The information contained in the User Manual has been compiled by Redi-Rock International, LLC to document the performance of the Redi-Rock products contained therein. It is accurate to the best of our knowledge as of the date of its issue. Information included in the User Manual has been prepared in accordance with generally recognized manufacturing principles and practices. This information should not be used without first securing competent advice with respect to its suitability for any general or specific application. Final determination of the suitability and appropriateness of this data for a given manufacturing purpose is the sole responsibility of the user.
No warranty of performance by Redi-Rock International, LLC or the User Manual authors is expressed or implied by the publishing of the following User Manual.
Revision Date: January 10, 2025
TABLE OF CONTENTS
Manufacturing Redi-Rock Blocks
Retaining Forms
Overview
General Production
28 in (710 mm) & 41 in (1030 mm) Middle Block
28 in (710 mm) & 41 in (1030 mm) Bottom Block
28 in (710 mm) & 41 in (1030 mm) Top Block
28 in (710 mm) & 41 in (1030 mm) Half Middle Block
28 in (710 mm) & 41 in (1030 mm) Half Bottom Block
28 in (710 mm) & 41 in (1030 mm) Half Top Block
28 in (710 mm) & 41 in (1030 mm) 9 in (230 mm) Tall Block
60 in (1520 mm) Middle Block
60 in (1520 mm) Bottom Block
60 in (1520 mm) Half Middle Block
60 in (1520 mm) Half Bottom Block
41 in (1030 mm) or 60 in (1520 mm) 9 in (230 mm) Setback Middle Block
41 in (1030 mm) or 60 in (1520 mm) 9 in (230 mm) Setback Bottom Block
41 in (1030 mm) or 60 in (1520 mm) 9 in (230 mm) Setback Half Middle Block
41 in (1030 mm) or 60 in (1520 mm) 9 in (230 mm) Setback Half Bottom Block
41 in (1030 mm) Planter Block
41 in (1030 mm) Half Planter Block
Modified Top Block
Modified Half Top Block
Short Middle Block
Short Top Block
28 in (710 mm) & 41 in (1030 mm) PC Middle Block
28 in (710 mm) & 41 in (1030 mm) PC Bottom Block
28 in (710 mm) & 41 in (1030 mm) PC Top Block
1-AT Middle Block
41 in (1030 mm) Anchor Middle Block
41 in (1030 mm) Anchor Bottom Block 41 in (1030 mm) Hollow-Core Block
Overview
General Production
52 in (1320 mm) XL Block
72 in (1830 mm) XL Block
96 in (2440 mm) XL Block
Overview
General Production
Straight Middle Block
Variable Radius Middle Block
Straight Bottom Block
Variable Radius Bottom Block
Straight Top Block
Variable Radius Top Block
Corner Middle Block
90 Degree Corner Block
Corner Bottom Block
Corner Top Block
Half Corner Middle Block
Half Corner Bottom Block
Half Corner Top Block
Straight Garden Top Block
Variable Radius Garden Top Block
Corner Garden Top Block
Half Corner Garden Top Block
Force Protection Middle Block
Force Protection Bottom Block
Force Protection Top Block
Freestanding Hollow-Core Block
Freestanding Half Hollow-Core Block
Freestanding Corner Hollow-Core Block
Freestanding Half Corner Hollow-Core Block
9 in (230 mm) Tall Corner Block
9 in (230 mm) Tall Garden Block
9 in (230 mm) Tall Two-Sided Block
Cap Forms
Overview
General Production
Two-Sided Cap
Three-Sided Cap
Four-Sided Cap
Three-Sided Half Cap
Step Forms
Overview
General Production
Three-Sided 48 in (1219 mm) Step
Three-Sided 72 in (1829 mm) Step
Column Forms
Overview General Production Solid Core Column
8 in (203 mm) Core Column
4 in (102 mm) Core Column
Column Cap
Textures
Limestone
Kingstone
Ledgestone
Cobblestone
Smooth
XL
Appendix
Block Setback Options
1-AT Geogrid Connection
Loop Holders & Lifteye Formers
Lifting Load Safety Sheet
XL Rebar Cages
Tools for Demolding Freestanding Blocks
J-Bolts and Clips
Product Data Sheets
Manufacturing Redi-Rock Blocks Safely
Thank you for choosing Redi-Rock International to help you make precast modular blocks. This user manual, used in conjunction with the Producer Secure Site, is intended to assist you in the manufacturing process.
This manual outlines general practices and procedures, but each manufacturer is responsible for creating a site-specific safety plan for their facility, as scenarios and situations vary across locations. If you need to set up a company safety program, we recommend visiting www.osha.gov or calling 1-800-321-OSHA (6742) to find safety-training materials specific to your company.
All manufacturers should abide by all federal, state, and local safety regulations.
Block Size Key
To help find the right block/form you’re looking for, throughout the Form Set Up areas in the manual each block section has its size labeled in color, in several areas. This is due to some forms having the capability to create more than one sized block.
If in need of assistance please refer to this key. Or call Redi-Rock at +1 866-222-8400.
length
block size options
RETAINING FORMS
Retaining Forms
General Production
28 in (710 mm) & 41 in (1030 mm) Middle Block
28 in (710 mm) & 41 in (1030 mm) Bottom Block
28 in (710 mm) & 41 in (1030 mm) Top Block
28 in (710 mm) & 41 in (1030 mm) Half Middle Block
28 in (710 mm) & 41 in (1030 mm) Half Bottom Block
28 in (710 mm) & 41 in (1030 mm) Half Top Block
28 in (710 mm) & 41 in (1030 mm) 9 in (230 mm) Tall Block
60 in (1520 mm) Middle Block
60 in (1520 mm) Bottom Block
60 in (1520 mm) Half Middle Block
60 in (1520 mm) Half Bottom Block
41 in (1030 mm) or 60 in (1520 mm) 9 in (230 mm) Setback Middle Block
41 in (1030 mm) or 60 in (1520 mm) 9 in (230 mm) Setback Bottom Block
41 in (1030 mm) or 60 in (1520 mm) 9 in (230 mm) Setback Half Middle Block
41 in (1030 mm) or 60 in (1520 mm) 9 in (230 mm) Setback Half Bottom Block
41 in (1030 mm) Planter Block
41 in (1030 mm) Half Planter Block
Modified Top Block
Modified Half Top Block
Short Middle Block
Short Top Block
28 in (710 mm) & 41 in (1030 mm) PC Middle Block
28 in (710 mm) & 41 in (1030 mm) PC Bottom Block
28 in (710 mm) & 41 in (1030 mm) PC Top Block
1-AT Middle Block
41 in (1030 mm) Anchor Middle Block
41 in (1030 mm) Anchor Bottom Block
41 in (1030 mm) Hollow-Core Block
Overview
The standard Redi-Rock Retaining form consists of a base and four hinged door panels – top, bottom and two sides – that close with binder clamps. The form can be configured with various inserts and extensions to create numerous precast modular blocks. By changing the face mold in the base of the form, various texture blocks can also be produced.
RETAINING FORM BASE 1 R002-A003 STANDARD TOP DOOR 1 R002-A007
BOTTOM DOOR 1 R002-A008
LEFT END PANEL WELDMENT 1 R002-A009 RIGHT END PANEL WELDMENT 1 R002-A010 RIGHT FORK SLOT INSERT WELDMENT 1 R002-A012 LEFT FORK SLOT INSERT WELDMENT 1 R002-A013 5-13 HEX NUT 4 5-13-HN 5 FLAT WASHER 4 5-FW 20 .75-10 -HN 10 .75-10 x3-HB
R002-A010 R002-A012
R002-A012
TITLE: Intro Form View: S PART No : R002-M009 PROPRIETARY AND
R002-A008
R002-A013
R002-A009
R002-A007
R002-A003
R002-A010
R002-A007
R002-A
2000-2005 Generational Door Panels
Retaining forms manufactured between 2000-2005 were fabricated with a “C-channel” structure on the top and bottom door panels. In 2005, the design was revised to an “angle” structure to improve rigidity during demolding.
It is strongly recommended to update the top and bottom door panels with the current angle structure design. Forms with the C-channel design may be susceptible to warping, which impacts the block dimensions, and increased demolding effort.
Setback Options
The block-to-block setback available with Redi-Rock is controlled by the size and location of the shear knobs cast into the precast modular blocks. While the 10-in (254-mm) diameter knob and the 1 5/8-in (41-mm) setback is the most common configuration, Redi-Rock has three different knob sizes and three different locations available for the retaining form.
See page ii in the Appendix for illustrations of the Block Setback Options.
"Angle" structure (2006-Current)
"C-Channel" Structure (2000-2006)
Figure A
Setback Option
Degree Setback
Knob Location
Retaining forms can be configured with different top panels to provide options for various knob locations.
Standard Panel R002-A007
Can be used to produce:
Standard Setback
Two-Way Panel
R002-A030
Can be used to produce:
Standard Setback
9 in (230 mm) Setback
Three-Way Panel R002-A018
Can be used to produce:
Standard Setback
9 in (230 mm) Setback
Planter Setback
Modification(s) to Create Setback Option
Universal Panel (Discontinued) R002-A007
Can be used to produce:
Standard Setback • Planter Setback
Knob Sizes
Retaining form knob formers can be modified to create various size knobs, which correlate to different setback options.
10 in (254 mm) Knob Former R002-A104
The knob casting is used to create standard 10-in (254-mm) diameter knobs.
Used to produce:
• Standard Setback
• 9 in (230 mm) Setback
• Planter Setback
7 ½ in (190 mm) Knob Insert R002-A160
Modified by inserts to produce:
• One Degree Setback
• Zero Degree Setback
The rubber insert is installed in the standard 10 in (254 mm) Knob Former to make a 7 1/2-in (190-mm) diameter knob.
Used to produce:
• One Degree Setback
Installation Instructions: Affix with silicone caulk. Do not overtighten.
Installation Instructions: Bolt to top panel of form.
6 ¾ in (171 mm) Knob Insert R002-A224
The rubber insert is installed in the standard 10 in (254 mm) Knob Former to make a 6 3/4-in (171-mm) diameter knob.
Used to produce:
• Zero Degree Setback
Installation Instructions: Affix with silicone caulk. Do not overtighten.
Product Data Sheets
For product data sheets, see these pages in the Appendix:
28 in (710 mm) retaining blocks ....................................................... page xxxix
41 in (1030 mm) retaining blocks ..................................................... page xli
28 in (710 mm) & 41 in (1030 mm) PC blocks page xliii
60 in (1520 mm) retaining blocks ..................................................... page xlv
Note: There are instructions specific to producing each Redi-Rock precast modular block throughout this manual. Please be sure to understand both the following general guidelines and the specific instructions before beginning to manufacture a Redi-Rock product.
Prep
1.
Set each of the forms as level as practical (level is not critical, however).
2.
To create the texture on the blocks, a rubber face mold is bolted to the face panel. When installing the mold, set it in place and close the form before tightening the bolts under the face mold. This ensures that the mold is centered in the form.
3.
Critical Note: Many of the face molds are reversible to increase the texture variations; however, the Limestone texture is not reversible. Be sure to install the face mold so that the thicker portion of the rubber is at the top of the form.
Scrape residual concrete from steel and rubber parts after each demolding operation. Concrete build-up will deform rubber molds and impact product quality.
Pay close attention to:
• Surfaces where steel contacts rubber
• The underside of the knob formers – this is critical for proper knob size and maintaining alignment during wall installation
• Around the loop holders before closing forms so debris does not fall onto the face mold
Helpful Hint: The rubber face mold should be free of debris before pouring blocks. Compressed air can be helpful if used safely.
4.
Apply a thin layer of release agent to the form surfaces. Over-applying release agent will adversely affect the finished product. Excess release agent can pool in the face mold, causing the surface to flake, spall off, or create bug holes.
Pay attention to hard to reach areas:
• Undersides of inserts
• Underside of knob formers
• Around and inside loop holders
For a list of appropriate release agents visit the secure site or call your business consultant.
5.
Place the lifting insert into the loop holder. Commercially available lifting inserts are offered by a number of manufacturers, and Redi-Rock producers have elected to use a variety of lifting inserts to safely handle Redi-Rock blocks.
Two inserts which are made from galvanized, A36 steel are shown here.
Manufactured by: American Step Company https://www.americanstep.com/ 830 East Broadway PO Box 137 Griffen, GA 30224-0137
Helpful Hint: Spraying the exterior surfaces of the forms will aid in cleaning but can also make them slippery.
Manufactured by: A.L. Patterson https://www.alpsupply.com/ (800) 332-7090 300 Ben Fairless Drive Fairless Hills, PA 19030
Helpful Hint: Depending on what lifting insert you choose to utilize, various loop holders are available to hold the insert in place. See page vi in the Appendix for a full breakdown of available options. Continued
3/8” Solid Loop Lifter
3/8” R Anchor
Safety Notes: For Step 5
• The Redi-Rock Licensed Manufacturer is responsible for safe lifting and handling of all concrete products created in Redi-Rock forms. The use of lifting inserts and associated hardware shall be in accordance with the printed safe lifting practices and procedures, as published by the manufacturer.
• The National Precast Concrete Association (NPCA) publishes the NPCA Quality Control Manual for Precast and Prestressed Concrete Plants. The manual provides guidance to help assure production of quality precast products, and includes many recommendations which are applicable to Redi-Rock Manufacturers. The section of this manual which addresses lifting inserts allows the use of smooth bars made of steel conforming to ASTM A36 for lifting inserts and apparatus (Commentary to Section 2.3.1). The manual also recommends that embedded steel shapes which will be exposed to moisture or other corrosive environments be galvanized (Commentary to Section 2.3.2).
• Wire rope lifting loops are not recommended due to accelerated corrosion potential that adversely affects block durability and safety.
• Blocks must be poured with concrete in accordance with ASTM C94. ASTM C94 specifies that mixing water shall be potable water. Do not use admixtures containing chlorides because Redi-Rock blocks contain metal embedments.
• Redi-Rock Manufacturers should obtain testing data which demonstrates the capacity of the lifting inserts exceeds the weight of the blocks with a factor of safety of 4 or greater. The capacity of the inserts should be checked when the blocks are in a green condition when they are stripped from the forms and in subsequent handling and setting conditions. For commercially available inserts, this test data should be available from the lifting insert manufacturer. If commercially available inserts are not used, the Redi-Rock Manufacturer should perform a testing program to demonstrate that the inserts are appropriate, meet all applicable specifications, and have a lifting capacity which will provide a minimum factor of safety of 4 or greater.
When closing the forms, close the side panels first, bottom panel second, and top panel third. Be sure to check the position of the lifting insert as the panel closes.
