of any abutting fixture.
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 B
Installation Summary •
Drainage systems to be in place.
•
Base course of compacted roadbase (minimum 100mm thickness for pedestrian applications). Drainage fall to be incorporated as required.
or
•
Prepare edge restraint system.
•
Roadbase, Bedding Sand and Jointing Sand to comply with grading given in the ‘Material Specification’ section, on the following page.
•
Pavers to be laid with a 3-5mm joint between all units.
•
The paving units should be compacted using a high frequency, low amplitude, vibrating plate compactor, continuously run over the entire surface until full compaction is achieved and joints are sand filled.
•
Concrete base (minimum 60mm thickness for pedestrian applications). Drainage fall to be incorporated as required.
•
Base for vehicle traffic pavement to be engineer designed (minimum recommended 100mm thickness of compacted roadbase or 75mm thickness reinforced concrete).
•
Do not over compact attempting to bring uneven pavers to level. If pavers are proud or sunken by more than 2mm, the paver must be lifted and the sand bed adjusted.
•
Plan location for expansion joints (if required).
•
•
Base course must be finished within 0 to +5mm of required level and any deficiencies rectified before sand spreading commences. Variations in base level must not be made up with sand as this will result in variable compaction which can also cause excessive lipping.
All guidelines, notes and details shown here should be submitted to the relevant project engineer for authorisation.
Fall to 100mm Ø holes through slab, 500mm deep. Fill with coarse gravel. Lay filter fabric over hole to retain bedding sand.
Steel mesh 20mm compacted bedding sand
Filter fabric Boral pavers
3-5mm joints filled with jointing sand
Base course typically fully compacted roadbase or concrete slab (to engineer's detail as required)
Concrete Base Natural soil
Fig B3 — Flexible Laying Systems with Unbound Bedding Sand
BORAL MASONRY DESIGN GUIDE
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B7
New South Wales Book 3 B
Flexible Laying System (Unbound Sand) Materials Specification In the absence of detailed project specifications, the following material properties can be used as a guide to assist with preliminary designs. Additional recommendations can be found in CMAA literature at www.cmaa.com.au
Granular Base Course (Roadbase) Unbound granular base course material shall comply fully with the requirements of a Class A material as set out in Table B1. This information is representative of specifications issued by Australian road authorities. To maximise the use of economically-available materials and as specifications vary among State and Municipal Authorities, the following information should be used as a guide only. Designers should take into account local specifications, materials available and experience. Granular materials should comply with local requirements for base course for an asphalt-surfaced pavement. The material may be either a crushed quarry material or a natural gravel. Table B1 — Granular Base Course Properties Maximum nominal aggregate size = 20mm Class A Material Property/Aggregate Size % passing sieve size 26.5mm 100 19.0mm 95 — 100 13.2mm 78 — 92 9.5mm 68 — 83 4.75mm 44 — 64 2.36mm 29 — 47 425 microns 12 — 20 75 microns 2—6 Liquid limit (max) 20 Plasticity index (max) 6 Los Angeles Test % loss (max) 40 CBR after soaking at 98% modified maximum dry density 100% (min)
Bedding Sand (Washed River Sand) The bedding sand should be a clean, well graded, angular sand, non-plastic, free from deleterious materials such as stones, tree roots, clay lumps and excessive organic material. The bedding sand should conform as close as practical to the grading detailed in Table B2. Table B2 — Bedding Sand Properties Sieve Size 9.52mm 4.75mm 2.36mm 1.18mm 600 microns 300 microns 150 microns 75 microns
% Passing 100 90 — 100 75 — 100 55 — 90 35 — 59 8 — 30 0 — 10 0-2
The sand grading shown above is a recommendation only. The final selection of sand for bedding is dependent upon the grades commercially available in the region. In the absence of other indications of suitability, concreting sands which comply with the requirements of the Concrete Structures Code, AS3600 for fine aggregates, and having less than 4% of material passing the 75 micron sieve should prove suitable. The sand shall be free of soluble salts or other contaminants that can cause or contribute to efflorescence. Where the pavement is to carry commercial vehicle traffic, the proportion of material smaller than 75 microns shall not exceed 2%. Bedding course sand should have a moisture content not exceeding 8% and be kept reasonably constant throughout the laying process. Bricklayers sand and single sized dune sands are NOT suitable.
Granular Base Course Compaction The base course should be compacted to not less than 92% of modified maximum dry density to AS1289 for Class A granular base material in pedestrian paving applications, and to not less than 96% of modified maximum dry density for light vehicle applications.
