1. home and garden
2. gardening and landscaping
3. landscaping

BORAL MASONRY
Build something great™
Masonry Design Guide
PAVING NATIONAL BOOK 3
www.boral.com.au/masonry
Updated July 2007
PAGE
PAGE
National Book 3 A
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
Products @ 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
Installation Guidelines
Flexible Laying System with Unbound Sand . . . . . . . . . . . . B4
C
Small Format Paving Systems
Handipave 40, 50 and 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . C3
D
Classicpave 50 and 60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C4
Large Format Paving Systems
Promenade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D5
Aspenstone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D7
Stoneworks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D6
Bradstone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D8
E
Stylestone Paving Systems
Stylestone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E4
Stylestone — Rusticstone and Rockpave . . . . . . . . . . . . . . E7
Stylestone — Honed, Shot-Blast and Tactile . . . . . . . . . . . . E6
F
Hydrapave Permeable Paving
Hydrapave LT 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
Coachstone 80 (Available QLD only) . . . . . . . . . . . . . . . . . . . G4
Interpave and Pavestone 80 . . . . . . . . . . . . . . . . . . . . . . . . G3
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
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 A
Stylestone
Large Format
Small Format
LA
Y
BORAL
SEGMENTAL
PAVING
PRODUCTS
IN
G
Fl
ex
S
ib
Y
S
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e
Sl
T
+
ab
Sa E M
+
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Sl
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+
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rm ds
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Sa abl
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lt
Te
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Pr
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t P S4
ag 456
e
The quickest way to find a Boral Masonry Paving Solution.
Simply follow the FAST FIND GUIDE on the right hand side of the table.
Handipave 40
P
P
C3
Handipave 50
LT
LT
C3
Classicpave 50
LT
LT
C4
Promenade 400 x 50
P
P
D5
Promenade 300 x 40
P
P
D5
Promenade 300 x 50
LT
LT
D5
Stoneworks
P
P
D6
Aspenstone
P
P
D7
Bradstone
P
P
400 x 400 x 40
P
P
300 x 300 x 40
P
P
Rusticstone/Rockpave
P
P
Tactile
P
P
Industrial
Hydrapave LT Permeable
P1
P2
P1
LT
Fast Find
a Boral
Solution
1
Laying systems are
indicated in the top row,
while products are listed
in the far left column.
2
D8
Maximum allowable
application for the
combination of product
and laying system is
indicated at the intersection
of the row and column.
E6
P
E6
E7
E6
F2
Pedestrian only
P1 Private Pedestrian
to 1.8kN (per AS1170)
P2 Public Pedestrian
to 4.5kN (per AS1170)
Interpave 80
IT
IT
G3
Pavestone 80
IT
IT
G3
Coachstone 80
IT
IT
G4
LT Light Vehicle Traffic
IT
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
|
July 2007
A3
National
Na
N
aati
ttio
ionaall BBook
ook 3 A
Small Format Pavers
for domestic and commercial
pedestrian and light vehicular
applications
• Handipave® 40 and 50’s
Square 40mm pavers are suitable for both
pedestrian and pool applications. Thicker 50mm
pavers allow for pedestrian and light vehicular
access applications.
• Classicpave® 50
Moulded rectangular concrete pavers are ideal
for pedestrian, pool and light vehicular access
applications.
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 40/50mm 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™, Aspenstone™
and Bradstone®
Premium quality handcrafted concrete pavers
for pedestrian and poolside applications. These
pavers emulate the naturally-aged appearance
of stone cut by master stonemasons from
generations past.
A4
July 2007 | BORAL MASONRY DESIGN GUIDE
National
N
Nat
atio
ion
onaall Book
BBoo
Bookk 3 A
Stylestone® Paving Systems
with infinite design possibilities for architectural
landscaping and commercial traffic applications
• Stylestone®
Stylestone high density concrete pavers are available in
40mm and 55mm thicknesses. The quality 40mm paver
is suitable for pedestrian applications. The 55mm has
the added benefit of superior strength to cater for light
vehicular access when laid with an appropriate rigid
laying system.
Stylestone Tactile paving system is manufactured
to meet AS/NZS1428.4 for cautional and directional
guidance of the visually impaired.
Permeable Paving System
for cost effective and environmentally friendly
control of stormwater run-off
Industrial Paving System
for heavy haulage and container terminals,
airports, service stations
and industrial sites
BORAL MASONRY DESIGN GUIDE
|
July 2007
• 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.
A5
National Book 3 A
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.
What’s in this Guide
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.
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.
Boral reserves the right to change the contents of this guide
without notice.
Please note that this guide is based on products available
at the time of publication from Boral Masonry. Product
details vary from state to state. Please contact your nearest
Boral Masonry Sales Office. Contact details are listed on the
outside back cover of 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.
• Terms and Conditions of Sale: For a full set of Terms
and Conditions of Sale, please contact your nearest Boral
Masonry sales office.
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.
Product Name or
other identifying
feature, such as
texture finish
Large Format Paving Systems
PAGE
National Book 3 D
BOOK
Book, Page
and Section
Identification
3
D8
®
Bradstone
Bradstone® Classic
Classic Style
Style Pavers
Pavers
Flagstone
Flagstone and
and cobblestones
cobblestones have
have enhanced
enhanced patios
patios and
and
gardens
gardens in
in Europe
Europe for
for centuries.