Attach binder on one side and apply pressure while pushing on the side panel to engage stops. Lock one binder. Position the other side panel if necessary to engage stops. Attach and lock the second binder. Double check the lifting insert remained in the correct position.
1. 2. Pour
Fill forms to the specified depth to produce blocks that conform to published dimensions and tolerances.
Finish the back of the block with a trowel.
Helpful Hint: After finishing the back of the block, make wedge-shaped notches on the side panel with your trowel in the wet concrete to aid in demolding the block.
Helpful Hint: Depending on your concrete mix, you may need to vibrate concrete during or after pouring to get the desired finished product.
After the back of the block is finished, place an appropriate lifting insert in the designated location.
Coding and dating blocks is easily done by scribing into fresh concrete on block back at this time.
Demolding
Safety Note:
Allow blocks to cure properly before lifting out of form. Proper cure times vary according to weather, concrete mix, and curing conditions. Lifting inserts typically have minimum concrete strength requirements to develop necessary lifting capacity.
To open the form, unlock and unhook the binders.
Use a pry bar at the upper corners. Do not hammer on forms.
Helpful Hint: If notches were trowelled into the back of the block, it can aid in prying open the side panels, especially if fork slots are installed.
Helpful Hint: Do not allow panels to slam open hard on rails. Protecting the form from unnecessary wear and tear will help to prolong the life of your investment.
To carefully lift the blocks, hook on to the back lifting insert(s). Before actually lifting blocks, shift the block back and forth once to break initial bond using a forklift or crane. This is important to avoid bending the steel frame within the face mold.
Safety Note:
The concrete blocks are heavy – refer to the specific information from the Block Library to determine requirements for safe lifting of each product. Always use load-rated chains, cables and hooks.
After bond has been broken, then lift vertically to clear the form before moving. Be careful that blocks do not swing and tear edges of the face mold.
To roll the blocks for storage purposes, lower the face onto a clean cushioned surface. These surfaces could include:
• Rubber belting
• Foam board
• Sand bed
• Old mattress
• Plywood
Critical Note: Once the block has been lifted, do not attempt to set it back in face mold. Serious damage may occur to the mold.
Gently roll the block onto the bottom by maneuvering forklift or crane.
It is recommended to break away concrete flashing at form seams and lift hook. This step makes wall installation easier and safe work for your customer.
Helpful Hint: Remember uncured concrete is easier to clean than cured concrete.
Storage
Moving the blocks into inventory can be done with a chain and hook, fork slots, or a lift/clamp.
Safety Note:
The height of the stacks of blocks will be determined by your specific location and safety standards.
Helpful Hint: For some blocks, lumber dunnage should be used to create level stacks.
Helpful Hint: For inventory purposes, it’s recommended to stack like blocks together. And remember, bottom blocks usually ship first.
Maintenance
Binder Adjustments
Binder tension loosens over time. When the forms are really easy to close or more flashing is appearing on blocks, it’s time to adjust the binders. Tension can be increased by tightening the nuts on the binder. Check regularly, and adjust as required.
Rubber/Polyurethane Mold Storage Worn Hinges
Redi-Rock molds are sensitive to ultraviolet exposure. Do not store in direct sunlight.
Protect all edges/lips of the mold from warping or deforming during storage.
If hinges are worn, consult RediRock for options.
R-28HT 28" (710mm) HALF
R-41T 41" (1030mm) TOP *
/ Limestone
28 in (710 mm)
Middle Block
28 in (710 mm) or 41 in (1030 mm) Middle blocks are used in gravity retaining walls.
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
Kingstone / Ledgestone
Kingstone / Ledgestone Cobble / Limestone
Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3). Half blocks contain a fork slot on only one side of the block. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102mm) tall. Smaller knob diameters are available.
Units for dimensions are inches (mm), typical unless noted otherwise.
Block production varies with each licensed Redi-Rock manufacturer.
Confirm availability before Specifying or Ordering.
Center of Gravity is measured from the back of block.
Knob formers (R003-A155) are bolted to the top panel with carriage bolts, heads inward.
STANDARD 41” POSITION
B = “B” Style Knob Covers
C = “C” Style Knob Covers
KF = Knob Former
Note Loop Holder position.
Loop holder is installed. See page vi in the Appendix for loop holder options.
Groove former (R002-A011) and face mold are installed.
Production Notes
Pour
To manufacture a 28-in (710-mm) block, measure 23 in (584 mm) above the parting line where the face mold meets the steel and pour to that line.
Helpful Hint: If the three-way top panel is installed, use the diagram to place knob formers and knob covers in the correct location to produce 41 in (1030 mm) Middle blocks.
To manufacture a 41-in (1030-mm) block, fill the form full.
Critical Note: Top of groove former should be 21 13/16 in (554 mm) from the top of the form.
Cobble / Limestone
Bottom Block
28 in (710 mm) or 41 in (1030 mm) Bottom blocks do not have the groove and are used at the base of gravity retaining walls.
R-28B 28" (710mm) BOTTOM
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
PARTS
R-28HB 28" (710mm) HALF BOTTOM
R-41B 41" (1030mm) BOTTOM
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
1. Units for dimensions are inches (mm), typical unless noted otherwise.
6. Half blocks contain a fork slot on only one side of the block.
7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102mm) tall. Smaller knob diameters are available.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
AND KIT NUMBERS FOR ORDERING
4. Actual block volumes and weights may vary.
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
5. Weights are
6. Half blocks
7. Interface Shear (102mm) tall.
8. * 41" (1030mm) applications.
Form Assembly
2. 1.
Helpful Hint: If the PC kit is installed, see page 99.
The bottom block setup is identical to the middle block except that the groove former is removed. After removing the groove former, holes in the bottom door panel may be plugged with bolts if desired.
Face mold, knob formers, and loop holder are the same as for middle block set up.
Production Notes
To manufacture a 41-in (1030-mm) block, fill the form full. Pour Storage
2. 1. 1.
To manufacture a 28-in (710-mm) block, measure 23 in (584 mm) above the parting line where the face mold meets the steel and pour to that line.
To stack bottom blocks in the yard, use a spacer, such as a block of 4-in (100-mm) tall wood, to stack the blocks level.
Top Block
28 in (710 mm) or 41 in (1030 mm) Top blocks do not have the knobs, which makes it easier to finish walls in the field with final landscaping or coping.
RETAINING BLOCKS
Note: If the two-way or three-way panel are installed, the top insert is different than with the standard panel
Block Library
R002-A155 A/R LIFTEYE FORMER TYPE #1, 2PC. 28 in (710 mm) 41 in (1030 mm)
COMPATIBLE OPTIONS (FL1)
PART NUMBER QTY
RETAINING BLOCKS
Block Library
28" (710mm) HALF
DESCRIPTION
R002-A105 A/R LOOP HOLDER #5 NO-RECESS HOLDER
R002-A145 A/R LOOP HOLDER #1 FOR 5/16" CABLE
R-41T 41" (1030mm) TOP * R-41M 41" (1030mm) MIDDLE
41" (1030mm) BOTTOM
/ Ledgestone
FL1) Compatible options must be selected separately and are not included in this assembly 2) GRAY COMPONENTS FOR REFERENCE ONLY
/ Ledgestone
/ Ledgestone
R-28M 28" (710mm) MIDDLE
R-28B 28" (710mm) BOTTOM
R-28HM 28" (710mm) HALF MIDDLE
R-28HB 28" (710mm) HALF BOTTOM
Center
Block Weight: Block Volume:
Cobble / Limestone Kingstone / Ledgestone
Face Texture:
Cobble / Limestone Kingstone / Ledgestone
Cobble / Limestone Kingstone / Ledgestone
Cobble / Limestone
Kingstone
R002-A058
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A097 (INSERT FOR STANDARD DOOR PANEL)
• R002-A170 (INSERT FOR 2-WAY OR 3-WAY DOOR PANEL)
PARTS LIST DESCRIPTION QTY PART NUMBER TOP BLOCK WELDMENT 1
COMPATIBLE OPTIONS (FL1)
PART NUMBER QTY DESCRIPTION
R002-A105 A/R LOOP HOLDER #5 NO-RECESS HOLDER
R002-A145 A/R LOOP HOLDER #1 FOR 5/16" CABLE
R002-A155 A/R LIFTEYE FORMER TYPE #1, 2PC.
2PC.
NOTES:
FL1) Compatible options must be selected separately and are not included in this assemb 2) GRAY COMPONENTS FOR REFERENCE ONLY
REVISION HISTORY
ZONE REV DESCRIPTION DATE APPROV C Added in loop holder for reference. Added in compatible option table. 6/2/2021
Form Assembly
1.
The top block insert (R002-A058 or R002-A169) is bolted to the top panel. The knob formers are removed, and studs align in holes. Tabs are provided to ease alignment.
2.
Groove former needs to be bolted to the bottom panel.
3.
Loop holder is bolted to the top insert in the center pair of holes.
Critical Note: Do not over tighten so as to deform rubber.
Critical Note: Knob formers may then be reinstalled if desired, but this may promote rust inside.
Critical Note: Top of groove former should be 21 13/16 in (554 mm) from the top of the form.
Helpful Hint: See page vi for loop holder options.
Top Block
Production Notes
Pour
1.
To manufacture a 28-in (710-mm) block, measure 23 in (584 mm) above the parting line where the face mold meets the steel and pour to that line.
2.
To manufacture a 41-in (1030-mm) block, fill the form full.
Storage
1.
To stack top blocks in the yard, use a spacer, such as a block of 4-in (100-mm) tall wood, to stack the blocks level.
Face
Block Weight:
Block Volume:
Center of Gravity:
Cobble / Limestone
Face
Cobble / Limestone
Half Middle Block
28 in (710 mm) or 41 in (1030 mm) Half Middle blocks are used to maintain a running bond in walls where necessary.
R-28HM 28" (710mm) HALF MIDDLE
R-41M 41" (1030mm) MIDDLE
Cobble / Limestone
Kingstone / Ledgestone
R-41HM 41" (1030mm) HALF MIDDLE
Cobble / Limestone Center of Gravity:
SHEAR KNOBS @ 23 (584) OC, TYP.
Kingstone / Ledgestone
R-41B 41" (1030mm) BOTTOM
R-28HB 28" (710mm) HALF BOTTOM
R-41HB 41" (1030mm) HALF BOTTOM
COMPATIBLE OPTIONS (FL1) PART NUMBER QTY DESCRIPTION
Kingstone / Ledgestone
Cobble / Limestone Cobble / Limestone
R002-A110 A/R LOOP HOLDER #2
R002-A148 A/R LIFTEYE FORMER TYPE #4, 1PC FOR 10" KNOB FORMER
/ Ledgestone
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3). Half blocks contain a fork slot on only one side of the block.
Interface Shear knobs are typically 10" (254mm) diameter by 4" (102mm) tall. Smaller knob diameters are available.
* 41" (1030mm) Top blocks are not typical and used in limited
Half
Kingstone
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A099 (WEDGE)
NOTE: A HALF-BLOCK RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
COMPATIBLE OPTIONS (FL1)
R002-A148 A/R LIFTEYE FORMER TYPE #4, 1PC FOR 10" KNOB FORMER
Form Assembly
1.
Knob formers and groove former are the same as for full blocks.
The half block rubber face mold is centered and bolted to the bottom of the form.
The half middle block wedge (R002-A060) is bolted to the bottom door panel. Be sure to center the wedge on the center rib of the face mold before tightening bolts.
4.
Two loop holders are bolted in the knob formers. It may be necessary to drill holes in the knob formers.
Critical Note: Do not over tighten so as to deform rubber.
Helpful Hint: See page vi in the Appendix for loop holder options.
28 in (710 mm) or 41 in (1030 mm) Half Bottom blocks do not have the groove and are used in the base course to maintain a running bond in walls where necessary.
41" (1030mm) BOTTOM
R-28HB 28" (710mm) HALF BOTTOM
R-41HB 41" (1030mm) HALF BOTTOM
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
1. Units for dimensions are inches (mm), typical unless noted otherwise.
6. Half blocks contain a fork slot on only one side of the block.
7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102mm) tall. Smaller knob diameters are available.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
6. Half blocks contain a fork slot on only one side of the block.
7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102mm) tall. Smaller knob diameters are available.
8. * 41" (1030mm) Top blocks are not typical and used in limited applications.
Kingstone / Ledgestone
Kingstone / Ledgestone
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A164 (WEDGE)
NOTE: A HALF-BLOCK RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
COMPATIBLE OPTIONS (FL1)
LOOP HOLDER
KNOB FORMER
SHEET: HALF BLOCK - BOTTOM WEDGE
To create the half bottom blocks, a bottom wedge (R002-A126) exists where there is no groove former cutout. Install the wedge into the form.
Helpful Hint: If you want to modify the standard wedge (R002-A060) for pouring half bottom blocks, two options exist:
• Tack thin steel plates in place to cover the groove former cutout.
• After production, flip the block over and fill the groove with concrete.
Half Top Block
28 in (710 mm) or 41 in (1030 mm) Half Top blocks are used at the top of walls to maintain a running bond and do not have knobs, which makes it easier to finish walls in the field with final landscaping or coping.
Block Library
R-41T 41" (1030mm) TOP *
R-28HT 28" (710mm) HALF TOP
Kingstone / Ledgestone
Face Texture:
of Gravity:
COMPATIBLE OPTIONS (FL1) PART NUMBER QTY DESCRIPTION
NOTES: FL1) Compatible options must be selected separately and are not included in this assembly 2) GRAY COMPONENTS FOR REFERENCE ONLY
Kingstone / Ledgestone
Cobble / Limestone
Cobble / Limestone
Kingstone / Ledgestone
R002-A127
RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
COMPATIBLE OPTIONS (FL1) PART NUMBER QTY DESCRIPTION
R002-A105 A/R LOOP HOLDER #5 NO-RECESS HOLDER
R002-A145 A/R LOOP HOLDER #1 FOR 5/16" CABLE
R002-A155 A/R LIFTEYE FORMER TYPE #1, 2PC.
Form Assembly
The top block insert and groove former are the same as for the full top block. See page 27 for top block assembly instructions.
2.
The half block rubber face mold is centered and bolted to the bottom of the form.
Half top block wedge (R002-A127) is bolted to the bottom door panel. Be sure to center the wedge on the center rib of the face mold before tightening bolts.
3. 4. 1.
Two loop holders are bolted to the top block insert in the outermost pairs of holes.
Critical Note: Do not over tighten so as to deform rubber.
Helpful Hint: See page vi in the Appendix for loop holder options.