B8
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 B
Joint Filling Sand The joint filling sand should be a clean, fine-graded round sand, free from deleterious materials such as clay and soluble salts or other contaminants, which can cause or contribute to efflorescence or staining. The joint filling sand should conform as close as practical to the following grading: Table B3 — Jointing Sand Properties Sieve Size 2.36mm 1.18mm 600 microns 300 microns 150 microns 75 microns
% Passing 100 90 — 100 75 — 100 55 — 90 35 — 59 8 — 30
The sand grading shown above is a recommendation only. The final selection of sand for jointing is dependent upon the grades commercially available in the region. The use of rigid jointing compounds is NOT recommended with flexible pavement installations.
BORAL MASONRY DESIGN GUIDE
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B9
New South Wales Book 3 B
Flexible Laying System (Pods) Installation Guidelines for Pavers laid on Pods Introduction Boral Stylestone pavers and Promenade pavers installed with pod laying systems are suitable for private and public pedestrian applications up to breaking load of 4.5kN as per AS1170. The dimensional accuracy of Stylestone pavers ensures ease of use and excellent performance with pod laying systems. Height adjustable pods should be used so that adjustment can be made to ensure that all pavers are evenly supported at each corner, and to allow for small variations in the base course level.
Drainage One of the primary applications for pod laying systems is to provide drainage via joint gaps between pavers into the cavity created beneath the pavers. When pod laying systems are used externally, the slab must have sufficient falls towards drains to prevent ponding of water under the pavers.
Base Course The base course should be a new or existing concrete slab, designed and built in accordance with good engineering practice. It is important that the surface of the concrete under the pavers be reasonably smooth to allow suitable placement of pods.
Laying Pavers Pavers are to be laid with open joints between adjacent units to allow for drainage. These gaps are generally controlled by spacers built into the pods. Height of pod is to be adjusted to ensure that the pavers are evenly supported all round. All full sized paving units should be laid first, prior to cutting edge pieces. Correct paver alignment must be maintained using a grid of stringlines. Pavers shall be placed so that the difference in level between any two adjacent units shall not exceed 2mm. Should it be necessary to manipulate individual paving units to ensure correct joint alignment, spacing or level, a wide blade instrument should be used. Under no circumstances should screwdrivers or other instruments be used. They are likely to cause damage to the finished edge of the paver. Allow for up to 5% damaged and/or unsuitable pavers. To minimise wastage, damaged paving units should be placed to one side and used for cuts.
Material Specification for Pods Paver spacer/drainer pods can either be of fixed height type or of a type which permits height adjustment. Height adjustable pods are recommended. Suitable height adjustable pods include Polypads manufactured by Tremco Pty Ltd, Tel (02) 9638 2755 for additional information.
Waterproof Membrane If required, install a suitable waterproof membrane over the concrete slab. Refer to your project engineer for details. Waterproof membrane if required
Boral Stylestone pavers
Pod
Concrete to fall to drain
Reinforced concrete slab
Fig B4 — Stylestone Paving Laid with Pods on Reinforced Concrete Slab
B10
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 B
Cutting of Pavers Pavers should be cut where necessary using a wet saw (or disc cutter with dust extraction equipment). All operators should wear approved safety equipment. Any paving units that are cut must be cleaned of any slurry residue to avoid potential staining of the surface and lack of adhesion to the bedding mix or adhesive. For large format pavers, cut pavers should be placed in areas away from traffic. If this cannot be done then the minimum plan area of the cut pavers should not be less than 50% of the normal (uncut) plan area. Where less than 25% of the paver needs to be cut away it may be used as a single flat. Where more than 25% of the paver must be cut away with a re-entrant corner then the remaining shape must be mitre-cut into two pieces. The cut should extend from the internal corner of the cut out toward the external corner of the paver, as detailed in Fig B5. Mitre-cut
45°
Fig B5 — Cutting of Pavers
BORAL MASONRY DESIGN GUIDE
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B11
New South Wales Book 3 B
Maintaining Pattern Alignment
Patterns Pattern Selection For driveway applications, Herringbone pattern offers the best resistance to lateral loads. Stretcher bond courses should be laid across the traffic flow. Pattern selection for pedestrian-only applications is primarily an aesthetic decision combined with available paver dimensions. Boral Masonry pavers come in many shapes and various plan dimensions and thicknesses to suit all possible applications. In general, patterns laid on the diagonal and those requiring many cuts will take longer to lay and therefore will be more difficult and more expensive to install.
