F O R T I C R E T EE N G I N E E R I N G

P R O D U C T S

S e p t e m b e r 2 0 0 1

C I / S f B

( F f 2 )

http://www.Forticrete.co.uk

The British Board of Agrémenthas approved Keystone for use as set out

in Agrément Certificate No. 98/R103.

CERTIFICATE NO. 98/R103

BRITISHBOARD OFAGREMENTBBA

MEMBERConstruction CPD Certification Service

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KEYSTONE

BEAUTIFUL, DRY BUILD RETAINING WALLS WITH HIDDEN STRENGTH

The Keystone retaining wall system is the structurally

sound, aesthetically appealing, easy-to-install and

economical solution to replace Gabion, Crib and

cast-in-situ retaining walls. As a gravity wall

system, the original Keystone Standard unit

provides the weight and stability to resist earth

pressures for walls up to 2 metres high. And it

doesn’t stop there. Keystone offers a wide variety

of products with different sizes, shapes, face

textures and colours for superior gravity

and reinforced walls that rise in height.

OUTER BEAUTY, INNER STRENGTH

The Keystone difference is its outer beauty and inner strength. Laid dry, Keystone uses a unique high strength fixing system which securely locks the components in place. At the centre of the system are pultruded pins which have a high shear strength and will last the life of the wall.

The combination of Keystone units, positive pinconnections and soil reinforcing geogrids deliversrock-solid stability and performance. When you arebuilding walls that need to hold literally tonnes of soil mass, you simply can’t hope the geogrid is whereit’s supposed to be. You need to know it’s locked inplace. Keystone’s fibreglass pin connection systemgives you that critical assurance.

AESTHETIC IMPACT

And this inner strength is matched by the aestheticimpact of a system capable of combining classic

lines, graceful curves, shadows and textures. Keystone components are laid to a running bondwhich ensures a finished structure of great character,with random appeal and natural texture. Keystone isavailable in a range of 12 natural colours and withclassic straight or rockface profiles.

With over 8,000,000 m2 built worldwide andover 30,000 m2 already in the UK, Keystoneis proven as one of the most successful,most versatile, most secure retaining wallsystems available.

TYPICAL REINFORCED SOIL APPLICATIONS

Basic wall without surcharge Sloping hillside surcharge Constant surcharge load Tiered walls

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EASY TO INSTALL

● Interlocked, mortarless assembly – No mortarrequired; allows free flow drainage through the wallreleasing hydrostatic loads

● Patented fibreglass pin system – Ensures properalignment, unit interlock and positive mechanical connectionbetween the structural units, geogrids and the retained soil mass

● Rapid installation – Straight-forward building systemallows for faster wall construction; no mortar, simple footing;general labour vs skilled labour

AESTHETIC

● Multiple colour options – Complements the naturallandscaping and aesthetics of site locations; designers havetrue freedom of expression

● Rockface split textures – Allow a more naturalappearance with heavy shadows from texture and geometry

● Multiple face styles – Offers creative design options to the designer with the ability to co-ordinate with any site orbuilding design

DURABLE

● High strength, low-absorption concrete – providesdurability to Keystone units and total structure

● Non-corrosive material – safe for the environment;stands up to nature’s toughest tests

VERSATILE

● Unique Design – Allows for easy construction of convexand/or concave curves to naturally meet the site contour

COST–EFFECTIVE

● Lower cost – Can be half the cost of a new reinforcedconcrete or crib wall

● Time saving – Rapid installation reduces construction time

● Mass produced – Units are quality controlled with high-rate factory production process; product is readily available ‘off the shelf’

● Long lasting – Greater life span offers outstanding life-cycle cost benefits

● Re-use of existing material – In many cases existing soils can be returned as backfill behind the Keystone, thus avoiding the need for imported fill

D I S COV E R T H E H I D D E N

B E N E F I T S O F K E YS T O N E

Citygrove Leisure's development in Bishops Stortford, Herts.Citygrove Leisure's development in Bishops Stortford, Herts.

CREATING GRAVITY ORUNREINFORCED WALLS UP TO 2 METRES IN HEIGHT

Keystone can be used to create gravity or unreinforced walls up to 2.0 metres in height. For most applications, no structuralfoundation is required and a simple levelling pad will suffice.Even in the case of unreinforced soil walls only the base course offacing units require bedding on mortar.

KEYSTONE PROVIDES THE PERFECTSOLUTION FOR:

Creating curved structures - Keystone products allow for the creation of graceful convex and concave curves

Creating water features - Keystone has been subjected torigorous testing for performance in water applications and isproven in use worldwide.

Creating beautiful terraces - designing terraced or tieredwalls with Keystone will give you innumerable options with orwithout the use of geogrids.

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North Dock Reclamation, Llanelli.

Private housing development,Macclesfield, Cheshire.Private housing development,Macclesfield, Cheshire.

Keystone’s ability to connectpositively with proprietorygeogrid systems has enabled itto be built to heights of over 15metres worldwide – making itideal for roadside and bridgelocations and its simple, drybuild construction enables it tohandle the most challenging sitedesign. Keystone is ideal for:

● Bridge Abutments● Embankments● Culverts

CREATING REINFORCED SOIL WALLS

For taller or more critical walls, Keystone units are combined withsoil reinforcement options to create larger composite structures.With this properly designed combination, the reinforced soil masscan support greater earth pressure and surcharge loads and thepin fixing concept allows geogrid material to be fully incorporatedinto the structure of the wall, providing an exceptionally strong‘mechanical’ link. These composite structures have permitted theconstruction of retaining wall structures over 15 metres highacross the world.