Tall Block
BLOCKS
Block Library
Block Library
28 in (710 mm) or 41 in (1030 mm) 9 in (230 mm) Tall blocks are predominantly used to gradually reduce the height of the wall from the traditional 18 in (457 mm) transition between courses.
BLOCKS
FREESTANDING BLOCKS
Block Library
Block Library
9" (230 mm) STEPDOWN TOP
Kingstone / Ledgestone
9" (230 mm) STEPDOWN TOP
Units for dimensions are inches (mm), typical unless noted otherwise.
1. Units for dimensions are inches (mm), typical unless noted otherwise.
Kingstone / Ledgestone
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A165 (9 IN TALL TOP INSERT)
• R002-A167 (9 IN TALL BOTTOM INSERT)
• R002-A166 (9 IN TALL GROOVE FORMER)
NOTE: A 9IN TALL RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
Form Assembly
9INCH TOP BLOCK
Remove the face mold and groove former from the form.
2. 1.
Install the 9 in (230 mm) bottom block insert (R002-A139) into the bottom panel using the groove former holes.
Note: If pouring middle or top blocks, install the 9 in (230 mm) block groove former (R002-A140) onto the insert before installing the insert in the form. There will not be a way to attach the groove former after the insert is installed.
Hint: If pouring bottom
the groove former.
R002-A144
R002-A144
R002-A139
R002-A140
Install the 9 in (230 mm) tall face mold (R002-A133) into the bottom of the form.
If pouring a top block, remove the knob formers and install the 3-in (76-mm) deep top insert (R002-A144) in the standard holes.
Production Notes
To manufacture a 28-in (710-mm) block, measure 23 in (584mm) above the parting line where the face mold meets the steel and pour to that line.
To manufacture a 41-in (1030-mm) block, fill the form full.
Maintenance, Tips & Tricks
The shallower groove former on 9 in (230 mm) tall blocks only fits over 6 3/4in (171 mm) or 7 1/2in (190 mm) knobs. Blocks used in the wall design beneath 9 in (230 mm) tall blocks should not have a standard 10 in (254 mm) knob.
Helpful Hint: If pouring a middle or bottom block, the knob formers would remain installed.
9 in Tall
Block
60 in (1520 mm)
Middle Block
60 in (1520 mm) Middle blocks are used in gravity retaining walls.
RETAINING BLOCKS
Block Library
R-60M 60" (1520mm) MIDDLE
Face Texture:
Cobble / Limestone
Kingstone / Ledgestone
R-60HM 60" (1520mm) HALF MIDDLE
Block Weight: Block Volume:
Center of Gravity:
Cobble / Limestone
Kingstone / Ledgestone
Face Texture:
Face Texture: Cobble / Limestone
Block Weight: Block Volume:
Center of Gravity:
R-60B 60" (1520mm) BOTTOM
Face Texture:
Block Weight: Block Volume:
Center of Gravity:
Cobble / Limestone
Kingstone / Ledgestone Kingstone / Ledgestone
R-60HB 60" (1520mm) HALF
Face Texture:
Block Weight: Block Volume:
Center of Gravity:
BOTTOM
Cobble / Limestone
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
60" (1520 mm) are typically used at the bottom of taller walls.
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A038 (60 IN KIT)
R002-A122 (OPTIONAL
60" MIDDLE WITH FORKSLOTS
WITH
Form Assembly
1.
The 60 in (1520 mm) retaining kit is a retro-fit kit for the standard 41 in (1030 mm) retaining block form. To install it, four holes will need to be drilled in each door panel.
2. 3.
Align the right side door panel extension (R002-A033) to the right side door panel using the ribs, inside surface and edges of the panel as a guide. Bend the ribs if necessary to align. Once the surface and edges are aligned, mark and drill top four 5/8-in (16-mm) or 3/4-in (19-mm) holes.
Install four bolts and tighten nuts. Check alignment again.
4.
Repeat step 2 and 3 for the left side door panel extension (R002-A036).
5.
Close the form and latch the binders. Place the top and bottom door panel extensions (R002-A034) on top and bottom door panels. Latch the binders on the extensions. Tighten binder spring tension if necessary. Grind the alignment tabs as necessary to make the panels flush.
6.
Check the alignment of the inside surfaces. Mark the four holes on each door panel. Remove the top and bottom extensions and drill four 5/8-in (16-mm) or 3/4-in (19-mm) holes on each panel.
Helpful Hint: The bottom panel extension has two holes for the middle wedge extension.
Place top and bottom extensions again. Install and finger tighten four bolts in each panel. Latch the binders again. Check the alignments of the inside surfaces with a straight edge. If shims are required, install now. 7.
9. 8.
Once all adjustments are final, tighten all eight bolts very tight with an impact wrench. This will hold everything in place.
If groove former, knob formers, loop holder, and fork slot extensions are not already installed, do so now.
Safety Note:
Make sure the lifting device insert has adequate capacity to lift the block. It may be necessary to use more than one insert in the back of the block.
Critical Note: Double check that extension doors are flat with existing doors often. If the extension becomes out of alignment, blocks will not be flat and adversely affect installation.
Middle Block
Production Notes
Pour
Safety Note:
With the height of the 60 in (1520 mm) form, using a safety ladder is recommended.
Demolding
1.
When opening the form, pry open the top and bottom door panels first to clear the stops.
2.
Pry open the side door panels using the two positions shown.
Critical Note: With the extensions on, the door panels are heavy. Do not allow them to slam against the bump rails.
Helpful Hint: If notches were created in the back of the block during the pouring process, they can aid in prying open the side door panels, especially if fork slots are installed.
Storage
Lift the block from the form using two rated chains and two lifting devices, if necessary.
Safety Note:
Helpful Hint: After troweling the back of the block, making wedge-shaped notches in the wet concrete along the side door panels can later help in the demolding process.
Critical Note: A 60-in (1520mm) block weighs about 3,300 lbs (1500 kg).
Use extreme caution when working around heavy loads like this. The load may fall causing injury or death. Never work under the load.
60 in (1520 mm)
Bottom Block
60 in (1520 mm) Bottom blocks are used in the base course in gravity retaining walls.
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
TH FORKSLOTS
Face Texture:
Center of Gravity:
Cobble / Limestone
5. Weights are based upon a concrete density of 143 lb/ft (2291kg/m3).
6. 60" (1520 mm) are typically used at the bottom of taller walls.
7. Half blocks contain a fork slot on only one side of the block.
8. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102mm) tall. Smaller knob diameters are available.
Bottom Block
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A038 (60 IN KIT)
• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)
60" BOTTOM WITH FORKSLOTS
Form Assembly
The bottom block setup is identical to the middle block except that the groove former is removed. After removing the groove former, holes in the bottom door panel may be plugged with bolts if desired.
Production Notes
Pour & Demold
Production for the 60 in (1520 mm) Bottom block is the same as the middle block. See page 46 for production notes.
Storage
Helpful Hint: To stack 60 in (1520 mm) Bottom blocks in the yard, use a spacer, such as block of wood 4 in (100 mm) tall, to stack the blocks level.
Bottom Block
(1520
Half Middle Block
60 in (1520 mm) Half Middle blocks are used to maintain a running bond in walls where necessary.
R-60HM 60" (1520mm) HALF MIDDLE
Cobble / Limestone
BOTTOM
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A038 (60 IN KIT)
• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)
• R002-A099 (WEDGE)
• R002-A103 (60IN WEDGE EXTENSION)
NOTE: A HALF-BLOCK RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
60" HALF MID
Form Assembly
1.
A 60-in (1520-mm) middle wedge extension (R002-A062) is availab extend the 41-in (1030-mm) middle wedge (R002-A060) to create the 60 in (1520 mm) Half Middle block.
2.
60" HALF MIDDLE
Once the 41-in (1030-mm) middle wedge is installed, slot the lifting loop of the 41-in (1030-mm) wedge into the hole on the bottom of the 60in (1520-mm) wedge extension. Then attach the wedge using the two holes on the bottom door panel.
otherwise. manufacturer.
60 in (1520 mm)
Half Bottom Block
60 in (1520 mm) Half Bottom blocks are used to maintain a running bond in the base course in gravity retaining walls.
R-60HB 60" (1520mm) HALF BOTTOM
R-60HB 60" (1520mm) HALF BOTTOM
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
6. 60" (1520 mm) are typically used at the bottom of taller walls.
7. Half blocks contain a fork slot on only one side of the block.
8. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102mm) tall. Smaller knob diameters are available. Cobble / Limestone Center of
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM, OR RR 41IN 3-WAY FORM
• R002-A038 (60 IN KIT)
• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)
• R002-A164 (WEDGE)
• R002-A103 (60IN WEDGE EXTENSION)
NOTE: A HALF-BLOCK RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
To create the half bottom blocks, a bottom wedge (R002-A126) exists where there is no groove former cutout. Install the wedge into the form, and attach the wedge extension (R002-A062).
Helpful Hint: If you want to modify the standard wedge (R002-A060) for pouring half bottom blocks, two options exist:
• Tack thin steel plates in place to cover the groove former cutout
• After production, flip the block over and fill the groove with concrete
41 in (1030 mm) 60 in (1520 mm)
Setback Middle Block
41 in (1030 mm) and 60 in (1520 mm) 9 in (230 mm) Setback blocks are used to create a large batter angle (27.5 degrees) for gravity walls.
BLOCKS
Note: See page 11 in the introduction to this section and page ii in the Appendix for more information on setback options.
BLOCKS
Block Library
Block Library
Kingstone / Ledgestone
RETAINING BLOCKS
RETAINING BLOCKS
Kingstone / Ledgestone
Block Library
Block Library
Block Library
60" (1520mm) MIDDLE 9" (230mm) SETBACK
Kingstone / Ledgestone
RETAINING BLOCKS Cobble / Limestone
Kingstone / Ledgestone
60"
Kingstone / Ledgestone
Kingstone / Ledgestone
Kingstone / Ledgestone
Face Texture:
Center of Gravity:
Cobble / Limestone
/ Ledgestone Kingstone / Ledgestone
Kingstone / Ledgestone
(800 mm)
Center of Gravity: Block Weight:
Kingstone / Ledgestone
Kingstone / Ledgestone
Form Assembly Option 1 - Two-Way Panel
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN 9IN SETBACK FORM
• R002-A038 (60 IN KIT)
• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)
PARTS LIST PART NUMBER QTY DESCRIPTION
R002-A024 2 COVER "D" ASSEMBLY
RR-G-KF10-S 2 10" KNOB FORMER .5-13-HN 14 5-13 HEX NUT
Note: The two-way panel (R002-A030) is sometimes also referred to as the 9 in (230 mm) setback panel.
1.
The two-way panel shown at right is installed on a standard retaining cell in place of the standard top panel. The panel can also make standard 41-in (1030-mm) retaining blocks.
2.
Install the knob cover D (R002-A024) in the standard knob hole locations. Install the two, 10 in (254 mm) knob formers (R003-A155) at the setback location.
3.
If pouring a 60-in (1520-mm) block and the form is not already configured, see page 42 for how to transform the standard retaining form to the 60-in (1520-mm) form.
Form Assembly Option 2 - Three-Way Top Panel
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN 3-WAY FORM
• R002-A038 (60 IN KIT)
• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)
2
RR-G-KF10-S 2 KNOB FORMER
5-13X1 5-CB 14 .5-13X1.5 CARRIAGE BOLT
5-13-HN 14 .5-13 HEX NUT
3WAY 9" SETBACK MIDDLE BLOCK
R002-A018
R002-A018
2. 1.
To set up your three-way top panel (R002-A018) to produce 9 in (230 mm) Setback blocks, see diagram.
9” SET BACK POSITION B = “B” Style Knob Covers
KF = Knob Former
D = “D” Style Knob Covers
Note Loop Holder position.
If pouring a 60-in (1520-mm) block and the form is not already configured, see page 42 for how to transform the standard retaining form to the 60-in (1520-mm) form.
Form Assembly Option 3 - Retrofit Standard Panel
A steel template (R002-0296) is available to retrofit your standard top panel to also create 9 in (230 mm) Setback blocks. The template will be used to cut holes in the standard top panel for the different knob location, and knob cover D (R002-A024) will be used to cover the original knob locations.
Align the template up with the existing knob and bolt holes. Clamp in place.
Mark and cut hole for the new knob location and drill holes for the bolt locations for the knob covers.
Turn the template over to mark the other half of the panel and repeat the process.
If pouring a 60-in (1520-mm) block and the form is not already configured, see page 42 for how to transform the standard retaining form to the 60-in (1520-mm) form.
Critical Note: Do not duplicate the line of holes in the center of the panel.
Notes
Double check that the loop holder is in the correct location for 9 in (230 mm) Setback blocks.
Storage
To stack 9 in (230 mm) Setback blocks in the yard, use a spacer, such as a block of wood 4-in (100-mm) tall, to stack the blocks level. Or alternate blocks as shown at right.
Block Library
41 in (1030 mm) 60 in (1520 mm)
Block Library
Setback Bottom Block
The 9 in (230 mm) Setback Bottom blocks are used at the bottom of large batter angle walls.
Note: See page 11 in the introduction to this section and page ii in the Appendix for more information on setback options.
RETAINING BLOCKS
Block Library
Face Texture:
Block Weight: Block Volume:
Center of Gravity:
Cobble / Limestone
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
Face Texture:
Center of Gravity: Block Weight:
of
Cobble / Limestone
Cobble / Limestone
Kingstone / Ledgestone
Ledgestone Kingstone / Ledgestone
1. Units for dimensions are inches (mm), typical unless noted otherwise.
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
6. Half blocks contain a fork slot on only one side of the block.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102 mm) tall.
4. Actual block volumes and weights may vary.
Form Assembly Option 1 - Two-Way Panel
• RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A038 (60 IN KIT)
• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)
IF POURING A 60 IN (1520 MM) 9 IN (230 MM) SETBACK BLOCK AND THE EXTENSION KIT IS NOT ALREADY INSTALLED, SEE PAGE 43 FOR INSTRUCTIONS.
The bottom block setup is identical to the middle block except that the groove former is removed. After removing the groove former, holes in the bottom door panel may be plugged with bolts if desired.
Face mold, knob formers, and loop holder are the same as for middle block set up.
Helpful Hint: Refer to the 9 in (230 mm) Setback Middle block instructions on page 55 for additional set-up instructions.
If pouring a 60-in (1520-mm) block and the form is not already configured, see page 42 for how to transform the standard retaining form to the 60-in (1520-mm) form.
Production Notes
Storage
To stack bottom blocks in the yard, use a spacer, such as a block of wood 4-in (100-mm) tall, to stack the blocks level.