The use of string lines at no more than 5m centres in each direction, in conjunction with edge-restraints laid correctly to line and level, will assist in maintaining control of alignment and bond and will assist in the maintenance of correct and adequate joint spacing.
Changes In Grade To accommodate abrupt changes in grade and to ensure that the finished project is aesthetically pleasing without ‘lipping’ of the pavers, the pavers with a smaller plan dimension may be required. This should be achieved by specifying a smaller paver size in the area of gradient change or selective cutting of pavers. In areas carrying traffic the reduced plan dimensions should remain proportional to the original paving dimensions.
Popular Patterns Design your own paving pattern or use these popular patterns to create a paving feature.
Stretcher Bond (rectangular pavers)
Half Basketweave
+
++
Stretcher Bond (square pavers)
45° Herringbone
+
+++
45° Stack Bond
Diamond
++
+++
90° Herringbone
++
45° Stretcher Bond +++ with flat header course
Basketweave
++
Stack Bond +++ with contrasting border
Simple
+ Minimum complexity and low number of paver cuts. Intermediate
+
+ Some design and set-out skill required. Moderate to high number of paver cuts.
+
+
B12
Advanced
+ Skilled preparation and set-out required. High number of paver cuts.
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 B
Cleaning and Sealing of Pavers To ensure optimum appearance and low maintenance, Boral Masonry recommends the use of KLEN cleaning and sealing products which have been purpose designed for use on Boral concrete pavers. For details of stockists contact KLEN Tel: 1800 819 939 in Queensland and New South Wales, and 1800 999 196 in other states. WARNING: Hydrochloric acid is NOT recommended for use with concrete pavers as irreparable surface damage may occur. The following tables provide a guide for the use of KLEN products, which must be used in accordance with the manufacturer’s recommendations. Always conduct a small test on an inconspicuous area before full scale application. KLEN and Boral Ltd strongly recommend the use of experienced applicators.
Cleaning Large Format Concrete Pavers
Sealing Large Format Concrete Pavers Table B7 — Cleaning Recommendations TYPE OF AREA Pressed/S-Blast Honed Polished Private Pedestrian A C C Public Pedestrian A A A Light Traffic A C C Heavy Traffic A A A Product Reference A = Stoneclear — 2 coats Guide A C = Tuscan Seal — 1 coat + Stoneseal — 1 coat Guide A & B
Colour and Finish Variation Concrete pavers are manufactured from naturally occuring materials and consequently may show variations in finish and colour. It is strongly recommended that products are taken from two or more packs and mixed during laying to minimise noticeable colour variations.
Table B6 — Cleaning Recommendations STAIN Pressed/S-Blast Honed Polished Efflorescence Light 1 1 1 Efflorescence Heavy 1.1 1 1 Mortar/Slurry 1 1 1 Grout Smear 3 3 3 Oils/Fats/Grease 7 7 7 Rust 1 1 1 Timber — Hardwood 4 4 4 Timber — Softwood (contact KLEN for advice) General Grime 2 2 2 Chewing Gum 6 6 6 Blood 7 7 7 Moss/Mould 4 4 4 Crayon 5 5 5 Paint 5 5 5 Nail Polish 5 5 5 rub Marks 2 2 2 Tyre Marks 2 2 2 Wine 7 7 7 Product Reference 1 = Anti Eff (20 parts water: 1 part Anti Eff) KLEN Guide #1 1.1 = Anti Eff (10 parts water: 1 part Anti Eff) KLEN Guide #1 2 = S21 Multi Purpose Cleaner KLEN Guide #2 3 = Amaze KLEN Guide #3 4 = Maestro KLEN Guide #4 5 = Multi-Strip KLEN Guide #5 6 = Chewing Gum Remover KLEN Guide #6 7 = H.D. Cleaner KLEN Guide #7
BORAL MASONRY DESIGN GUIDE
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August 2009
All concrete products may suffer from efflorescence. This occurs naturally and will disappear with use. It is in no way detrimental to the performance of the product. No responsibility can be accepted for this natural reaction.
Colour and Texture Variations The colours shown in this brochure are provided as an indication of the colours and textures available. Some variations in colour will occur due to changes in raw materials. In addition, variation can occur within and between production batches due to the curing process. Please ask to see a sample of your chosen colour/texture before specifying or ordering.
B13
New New w So S South ou uth th Wal W Wales aleess Boo Bo Book ookk 3 B
NOTES
B14
August 2009 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide PAVING NEW SOUTH WALES BOOK 3 C SMALL FORMAT PAVING SYSTEMS
3
C
New South Wales Book 3 C
Small Format Pavers for domestic and commercial pedestrian and light vehicular applications
C2
• Pavestone Moulded rectangular concrete pavers are ideal for pedestrian, pool and light vehicular access applications.