centuries. Now
Now it
it is
is possible
possible to
to
Application
Application
and usage
and usage
Product
Product
450
450 Old Town
Old Town
Product Icons
with dimensions
for products
available in your
region/state
7.4 units
7.4
perunits
sq
per
e
metrsq
metre
40
40
300
300
2.22
2.22per
units
units
per
lineal
lineal
metre
metre
7.4 units
7.4
perunits
sq
per
sq
metre
metre
40
40
300
450
300
450
Old
Town Bullnose
Old Town Bullnose
50
50
300
450
Cobblestone 300
450
*C
Cobblestone
7.5 units
7.5
perunits
sq
per
sq
metre
metre
*C
40
*B
600
*B
600
40
300
40
450
450
40
300
300
300
Old Town Random
300
Old Town Random
300
*A
*A
40
30040
Available
Available
by
region
by region
Colours available by region
Colours available by region
Unit
Unit(kg)
weight
weight (kg)
National
National
Grey Green, Gironde
Grey Green, Gironde
12.1
12.1
National
National
Grey Green, Gironde
Grey Green, Gironde
12.1
12.1
National
National
Grey Green, Gironde
Grey Green, Gironde
15.5
15.5
National
National
Grey Green, Gironde
Grey Green, Gironde
A) 8.3
A) 8.3
B) 12.1
B) 12.1
C) 16.5
C) 16.5
Suitable application legend
Suitable application legend
Pedestrian
Pedestrian
Domestic driveways
Domestic driveways
Pools
Pools
300
grey green
grey green
gironde
gironde
Specifications and additional information
Specifications and additional information
Colour Swatch
Content
Content
Dimensional
Category
Dimensional Category
Characteristic
Breaking Load (kN)
Characteristic
Breaking
Load (kN)
Abrasion
Resistance
Class
Abrasion
Resistance
Slip
Resistance
ClassClass
Slip Tested
Resistance
Class
Salt
to AS/NZS4456.10
Salt Tested
to AS/NZS4456.10
Liability
to Effloresce
Liability to Effloresce
Manufacturing
and Test Standard
Manufacturing
& Test Standard
Ordering
Requirements
Lead
TimeRequirements
Ordering
Bulk
Lead Ordering
Time
Application
Bulk Ordering
Application
D8
A6
recreate
recreate this
this warm,
warm, character-filled
character-filled look
look in
in Australia
Australia with
with
internationally
internationally renowned
renowned Bradstone
Bradstone from
from Boral.
Boral.
Cement, sand, aggregate, colour oxide
Cement, sand, aggregate, colour oxide
DPB1
DPB1
5
5
3,5
3,5
V
V
Yes
Yesto Slight
Nil
Nil to Slight 4456 and 4586
AS/NZS4455,
AS/NZS4455,
4456 quantity
& 4586 applies
No
minimum order
0-2
weeks
No minimum
order quantity applies
Requires
0-2 weeksextended lead times
Refer
to product/laying
Requires
extended lead system
times selection table on
pageA3
in this guide? Random
pattern table
on D9
Refer to product/laying
system selection
on
page A3 in this guide? Random pattern on D9
Product Information
relating to features,
applications, colours
available by region
Application Icons Legend.
These products are
recommended for the
indicated applications
(subject to appropriate
laying systems and site
conditions and to region
available)
Product
Specifications
July 2007 | BORAL MASONRY DESIGN GUIDE
July 2007 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide
PAVING NATIONAL BOOK 3
B PLANNING AND DESIGN
3
B
National 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 or by Tel: 02 9903 7760.
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 vehicles 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.
July 2007 | BORAL MASONRY DESIGN GUIDE
National 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
@ 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
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 onsite detention, treatment and various end-use options.
This internationally proven 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 .
Industrial and Heavy Vehicle Applications
Boral Interpave 80 and Pavestone 80 form another group
of products which have a long history of success utilising
flexible laying systems. These industrial and heavy traffic
applications 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 (02) 9903 7760 or on their website www.cmaa.com.au
• Flexible Base Course (Roadbase) plus pavers laid
with Unbound Sand
• Concrete Slab plus pavers laid with Unbound Sand
• Concrete Slab plus pavers laid with Pods
• Permeable Pavement Systems
BORAL MASONRY DESIGN GUIDE
|
July 2007
B3
National 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
July 2007 | BORAL MASONRY DESIGN GUIDE
National 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 suitable 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
|
July 2007
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
National 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.
July 2007 | BORAL MASONRY DESIGN GUIDE
National 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
•
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 200mm thickness
of compacted roadbase or 75mm thickness reinforced
concrete).
•
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.
•
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.
•
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.
•
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
|
July 2007
B7
National 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
July 2007 | BORAL MASONRY DESIGN GUIDE
National 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
% Passing
100
90 — 100
75 — 100
55 — 90
35 — 59
8 — 30
2.36mm
1.18mm
600 microns
300 microns
150 microns
75 microns
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
|
July 2007
B9
National Book 3 B
Flexible Laying System (Pods)
Installation Guidelines for
Pavers laid on Pods
Introduction
Boral Stylestone 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.
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.
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.
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
July 2007 | BORAL MASONRY DESIGN GUIDE
National 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
|
July 2007
B11
National 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.
July 2007 | BORAL MASONRY DESIGN GUIDE
National 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.
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
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
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
|
July 2007
B13
National
N
Nat
atio
tion
ona
nall Boo
Bo
Book
ookk 3 B
NOTES
B14
July 2007 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide
PAVING NATIONAL BOOK 3
C SMALL FORMAT PAVING SYSTEMS
3
C
National Book 3 C
Small Format Pavers
for domestic and commercial
pedestrian and light vehicular
applications
• Handipave® 40, 50 and 60
Square 40mm pavers are suitable for both
pedestrian and pool applications. Thicker 50
and 60mm pavers allow for pedestrian and light
vehicular access applications.
• Classicpave® 50
Moulded rectangular concrete pavers are ideal
for pedestrian, pool and light vehicular access
applications.
C2
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 C
Handipave® Smooth Face Concrete Pavers
Boral Handipave 40 and 50’s are small format moulded
concrete pavers which emulate a traditional earthy and
naturally smooth surface.
Application
and usage
Product
40
200
200
25 units
per sq
metre
Available
by region
Unit
weight (kg)
The Boral Handipave range is available in a vast array of
colours to complement today’s building materials. Refer to
the complete colour swatch below.
Ask your Boral representative on colour availability in
your region.