IF POURING A 60 IN (1520 MM) 9 IN (230 MM) SETBACK BLOCK AND THE EXTENSION KIT IS NOT ALREADY INSTALLED, SEE PAGE 43 FOR INSTRUCTIONS.
R002-A018
The bottom block setup is identical to the middle block except that the groove former is removed. After removing the groove former, holes in the bottom door panel may be plugged with bolts if desired.
Face mold, knob formers, and loop holder are the same as for middle block set up.
Helpful Hint: Refer to the 9 in (230 mm) Setback Middle block instructions on page 57 for additional set-up instructions.
If pouring a 60-in (1520-mm) block and the form is not already configured, see page 42 for how to transform the standard retaining form to the 60-in (1520-mm) form.
Production Notes
Storage
To stack bottom blocks in the yard, use a spacer, such as a block of wood 4-in (100-mm) tall, to stack the blocks level.
41 in (1030 mm) 60 in (1520 mm)
Setback Half Middle Block
The 9 in (230 mm) Setback Half Middle blocks are used to maintain a running bond in walls where necessary.
Note: See page 11 in the introduction to this section and page ii in the Appendix for more information on setback options.
Block Library
NOTE: FORM SHOWN WITH 60 IN (1520 MM) EXTENSION AND STANDARD DOOR PANEL. USE A TWO-WAY OR THREE-WAY PANEL TO ACHIEVE THE 9 IN (230 MM) SETBACK POSITION OF THE KNOBS AND ONLY POUR TO 41 IN (1030 MM) IF NECESSARY.
• RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A038 (60 IN KIT)
• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)
• R002-A099 (WEDGE)
• R002-A103 (60IN WEDGE EXTENSION)
NOTE: A HALF-BLOCK RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
60" HALF MIDD
3WAY 9" SETBACK MIDDLE BLOCK
SHOWN WITH 60 IN (1520 MM)
R002-A020
Form Assembly
1.
Set up is the same as for the standard half middle block, except the knob formers are in the 9 in (230 mm) Setback position.
Helpful Hint: See page 31 for 41-in (1030-mm) set up and page 50 for the 60-in (1520-mm) set up instructions.
Production Notes
Production is the same as for the standard half middle block. 1.
Helpful Hint: See page 31 for 41-in (1030-mm) set up and page 50 for the 60-in (1520-mm) set up instructions.
/ Ledgestone
noted otherwise. manufacturer.
Setback Half Bottom Block
The 9 in (230 mm) Setback Half Bottom blocks are used to maintain a running bond in the bottom course of large batter walls.
Note: See page 11 in the introduction to this section and page ii in the Appendix for more information on setback options.
Face Texture:
Face Texture:
Block Weight: Block Volume:
Block Weight:
Center of Gravity:
Cobble / Limestone
Cobble / Limestone
Kingstone / Ledgestone
Kingstone / Ledgestone
Face Texture:
Block Weight:
Block Volume:
Center of Gravity:
Cobble / Limestone
Kingstone / Ledgestone
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
1. Units for dimensions are inches (mm), typical unless noted otherwise.
6. Half blocks contain a fork slot on only one side of the block.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
5-13-HN 5-FW 9 in (230 mm)
3. Center of Gravity is measured from the back of block.
7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102 mm) tall.
4. Actual block volumes and weights may vary.
6. Half blocks contain a fork slot on only one side of the block.
7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102 mm) tall.
8. 60" (1520 mm) Blocks are typically used at the bottom of taller walls.
• RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A038 (60 IN KIT)
• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)
• R002-A164 (WEDGE)
• R002-A103 (60IN WEDGE EXTENSION)
NOTE: A HALF-BLOCK RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE. PARTS LIST
NOTE:
3WAY 9" SETBACK MIDDLE BLOCK
FORM SHOWN WITH 60 IN (1520 MM) EXTENSION AND STANDARD DOOR PANEL. USE A TWO-WAY OR THREE-WAY PANEL TO ACHIEVE THE 9 IN (230 MM) SETBACK POSITION OF THE KNOBS AND ONLY POUR TO 41 IN (1030 MM) IF NECESSARY.
R002-A018
Form Assembly
Set up is the same as for the standard half middle block, except the knob formers are in the 9 in (230 mm) Setback position. 1.
Helpful Hint: See page 34 for 41-in (1030-mm) set up and page 52 for the 60-in (1520-mm) set up instructions.
Production Notes
Production is the same as for the standard half middle block. 1.
Helpful Hint: See page 34 for 41-in (1030-mm) set up and page 52 for the 60-in (1520-mm) set up instructions.
Half Bottom Block
41 in (1030 mm)
Planter Block
41 in (1030 mm) Planter blocks are used to create large batter walls with a 16 5/8-in (422-mm) setback.
Block Library
Note: See page 11 in the introduction to this section and page ii in the Appendix for more information on setback options.
RETAINING BLOCKS R-41PL 41" (1030mm) PLANTER
R-41PL 41" (1030mm) PLANTER
(1030mm)
Form Assembly Option 1 - Three-Way Panel
PARTS AND KIT NUMBERS FOR ORDERING
FL1
1.
See diagram for planter setback knob former and cover positions.
The planter block insert (R002-A174) is bolted through the outside holes in the D knob covers.
Groove former is bolted to the bottom panel.
2. 3. 4.
Loop holder is bolted to a planter block insert in the center pair of holes.
RR-G-KF10-S
R002-A020
R002-A024
.5-13x1.5-CB 5-13-HN
Critical Note: Do not over tighten so as to deform rubber.
Helpful Hint: For no planter trough, cover lower holes with D style knob covers instead of using the planter insert. It is often desirable to omit the insert to create a large batter wall without the need for soil to fill in the trough.
Form Assembly Option 2 - Legacy Universal Panel
PARTS AND KIT NUMBERS FOR ORDERING
•
•
• R002-A101 (INSERT)
R002-A059
1.
The planter block insert (R002-A059) is bolted to the universal top panel. Universal top panels designed for planter blocks have four holes in them.
2.
Knob formers are placed in the top two holes while the planter insert covers the bottom two holes.
3.
Groove former is bolted to the bottom panel.
4.
Helpful Hint: When all other blocks are poured, knob formers are installed in the bottom two holes, while the top two holes are covered with knob covers.
UNIVERSAL PANEL PLANTER BLOCK
Loop holder is bolted to the planter block insert in the center pair of holes.
Critical Note: Do not over tighten so as to deform rubber.
Storage
1. Production Notes
To stack 41 in (1030 mm) Planter blocks in the yard, use a spacer, such as a block of wood 4-in (100-mm) tall, to stack the blocks level or alternate blocks.
Helpful Hint: For no planter trough, cover lower holes with knob covers instead of using planter insert. It is often desirable to omit the insert to create a large batter wall without the need for soil to fill in the trough.
41 in (1030 mm)
Half Planter Block
41 in (1030 mm) Half Planter blocks are used to maintain a running bond in large batter walls with a 16 5/8-in (422-mm) setback.
Note: See page 11 in the introduction to this section and page ii in the Appendix for more information on setback options.
R-41HPL 41" (1030mm) HALF PLANTER
R-41HPL 41" (1030mm) HALF PLANTER
Face
•
Form Assembly
Planter block insert is the same as for full planter block. Use the appropriate insert for your top panel.
Groove former same as for full planter block.
Remove full block face mold and install the half block rubber face mold.
The half planter block wedge (R002-A131) is bolted to the bottom panel. Center before tightening bolts.
Two loop holders are bolted to planter block insert in outer pairs of holes.
Critical Note: Do not over tighten so as to deform rubber.
Open holes may be covered with bolts.
Half Planter Block
Modified Top Block
31 in (803 mm) Modified Top blocks are used as an alternative to the existing top block with 8 in (203 mm) of recess to provide more space for soil and finished landscaping on top of the wall.
R-MT MODIFIED TOP
Face Texture:
Face Texture:
Cobble / Limestone
Cobble / Limestone
Face Texture:
Kingstone / Ledgestone Block Weight:
Block Weight:
Face Texture:
Block Volume:
Block Weight: Block Volume:
Center of Gravity:
Center of Gravity:
SPECIALITY BLOCK
(540 kg)
/ Ledgestone
Face Texture:
/ Limestone
R002-A105 A/R LOOP HOLDER TYPE #5 NO-RECESS HOLDER
Block Weight:
Block Volume:
Block Weight: Block Volume:
R002-A145 A/R LOOP HOLDER TYPE #1 FOR 5/16" CABLE R002-A146 A/R LOOP HOLDER TYPE #4
Center of Gravity:
Center of Gravity:
/ Ledgestone
(527
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
Half blocks contain a fork slot on only one side of the block.
3. Center of Gravity is measured from the back of block.
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
4. Actual block volumes and weights may vary. 5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
7. Interface Shear knobs are typically 10" (254 mm) diameter by 4" (102 mm) tall.
6. Half blocks contain a fork slot on only one side of the block.
7. Interface Shear knobs are typically 10" (254 mm) diameter by 4" (102 mm) tall.
R002-A105 A/R LOOP HOLDER TYPE #5 NO-RECESS HOLDER
R002-A145 A/R LOOP HOLDER TYPE #1 FOR 5/16" CABLE
COMPATIBLE OPTIONS (FL1) PART NUMBER QTY DESCRIPTION
R002-A105 A/R LOOP HOLDER TYPE #5 NO-RECESS HOLDER
R002-A145 A/R LOOP HOLDER TYPE #1 FOR 5/16" CABLE
R002-A146 A/R LOOP HOLDER TYPE #4
R002-A146 A/R LOOP HOLDER TYPE #4 FL1 PARTS LIST DESCRIPTION QTY PART NUMBER 5-13 HEX NUT 4 .5-13-HN 5 FLAT WASHER 4 5-FW MODIFIED TOP BLOCK INSERT 1 R002-A135
NOTE: FL1) COMPATIBLE OPTIONS MUST BE SELECTED SEPARATELY AND ARE NOT INC 2) GRAY COMPONENTS ARE FOR REFERENCE ONLY
Form Assembly
1.
Modified top block insert (R002-A135) is bolted to the top panel. The knob formers are removed and the studs on the insert are aligned in the same holes.
Critical Note: Holes may need to be drilled in the top panel at initial set up to get proper alignment for the insert depending on what top panel is on the form.
Helpful Hint: To achieve a better center of balance for lifting, you may need to relocate the loop holders.
2.
Groove former and face mold are the same as for all standard retaining blocks.
Production Notes
Pour
1.
To manufacture a 31 in (803 mm) Modified Top block, pour to the bend in the insert before it begins to taper.
Critical Note: Do not overpour Modified Top blocks, as the steel eye used to install the insert into the form may create a die lock condition.
Pour to here
Modified Half Top Block
Face Texture:
Block Weight:
31 in (803 mm) Modified Half Top blocks are used at the end of a wall or start of a run to maintain a running bond when the modified top blocks are being used for landscaping on top of the wall. 4.45 ft3 (0.13 m3)
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
6. Half blocks contain a fork slot on only one side of the block.
7. Interface Shear knobs are typically 10" (254 mm) diameter by 4" (102 mm) tall.
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
6. Half blocks contain a fork slot on only one side of the block.
7. Interface Shear knobs are typically 10" (254 mm) diameter by 4" (102 mm) tall.
•
• R002-A138 (INSERT)
• R002-A157 (WEDGE)
R002-A136
Form Assembly
1.
The modified half top block wedge (R002-A136) needs to be bolted to the bottom panel. Center the insert before tightening the bolts. 2.
The modified top insert (R002-A135) and groove former are the same as for full Modified Top blocks.
3.
Remove full block face mold. Half block face mold is centered and bolted to the bottom of the form.
Critical Note: The steel eye used to install the insert into the form must be removed so it does not interfere with the wedge.
Production Notes
1. Pour
To manufacture a 31 in (803 mm) Modified Half Top block, pour to the bend in the insert before it begins to taper.
Helpful Hint: To achieve a better center of balance for lifting, you may need to relocate the loop holders.
NOTE:
Pour to here
Center of Gravity:
(533 mm)
Short Middle Block
Short Middle blocks are used in walls with double 90 degree corners to maintain the batter angle.
R-SM
SHORT MIDDLE
Face Texture:
Block Weight:
Block Volume:
Center of Gravity:
R002-A108 A/R LOOP HOLDER #1
Face Texture:
R002-A145 A/R LOOP HOLDER #8
(487 mm)
R002-A155 A/R LIFTEYE FORMER #1
Center of Gravity:
NOTES: GRAY COMPONENTS ARE FOR REFERENCE ONLY
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knob diameters are available. Cobble / Limestone
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
6. 27" (695) wide blocks contain a fork slot on only one side of the block. These are speciality blocks and may have limited availability and is only used in double 90 degree corner applications.
R002-A108
R002-A145
R002-A145
R002-A155
#1
R002-A155 A/R LIFTEYE FORMER #1
Form Assembly
1.
To install the 42.5 in (1080 mm) retaining block left and right inserts (R002-A184 and R002-A185), the fork slots will need to be removed. Then, install the inserts on the side panels.
2.
Critical Note: If the form has been modified to produce PC blocks, the steel wing kit must be removed prior to pouring blocks. They will interfere with the inserts on the side panels and prevent the form from closing.
Helpful Hint: If you want to use the fork slots, they will need to be attached to the inserts before the inserts are installed in the form. Trim the studs as needed to fit.
Install the 42.5 in x 18 in (1080 mm x 457 mm) face mold to pour Short Middle blocks.
Production Notes
Pour
Critical Note: When pouring short PC blocks, you must trowel a chamfer on the top edge of the block to avoid sharp edges that would be abrasive or could cut the geogrid when installed.
noted otherwise. manufacturer.
Short Top Block
Short Top blocks are used at the top of walls with double 90 degree corners to maintain the batter.
R-ST SHORT TOP Face
Face Texture:
Block Weight: Block Volume:
Block Weight: Block Volume:
Center of Gravity:
(0.13
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
6. 27" (695) wide blocks contain a fork slot on only one side of the block. These are speciality blocks and may have limited availability and is only used in double 90 degree corner applications.
7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knob diameters are available.
PARTS AND KIT NUMBERS FOR ORDERING
•
Form Assembly
1.
To install the 42.5 in (1080 mm) left and right top block inserts (R002-A181 and R002-182), the fork slots will need to be removed. Then, install the inserts on the side panels.
Helpful Hint: If you want to use the fork slots, they will need to be attached to the inserts before the inserts are installed in the form. Trim the studs as needed to fit.
If the top block insert is not already installed, install now. See page 27 for instructions.
3.
Install the 42.5 in x 18 in (1080 mm x 457 mm) face mold to pour Short Top blocks.