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 C
Pavestone™ Concrete Pavers Boral Pavestone 50 is a small format moulded smooth textured concrete paver.
Product
Boral Pavestone 50 Pavers have been tested to AS/ NZS4456.10 in NSW. Refer to page B13 for further information on sealing pavers.
Application and usage
50
Unit weight (kg)
2.8
38 units per sq metre
230 115
Suitable application legend
charcoal
Pedestrian
fudge
Domestic driveways
Pools
sandune
Specifications and additional information Content Dimensional Category Characteristic Breaking Load (kN) Slip Resistance Class Salt Tested to AS/NZS4456.10 Manufacturing and Test Standard Ordering Requirements Lead Time Bulk Ordering Light Vehicle Traffic Light Commercial Vehicles
BORAL MASONRY DESIGN GUIDE
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Cement, sand, aggregate, colour oxide DPB1 5 V Yes (NSW) AS/NZS4455, 4456 and 4586 No minimum order quantity applies 0-2 weeks Requires extended lead times Use Herringbone pattern - refer to product/laying system selection table on page A3 in this guide Max. 10 tonne mass weight
C3
New South Wales Book 3 C
NOTES
C4
August 2009 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide PAVING NEW SOUTH WALES BOOK 3 D LARGE FORMAT PAVING SYSTEMS
3
D
New South Wales Book 3 D
Boral Masonry Large Format Pavers • Promenade™ Pavers Promenade 300 pavers are a 300 x 300mm format with a smooth face and 4 bevelled edges. The 50mm thickness is suitable for light vehicular traffic applications. The availability of bullnosed pavers also makes the 50mm range ideal for pool coping and step applications.
• Precinct® Moulded smooth face bevelled edge concrete pavers, made up of a collection of square and rectangular shaped pavers to form a french pattern. Sizes are 444x444, 444x295, 295x295, 295x146 and 146x146 all pavers are 50mm thick.
Promenade 400 is a smooth face 400 x 400 x 50mm paver with 4 bevelled edges. Promenade 400 is designed for residential and light commercial pedestrian applications. Smooth — Finely textured finish created through the standard moulding process.
D2
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 D
Boral Masonry Large Format Pavers
• Stoneworks® and Aspenstone™ Stoneworks and Aspenstone are prestigious handcrafted pavers for quality and style conscious projects. The availability of bullnosed pavers in these ranges makes them perfect for pool coping and steps.
BORAL MASONRY DESIGN GUIDE
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D3
New South Wales Book 3 D
• Bradstone® Bradstone is well-known internationally, particularly in the UK and Europe as a quality paving range that combines the look and feel of traditional stone with the high performance, long life and low maintenance qualities of modern materials. Now it is possible to recreate this character filled look in Australia, with Bradstone Old Town Flagstone and Cobbles, exclusive to Boral.
D4
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 D
Promenade™ Pavers Promenade Pavers offers a range of large format concrete pavers available in a vast array of colours and surface textures for commercial and architectural applications. The Promenade 300 and 400 series has four bevelled edges to enhance and accentuate the chosen laying pattern.
Product
400
400
Boral Promenade Pavers have been tested to AS/NZS4456.10 and can be used in saline environments. Refer to page B13 for further information on sealing pavers.
Units per m2
Application
50
6.25
50
2.5
Notes
Unit weight (kg)
Characteristic Breaking Load (kN)
17.3
5
16.9
5
9.6
7
9.4
5
400
* Per lineal metre
400
300
300
300
300
50
11.1
50
3.3
Pedestrian
Suitable application legend
) paperbark
) almond
charcoal
* Per lineal metre
Domestic driveways
sandune
Pools
fudge
) Only available in 400x400x50
Specifications and additional information Content Dimensional Category Abrasion Resistance Class Slip Resistance Class Salt Tested to AS/NZS4456.10 Manufacturing and Test Standard Ordering Requirements Lead Time Bulk Ordering Application Light Commercial vehicles
BORAL MASONRY DESIGN GUIDE
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August 2009
Cement, sand, aggregate, colour oxide DPB1 7 V Yes AS/NZS4455, 4456 and 4586 No minimum order quantity applies 0-2 weeks Requires extended lead times Refer to product/laying system selection table on pageA3 in this guide Max. 10 tonne mass weight
D5
New South Wales Book 3 D
Precinct® French Style Pavers Precinct garden and path pavers feature an assortment of shapes and sizes that is often referred to as ‘French Pattern’ paving.