NSW
VIC
3.5
QLD
(Not bevelled in NSW)
25 units
per sq
metre
VIC
4.4
11.1 units
per sq
metre
VIC
9.6
40
11.1 units
per sq
metre
VIC
7.6
50
3.3 units
per sq
metre
VIC
9.6
13.5 units
per sq
metre
VIC
7.3
40
21 units
per sq
metre
SA
4.1
50
21 units
per sq
metre
SA
5.2
60
21 units
per sq
metre
SA
5.6
50
200
200
50
300
300
300
220
220
220
antique copper
charcoal
clinker red
desert sand
heritage red
natural
sahara
sunset
tuscan
terracotta
terrain
300
300
300
40
190
alabaster
390
220
220
220
Suitable application legend
Pedestrian
wilderness
Domestic driveways
Commercial Vehicle
Pools*
* Applies to NSW and QLD only.
Specifications and additional information
Content
Dimensional Category
Slip Resistance Class
Salt Tested to AS/NZS4456.10
Liability to Effloresce
Manufacturing and Test Standard
Ordering Requirements
Lead Time
Bulk Ordering
Light Commercial Vehicles
BORAL MASONRY DESIGN GUIDE
|
July 2007
Cement, sand, aggregate, colour oxide
DPB1
V
Yes (NSW and QLD only)
Nil to Slight
AS/NZS4455, 4456 and 4586
No minimum order quantity applies
0-2 weeks
Requires extended lead times
Max. 10 tonne mass weight
C3
National Book 3 C
Classicpave™ Texture Face Concrete Pavers
Boral Classicpave 50 is a small format moulded concrete
paver which emulates a stone surface.
50
100
200
50
100
Available
by region
Unit
weight (kg)
50 units
per sq
metre
NSW
2.1
50 units
per sq
metre
VIC
2.2
41.5 units
per sq
metre
SA
2.0
41.5 units
per sq
metre
SA
2.6
41.5 units
per sq
metre
SA
3.0
37 units
per sq
metre
QLD
2.8
Application
and usage
Product
200
Boral Classicpave Pavers have been tested to AS/NZS4456.10
in NSW and QLD and can be used in saline environments.
Refer to page B13 for further information on sealing
pavers.
Ask your Boral representative on colour availability in
your region.
(4 bevels)
40
220
110
50
220
110
60
220
110
50
230
115
Suitable application legend
Pedestrian
Domestic driveways
Commercial Vehicle
alabaster
antique copper
desert sand
heritage red
tuscan
terracotta
charcoal
clinker red
natural
sahara
sunset
wilderness
Pools
terrain
Specifications and additional information
Content
Dimensional Category
Characteristic Breaking Load (kN)
Slip Resistance Class
Salt Tested to AS/NZS4456.10
Liability to Effloresce
Manufacturing and Test Standard
Ordering Requirements
Lead Time
Bulk Ordering
Light Vehicle Traffic
Light Commercial Vehicles
C4
Cement, sand, aggregate, colour oxide
DPB1
5
V
Yes (NSW and QLD only)
Nil to Slight
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
July 2007 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide
PAVING NATIONAL BOOK 3
D LARGE FORMAT PAVING SYSTEMS
3
D
National 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 40mm
thickness range is suitable for pedestrian applications,
while 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.
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. A choice of smooth, honed or shot-blast
textures ensure the perfect finish for every location.
D2
Promenade Pavers are available in the following
surface textures:
Smooth — Finely textured finish created through the
standard moulding process.
Honed — 2-3mm is grinded off the moulded product
surface producing a sawn-like exposed-aggregate finish.
Available only in the 400 series.
Shot-Blast — This process subtly exposes the aggregates,
producing a weathered finish. Available only in the
400 series.
July 2007 | BORAL MASONRY DESIGN GUIDE
National 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
|
July 2007
D3
National 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
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 D
Promenade™ Pavers
Boral 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
Application
Units
per m2
Regions
Available
Notes
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.
Unit
weight (kg)
Characteristic
Breaking Load (kN)
17.3
5
16.5
5
16.9
5
9.6
7
7.6
2
9.4
5
4.8
5
11.5
5
NSW
6.25
50
400
400
400
VIC
400
50
6.25
QLD
50
2.5
NSW*
400
* Per lineal metre
400
SA
11.1
50
300
40
300
Nibs
QLD
300
11.1
SA
3.3
SA*
22.2
SA
11.1
SA
300
* Per lineal metre
50
300
300
50
150
300
60
300
Max 10 tonne
mass weight
300
Pedestrian
Suitable application legend
paperbark
sahara
charcoal
Domestic driveways
kota green
Commercial Vehicle
Pools
sandune
Specifications and additional information
Content
Dimensional Category
Abrasion Resistance Class
Slip Resistance Class
Salt Tested to AS/NZS4456.10
Liability to Effloresce
Manufacturing and Test Standard
Ordering Requirements
Lead Time
Bulk Ordering
Application
Product made to order
Light Commercial vehicles
BORAL MASONRY DESIGN GUIDE
|
July 2007
Cement, sand, aggregate, colour oxide
DPB1
7
V
Yes
Nil to Slight
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
All Honed and Shot-Blast
Max. 10 tonne mass weight
D5
National Book 3 D
Stoneworks™ Hand-made Stone
Boral 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.
40
400
400
40
400
400
Available
by region
Colours available
Unit
weight (kg)
6.25
units per
sq metre
Nationally
Sandstone, Limestone
14.5
2.5 units
per lineal
metre
Nationally
Sandstone, Limestone
14.5
1 per
corner
Nationally
Sandstone, Limestone
14.5
Sandstone, Limestone
14.5
Tuscany
3.6
Application
and usage
Product
Boral Stoneworks Pavers have been tested to AS/NZS4456.10
and can be used in saline environments. Stoneworks pavers
have been pre-sealed.
Bullnose
450
450
40
400
400
Bullnose Internal Corner (made-to-order)
40
1 per
corner
Nationally
400
400
Bullnose External Corner
40
400
100
2.5 per
lineal
metre
Nationally
Cobble Edging
Suitable application legend
sandstone
Pedestrian
Domestic driveways
Pools
limestone
Specifications and additional Information
Content
Dimensional Category
Characteristic Breaking Load (kN)
Abrasion Resistance Class
Slip Resistance Class
Salt Tested to AS/NZS4456.10
Liability to Effloresce
Manufacturing and Test Standard
Ordering Requirements
Lead Time
Bulk Ordering
Application
D6
Cement, sand, aggregate, colour oxide
DPB1
5
3.5
V
Yes
Nil to Slight
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
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 D
Aspenstone™
Boral Aspenstone is stone-like in colour and feel, yet
contemporary in its large rectangular format.