Production Notes
Critical Note: When pouring short PC blocks, you must trowel a chamfer on the top edge of the block to avoid sharp edges that would be abrasive or could cut the geogrid when installed.
Short Top Block
R-28PCT 28" (710mm) PC TOP
R-28PCT 28" (710mm) PC TOP
Kingstone / Ledgestone
R-41PCT 41" (1030mm) PC TOP
Face Texture:
Kingstone / Ledgestone
Positive Connection Middle Block
28 in (710 mm) and 41 in (1030 mm) Positive Connection (PC) Middle blocks are used in reinforced wall applications where geogrid wraps through the center core slot to tie the blocks into the earth behind the wall.
R-28PCM 28" (710mm) PC MIDDLE R-41PCM 41" (1030mm) PC MIDDLE
28" (710mm) PC MIDDLE R-41PCM 41" (1030mm) PC MIDDLE
Face Texture:
Face Texture:
Kingstone / Ledgestone
Face Texture:
Face Texture:
Kingstone / Ledgestone
Block Weight: Block Volume:
Block Weight: Block Volume:
R002-A043
Center of Gravity:
Center of Gravity:
Block Weight: Block Volume:
Block Weight: Block Volume:
R002-A045 BOTTOM LEFT STEEL WING 1
R002-A051
23 (584) OC, TYP
R002-A052
R002-A053
Center of Gravity:
Center of Gravity:
R002-A050 BOTTOM RIGHT STEEL WING 1
SHEAR KNOBS @ 23 (584) OC, TYP.
R-28PCB 28" (710mm) PC BOTTOM
R-28PCB 28" (710mm) PC BOTTOM
COMPATIBLE OPTIONS (FL1) PART NUMBER QTY DESCRIPTION
Face Texture:
Face Texture:
Block Weight: Block Volume:
Block Weight: Block Volume:
R002-0129 1 (FL2) PC - RELIEF PLATE - BOTTOM PANEL
Kingstone
Face Texture: R-41PCB 41" (1030mm) PC BOTTOM
Face Texture: R-41PCB 41" (1030mm) PC BOTTOM
R002-0358 A/R PC - DRILL TEMPLATE #2 - TOP DOOR
Center of Gravity:
Center of Gravity:
Block Weight: Block Volume:
Block Weight: Block Volume:
R002-0359 A/R PC - DRILL TEMPLATE #1 - BOTTOM DOOR
Center of Gravity:
Center of Gravity:
1. Units for dimensions are inches (mm), typical unless noted otherwise.
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
4. Actual block volumes and weights may vary.
NOTE:
3) GRAY COMPONENTS ARE FOR REFERENCE ONLY
Weights are based upon a concrete density of 143
(2291kg/m3). Blocks contain a vertical slot for a 12" (300 mm) strip of geogrid soil
Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
Interface Shear knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knob diameters are available.
Interface Shear knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knob diameters are available.
FL1) COMPATIBLE OPTIONS MUST BE SELECTED SEPARATELY AND ARE NOT INCLUDED IN THIS ASSEMBLY FL2) COMPONENT REQUIRED WHEN USING KIT. INCLUDE IF NOT PRESENT IN FORM, EXCLUDE IF PRESENT IN FORM
REVISION HISTORY
ZONE REV DESCRIPTION DATE APPROVED A INITIAL RELEASE 16DEC2019 C NADOLSKY
R002-
COMPONENT REQUIRED WHEN USING KIT INCLUDE IF NOT PRESENT IN FORM,
NOTE: FL1) COMPATIBLE OPTIONS MUST BE SELECTED SEPARATELY AND ARE NOT INCLUDED IN THIS
FL2) COMPONENT REQUIRED WHEN USING KIT INCLUDE IF NOT PRESENT IN
3) GRAY COMPONENTS ARE FOR REFERENCE ONLY
Form Assembly
Remove all existing inserts from the top panel in the standard retaining form. Leave the bottom groove former and fork slot attachments.
Center drill template #2 (R002-0358) on the top panel.
Mark holes on the panel with paint or marker.
Drill 3/4-in (19-mm) diameter holes.
Critical Note: If your form is older and has angle iron rebar holders on the bottom panel, you will have to remove this before installing the PC kit.
Helpful Hint: Some holes may fit existing holes on the panel.
Helpful Hint: A MAG drill is recommended.
5.
To create the two slotted holes, drill three holes at the top, middle, and bottom of each slot then use a die grinder with a 1/2-in (13-mm) deburring tool to connect the holes.
Helpful Hint: Some people use a plasma cutter to cut the slotted holes.
Center the PC plate (R002-0130) between the 10-in (254-mm) knob holes. Place bolts through the top two lifting hook holder holes to hold the plate in place. The top of the mounting plate should be 19 1⁄4 in (489 mm) from the top of the panel.
After tightening bolts, hold the mounting plate flush against the top panel and tack weld it in place, so it seals tight against the top panel. The recommended weld locations are shown.
Bolt the PC top panel insert (R002-A043) in place. Tighten nuts on rubber insert until they are snug, and the washer no longer spins.
Helpful Hint: To help line up the placement of the rubber insert and steel wings so that the form will fully close, you can clamp the form shut with the side panels pushed out as far as they will go against the stops. Then mark the inside edge of the side panels on the top panel. Steel wings and inserts should be installed inside of this line.
Critical Note: Do not overtighten rubber insert or it will deform.
Bolts
Welds
Bolt the four steel wing inserts (R002-A050, R002-A051, R002-A052, R002-A053) in place. Fully tighten the nuts to secure the steel inserts to the top panel and provide a tight seal between the steel and rubber.
Bolt the PC slot insert (R002-A041) in place. Hold the insert in place and install two 7-in (178-mm) long, 1/2-in (13-mm) diameter bolts and 2-in (51-mm) springs through the top panel and into the rubber insert.
Replace 10 in (254 mm) knob formers.
Center drill template #1 (R002-0359) on bottom panel.
11.
12.
Adjust the groove former so the template is flush with the top of the bottom panel.
Critical Note: The top of the groove former should be 21 13/16 in (554 mm) from the top of the panel.
Mark holes on the panel with paint or marker.
Drill 3/4-in (19-mm) diameter holes. 15.
Bolt the PC bottom panel insert (R002-A045) in place.
Critical Note: Do not overtighten rubber insert or it will deform.
Helpful Hint: Some holes may fit existing holes on the panel.
Helpful Hint: A MAG drill is recommended.
The PC bottom plate (R002-0129) is a required component. If it is already in your form, skip this step. If it is not, weld the plate below the groove former now.
Critical Note: This plate is required.
Production Notes
When opening or closing the PC form, always work with the bottom panel first.
Check to ensure all rubber parts seal tight to each other.
• Check for a tight seal between the PC top panel insert (R002-A043) and the PC slot insert (R002-A041).
• Check for a tight seal between the PC bottom panel insert (R002-A045) and the PC slot insert (R002-A041).
• Check for a tight seal between the PC slot insert (R002-A041) and the PC plate (R002-0130).
When applying form oil, make sure the oil is applied to the underside of the PC slot insert (R002-A041). 2. 3.
When pouring a 28-in (710-mm) block, fill the form to the bottom edge of the flat spot on the steel wing kit. If the form is overpoured, flashing will occur that could cut the geogrid on the blocks above it.
Demolding
When demolding, pay close attention to lift the block from the form favoring the bottom panel. This will help pull the PC slot insert (R002-A041) from the block and reduce the opportunity for the insert to bind between the block and form and bend. It will also significantly extend the life of the rubber insert.
(710mm) PC MIDDLE
R-28PCM 28" (710mm) PC MIDDLE R-41PCM 41" (1030mm) PC
R-41PCM 41" (1030mm) PC MIDDLE
Kingstone / Ledgestone
Kingstone / Ledgestone
Kingstone / Ledgestone
Kingstone / Ledgestone
Positive Connection Bottom Block
28 in (710 mm) and 41 in (1030 mm) Positive Connection (PC) Bottom blocks are used at the bottom of reinforced wall applications where geogrid wraps through the center core slot to tie the blocks into the earth behind the wall.
PARTS LIST
R-28PCB 28" (710mm) PC BOTTOM
R-28PCB 28" (710mm) PC BOTTOM
R002-A045
R002-A052
R002-A053
R002-A176
Kingstone / Ledgestone
/ Ledgestone
R-41PCB 41" (1030mm) PC BOTTOM
Block Weight: Block Volume:
Center of Gravity:
41" (1030mm) PC BOTTOM
Kingstone / Ledgestone
/ Ledgestone
1. Units for dimensions are inches (mm), typical unless noted otherwise.
1. Units for dimensions are inches (mm), typical unless noted otherwise.
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
R002-0129 1 (FL2) PC - RELIEF PLATE - BOTTOM PANEL
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
6. Blocks contain a vertical slot for a 12" (300 mm) strip of geogrid soil reinforcement.
6. Blocks contain a vertical slot for a 12" (300 mm) strip of geogrid soil reinforcement.
R002-0358 A/R PC - DRILL TEMPLATE #2 - TOP DOOR
3. Center of Gravity is measured from the back of block.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
4. Actual block volumes and weights may vary.
R002-0359
7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knob diameters are available.
7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knob diameters are available.
R002-A173 (BOTTOM PC KIT)
Form Assembly
Remove all existing inserts from the top panel in the standard retaining form. Leave the bottom groove former and fork slot attachments.
Center drill template #2 (R002-0358) on the top panel.
Mark holes on the panel with paint or marker.
Drill 3/4-in (19-mm) diameter holes.
Critical Note: If your form is older and has angle iron rebar holders on the bottom panel, you will have to remove this before installing the PC kit.
Helpful Hint: Some holes may fit existing holes on the panel.
Helpful Hint: A MAG drill is recommended.
5.
To create the two slotted holes, drill three holes at the top, middle, and bottom of each slot then use a die grinder with a 1/2-in (13-mm) deburring tool to connect the holes.
Helpful Hint: Some people use a plasma cutter to cut the slotted holes.
Center the PC plate (R002-0130) between the 10-in (254-mm) knob holes. Place bolts through the top two lifting hook holder holes to hold the plate in place. The top of the mounting plate should be 19 1⁄4 in (489 mm) from the top of the panel.
After tightening bolts, hold the mounting plate flush against the top panel and tack weld it in place, so it seals tight against the top panel. The recommended weld locations are shown.
Bolt the PC top panel insert (R002-A043) in place. Tighten nuts on rubber insert until they are snug, and the washer no longer spins.
Helpful Hint: To help line up the placement of the rubber insert and steel wings so that the form will fully close, you can clamp the form shut with the side panels pushed out as far as they will go against the stops. Then mark the inside edge of the side panels on the top panel. Steel wings and inserts should be installed inside of this line.
Critical Note: Do not overtighten rubber insert or it will deform.
Bolts
Welds
Bolt the four steel wing inserts (R002-A050, R002-A051, R002-A052, R002-A053) in place. Fully tighten the nuts to secure the steel inserts to the top panel and provide a tight seal between the steel and rubber.
Bolt the PC slot insert (R002-A041) in place. Hold the insert in place and install two 7-in (178-mm) long, 1/2-in (13-mm) diameter bolts and 2-in (51-mm) springs through the top panel and into the rubber insert.
Replace 10 in (254 mm) knob formers. 11.
Center drill template #1 (R002-0359) on bottom panel.
12.
Adjust the groove former so the template is flush with the top of the bottom panel.
Critical Note: The top of the groove former should be 21 13/16 in (554 mm) from the top of the panel.
Mark holes on the panel with paint or marker.
15.
Drill 3/4-in (19-mm) diameter holes.
Bolt the PC bottom panel insert (R002-A045) in place.
Critical Note: Do not overtighten rubber insert or it will deform.
Helpful Hint: Some holes may fit existing holes on the panel.
Helpful Hint: A MAG drill is recommended.
17.
The PC bottom plate (R002-0129) is a required component. If it is already in your form, skip this step. If it is not, weld the plate below the groove former now.
18.
Critical Note: This plate is required.
Remove the groove former from the bottom panel and install the PC groove former (R002-A176) partial groove insert. Make sure this partial groove fits tightly up against the PC bottom panel insert (R002-A045).
Critical Note: The top of the partial groove former should be 21 13/16 in (554 mm) from the top of the panel.
Production Notes
When opening or closing the PC form, always work with the bottom panel first.
Check to ensure all rubber parts seal tight to each other.
• Check for a tight seal between the PC top panel insert (R002-A043) and the PC slot insert (R002-A041).
• Check for a tight seal between the PC bottom panel insert (R002-A045) and the PC slot insert (R002-A041).
• Check for a tight seal between the PC slot insert (R002-A041) and the PC plate (R002-0130).
When applying form oil, make sure the oil is applied to the underside of the PC slot insert (R002-A041).
When pouring a 28-in (710-mm) block, fill the form to the bottom edge of the flat spot on the steel wing kit. If the form is overpoured, flashing will occur that could cut the geogrid on the blocks above it.
When demolding, pay close attention to lift the block from the form favoring the bottom panel. This will help pull the center insert from the block and reduce the opportunity for the insert to bind between the block and form and bend. It will also significantly extend the life of the center insert.
28 in (710 mm) 41 in (1030 mm)
Positive Connection Top Block
28 in (710 mm) and 41 in (1030 mm) Positive Connection (PC) Top blocks are used at the top of reinforced wall applications where geogrid wraps through the center core slot to tie the blocks into the earth behind the wall.