Product
Application and usage
Unit weight (kg)
50 146
146
146 x 146
50 295 146
295 x 146
50
295
295
Sold as a 14 paver set. Per set = 1.41 sq m
2.1
Sold as a 14 paver set. Per set = 1.41 sq m
4.4
Sold as a 14 paver set. Per set = 1.41 sq m
9.8
Sold as a 14 paver set. Per set = 1.41 sq m
14.1
Sold as a 14 paver set. Per set = 1.41 sq m
20.3
295 x 295
50 444 295
444 x 295
50
444
444
444 x 444 Suitable application legend
charcoal
Pedestrian
almond
Specifications and additional information Content Dimensional Category Characteristic Breaking Load (kN) Abrasion Resistance Class Slip Resistance Class Salt Tested to AS/NZS4456.10 Manufacturing and Test Standard Ordering Requirements Lead Time Bulk Ordering Application
D6
Cement, sand, aggregate, colour oxide DPB1 5 3,5 V Yes AS/NZS4455, 4456 and 4586 No minimum order quantity applies 0-2 weeks Requires extended lead times Refer to product/laying system selection table on pageA3 in this guide Random pattern on D7
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 D
Precinct® French Pattern The variation in paver sizes makes Precinct® amazingly versatile. Whether you have a large open area or a narrow pathway, the random look will add originality, depth and character. Precinct® paving is a pre-selected arrangement of five different paver sizes, allowing you to create a random look with two different laying patterns.
By creating a random pattern with the collection of square and rectangular shapes, in various sizes, a bland entertaining area can be transformed into a charming exterior space. Precinct® Random paving range is available in 7m2 and 14m2 quantities. Please refer to the recommended laying pattern below as a guide.
146 x 146 x 50mm
295 x 146 x 50mm
295 x 295 x 50mm
444 x 295 x 50mm
50mm 444 x 444 x 50
A B C D E
= 295 x 444 = 146 x 295 = 295 x 295 = 444 x 444 = 146 x 146
Pattern 1
Pattern 2
Pattern 2
Pattern 1
Pattern 1
Pattern 2
1.41m
BORAL MASONRY DESIGN GUIDE
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1.41m
1 standard unit = 2m2
August 2009
D7
New South Wales Book 3 D
Stoneworks™ Hand-made Stone Stoneworks pavers are premium quality pavers hand made in the traditional manner, the colours are blended by eye so that no two Stoneworks pavers are alike.
Product
Application and usage
40 400
400
400
400
Stoneworks Pavers have been tested to AS/NZS4456.10 and can be used in saline environments. They are pre-sealed.
Unit weight (kg)
6.25 units per sq metre
23
40
2.5 units per lineal metre
14.5
2.5 per lineal metre
18.4
Bullnose 40 400 100
Cobble Edging Suitable application legend
sandstone custard
limestone
Pedestrian
tuscany
Pools
sandstone mocha
sandstone cream
Specifications and additional Information Content Dimensional Category Characteristic Breaking Load (kN) Abrasion Resistance Class Slip Resistance Class Salt Tested to AS/NZS4456.10 Manufacturing and Test Standard Ordering Requirements Lead Time Bulk Ordering Application
D8
Cement, sand, aggregate, colour oxide DPB1 5 3.5 V Yes AS/NZS4455, 4456 and 4586 No minimum order quantity applies 0-2 weeks Requires extended lead times Refer to product/laying system selection table on pageA3 in this guide
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 D
Stoneworks™ Travertine For contemporary styling with impact, Stoneworks Travertine delivers. With its naturally-aged stone finish and modern
Application and usage
Product
40 500
tones in Chalk and Smoke, this impressive paver gives any outdoor area style and presence.
Unit weight (kg)
4 units per sq metre
23
2 units per lineal metre
23
2 units per lineal metre
18.4
500
Standard 40
500
500
500 Bullnose 40
400
500
400 Bullnose Suitable application legend
chalk
Pedestrian
Pools
smoke
Specifications and additional information Content Dimensional Category Characteristic Breaking Load (kN) Abrasion Resistance Class Slip Resistance Class Salt Tested to AS/NZS4456.10 Manufacturing and Test Standard Ordering Requirements Lead Time Bulk Ordering Application
BORAL MASONRY DESIGN GUIDE
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August 2009
Cement, sand, aggregate, colour oxide DPB1 5 3,5 V Yes AS/NZS4455, 4456 and 4586 No minimum order quantity applies 0-2 weeks Requires extended lead times Refer to product/laying system selection table on pageA3 in this guide
D9
New South Wales Book 3 D
Aspenstone® Aspenstone is stone-like in colour and feel, yet contemporary in its large rectangular format.