Available
by region
Colours available
Unit
weight (kg)
4.17
units per
sq metre
Nationally
Aspenstone
21.7
1.66 per
lineal
metre
Nationally
Aspenstone
21.7
Application
and usage
Product
40
600
Boral Aspenstone Pavers have been tested to AS/NZS4456.10
and can be used in saline environments.
400
40
600
400
Bullnose
Suitable application legend
Pedestrian
Domestic driveways
Pools
aspenstone
Specifications and additional Information
Content
Dimensional Category
Characteristic Breaking Load (kN)
Abrasion Resistance Class
Slip Resistance Class
Salt Tested to AS/NZS4456.10
Liability to Effloresce
Manufacturing and Test Standard
Ordering Requirements
Lead Time
Bulk Ordering
Application
BORAL MASONRY DESIGN GUIDE
|
July 2007
Cement, sand, aggregate, colour oxide
DPB1
5
3.5
V
Yes
Nil to Slight
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
D7
National Book 3 D
Bradstone® Classic Style Pavers
Flagstone and cobblestones have enhanced patios and
gardens in Europe for centuries. Now it is possible to
40
300
450
Available
by region
Colours available by region
Unit
weight (kg)
7.4 units
per sq
metre
National
Grey Green, Gironde
12.1
2.22
units per
lineal
metre
National
Grey Green, Gironde
12.1
7.4 units
per sq
metre
National
Grey Green, Gironde
15.5
7.5 units
per sq
metre
National
Grey Green, Gironde
Application
and usage
Product
recreate this warm, character-filled look in Australia with
internationally renowned Bradstone from Boral.
Old Town
40
300
450
Old Town Bullnose
50
300
450
Cobblestone
*C
40
*B
600
300
40
300
B) 12.1
C) 16.5
*A
40
450
A) 8.3
Suitable application legend
Pedestrian
Domestic driveways
Pools
300
300
Old Town Random
grey green
gironde
Specifications and additional information
Content
Dimensional Category
Characteristic Breaking Load (kN)
Abrasion Resistance Class
Slip Resistance Class
Salt Tested to AS/NZS4456.10
Liability to Effloresce
Manufacturing and Test Standard
Ordering Requirements
Lead Time
Bulk Ordering
Application
D8
Cement, sand, aggregate, colour oxide
DPB1
5
3,5
V
Yes
Nil to Slight
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 D9
July 2007 | BORAL MASONRY DESIGN GUIDE
National 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
BORAL MASONRY DESIGN GUIDE
|
July 2007
1 standard unit = 2m2
1.350m
1 standard unit
1 standard unit = 2m2 = 15 pavers
(5 of each size)
D9
National Book 3 D
NOTES
D10
July 2007 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide
PAVING NATIONAL BOOK 3
E STYLESTONE™ PAVING SYSTEMS
3
E
National 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.
Polished Face
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.
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 E
• Stylestone™
Stylestone high density concrete pavers are available in
40mm and 55mm thicknesses. The quality 40mm paver is
suitable for pedestrian, pool and light vehicular access. The
55mm has the added benefit of superior strength to cater for
commercial vehicular access when laid with an appropriate
rigid laying system.
Rockpave
Stylestone Tactile paving system is manufactured to meet
AS/NZS1428.4 for cautional and directional guidance to the
visually impaired.
The Stylestone range offers a vast array of textures, pressed
patterns and colours to accentuate any project.
Tactile
BORAL MASONRY DESIGN GUIDE
|
July 2007
E3
National Book 3 E
Infinite Design Possibilities
Boral Stylestone truly provides infinite design possibilities
when the range of colours is multiplied by the range of
size formats and the range of surface finishes. Here again
Stylestone caters for all tastes and locations with finishes
including honed face, shot-blast face and textured pressed
patterns. (Refer to table on page E5.)
Stylestone™
Boral Masonry is at the forefront in design and manufacture
of paving systems developed specifically for commercial,
architectural and public area landscaping.
Boral Stylestone is a whole new generation of paving,
embracing the innovative use of materials and technology
to create paving that has the design flair and engineering
qualities to exceed expectations in even the most challenging
paving projects.
World Leading Technology
Stylestone is manufactured on a state-of-the-art hydraulically
driven press which applies progressively increasing
pressure of up to 540 tonnes. A PLC controlled batching
system accurately controls material quantities and mixing
operations, resulting in a high strength product with accurate
and consistent dimensions and physical properties.
Boral Stylestone is produced with an emphasis on consistent
colour which is enhanced by the use of contrasting
aggregates, and is manufactured in a dynamic range of
colours to complement or contrast to other design elements
used within a project. Pavers are cured naturally within
a controlled environment and without the use of steam,
preventing colour leeching.
E4
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 E
Pavers
Architectural Textures
Honed
Pressed Patterns
Shot-Blast
Rockpave
Rusticstone
Ash White
Sandstone
Wheat
Paperbark
Kota Green
Charcoal
Tactile Pavers
Cautional
Directional
Architectural Textures:
Honed — The honing process produces a matt finish
with soft yet accentuated colour and aggregate
matrix.
Ivory
Shot-Blast — This process subtly exposes the
aggregates, producing weathered finish.
Yellow
Pressed Patterns:
Rockpave — A moderately textured surface combined
with gentle colour variations to emulate the texture of
hand-split stone.
Red
Rusticstone — A lightly textured moulded paving
surface with gentle colour variations.
Charcoal
Note: Colours available vary by state. Please check with your local Boral Masonry sales office.
BORAL MASONRY DESIGN GUIDE
|
July 2007
E5
National Book 3 E
Stylestone™ Honed, Shot-Blast and Tactile
Boral 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.
for pedestrian applications including areas such as road
crossing.