THE ADVANTAGES OF GEOGRIDREINFORCED STRUCTURESINCLUDE:

● Economical construction by utilising a wider range of site soils forthe reinforced fill zone, minimising the need to import select fill

● Construct walls faster without waiting for curing time of site castconcrete; the wall structure and backfill are constructed at thesame time

● Eliminates the need for deep structural footing and excavation

● Provides durability; long-term performance resists the effects of water, micro-organisms, alkali or acidic soils

T H E B E U T I F U L LY S T R O N G

S O L U T I O N F O R H I G H WAY

A P P L I C AT I O N S

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Bluewater Retail Park, Kent, for Bluewater Construction Management.

Heathrow Airport , London.

Hazlewood Foods, Worksop.

Bluewater Retail Park, Kent, for Bluewater Construction Management.

Hazlewood Foods, Worksop.

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Keystone provides design flexibility to meet the unique challenges of commercial sites; tall walls, short walls…curves, corners…rapidchanges in elevation…co-ordination with the materials for thebuilding architecture. A Keystone retaining wall makes a lastingstatement of beauty and attention to detail. A positive solution to the most challenging and demanding design and constructionrequirements.

T H E P E R F EC T S O L U T I O N

F O R CO M M E R C I A L A N D

R E TA I L A P P L I C AT I O N S

B&Q Warehouse in Stockport, Cheshire.

Hazlewood Foods, Worksop. Tesco superstore, Stalybridge, Manchester.

Footbridge, St Helens, Merseyside.

Atlantic Village, Bideford. Sir Francis Xavier College, Liverpool.

B&Q Warehouse in Stockport, Cheshire.

Standard

The Keystone Standard unit has been designed with a height-to-depth ratio which delivers a structurally sound, engineeredwall system with superior construction stability, durability andstrength. It is the choice for tall walls and critical structures.

Weight 47kg

Size (H x W x D) 200 x 455 x 533mm

Exposed face area 0.091m2

COMPAC

The Keystone Compac is the perfect choice where deepembedment length of the Standard unit is not required. Aninstaller’s favourite, its lighter weight and shorter tail designmakes it easy to handle for smaller walls. It is available with asplit or textured finish.

Weight 38kg

Size (H x W x D) 200 x 455 x 305mm

Exposed face area 0.091m2

MInI and Cap

The Keystone Mini is a great solution for smaller, non-criticalapplications or as an accent when integrated with theStandard or Compac units. For capping, the unit is availablewith a smooth top surface, straight or angled sides and inClassic or Rockface profiles.

Weight 22kg

Size (H x W x D) 100 x 455 x 267mm

Exposed face area 0.045m2

CORNER BLOCK

The Keystone corner block is used to create 90ocorners. It is

textured on two faces with left and right hand units available.

Weight 41.5kg

Size (H x W x D) 200 x 455 x 228mm

Exposed face area 0.136m2

LOCATION PINS

Keystone’s patented pin system featureshigh strength, pultruded fibreglass pinsthat provide a shear connector, positivegeogrid connection and alignmentdevice all in one piece. The systemensures a positive mechanicalconnection between structural wall unitsand geogrids, making the criticaldifference for safety and security.

A COMPLETE SYSTEM

The Keystone system comprises four units – Standard, Compac, Mini & Caps – providing the ability to vary heightand the opportunity to further explore the variations created by light and shadow by introducing string courses.

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Classic Rockface

Classic Rockface

Classic Rockface

COMPOSITION

Keystone walling components are manufactured from a carefully controlled mixture of limestoneaggregates and cement.

DRYING SHRINKAGE

Forticrete Keystone units have a value considerablybelow those permitted by BS 6073: Part1: 1981.

DENSITY

Typical material density = 2100 kg/m3.

COMPRESSIVE STRENGTH

The minimum average concrete compressive strengthis 30 N/mm2.

FIRE RESISTANCE

All products are manufactured from limestoneaggregate which has Class 1 fire resistance.

WATER ABSORPTION

Under test conditions for water absorption theperformance of Keystone products surpassed the highest appropriate standards.

LOCATION PINS

KEYSTONE units are located using pultruded non-corrodable fibreglass pins manufactured under BS EN ISO 9002. The pins are, nominally, 12.7mm in diameter and 133mm in length.

The pins have a minimum:Flexural Strength – 882 N/mm2

Tensile Strength – 785 N/mm2

Short Beam Shear Strength – 44 N/mm2

QUALITY CONTROL

All Forticrete masonry plants are registered under theBSI system for the registration of Firms of AssessedCapability, commonly known as the BSI RegisteredFirms Scheme. This is a Third Party Quality Assurancescheme based on BS EN ISO 9002, which is theinternational standard for quality systems.K E Y S T O N E

C O L O U R S

The reproduction of colour is as close as is possible within the photographic and printed processes. Where precise colour tolerances are vital, you are advisedto view actual product samples.

Hamstone

Sandstone Chrome Flint Bathstone

Straw Russet Terracotta Peat

Ivory Pewter Yorkstone

Forticrete Ltd, Hillhead Quarry, Harpur Hill, Buxton, Derbyshire SK17 9PS.Tel: 01298 23333 Fax: 01298 23000

Information and advice can also be obtained by calling the Forticrete Technical Hotlineon: Freephone 0800 262136 or by e-mail at Technical@Forticrete.co.uk

Information on the complete range of Forticrete products can be found on the Internetat www.Forticrete.co.uk

® FORTICRETE is a registered trademark of Forticrete Ltd. © 2001 Forticrete Ltd.

S P E C I F I C A T I O N

Information regarding design andinstallation procedures is contained

within the Agrément Certificate 98/R103,copies of which are available on request.

CERTIFICATE NO. 98/R103

BRITISHBOARD OFAGREMENTBBA