Product
Aspenstone Pavers have been tested to AS/NZS4456.10 and can be used in saline environments.
Unit weight (kg)
Application and usage
40
4.17 units per sq metre
21.7
1.66 per lineal metre
21.7
600 400
40 600 400
Bullnose
Suitable application legend
buttermilk
cappuccino
Pedestrian
Pools
vanilla
Specifications and additional Information Content Dimensional Category Characteristic Breaking Load (kN) Abrasion Resistance Class Slip Resistance Class Salt Tested to AS/NZS4456.10 Manufacturing and Test Standard Ordering Requirements Lead Time Bulk Ordering Application
D10
Cement, sand, aggregate, colour oxide DPB1 5 3.5 V Yes AS/NZS4455, 4456 and 4586 No minimum order quantity applies 0-2 weeks Requires extended lead times Refer to product/laying system selection table on pageA3 in this guide
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 D
Bradstone® Classic Style Pavers Flagstone and cobblestones have enhanced patios and gardens in Europe for centuries. Now it is possible to
Product
recreate this warm, character-filled look in Australia with internationally renowned Bradstone from Boral.
Application and usage
Unit weight (kg)
40 300
450
7.4 units per sq metre
12.1
2.22 units per lineal metre
12.1
7.4 units per sq metre
15.5
Old Town
40 450
300
Old Town Bullnose
50 450
300
Cobblestone *A 40 300
300
*B
A) 8.3 40 450
7.5 units per sq metre
300
B) 12.1 C) 16.5
*C 40 600 300 Old Town Random
Suitable application legend
grey green
Pedestrian
Pools
gironde
Specifications and additional information Content Dimensional Category Characteristic Breaking Load (kN) Abrasion Resistance Class Slip Resistance Class Salt Tested to AS/NZS4456.10 Manufacturing and Test Standard Ordering Requirements Lead Time Bulk Ordering Application
BORAL MASONRY DESIGN GUIDE
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Cement, sand, aggregate, colour oxide DPB1 5 3,5 V Yes AS/NZS4455, 4456 and 4586 No minimum order quantity applies 0-2 weeks Requires extended lead times Refer to product/laying system selection table on pageA3 in this guide Random pattern on D10
D11
New South Wales Book 3 D
Bradstone® Old Town Random Pattern The variation in paver makes Bradstone Old Town flagstones amazingly versatile. Whether you have a large open area or a narrow pathway, the random look will add originality, depth and character. Bradstone Old Town Random is a pre-selected arrangement of the three different paver sizes, each with different but complementary natural surfaces that together achieve this. The medium sized paver from these three is also available separately, its 450 x 300 x 40mm sizing holds great appeal when laid en-masse.
Additionally, a matching 450 x 300mm bullnose paver, that works equally well with either look, elegantly finishes swimming pools, courtyards and steps. Bradstone Old Town Random paving range is available in 6m2 and 12m2 quantities. Please refer to the recommended laying pattern below as a guide. Each pallet has a comprehensive pattern guide so that the random pattern is simple and achievable.
300 x 300 x 40mm
450 x 300 x 40mm
300 x 300 x 40mm
600 x 300 x 40mm 1 standard unit
450 x 300 x 40mm 600 x 300 x 40mm
1 standard unit
1 standard unit
1.5m
1 standard unit
6 standard units = 12m2 = 1 pallet
D12
1 standard unit = 2m2
1.350m
1 standard unit
1 standard unit = 2m2 = 15 pavers (5 of each size)
August 2009 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide PAVING NEW SOUTH WALES BOOK 3 E STYLESTONE™ PAVING SYSTEMS
3
E
New South Wales Book 3 E
Boral Masonry Stylestone™ Paving Systems • Stylestone™ Stylestone by Boral Masonry is a range of large format pavers created with world class technology. The unique moulding process ensures a high level of dimensional accuracy, a uniform finish and a high density product with optimum load bearing capabilities. Honed Texture
E2
Stylestone offers outstanding scope for creative and detailed landscape design through a vast choice of colours, textures and sizes. Choose from an extensive standard range or customise to create an individual look. A range of finishes is available, including pressed patterns, Shot-Blast and Honed.