RETAINING BLOCKS
RETAINING BLOCKS
Block Library
Block Library
R-28PCT 28" (710mm) PC TOP
R-28PCT 28" (710mm) PC
R002-A045
R-41PCT 41" (1030mm) PC
R-41PCT 41" (1030mm)
Kingstone / Ledgestone Kingstone / Ledgestone
BOTTOM LEFT STEEL WING 1 R002-A050
BOTTOM RIGHT STEEL WING 1 R002-A051 TOP LEFT STEEL WING 1 R002-A052
TOP RIGHT STEEL WING 1 R002-A053
TOP BLOCK CENTER INSERT 1 R002-A172 DIE SPRING: 1" O.D. x 1/2" I.D. x 1-1/2" 2 STD-0046 .5-13 HEX NUT 20 .5-13-HN 1/2-13x11" - HEX
COMPATIBLE OPTIONS (FL1)
R-28PCM 28" (710mm) PC MIDDLE
PART NUMBER QTY DESCRIPTION
41" (1030mm) PC MIDDLE
Face Texture:
Face Texture:
R002-0129 1 (FL2)
Block Weight: Block Volume:
Block Weight: Block Volume:
Center of Gravity:
Center of Gravity:
41" (1030mm) PC MIDDLE R-28PCB 28" (710mm) PC BOTTOM
Face Texture:
PC - RELIEF PLATE - BOTTOM PANEL
Block Weight: Block Volume:
R002-0358 A/R DRILL TEMPLATE #2 TOP DOOR
R002-0359 A/R DRILL TEMPLATE #1 BOTTOM DOOR
Center of Gravity:
R-28PCB 28" (710mm) PC BOTTOM
Face Texture:
Face Texture:
Block Weight: Block Volume:
Kingstone / Ledgestone Kingstone / Ledgestone Kingstone / Ledgestone PARTS LIST
R-41PCB 41" (1030mm) PC BOTTOM
Center of Gravity:
Center of Gravity:
NOTE:
FL1) COMPATIBLE OPTIONS MUST BE SELECTED SEPARATELY AND ARE NOT INCLUDED IN THIS ASSEMBLY FL2) COMPONENT REQUIRED WHEN USING KIT INCLUDE IF NOT PRESENT IN FORM, EXCLUDE IF PRESENT IN FORM 3) GRAY COMPONENTS ARE FOR REFERENCE ONLY
REVISION HISTORY
ZONE REV DESCRIPTION DATE APPROVED B-1 B ADDED (2) STD-0046 & HB FROM R002-A172 28OCT2021 L.RADOY
R002-A045
.5-FW
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A171 (TOP PC KIT)
• R002-A097 (INSERT FOR STANDARD DOOR PANEL) OR R002-A170 (INSERT FOR 2-WAY OR 3-WAY DOOR PANEL)
FL2) COMPONENT
3) GRAY COMPONENTS ARE FOR REFERENCE ONLY
Form Assembly
To modify a 5-in (127-mm) steel top block insert (R002-A097 or R002-A170) for a PC block, remove the 3/8-in (9.5-mm) square bar (if present) from the face of the top block insert.
Center drill template #2 (R002-0358) on the outside of the top block insert.
Mark holes on insert with paint or marker.
Drill 3/4-in (19-mm) diameter holes.
Helpful Hint: Some holes may fit existing holes on the panel.
Helpful Hint: A MAG drill is recommended.
To create the two slotted holes, drill three holes at the top, middle, and bottom of each slot then use a die grinder with a 1/2-in (13-mm) deburring tool to connect the holes.
Critical Note: Do not overtighten rubber insert or it will deform.
Helpful Hint: Some people use a plasma cutter to cut the slotted holes.
Bolt the PC top panel insert (R002-A043) in place. Tighten nuts on rubber insert until they are snug, and the washer no longer spins.
Critical Note: Longer slots are required for the top block insert than the slots machined on the template.
Bolt the four steel wing inserts (R002-A050, R002-A051, R002-A052, R002-A053) in place. Fully tighten the nuts to secure the steel inserts to the top panel and provide a tight seal between the steel and rubber.
Cut a slot between the existing center solid loop holder holes. 8.
Place new rubber loop holder over new slotted hole. Mark the location of the two new side holes with a pencil. 9.
Helpful Hint: The holes are off center and should be located approximately 26 3/4 in (680 mm) from the top of the top block insert.
Bolt Loop Holder #5 on the bottom of the top block insert.
Note: Holes are offset towards the bottom of the Insert/front of block.
Use a forklift to place the modified top block insert into the form and bolt it in place.
Bolt the Top block center insert (R002-A172) in place. Hold the insert in place and install two 11-in (779-mm) long, 1/2-in (13-mm) diameter bolts with two 1 1/2-in (38-mm) springs through the top panel and top block insert and into the PC rubber insert.
Center drill template #1 (R002-0359) on bottom panel.
Adjust the groove former so the template is flush with the top of the bottom panel.
Critical Note: The top of the groove former should be 21 13/16 in (554 mm) from the top of the panel.
Mark holes on the panel with paint or marker.
Drill 3/4-in (19-mm) diameter holes. 16.
Bolt the PC bottom panel insert (R002-A045) in place.
Critical Note: Do not overtighten rubber insert or it will deform.
Helpful Hint: Some holes may fit existing holes on the panel.
Helpful Hint: A MAG drill is recommended.
Critical Note: This plate is required.
18.
The PC bottom plate (R002-0129) is a required component. If it is already in your form, skip this step. If it is not, weld the plate below the groove former now.
Production Notes
When opening or closing the PC form, always work with the bottom panel first.
2.
Check to ensure all rubber parts seal tight to each other.
• Check for a tight seal between the PC top panel insert (R002-A043) and the top block center insert (R002-A172).
• Check for a tight seal between the PC bottom panel insert (R002-A045) and the top block center insert (R002-A172).
• Check for a tight seal between the top block center insert (R002-A172) and the top block insert (R002-A097 or R002-A170).
3.
When applying form oil, make sure the oil is applied to the underside of the Top block center insert (R002-A172).
When pouring a 28-in (710-mm) block, fill the form to the bottom edge of the flat spot on the steel wing kit. If the form is overpoured, flashing will occur that could cut the geogrid on the blocks above it.
Demolding
1.
When demolding, pay close attention to lift the block from the form favoring the bottom panel. This will help pull the center insert from the block and reduce the opportunity for the insert to bind between the block and form and bend. It will also significantly extend the life of the center insert.
1-AT Middle Block
1-AT Middle blocks are used in reinforced walls with an anchored tail of geogrid wrapped around a fiberglass rod and sandwiched between the blocks. This is a legacy element of the Redi-Rock system.
R-1AT 1-AT MIDDLE BLOCK
Face Texture:
R-28M 28" (710mm) MIDDLE
Block Weight: Block Volume: Face Texture:
Center of Gravity:
(710mm)
Center of Gravity:
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block.
4. Actual block volumes and weights may vary.
5. Weights are based upon a concrete
6. Half blocks contain a fork slot on only
Interface Shear knobs are typically (102mm) tall. Smaller knob diameters
Form Assembly Option 1 - Two-Way and Three-Way Panel
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A178 (LEGACY INSERT FOR 2-WAY OR 3-WAY DOOR PANEL)
R002-A177
Form Assembly Option 2 - Standard Panel
PARTS
AND KIT NUMBERS FOR ORDERING
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A117 (LEGACY INSERT FOR STANDARD DOOR PANEL)
1.
Install geogrid insert (R002-A116) in predrilled holes on the top panel.
Critical Note: Do not overtighten connector or it may deform.
Helpful Hint: For Redi-Rock forms purchased prior to March 2003, you need to drill six holes in order to fit the insert.
Production Notes
Inspect that the insert is sealed to the panel and has not been dented or damaged prior to pouring. Any damage to this insert will adversely affect the geogrid connection in the field.
Pour concrete to the top edge of the insert (see arrow).
Critical Note: Do not overpour the 28 in (730 mm) block. The insert is designed to taper at the back of the block to eliminate a rough back edge of the block, which could tear the geogrid under pressure.
Maintenance, Tips & Tricks
Maintenance
Regularly inspect the 1-AT insert to ensure it has not been dented or damaged. If the channel for the fiberglass rod is compromised the fiberglass rod won’t sit flat and it then reduces the connection strength.
Tips & Tricks
See page v in the Appendix for more information about the 1-AT geogrid connection.
41 in (1030 mm)
Anchor Middle Block
41 in (1030 mm) Anchor Middle blocks are used in reinforced wall scenarios that use soil anchors instead of geogrid to tie into the earth behind the wall.
R-AM ANCHOR MIDDLE
Anchor
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A180 (ANCHOR INSERT)
1. PARTS AND KIT NUMBERS FOR ORDERING
Form Assembly
Install the Anchor Block Insert (R002-A179) into the standard 41-in (1030-mm) retaining form in existing holes in top panel.
Anchor Bottom Block
RETAINING BLOCKS
41 in (1030 mm) Anchor Bottom blocks are used at the bottom of reinforced wall scenarios that use soil anchors instead of geogrid to tie into the earth behind the wall.
Block Library
R-AB ANCHOR BOTTOM
R-AM ANCHOR MIDDLE
Kingstone / Ledgestone
/ Ledgestone
Anchor Bottom Block
PARTS AND KIT NUMBERS FOR ORDERING
• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM
• R002-A180 (ANCHOR INSERT)
Form Assembly
1.
Install the anchor block insert (R002-A179) into the standard 41-in (1030-mm) retaining form in existing holes in top panel.
2.
Remove the groove former from the bottom panel of the form.
Hollow-Core Block
41 in (1030 mm) Hollow-Core block is used in retaining wall applications and reduces the concrete used by 28% from a solid 41 in (1030 mm) block.
RETAINING BLOCKS
Block
Center of Gravity:
Limestone
Cobble / Limestone
/ Ledgestone
Hollow-Core Block
STANDARD PARTS LIST DESCRIPTION QTY PART NUMBER 10" XL KNOB FORMER 2 R001-0386 PC - MOUNTING PLATE - TOP PANEL 1 R002-0130
Top Door Insert, 41" Retaining H.C. 1 R002-A068 Side Door Insert, 41" Retaining H C 2 R002-A073
NOTES: FL1) Compatible options must be selected seperately and are not included in this as 2) This kit is configurable on Standard & Universal type retaining forms only
Changed loop holder from R002-0297 to R002-A105 Title Change 6/2/2021
.5-13x1.5-CB .5-13x2-HB
NOTES: FL1) Compatible options must be selected seperately and are not included in this assembly 2) This kit is configurable on Standard & Universal type retaining forms only. **CRITICAL LENGTH FOR ASSEMBLY*
AND
R002-A081 R002-A073 R002-A073
R002-A010
R002-A129
R002-A068
R002-A105
R002-0130
R001-0386
R002-A081
R002-A073
R002-A068
R002-A105
1.
Remove all applicable internal components from existing form as specified below.
• Knob castings
• Groove former
• Fork slots
• Hook/loop holder
• Bolted PC inserts
Helpful Hint: Face mold does not have to be removed from the form; however, removal is recommended to avoid damaging mold during form modification.
• All carriage and plug bolts
• All letter knob cover plates
• Any other options (i.e. 60 in (1520 mm) extension, half block insert, top block insert, etc.)
For forms currently equipped with PC plate only: Verify existing welded PC plate placement is correct by placing template #1 (R002-0245) on top door panel as shown.
• If PC plate mates to template, proceed to step 4.
• If PC plate mate does not match to template, remove plate with grinder. Make sure finished surface is smooth and flat.
Clamp template #1 (R002-0245) to top door panel, insert supplied PC plate as shown and tack weld plate to door.
3. 4.
Using center punch, mark six hole center locations given per template #1.
Critical Note: Template must be centered on panel. Actual panel(s) width may vary ± 1/32 in (0.8 mm) against template, adjust centering placement accordingly.
Remove template #1 from the top panel. If using the standard panel, proceed to the next step. If using the universal panel, reinstall existing 16-in (406-mm) setback knob covers. 5.
Hollow-Core Block
Using MAG drill with 5/8-in (16-mm) drill bit, drill all applicable holes through top door panel. Deburr all drilled holes as needed.
Helpful Hint: When using the universal panel, holes will also go through the knob covers.
Fully weld PC plate (R002-0130) to top door as per locations indicated in red.
Verify loop holder is installed to top door insert (R002-A068). If the holder was not previously installed, secure to the top insert.
Critical Note: Do not overtighten.
9.
Place supplied top insert (R002-A068) with loop holder into door as shown. Do not secure the insert to the panel at this step.
Install 10 in XL knob former (R001-0386).
Critical Note: Install knobs properly as shown to prevent die-lock condition.
After knobs are installed, secure the top insert (R002-A068) to the panel.
Reinstall all existing carriage (plug) bolts to top panel except for holes indicated in picture.
If the bottom panel on the form contains two angle structures, remove them with a grinder as shown. Make sure the finished surface is smooth and flat. If the panel doesn’t contain the angle structures, proceed to the next step.
Clamp template #3 (R002-0303) to the bottom panel.
Critical Note: Template must be centered on door panel. Actual door(s) width may vary ± 1/32 in (0.8 mm) against template, adjust centering placement accordingly.
Hollow-Core
Block
Using center punch, mark six hole center locations given per template #3, then remove it from the bottom panel.
Using MAG drill with 5/8-in (16-mm) drill bit, drill all applicable holes through the bottom panel. Deburr all drilled holes as needed.
17.
Place supplied groove former (R002-A074) into bottom door panel, then secure.
Critical Note: Groove former assembly orientation in panel is critical. Incorrect assembly will not allow the form to fully close.
Place supplied bottom door insert (R002-A081) into bottom door panel, then secure.
19.
Clamp template #2 (R002-0247) to a side panel.
Critical Note: Template must be centered on door panel. Actual door(s) width may vary ± 1/32 in (0.8 mm) against template, adjust centering placement accordingly.
Using center punch, mark six hole center locations given per template #2, then remove it from the door panel.
Using MAG drill with 5/8-in (16-mm) drill bit, drill all applicable holes through the bottom panel. Deburr all drilled holes as needed.
Place supplied side door insert (R002-A073) into side door panel and secure.
Repeat steps 19 - 22 on other side panel.
Hollow-Core
Block
•
STANDARD PARTS LIST DESCRIPTION QTY PART NUMBER
PC - MOUNTING PLATE - TOP PANEL 1 R002-0130 10" 3-WAY KNOB FORMER; HOLLOW CORE 2 R002-0254
Form Assembly Option 2: Two-Way Panel & Three-Way Panel
Top Door Insert, 41" Retaining H.C. Side Door Insert, 41" Retaining H.C. Groover Former, 41" Retaining H C Bottom Door Insert, 41" Retaining H C LOOP HOLDER #5 NO-RECESS HOLDER
R002-0247 A/R Drill Te R002-0303 A/R Drill Te options must be selected seperately and are not included in this assembly. nfigurable on 9" Set-back & 3-Way type retaining forms only
REVISION HISTORY
AND
R002-A081
R002-0254
R002-A074
1.
Remove all applicable internal components from existing form as specified below.
• Knob castings
• Groove former
• Fork slots
• Hook/loop holder
• Bolted PC inserts
2.
• All carriage and plug bolts
• All letter knob cover plates
• Any other options (i.e. 60 in (1520 mm) extension, half block insert, top block insert, etc.)
For forms currently equipped with PC plate only: Verify existing welded PC plate placement is correct by placing template #1 (R002-0245) on top door panel as shown.
• If PC plate mates to template, proceed to step 4.
• If PC plate mate does not match to template, remove plate with grinder. Make sure finished surface is smooth and flat.
3.
Clamp template #1 (R002-0245) to top door panel, insert supplied PC plate as shown and tack weld plate to door.