Boral Stylestone Pavers have also been tested to AS/
NZS4456.10 and can be used in saline environments. Refer
to page B13 for further information on sealing pavers.
Stylestone Tactile pavers are designed to provide vital
orientation and cautional information for people with vision
impairment. They meet the AS/NZS1428.4, and are suitable
Cautional — Used to advise
of possible danger and at
changes in direction.
Application
and usage
Product
11.1
units
per m2
40
300
300
Cautional Pattern
AS/NZS1428.4 : 1992,
Type B
Available
by region
Nationally
Unit
weight (kg)
Characteristic
breaking load
9
Product
40
>5.0
400
400
Honed Bullnose
11.1
units
per m2
55
300
300
Nationally
10.8
55
>7.0
400
400
Honed Bullnose
40
400
400
6.25
units
per m2
Nationally
15.5
Directional Pattern
AS/NZS1428.4 : 1992,
Type C
Directional — Used to
guide vision impaired
people along pathways.
40
>5.0
300
300
Application
and usage
Available
by region
Unit
weight (kg)
Characteristic
breaking load
2.5
per
lineal
metre
Nationally
15.5
>5.0
2.5
per
lineal
metre
Nationally
19.2
>7.0
11.1
units
per m2
Nationally
9
>5.0
11.1
units
per m2
Nationally
9
>5.0
Cautional Pattern
55
400
400
6.25
units
per m2
40
Nationally
Suitable application legend
19.2
>7.0
300
300
Directional Pattern
Pedestrian
Domestic driveways
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
Liability to Effloresce
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)
Nil to Slight
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.
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 E
Stylestone™ Rusticstone and Rockpave Textured Face Pavers
Boral Stylestone Rusticstone and Rockpave pavers are large
format, premium quality moulded concrete pavers which
combine elegant textures and colours to enhance today’s
modern architectural styling.
Product
Available
by region
Unit
weight (kg)
Characteristic
breaking load
6.25
units
per m2
Nationally
15.5
>5
2.5
per lineal
metre
Nationally
15.5
>5
400
40
400
A wide variety of colours are available. Please refer to swatch
information that is detailed on page E5.
Application
and usage
40
400
Boral 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.
400
Honed Bullnose
* Thicknesses vary slightly by state. Check with your local Boral Sales Office
Suitable application legend
Pedestrian
Domestic driveways
Pools
Commercial vehicle
Specifications and additional information
Colour/Textures
Content
Dimensional Category
Characteristic Breaking Load (kN)
Abrasion Resistance Index
Characteristic Flexural Strength
Slip Resistance Class
Salt Tested to AS/NZS4456.10
Liability to Effloresce
Manufacturing and Test Standard
Ordering Requirements
Lead Time
Bulk Ordering
Application
BORAL MASONRY DESIGN GUIDE
|
July 2007
Refer to swatch information on page E5
Cement, sand, aggregate, colour oxide
DPB2
5
3.5
73.5
V
Yes
Nil to Slight
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.
E7
National Book 3 E
NOTES
E8
July 2007 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide
PAVING NATIONAL BOOK 3
F HYDRAPAVE™ PERMEABLE PAVING
3
F
National Book 3 F
Hydrapave™ LT (Light Traffic)
Patented 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 LT Paving benefits:
• Drains up to 4,500 litres/m2/hour.
• 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.
natural
sahara
charcoal
• Water from tanked systems available for non-potable
secondary use.
clinker red
Specifications and additional information
Content
Dimensional Category
Characteristic Breaking Load (kN)
Abrasion Resistance Index
Slip Resistance Class
Salt Safe
Liability to Effloresce
Manufacturing and Test Standard
Ordering Requirements
Lead Time
Units per square metre
Avg. unit weight
F2
Cement, sand, aggregate, colour oxide
DPB1
>7
<7
W
Yes
Nil to Slight
AS/NZS4455, 4456 and 4586
No minimum order quantity applies
4-6 weeks
41.3
4.2kg
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 F
Typical System Layout
The Hydrapave™ LT paving system is
engineered for pedestrian and lightly
trafficked areas such as malls, car park
areas and driveways.
Standard kerbing
Header
course
Light dressing
of 3mm clean
crushed aggregate
during compaction
Filter fabric and perimeter
membranes brought up to kerb
and cut off flush with surface of
Hydrapave™ pavers.
Bedding course
of 5mm clean
crushed aggregate
Filter fabric
Sub-base of crushed aggregate
(in two layers — details below)
Impermeable membrane or filter
fabric to suit system design
PVC outlet pipe
(tanked systems)
Collection drain wrapped in
filter fabric (tanked systems)
Hydrapave LT Paver
An 80mm thick concrete paver with a unique edge chamfer and bevel
which permits butt joining and eliminates the need for jointing sand.
A vertical drainage channel incorporated into the ends of the paver
collects and directs stormwater into the sub-base.
Bedding Course
50mm thickness of 5mm single size crushed aggregate.
Filter Fabric
Standard or heavy grade depending on pavement design.
Sub-base
Typically 100mm thickness of 20 - 5mm crushed aggregate over 250mm
thickness of 63 — 10mm crushed aggregate. Aggregate gap graded, and yielding
30% voids. Thickness may be varied depending on pavement design.
Perimeter Membrane
Either impermeable plastic membrane (for tanked systems) or permeable
filter fabric for infiltration systems.
BORAL MASONRY DESIGN GUIDE
|
July 2007
F3
National Book 3 F
Alternative Hydrapave
Systems
There are two main types of systems.
Infiltration Systems are intended for applications
where the stormwater is to be allowed to infiltrate
back into the water table.
Tanked Systems are intended for applications where
the stormwater is to be collected for re-use or for
controlled release.
Typical Infiltration System
This system is underlaid with a filter
fabric layer and is suitable for use
where water it is proposed to infiltrate
directly into a suitable sub-grade.
Hydrapave LT Pavers
Direct infiltration rates of up to
800mm per hour can be achieved
in these systems even after many
years of service (depending on
suitable native sub-grade).
5mm Aggregate
The specification of the filter fabric
may vary according to the application,
end-use or site. Refer to your project
engineer for specification.