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 E
• Stylestone™ Stylestone high density concrete pavers are available in 40mm and 55mm thicknesses. These pavers are suitable for pedestrian and pool applications. The Stylestone range offers a vast array of textures, pressed patterns and colours to accentuate any project. Quarry
BORAL MASONRY DESIGN GUIDE
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August 2009
E3
New South Wales Book 3 E
Colours and Textures Pressed Patterns Quarry
Beach
Dune
Sandbank
Sandstone
For availability on Architectural Textures (Honed and Shot-Blast) please call 1300 360 255.
E4
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 E
Stylestone™ Quarry and Sand Textured Face Pavers Stylestone Quarry and Beach pavers are large format, premium quality moulded concrete pavers which combine elegant textures and colours to enhance today’s modern architectural styling.
Product
Stylestone Pavers have been tested to AS/NZS4456.10 and can be used in saline environments. Refer to page B13 for further information on sealing pavers. A wide variety of colours are available. Please refer to swatch information that is detailed on page E4.
Unit weight (kg)
Characteristic breaking load
6.25 units per m2
15.5
>5
2.5 per lineal metre
15.5
>5
Application and usage
40 400
400
400
400
40
Suitable application legend
Pedestrian
Pools
Specifications and additional information Colour/Textures Content Dimensional Category Characteristic Breaking Load (kN) Abrasion Resistance Index Slip Resistance Class Salt Tested to AS/NZS4456.10 Manufacturing and Test Standard Ordering Requirements Lead Time Bulk Ordering Application
BORAL MASONRY DESIGN GUIDE
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August 2009
Refer to swatch information on page E4 Cement, sand, aggregate, colour oxide DPB2 5 3.5 V Yes AS/NZS4455, 4456 and 4586 No minimum order quantity applies 0-2 weeks Requires extended lead times Refer to product/laying system selection table on pageA3 in this guide.
E5
New South Wales Book 3 E
Stylestone™ Honed and Shot-Blast Stylestone is a range of large format pavers created with world class technology. The unique moulding process ensures a high level of dimensional accuracy, a uniform finish and a high density product with optimum load bearing capabilities.
Product
Unit weight (kg)
Characteristic breaking load
6.25 units per m2
15.5
>5.0
6.25 units per m2
19.2
>7.0
2.5 per lineal metre
15.5
>5.0
2.5 per lineal metre
19.2
>7.0
Application and usage
40 400
400
400
400
53
Stylestone Pavers have been tested to AS/NZS4456.10 and can be used in saline environments. Refer to page B13 for further information on sealing pavers.
40 400
400
Honed Bullnose
40 400
400
Honed Bullnose Suitable application legend
Pedestrian
Pools
Specifications and additional information Colour/Textures Content Dimensional Category Characteristic Breaking Load (kN) Abrasion Resistance Index Slip Resistance Class Salt Tested to AS/NZS4456.10 Oil Wet Ramp Test Manufacturing and Test Standard Ordering Requirements Lead Time Bulk Ordering Application
E6
Refer to swatch information on page E5 Cement, sand, aggregate, colour oxide DPB2 7 for 55mm and 5 for 40mm 3.5 V (Excl. Polished finish — available ‘Made-to-order’) Yes R13 (Applies to Tactile pavers only) AS/NZS4455, 4456, 4586 and 1428.4 Minimum order quantity applies to 300 x 300mm 6-8 weeks Requires extended lead times Refer to product/laying system selection table on pageA3 in this guide.
August 2009 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide PAVING NEW SOUTH WALES BOOK 3 F HYDRAPAVE™ PERMEABLE PAVING
3
F
New South Wales Book 3 F
Hydrapave™ The Hydrapave system allows storm water to infiltrate through small channels formed in the ends of the concrete pavers and through a filter treatment as it passes into a prepared sub-base. The water can then pass through a secondary filter into suitable subgrade or be stored for controlled release or harvested for non-portable use.
Hydrapave Paving benefits: • Drains up to 4,500mm/hr or 1.25 litres/sec/m2. • Low life-cycle cost including low maintenance cost. • No need to upsize culverts or water courses. • On-site natural treatment of pollutants. • Control of run-off to eliminate flooding.
Alternative systems provide for:
• Elimination of surface ponding.
• Detention/treatment/infiltration into the surrounding natural soil; • Detention/treatment/discharge to stormwater system;
• Reduces potential for erosion and silt deposition. • No need for detention pits.
• Detention/treatment/reuse;
• Safe collection, detention and discharge with no dangerous open drains or pits.
• Detention/treatment/infiltration and overflow discharge;
• Roof water can also be discharged into sub-base.
• Detention/treatment/secondary treatment/discharge or re-use.