Critical Note: Template must be centered on panel. Actual panel(s) width may vary ± 1/32 in (0.8 mm) against template, adjust centering placement accordingly.
Helpful Hint: Face mold does not have to be removed from the form; however, removal is recommended to avoid damaging mold during form modification.
4.
Using center punch, mark six hole center locations given per template #1.
Hollow-Core
Block
Standard Form
Remove template #1 from the top panel. If using the twoway panel, reinstall existing D knob covers over the 9-in (230-mm) setback position. If using the three-way panel, reinstall existing B and C knob covers.
Using MAG drill with 5/8-in (16-mm) drill bit, drill all applicable holes through top door panel. Deburr all drilled holes as needed.
Helpful Hint: When using the three-way panel, holes will also go through the B knob covers.
Fully weld PC plate (R002-0130) to top door as per locations indicated in red. 7.
Verify loop holder installed to top door insert (R002-A068). If the holder was not previously installed, secure to top insert.
Critical Note: Do not overtighten.
Place supplied top insert (R002-A068) with loop holder into door as shown. Do not secure insert to door at this step.
Install the 10 in 3-way Knob Former (R002-0254).
Critical Note: Install knobs properly as shown to prevent die-lock condition.
After the knobs are installed, secure the top insert to the top panel.
Hollow-Core
Block
12.
Reinstall all existing carriage (plug) bolts to top panel except for holes indicated in picture.
If the bottom panel on the form contains two angle structures, remove them with a grinder as shown. Make sure the finished surface is smooth and flat. If the panel doesn’t contain the angle structures, proceed to the next step. 13.
14.
Clamp template #3 (R002-0303) to the bottom panel.
Critical Note: Template must be centered on door panel. Actual door(s) width may vary ± 1/32 in (0.8 mm) against template, adjust centering placement accordingly.
Using center punch, mark six hole center locations given per template #3, then remove it from the bottom panel.
Using MAG drill with 5/8-in (16-mm) drill bit, drill all applicable holes through the bottom panel. Deburr all drilled holes as needed.
Place supplied groove former (R002-A074) into bottom door panel, then secure. 17.
Critical Note: Groove former assembly orientation in panel is critical. Incorrect assembly will not allow the form to fully close.
18.
Place supplied bottom door insert (R002-A081) into bottom door panel, then secure.
19.
Clamp template #2 (R002-0247) to a side panel.
Critical Note: Template must be centered on door panel. Actual door(s) width may vary ± 1/32 in (0.8 mm) against template, adjust centering placement accordingly.
Using center punch, mark six hole center locations given per template #2, then remove it from the door panel. 20.
Using MAG drill with 5/8-in (16-mm) drill bit, drill all applicable holes through the bottom panel. Deburr all drilled holes as needed.
Hollow-Core
Block
22.
Place supplied side door insert (R002-A073) into side door panel and secure.
23.
Repeat steps 19 - 22 on other side panel.
Production Notes
Pour
1.
Ensure proper placement of lift hooks. See drawings.
Protruding Style: 1x Rear Lift Loop required
Exposed Height: 2.5 in (64 mm)
Continued
Recessed Style: 2x Rear Lift Loops Required
Demolding 1.
Edge Distance: 4 in (102 mm) (2 places)
With the hollow-core block, make sure the concrete has cured sufficiently before demolding to avoid cracked blocks and broken knobs.
Maintenance, Tips & Tricks
Tips
1.
To ensure the form will perform as expected after the 41 in (1030 mm) Hollow-Core Insert is installed, fully close the binder clamps and inspect the interior seal surfaces between the top and bottom door panels and side inserts. The maximum allowable gap is 1/16 in (1.6 mm).
Helpful Hint: If a feeler gage is not available, a standard washer for 3/8 in (9.5 mm) fastener applications is approximately 1/16 in (1.6 mm) thick and can be used to reference gap size.
Hollow-Core
Block
To ensure the form is within tolerance after the 41 in (1030 mm) Hollow-Core Insert is installed, fully close the binder clamps and using a measuring tape, measure the form width at three locations as shown. Each actual measure must be between 17 27/32 in - 18 1/32 in (453 mm - 458 mm). 2.
If the form will not fully close after the 41 in (1030 mm) Hollow-Core Insert is installed, make sure the carriage/ plug bolts are not interfering with the side inserts and groove former.
A gap up to 1/8 in (3.2 mm) is allowable between the top and bottom hollow-core inserts when the form is fully closed. This design-intended gap assists in maintaining proper block height.
Some removal of primer occurring during cycling of the forms is to be expected. The primer is intended to provide corrosion protection until initial use only. Consistent application of release agent and proper storage is recommended to provide continuous protection.
XL RETAINING FORMS
XL Retaining Forms
52 in (1320 mm) XL
72 in (1830 mm) XL
96 in (2440 mm) XL
Overview
R001-0202
R001-0386
R001-0554
R001-A029
R001-A030
R001-A031
R001-A047
R001-A048
R001-A137
PARTS LIST DESCRIPTION QTY
REDI-ROCK NAMEPLATE 2
10" XL KNOB FORMER 2
PUSH PAD 8
EJECTOR PLATE 1 2
The Redi-Rock XL form is comprised of a base frame with wheeled, modular doors to create the upper and lower face of the blocks. Each door rolls along the floor between open and closed form positions, while mating to the stationary base frame. This form design provides safe and predictable motion during operation.
R001-A138
R001-A149
R001-A150
The Redi-Rock XL form is used to manufacture R-5236HC, R-7236HC, and R-9636HC.
PARTS LIST
DESCRIPTION QTY PART NUMBER
R001-0202 10" XL KNOB FORMER 2 R001-0386 PUSH PAD 8 R001-0554
NOTES: 1) MUST CONFORM TO INSPECTION REQUIREMENTS PER QIS-R001-A000
REPLACED POLY SEAL FLAPS (R001-A007/A008) WITH STEEL (R001-A158/A162) 26JAN2023 L
R001-A031
Minimum Requirements
On the following pages, you will find the minimum requirements for use of the Redi-Rock XL form in regard to:
• Facility size
• Floor flatness
• Foundation strength
• Block reinforcement
• Release agents
• Lifting hooks
The Redi-Rock XL form open and closed envelope is shown below. Given precast operations vary, additional clearance for operator accessibility, pour method, block removal method, etc. are up to the individual manufacturer.
in.
in. (2,110 mm) 108 in. (2,720 mm)
mm) 64 in. (1,600 mm)
Flatness
in. (3,325 mm)
Since the base frame and doors each directly contact the manufacturing facility floor, a maximum flatness tolerance of ± 1/4 in (7 mm) is necessary for entire form contact area (130 x 66 in; 3,300 x 1,675 mm) to ensure proper and safe operation of the Redi-Rock XL form.
A fully equipped form filled with concrete and operator have a total maximum weight of 12,000 lbs (5,444 kg). Ensure floor foundation has adequate strength for the load. Facility Size
Figure 1
Figure 2
66 in. (1,560 mm)
Reinforcement
All Redi-Rock XL Hollow-Core Retaining blocks, including R-5236HC, R-7236HC, and R-9636HC, require steel reinforcement cages per Redi-Rock specification. This is a safety critical requirement to protect against crack propagation transferring through thin-walled sections of the precast modular blocks (PMBs).
See page xxi in the Appendix for steel reinforcement specifications.
Release Agent
Be sure to use a release agent that is approved by Redi-Rock International. Call 866-222-8400 for further details.
Lifting Hooks
All Redi-Rock XL blocks must be produced with specified lift hooks. Redi-Rock International has completed verification testing to ensure the lift hooks meet safe working load requirements with an adequate factor of safety. See below for the two approved options, and see page 148 for lift hook placement.
Manufactured by: American Step Company americanstep.com
Item Number: 500-975"
Description: Solid Loop Lifter, Ø1/2" X 9 3/4", A36 Steel, Epoxy coated per ASTM A 934
Note: The Redi-Rock Licensed Manufacturer is responsible for safe lifting and handling of all concrete products created in Redi-Rock forms. The use of lifting devices and associated hardware shall be in accordance with the printed safe lifting practices and procedures, as published by the manufacturer.
Manufactured by: A.L. Patterson
Website: alpsupply.com
Item Number: LRA7169G
Description: R-Anchor, Ø 7/16" X 9", Hot Dip Galvanized
1/2" Solid Loop Lifter
7/16" R Anchor
Safety
Each manufacturer is responsible for addressing their own site-specific safety plan when using the Redi-Rock XL form, following all state and federal laws and regulations.
When updating your safety plan in regard to using the XL form, please be sure to take into account these safety factors:
• Depending on the form configuration, the operator will be performing tasks at a height of up to 10 feet (3 meters), and a safe working platform is needed.
• Make sure to have proper accessibility clearance beyond the full open form envelope.
• Keep working area clean to reduce debris around the form which could hinder the smooth opening and closing of the sliding form doors.
• Do NOT climb on the form.
• Be aware of slippery surfaces created by the release agents used on the form.
• Always wear proper personal protection equipment (safety glasses, steel toed shoes, hearing protection, etc.) when using the XL form.
• Operator should use caution when opening and closing the binder clamps.
• Operator should be aware of potential energy being applied during demolding, especially when applying torque to ejector screws.
• Be sure XL blocks reach a compressive strength of 1,500 psi (7 mPa) before demolding and moving the block.
• Use rigging and lifting devices of adequate strength for the lifting loads (see page xix in the Appendix for load multiplier chart)
Product Data Sheets
For product data sheets, see these pages in the Appendix: 52 in (1320 mm) XL Hollow-Core Retaining blocks .......................... page xlix 72 in (1830 mm) XL Hollow-Core Retaining blocks page li 96 in (2440 mm) XL Hollow-Core Retaining blocks .......................... page liii
General Production
Note: There are instructions specific to producing each Redi-Rock precast modular block throughout this manual. Please be sure to understand both the following general guidelines and the specific instructions before beginning to manufacture a Redi-Rock product.
Prep
1.
If not cleaned after last demolding, clean all surfaces of the form.
(See cleaning notes on page 152 for reference.) Retract all ejector screws to the fully retracted position.
2.
With the doors fully open, spray a thin film of release agent on all the internal surfaces, take special care to get:
A. Underside of the hollowcore Inserts closest to the face mold
B. Around and inside the lift hook slot
C. Underside of knob formers
D. Spray the face mold with release agent
Critical Note: Confirm all ejector screws are in the fully retracted/pour position.
Helpful Hint: When applying release agent, make sure the doors are in the fully open position, and allow sufficient time for release agent to drip before closing the doors. Excessive release agent pooling in the face mold will adversely affect the block surface.
Apply shake-on color to the face mold if desired.
Insert the specified lift hook into the lift hook embed.
Note: See page x in the Appendix for lift hook specifications. Non-specified or smaller hooks may fall out of the hook embed while pouring and are not adequately rated for lifting conditions.
Add cross-tubes on top of the form.
Position and tie the reinforcement cage to the cross-tubes.
Critical Note: All Redi-Rock XL Hollow-Core Retaining blocks, including R-5236HC, R-7236HC, and R-9636HC, require steel reinforcement cages per Redi-Rock specification. This is a safety critical requirement to protect against crack propagation transferring through thin-walled sections of the precast modular blocks (PMBs). See page xxi in the Appendix for steel reinforcement specifications.
Close the doors and tightly secure all binder clamps (starting with lower clamps).
Helpful Hint: Binder clamps may need to be adjusted to ensure proper form closure.
8.
Remove cross-tubes, make sure cage is centered/positioned properly.
Note: This section should be used for general guidance only, as sitespecific factors such as mix characteristics, vibration methods, operator experience, etc. determine pouring method. It is recommended that manufacturers follow ASTM C 1776 Standard Specification for WetCast Precast Modular Retaining Wall Units.
Internal Vibration Method: Pour
Begin placing concrete via the top of the form opening, targeting the hollow-core insert so that the concrete does not drop the full height of the form. While placing concrete, ensure that the rebar cage does not shift position.
At appropriate intervals, pause pouring to internally vibrate concrete as needed.
Note: Be careful to not get vibrator stuck between the rebar cage and form.
Fill form to desired block size.
Screed rear block surface. Add two lift hooks positioned as shown in drawing below. Edge distance and exposed height applies to all three block sizes.
Note: Improper lift hook placement reduces the lifting capacity/ safe working load.
Edge Distance: 6 in. (152.4 mm)
Exposed Height: 3 in. (76.2 mm)
External Vibration Method: All XL forms are standard configured with wedge vibration brackets. The two locations are shown.
With bottom door vibrator activated, begin pouring concrete via top of form opening. Target the hollow-core insert so that the concrete does not drop the full height of the form. While placing concrete, ensure that the rebar cage does not shift position.
Activate upper door vibrator as form is filled.
Deactivate vibrators once the form is filled to desired block size.
Screed rear block surface. Add two lift hooks positioned as shown in drawing on the previous page. Edge distance and exposed height applies to all three block sizes.
Note: Improper lift hook placement reduces the lifting capacity/safe working load
Demolding
Redi-Rock XL bocks must meet a minimum compressive strength of 1,500 psi (7 mPa) before demolding.
1.
Once the concrete has cured, release all binder clamps on both sides starting with lower clamps.
2.
Tighten all ejector screws on each door with an impact driver or wrench. Apply torque in a criss-cross pattern (upper right, lower left, upper left, lower right) until door releases.
3.
Apply drive torque to the two lower ejector screws on each door until screw travel limit is reached (each door will be partially open). Alternate the left and right ejector screws equally during the process.
Helpful Hint: Binder clamps may need to be adjusted to ensure proper form closure.
Critical Note: After the door releases from the block, DO NOT torque the upper two ejector screws on each door. Doing so will create binding between form and block, which may damage the block and form components.
4.
Push doors to fully open position, then retract all ejector screws to pouring position (hand tight).
Remove block with preferred method.
Option 1: Secure lift device to two rear lift hooks and remove block from form.
Option 2: Secure forklift to lower block recess geometry and remove block from form.
Rotate block 90 degrees to standard orientation via preferred method (coffing hoist, upender, etc).
Scrape residual concrete from steel and rubber parts after each demolding operation.
Pay close attention to:
A. Near all hollow-core inserts
B. Underside of the carriage doors -- this is critical for maintaining proper form sealing
C. Face mold
D. Behind ejector pad before retracting screw
E. Base frame tracks
F. All door seals
G. Near all face mold flaps
Use compressed air or a vacuum to remove all concrete debris.