Filter Fabric to suit
Filter Fabric to suit
20-5mm Aggregate
Sub-base
63-10mm Aggregate
Sub-base
Sub-grade
Typical Tanked System
This system is underlaid by an
impermeable plastic membrane
and is suitable for use where it
is proposed to detain stormwater
before releasing it in a controlled
manner, or where it is proposed to
harvest the water for re-use.
Hydrapave LT Pavers
5mm Aggregate
The type of membrane used and
the method of sealing will depend
upon the excavated surface. In some
circumstances the membrane will
require sand bedding or geotextile
protection from puncturing
and specialist advice should be
obtained.
Filter Fabric to suit
20-5mm Aggregate
Sub-base
63-10mm Aggregate
Sub-base
Impermeable
Membrane to suit
Sub-grade
Collection drain
wrapped in Filter Fabric
PVC outlet pipe
The impermeable membrane prevents
water from entering the sub-grade,
and preserves sub-grade structural
integrity.
F4
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 F
Additional Options
Design Considerations
Design Assistance
Filter Fabric
Filter Fabric
Infiltration and Overflow
Boral can recommend stormwater engineers to assist
with the design of the Stormwater source control system
to suit specific sites. Please contact your Boral Masonry
representative.
Applications
Boral Hydrapave LT (Light Traffic) stormwater site control
systems are suitable for use on car parks, footpaths,
pedestrian concourses, domestic drives, garages and other
light to medium duty applications.
Boral Hydrapave LT is suitable for installation with a
maximum 1 in 12 slope (5°). On sites exceeding 1 in 20
slope, or where turning traffic is expected, reinforcement
of the subgrade using geogrid is recommended. Refer to the
illustration below.
Filter Fabric
On-site Water Treatment
Impermeable
membrane
Tanked and Directed for Re-use
Tanked with Additional Treatment
When installed, the Hydrapave LT system is capable of
draining up to 2.5 litres/sec/m2 ensuring it has the capacity
to deal with rainfall intensities well in excess of the most
extreme Australian urban design conditions (Darwin, 100
year storm, 10 minute duration).
Filter Fabric
The sub-base has a reservoir capacity of approximately 30%.
As a quick rule of thumb, 10m2 of Hydrapave LT system
with a sub-base depth of 350mm will accommodate 1 cubic
metre of water.
Impermeable
membrane
Where it is proposed to shed stormwater from impermeable
surfaces onto areas of Hydrapave, it is recommended that a
maximum ratio of 2:1 impermeable to Hydrapave be used.
Consideration must be given to the increased loading on
the Hydrapave system in these cases.
The Hydrapave™ LT system provides effective on-site water
treatment in the following ways:
• Organic matter and loam are caught on the filter fabric
and held in the layer of 5mm aggregate.
• Oils and heavy metals coat the surface of the organic
matter and loam.
Geogrid
reinforcement
(for site typically
exceeding 1:20 slope)
• Severe hydrocarbon contamination can be treated by
seeding with specialist microbes and slow release
fertilisers. Specialist advice should be obtained.
Geogrid Reinforcement for
Sloping Surface or Turning Traffic
BORAL MASONRY DESIGN GUIDE
|
• Natural microbial filament growth in the sub-base digests
low level hydrocarbon pollution.
July 2007
F5
National Book 3 F
The water harvested from tanked Hydrapave systems can
generally be used for non-potable purposes such as flushing
lavatories, irrigation of lawns and plants. Testing should
be carried out after installation to ensure that appropriate
water quality will be discharged.
Roof Water
Roof water from typical domestic residences can be
discharged directly onto the Hydrapave surface or into the
sub-base.
Roof runoff from large industrial buildings should be
introduced into the sub-base by means of a sump with a
manhole cover adjacent to the paved area. Any roof litter,
leaves etc., contained in the runoff can be easily caught and
cleared in the manhole.
Tree Soil
The Hydrapave system has been widely used in conjunction
with load bearing tree soil. This enables hard surfacing to
be used right up to tree pits without being detrimental to
the trees.
Soil respiration and moisture availability are key elements
in the successful establishment and future growth of trees.
With other hard surface paving systems, the only access for
air and water has been through the tree grill or irrigation
system. However, with the use of permeable paving blocks,
soil respiration is dramatically improved and natural rainfall
is made available to the tree in a way that was previously
not possible.
Long-term Performance
Extensive research on the siltation of blocks and laying
course undertaken at the University of South Australia
has verified the long-term performance of the Hydrapave
system. This research assumed rainfall of 580mm per
annum with a loading of 200 parts per million of sediments
(this loading corresponds to that of an established urban
catchment). The results concluded that even after a thirty
five year service life, the permeability of the system was
reduced to approximately 800mm/hour, due to the siltation
of the filter fabric, a value still greater than the design storm
intensity used anywhere in Australia.
Salt Tested
Boral Hydrapave LT Pavers have been tested to AS/
NZS4456.10 and can be used in saline environments.
Boral recommends applying an appropriate penetrative
sealer to further safeguard against saline effects in salt
pool surround applications and other constant saline
environments.
Colour and Finish Variation
Hydrapave™ LT pavers are manufactured from naturally
occurring materials and consequently may show slight
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.
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.
Scheduled Maintenance
Hydrapave LT pavers have a design life equivalent to other
Boral concrete pavers.
The surface of pavers should be brushed at least twice a
year with a mechanical suction brush. It is recommended
that this should be carried out in the spring and after leaf
fall in autumn.
Rehabilitation
Access to services in or underneath the Hydrapave system
must be undertaken in a disciplined and progressive way.
Detailed procedures for lift and rehabilitation are available
from your Boral representative.
Ultimately, perhaps after 25 years or more, areas of the
laying course may become filled with silts and toxins. If this
occurs the surface pavers should be lifted and the affected
areas of laying-course material and filter fabric disposed of.
The existing sub-base can be left in situ. Fresh filter fabric
and laying course stone should be installed and the existing
surface pavers re-used.