• Can recharge ground water base flows. • Water from tanked systems available for non-potable secondary use.
Specifications and additional information Content Dimensional Category Characteristic Breaking Load (kN) Abrasion Resistance Index Slip Resistance Class Salt Safe Manufacturing and Test Standard Ordering Requirements Lead Time Units per square metre Avg. unit weight
F2
Cement, sand, aggregate, colour oxide DPB1 >7 10 < 5 (for roads) V Yes AS/NZS4455, 4456 and 4586 Made-to-Order (Minimum quantity applies) 4-6 weeks Requires extended lead times of more than 6 weeks
G3
New South Wales Book 3 G
NOTES
G4
August 2009 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide PAVING NEW SOUTH WALES BOOK 3 H ACCESSORIES
3
H
New South Wales Book 3 H
Geo-Fix™ Paving Joint Mortar Paved areas have never looked this good. Simply open the bag, pour the contents onto the paving and sweep into the joints. It’s as easy as that. Geo-Fix™ is an air-curing joint filler for pavers and retaining wall faces.
• 20 times faster than traditional methods with easy broom no mess clean up. • Durable. • Resists weed and plant growth between joints.
Features and Benefits
• Water and air permeable.
• Permanent sand coloured joint unaffected by wind, rain and mechanical cleaning equipment.
• Sold in more than 18 countries worldwide.
• Non-staining.
Preparation
Mixing
Curing and Storage
Ensure that the paving to be jointed is completely dry and free from loose dirt, debris, oil and grease.
Boral Paving Joint Mortar is supplied ready to use and does not require any further mixing or dilution. Because of the vacuum used to store the product, bags should be hard to touch, but the material inside should be soft and lump free.
Curing takes 2-12 hours depending on temperature.
It is essential that joint widths have a minimum width of 5mm and a minimum depth of 25mm. A trial area should always be undertaken.
Store in a cool dry place. Protect the pack, both outer and inner, from punctures or piercing. Exposure to air will start the curing process. Shelf life is a minimum of 24 months when stored in unopened vacuum sealed packaging.
Application
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
Carefully open the vacuum-packed bag and sprinkle Boral Paving Joint Mortar over the area to be jointed.
Using a soft brush, push the Boral Paving Joint Mortar into the joints at a 45° angle.
Firmly compact the Boral Paving Joint Mortar with a jointing tool. Refill and repeat ensuring a fully compacted joint.
Finish the surface decorativley giving a smooth, flat finish with a jointing tool then move onto the next area. Firm compaction is the key to successful laying of Boral Paving Joint Mortar.
After application brush excess with a soft brush, taking care not to brush out any Boral Paving Joint Mortar from treated joints. once cured, sit back and enjoy your new patio.
Coverage (m2) Coverage Joint Width 5mm
Paving Dimension (with joint depth of 25mm) 300x300mm 6.50
400x400mm 8.50
450x450mm
500x500mm
11.00
11.25
6mm
5.50
7.00
9.50
9.25
7mm
4.50
6.00
8.25
8.00
8mm
4.00
5.25
7.25
7.00
9mm
3.50
4.75
6.00
6.25
10mm
3.25
4.25
5.50
5.50
H2
August 2009 | BORAL MASONRY DESIGN GUIDE
New South Wales Book 3 H
NOTES
BORAL MASONRY DESIGN GUIDE
|
August 2009
H3
eBC 04151 August 2009
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.
Technical Enquires
Specifier Line Internet
1300 360 255 www.boral.com.au/masonry
Orders, Product Samples and Sales Enquires NSW
ACT
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
16 Whyalla Street, Fyshwick, 2609
T: (02) 6239 1029 F: (02) 6280 6262
Other Regional Sales Offices Victoria
Level 1 Port IT, 63-85 Turner Street, Port Melbourne, 3207
T: (03) 9363 1944
South Australia
Main North Road, Pooraka, 5095
T: (08) 8262 3529 F: (08) 8260 3011
Queensland
62 Industrial Ave, Wacol, 4076
T: (07) 3271 9292 F: (07) 3271 1581
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
F: (03) 9363 6008
North Queensland:
™ Pavestone, Promenade, Stoneworks, Stoneworks™ Travertine, Stylestone and Geo-Fix are registered trademarks of Boral Masonry Limited. ® Aspenstone, Bradstone, Hydrapave and Interpave are registered trademarks of Boral Masonry Limited. ® Bradstone is a registered trademark of Aggregate Industries, used under license by Boral Masonry Limited ABN 13 000 223 718. © Boral Masonry - all rights reserved 2009.