This research has shown that over 90% of the surface
permeability of the paving can be lost through silting, and
the system will still perform to twice the greatest design
storm intensity used in Australia. (Darwin 400mm/hr).
F6
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 F
Hydrapave™ LT
Construction Guidelines
Preparation
All construction work on pavements should be carried out
following completion of general site works and after topsoiling
of adjacent areas to prevent wash down of fine materials.
Sub-grade
Excavate to sub-grade levels shown on site drawings to
provide a minimum fall of 1:1000 to strip drain. Where
it is proposed to infiltrate, no falls or strip drains are
necessary.
The subgrade should be compacted with a vibrating plate
or roller to the requirements of the specification. Prior to
compaction all soft areas should be removed and filled with
suitable replacement material to provide a stable subgrade.
Kerbs
The paved areas must be firmly restrained with kerbs and
kerb haunching designed to suit the intended use.
Membrane
For tanked systems, lay membrane taking care to overlap
the joints by 300mm using double-sided tape. Where
methane or a high water table is present, a specialist heavyduty membrane may be required, and the joints should be
welded. Where the sub-grade is rough, a layer of sand and/or
geotextile may be required to protect the membrane. A filter
fabric layer can be placed over the membrane to protect
against puncture damage from the sub-base.
If it is proposed to drain by infiltration to the sub-grade, use
a filter fabric (instead of membrane) to stop the ingress of
sub-grade material into the sub-base.
Sub-base
The sub-base is comprised of two layers with a total nominal
thickness of 350mm. The specified 350mm thickness of
sub-base may be varied by the project engineer to suit
site requirements.
The upper sub-base is a layer of 20 — 5mm stone up to
100mm thick.
Filter Fabric
Lay filter fabric on top of the sub-base overlapping joints
by 300mm.
Bedding Course
Lay and loose screed 5mm single sized crushed stone
to approximately 50mm depth. It is important that the
final level of the 5mm stone is accurate, as the stone will
compact down much less than sand would when the pavers
are vibrated. The particle shape of the 5mm stone will also
affect the degree of compaction. A small trial area should
be laid prior to construction to determine the accuracy of
final levels.
Paver Laying
Hydrapave LT pavers must be laid in a 90° herringbone
pattern, tightly butt jointed to ensure that a close fit is
achieved.
A single header course or double stretcher course of
Hydrapave LT pavers must be used around the perimeter
of the paved areas and also at the edges of any separately
restrained areas, such as tree pits.
It is strongly recommended that products are taken from
two or more packs and mixed during laying to minimise
noticeable colour variations.
Where pavers need cutting, they should be cut to a tight fit
and none are to be smaller than 30% of the paver size. Where
Hydrapave LT pavers are cut they must be cut across the
110mm and not the 220mm dimension. Pavers should be
cut vertically and not underscored. All paver cutting should
be carried out with a disc cutter. Occupational, health and
safety requirements should be observed at all times.
Paver Compaction
The pavers should be vibrated with a high-frequency, lowamplitude vibrating plate compactor, over carpet or similar
to prevent marking the paver surface. Following the first
pass with a vibrating plate, spread a light dressing of 3mm
single size clean stone at the rate of approximately 1 - 2
kg/m2 over the surface and brush into the joints. The pavers
should again be vibrated and any debris brushed off.
The lower layer is to be (63 — 10mm) stone up to 250mm
thick. The lower layer of sub-base should be placed in two
separate layers, each layer being compacted with a vibrating
roller or heavy-duty vibrating plate. Compaction should
continue until 95% of the compacted bulk density achievable
under laboratory conditions has been reached.
BORAL MASONRY DESIGN GUIDE
|
July 2007
F7
National Book 3 F
Sub-base — Lower Layer
Materials Specification
A 250mm deep layer of stone. Grading to comply with:
Subgrade
The subgrade must have a minimum CBR of 5. Engineering
advice should be obtained where the subgrade does not meet
this specification.
Membrane/Filter Fabric
Membrane (typical)
Sieve Size
% Passing
100mm
100
63mm
90-100
37.5mm
60-80
20mm
15-30
10mm
0-5
Typical Dimensions: 4m x 12.5m x 50μm - 23kg.
Tear Resistance: 40N/mm minimum.
Tensile Strength: 14.4mPa.
Durability: The membrane must remain flexible and not
degrade. It shall be resistant to U.V. light and puncturing.
Sub-base — Upper Layer
Where methane or a high water table is present in the
subgrade it will be necessary to use a heavy-duty membrane
and to weld the joints.
The upper filter fabric grade will vary according to the precise
application. For information on geotextiles and filter fabrics
contact Polyfabrics Australia Pty Ltd (02) 9829 5599.
The membrane should be protected against puncturing.
Laying Course
Filter Fabric
50mm depth of 2 - 5mm single size (near as possible) clean
crushed stone.
The grade will vary according to the precise application.
Refer to the project hydraulic or stormwater engineer for
specifications.
A 100mm deep layer of graded 20-5mm crushed stone.
Filter Fabric
Paver
Pavers are to be Hydrapave™ LT as manufactured by Boral
Masonry. Colour to be specified by project engineer.
Sub-base
A sub-base of 350mm as detailed on page F7 will enable the
Hydrapave LT system to have a holding capacity of 1m3 of
water for every 10m2 of paved area. The permeability of the
pavers themselves is 9,000L/m2/hour. The depth of sub-base
can accordingly be varied at the discretion of the engineer.
The granular sub-base material shall comprise crushed
gravel, rock or concrete possessing well defined edges. It must
be sound, clean, non friable and free from clay or other
deleterious matter.
Joint Filling
2 - 5mm single size clean stone applied at the rate of
approximately 1 - 2 kg/m2.
Strip Drain
Specification of strip drains should be provided by the
project hydraulic or stormwater engineer.
The material must be non-plastic.
The crushed stone used for the laying course and sub-base
must have a minimum 10% fines value of 150kN.
The selected test samples shall not be oven dried and should
be soaked in water at room temperature for 48 hours before
the test.
30
110
50
220
30
4
4
20
80
60
Hydrapave LT
F8
July 2007 | BORAL MASONRY DESIGN GUIDE
BORAL MASONRY
Build something great™
Masonry Design Guide
PAVING NATIONAL BOOK 3
G INDUSTRIAL TRAFFIC PAVING SYSTEMS
3
G
National Book 3 G
Boral Masonry Industrial
TrafficPaving Systems
engineered for heavy haulage and container terminals,
airports, service stations, warehousing and industrial sites
Interpave’s sixteen sided interlocking shape actually
becomes stronger under traffic flow — ‘locking
together’ to provide a superior pavement with proven
long-term stability.
• Pavestone™ 80
• Interpave™ 80
Boral Interpave 80 is a segmental paving system,
engineered to suit high volume traffic, heavy loading
and poor foundation support applications.
Interpave’s unparalleled
performance stems from the
innovative interlocking shape,
high strength and long-term
durability of every unit.
Boral Pavestone is a rectangular paver
generally used as header and border
courses in Interpave applications.
• Coachstone™ 80
(Available QLD only)
Boral Coachstone is a small format segmental concrete
paving system used for header courses and borders.
The product can be machine
laid, thus increasing productivity on site.
G2
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 G
Interpave™ and Pavestone™ 80 Pavers
Boral Interpave 80 is a high performance segmental
concrete paving system engineered for high volume traffic,
heavy loadings and poor foundation support. Interpave 80
is ideal for areas such as heavy transport and container
terminals, industrial facilities, aircraft terminals etc.
Pavestone 80 is generally used as header and border rows
in Interpave 80 installations.
Interpave and Pavestone 80 benefits:
• Resistance to rutting.
• Strength to withstand high point loadings.
• Elimination of shrinkage, cracking and joint stepping.
• Ready access to underground services and easy
rehabilitation.
• High skid resistance.
Application
and usage
Product
80
225
112
40 units
per sq
metre
Unit
weight (kg)
Available
by region
Colours available
NSW,
VIC, SA
Natural, Sahara, Terracotta, Charcoal
QLD
Natural, Sahara, Terracotta, Charcoal, Heritage Red, Clinker Blend, Bronze Blend, Desert Sand
NSW,
VIC, SA
Natural, Sahara, Terracotta, Charcoal
4.3
Interpave
80
230
115
37 units
per sq
metre
4.3
QLD
Natural, Sahara, Terracotta, Charcoal, Heritage Red, Clinker Blend, Bronze Blend, Desert Sand
Pavestone
Suitable application legend
natural
sahara
Pedestrian
terracotta
Domestic driveways
charcoal
Pools
heritage red
Commercial vehicle
clinker blend
bronze blend
Industrial vehicle
desert sand
Extensive design and installation information and assistance is available from the Lockpave
program which is available from the Concrete Masonry Association of Australia, (CMAA)
Tel: (02) 9903 7760, or visit the Website: www.cmaa.com.au
Boral Interpave and Pavestone 80 pavers have been tested to AS/NZS4456.10 and can be used
in saline environments. Refer to page B21 for further information on sealing pavers.
Specifications and additional information
Content
Dimensional Category
Characteristic Breaking Load (kN)
Abrasion Resistance Index
Slip Resistance Class
Salt Tested to AS/NZS4456.10
Liability to Effloresce
Manufacturing and Test Standard
Ordering Requirements
Lead Time
Bulk Ordering
BORAL MASONRY DESIGN GUIDE
|
July 2007
Cement, sand, aggregate, colour oxide
DPB1
> 10
< 5 (for roads)
V
Yes
Nil to Slight
AS/NZS4455, 4456 and 4586
Made-to-Order (Minimum quantity applies)
4-6 weeks
Requires extended lead times of more than 6 weeks
G3
National Book 3 G
Coachstone 80™ (Available in QLD only)
Boral Coachstone 80 is a small format concrete segmental
paving system suitable for applications up to and including
industrial traffic. Coachstone 80 is generally used for header
courses and borders in Interpave 80 installations.
Coachstone 80 benefits:
• Ready access to underground services and easy rehabilitation.
• High skid resistance.
Coachstone 80 paver has been tested to AS/NZS4456.10
and can be used in saline environments. Refer to page B13
for further information on sealing pavers
• Resistance to oil and petrol attack.
• Elimination of shrinkage, cracking and joint stepping.
Application
and usage
Product
80
230
37 units
per sq
metre
Available
by region
Colours available
Unit
weight (kg)
QLD
Natural, Sahara, Charcoal, Heritage Red, Clinker Blend, Bronze Blend, Desert Sand
4.2
115
Suitable application legend
natural
sahara
Pedestrian
charcoal
Domestic driveways
heritage red
Pools
clinker blend
Commercial vehicle
bronze blend
Industrial vehicle
desert sand
Specifications and additional information
Content
Dimensional Category
Characteristic Breaking Load (kN)
Abrasion Resistance Index
Slip Resistance Class
Salt Tested to AS/NZS4456.10
Liability to Effloresce
Manufacturing and Test Standard
Ordering Requirements
Lead Time
Bulk Ordering
G4
Cement, sand, aggregate, colour oxide
DPB1
> 10
<7
V
Yes
Nil to Slight
AS/NZS4455, 4456 and 4586
Made-to-Order (Minimum quantity applies)
2 - 3 weeks
Requires extended lead times
July 2007 | BORAL MASONRY DESIGN GUIDE
National Book 3 G
NOTES
BORAL MASONRY DESIGN GUIDE
|
July 2007
G5
eBC 03149 July 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.
Technical Enquires
Specifier Line
Internet
1300 360 255
www.boral.com.au/masonry
Orders, Product Samples and Sales Enquires
Victoria
Level 1 Port IT, 63-85 Turner Street, Port Melbourne, 3207
T: (03) 9363 1944
F: (03) 9363 6008
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
North Queensland:
Other Regional Sales Offices
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
™ Coachstone, Edgestone, Hydrapave, Interpave, Pavestone, Sedonastone, Stoneworks and
Stylestone are registered trademarks of Boral Masonry Limited.
® Aspenstone, Classicpave, Handipave and Promenade 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 2004.