In addition to your own site-specific safety plan, when storing RediRock XL blocks maintain the following standards:
• Maximum stacking height of three blocks
• Ensure the storage surface is level, compacted, and allows drainage
• Maintain a safe clearance distance around stacked XL blocks
Tips & Tricks
Flap Seals: Each door has a right and a left tapered flap seal. Make sure to select the correct part for replacement.
Top Door Left Flap
Top Door Right Flap
Bottom Door Right Flap
Bottom Door Left Flap
Remove two 3/8-inch-16 thread nuts from the seal assembly clamped between the door and the carriage.
On interior of carriage, remove face mold flap seal.
2. 1. 3.
Replace old seal with new seal in same slots (tapered surface toward the center of the block).
Critical Note: Make sure rear side of seal contacts carriage flange. If a gap between flap end and carriage flange exists, edges of PMB may break during demolding.
4.
Fully secure two 3/8-inch-16 thread nuts on the flap studs.
Ejector Screw and Plate Assembly:
Shoulder bolts, ejector screws and pads are common throughout the form; however, there are three different plate assemblies. The step-by-step instructions show replacement of one ejector screw and plate assembly, and the method is similar for the other two assemblies.
Note: Mating shoulder bolt (McMaster 91259A903 or equivalent), ejector screw (R001-A169), and plate assembly (R001-A029, R001-A030 or R001-A031) must be replaced simultaneously.
NOTE: PUSH PADS AND SHOULDER BOLTS INSTALLED FROM INTERIOR SIDE OF F
R001-A029
STD-0103
R001-0554
R001-A169
R001-A030
Unfasten shoulder bolt from the ejector pad. Set aside pad.
Remove ejector screw.
Remove all fasteners securing the plate assembly to the form.
Secure new plate assembly to form by hand tightening fasteners.
Install new ejector screw.
Reinstall the ejector pad and secure with new shoulder bolt.
7.
Unfasten shoulder bolt from the ejector pad. Set aside pad.
Helpful Hint: If the Ejector Pad is not seated flush, shift plate vertically and/or horizontally as needed to achieve alignment.
8.
Fully tighten plate assembly with fasteners.
Door Seals: There are six different door seals for the XL forms -- two for each door segment geometry. Make sure you have the proper seal for each door segment. Geometry should match the door segment and the magnets should directly contact the doors with alignment pins.
R001-A068
R001-A070
R001-A048
R001-A067
R001-A069
R001-A047
Remove polyurethane seals from the alignment pins on the frame door segment(s).
Clean all concrete residue from the frame surface.
Align holes on new polyurethane seals with corresponding alignment pins then press into place until magnets secure the seal to the metal frame.
Casters: There are eight, 6-inch (150-millimeter) diameter casters per XL Form. Four v-channel casters are nearest the center of the form and ride on the frame track, while four standard casters are on the outside of the carriage and ride on the floor. The following instructions show replacement of casters on one side of the form.
& NUT INSTALLED ON TOP OF 52" DOOR FLANGE
WASHERS & NUT INSTALLED ON TOP OF 52" DOOR FLANGE
NOTE: WHEELS INSTALLED WITH GREASE FITTING TOWARDS OUTSIDE OF FORM
PROJECT:
TITLE: 52IN XL RETAINING FORM
2X CARRIAGES ASSEMBLED IDENTICALLY
Remove two backstop nuts/bolts/washers from frame slots. Check for excessive wear on the bolt (replace as needed), set aside.
Slide carriage door assembly completely off frame.
Use properly rated lifting device and equipment to elevate carriage door assembly. Place on stable stand with 6-inch (150-millimeter) minimum clearance beneath the carriage.
Note: Lifting device, equipment, and stands must have a safe working load limit of 2,500 pounds (1,135 kilograms) minimum.
Remove one nut/bolt/washer from caster axle. Check for excessive wear on the bolt (replace as needed), set aside.
Slot new caster in place.
Note: Ensure v-channel casters are used on the front of the carriage and standard casters on the rear of the carriage. 4. 3. 5.
Insert and secure nut/bolt/washer in axle of caster.
Use lifting device to remove carriage from stands and place back on frame.
Reinstall two backstop nuts/bolts/washers on frame slots
In the rear hollow insert of the top door, remove two nuts and washers. Lift Hook Holder
Remove rubber lift hook holder from bolts.
2. 1. 3.
Replace rubber lift hook holder, making sure to align hook slot properly, and reattach with two nuts/washers. Do not overtighten nuts, doing so will deform and damage lift holder.
How to Change the Face Mold Texture: All bolts, nuts, and washers are 1/2-in (13-mm) diameter (13 threads per inch) unless otherwise specified.
With doors fully open, remove four hex bolts and washers securing the outer corners of the face mold to the base frame.
Critical Note: Do NOT remove bolts securing face mold to fork tab weldment.
Use the fork tabs to lift the face mold from the base frame.
1.
2.
3.
4.
Do not stack face molds directly on top of each other. Maintaining a gap between the face molds in storage is critical for mold longevity. Select desired face mold and secure the face mold to the base frame with the four hex bolts and washers at the outer corners.
Tips & Tricks
Critical Note: Battered face molds have one alignment bolt on the underside of the mold. Check for proper orientation to align with mating hole of base frame. If the placement orientation is incorrect, the face mold will not seat within the base frame.
Flashing: Flashing is typically located at the parting line between the face mold and mating steel carriage of the Redi-Rock XL form. Flashing thickness should be limited to approximately 1/16 in (1.5 mm) thick and MUST be removed during demolding. Failure to remove specific flashing from Redi-Rock XL blocks can locally increase the PMB’s height out of tolerance. If face mold flashing greater than 1/8 in (3 mm) thick is observed, this is likely due to non-flat production space (see page 142) or inadequate cleaning (see page 152).
Critical Height: All configurations of the Redi-Rock XL form are manufactured to maintain a PMB height of 36 in (914 mm) ± 1/16 in (1.5 mm). Form tolerance requirements are much more stringent than PMB requirements per ASTM C1776. It is important to target more stringent tolerances and apply form and PMB verification measurements to your production specific quality procedures.
Critical Note: Many vertical surfaces of XL blocks are drafted. Use a straight edge, square, or similar aid to measure block height properly; directly contacting drafted surfaces of the PMB with a tape measure will give an incorrect (artificially increased) height.
Texture Face Damage: The thinnest sections of the XL blocks are located at the corners of the textured face. If minor corner chipping is observed during demolding, refer to the following checks:
Flap Seal Gap: Confirm the rear side of the flap seal contacts carriage flange. If a gap is present, reposition the flap seal to eliminate the gap (see page 153).
Demold Sequence: Applying drive torque to the upper two ejector screws after the PMB has released from the door segment(s) may cause the door to tilt off the base frame, causing door segment to pinch against the XL block. Confirm the demolding procedure is followed properly (see page 150).
Carriage Caster: Confirm all casters are undamaged. Cracked or broken caster(s) will reduce the carriage height, allowing carriage (and mating doors) to bind against the PMB during door opening (see page 159).
Cleaning: Residual concrete build up located on the underside of the carriage door(s) may cause polyurethane face mold to locally deform (during form closure). This condition creates negative draft, which results in demolding shear condition between the form and block. Follow cleaning procedure (see page 152).
52 in (1320 mm)
XL Block
52 in (1320 mm) XL Hollow-Core blocks are used in
RETAINING BLOCKS
Block Library
R-5236HC 52" (1320 mm) XL HOLLOW-CORE Face
R-5236HC 52" (1320 mm) XL Hollow-Core
Block Weight: Block Volume:
Infill Volume:
R-7236HC 72" (1830 mm) XL Hollow-Core
R-9636HC 96" (2440 mm) XL Hollow-Core
• R001-A051 (FORM)
R001-A008
R001-A029
R001-A030
R001-A031
R001-A047
LEFT FLAP ASSEMBLY 2
EJECTOR PLATE 1 2
EJECTOR PLATE 2 2
EJECTOR PLATE 3 4
52" DOOR SEAL 1 1
PARTS AND KIT NUMBERS FOR ORDERING
R001-A048
R001-A137
R001-A138
R001-A149
NOTE: A 36 IN TALL RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
PART NUMBER
R001-0202
PARTS LIST
DESCRIPTION QTY
REDI-ROCK NAMEPLATE 2
R001-A150
R001-A151
R001-A152
R001-A157
R001-A160
52" DOOR SEAL 2 1
52" BOTTOM DOOR WELDMENT 1
52" TOP DOOR WELDMENT 1
52" TOP DOOR INSERT 1
BOTTOM DOOR INSERT 1
GROOVE FORMER 1
52IN CAP 2
FACE MOLD CRADLE 1
DOOR SUPPORT CARRIAGE 2
R001-0386 PUSH PAD 8
10" XL KNOB FORMER 2
R001-0554
R001-A007
R001-A008
R001-A029
R001-A030
R001-A031
R001-A047
R001-A048
R001-A137
R001-A138
R001-A149
R001-A150
R001-A151
R001-A152
R001-A157
R001-A160
R001-A169 STD-0034
5-13-HN
5-13x1 5-HB
.5-13x2-HB 5-13x4-HB
.5-FW
75-4 5-HN
75-4 5x2-HB
.375-16-HN
375-FW
125x 375- 500-B
RIGHT FLAP ASSEMBLY 2
LEFT FLAP ASSEMBLY 2
EJECTOR PLATE 1 2
EJECTOR PLATE 2 2
EJECTOR PLATE 3 4
52" DOOR SEAL 1 1
52" DOOR SEAL 2 1
52" BOTTOM DOOR WELDMENT 1
52" TOP DOOR WELDMENT 1
52" TOP DOOR INSERT 1
BOTTOM DOOR INSERT 1
GROOVE FORMER 1
52IN CAP 2
FACE MOLD CRADLE 1
DOOR SUPPORT CARRIAGE 2
EJECTOR SCREW WELDMENT 8
R001-A169
STD-0034
STD-0035
STD-0103
.5-13-HN
EJECTOR SCREW WELDMENT 8
6" V-GROOVE WHEEL 8
6" METAL WHEEL 4
ALLOY STEEL SHOULDER SCREW 8
.5-13 HEX NUT 42
5-13x1 5-HB 5-13 x 2 HEX BOLT 8 5-13x2-HB .5-13 x 4 HEX BOLT 12 .5-13x4-HB
Redi-Rock XL forms will be delivered in two pieces if the full 96-in (2440-mm) form is ordered. The 52-in (1320-mm) form is ready to be placed in your facility for production upon delivery.
Helpful Hint: The 72-in (1830-mm) and 96-in (2440mm) door extensions will be bolted together. If you would like to convert the form to produce these size blocks, see following sections.
See page xxiii in the Appendix for 52-in (1320-mm) rebar reinforcement cage specifications.
Safety Note:
Proper rebar reinforcement cages are a safety critical requirement to protect against crack propagation transferring through the thin-walled sections of the precast modular block.
XL Block
72 in (1830 mm)
XL Block
72 in (1830 mm) XL Hollow-Core blocks are used in various retaining wall applications.
R-7236HC 72" (1820
Face
mm) XL HOLLOW-CORE
R-7236HC 72" (1830 mm) XL Hollow-Core
• R001-A051 (FORM)
• R001-A052 (72 IN EXTENSION)
PARTS AND KIT NUMBERS FOR ORDERING
PARTS LIST DESCRIPTION QTY PART NUMBER
R001-A069
R001-A070
R001-A143
NOTE: A 36 IN TALL RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE. PARTS LIST
R001-A144
R001-A153
72" DOOR SEAL 1 1
6 FT DOOR SEAL 2 1
72" TOP DOOR WELDMENT 1
72" BOTTOM DOOR WELDMENT 1
72" INSERT 2
72" CAP WELDMENT 2 R001-A156 5-13 HEX NUT 18 5-13-HN
5 FLAT WASHER 18 5-FW
75-4 5-HN
BOTTOM DOOR WELDMENT 1
INSERT 2
CAP WELDMENT 2
75-4 5 HEX NUT 14
75-4 5x2-HB 8 .75-FW
75-4 5 x 2 HEX BOLT 14
NOTE: GRAY COMPONENTS ARE SHOWN FOR REFERENCE ONLY
REVISION HISTORY
ZONE REV DESCRIPTION DATE APPROVED B FULLY REVISED 11JUN2021 C NADOLSKY
1. Form Assembly
With the form fully open, remove two nuts and washers on the rear of the top door, and one nut/ washer in the rear hollow insert, then remove 52in (1320-mm) cap from inside of the form. Repeat with bottom door.
Remove two nuts/washers from each ejector screw plate assembly on top and bottom doors.
Beginning with bottom door, use a crane to align the 72-in (1830-mm) door segment over the 52-in (1320-mm) door flange.
Remove two nuts/washers from each ejector screw plate assembly on top and bottom doors.
5.
Lower the door segment while seating the flange pins.
Helpful Hint: Use a guide bar to align door segments if needed as shown. If studs still do not align properly, loosen upper two nuts/ washers from hollow insert. Do not remove nuts/washers.
Secure door segment with seven 3/4-in (19-mm) nuts and bolts on the bottom door flange.
Repeat steps 4-6 with the top door.
Reassemble four ejector screw plate assemblies with two nuts/ washers per plate.
Install two nuts/washers to the studs at the rear of each door.
Add 72-in (1830-mm) caps (R001-A037) on both top and bottom door. Install four nuts/washers on the rear of each door and one nut washer in the rear hollow insert for each door.
Shut form doors slowly and secure all binder clamps starting with the lowest.
Helpful Hint: Binder clamps may need to be adjusted to ensure proper form closure.
Helpful Hint: If the alignment pins at the door seals don’t mate properly follow these steps:
• Loosen but do not remove the eight (four on the cap, four on the hollow core insert) nuts and washers from the rear of each door
• Shut the door slowly so the hollow-core inserts can self align.
• Fully close the door and secure binder clamps.
• Re-tighten the eight nuts and washers on the rear of each door.
See page xxv in the Appendix for 72-in (1830-mm) rebar reinforcement cage specifications.
Safety Note:
Proper rebar reinforcement cages are a safety critical requirement to protect against crack propagation transferring through the thin-walled sections of the precast modular block.
96 in (2440 mm)
XL Block
96 in (2440 mm) XL Hollow-Core blocks are used in various retaining wall applications.
R-9636HC 96" (2440 mm) XL HOLLOW-CORE
Face Texture:
Ledgestone
Block Weight: 4840 lb (2190 kg)
Block Volume: 33.83 ft³ (0.958 m³)
Center of Gravity: 55.3" (1405 mm)
R-9636HC 96" (2440 mm) XL Hollow-Core
Face Texture:
Block Weight:
Block Volume:
Infill Volume:
Center of Gravity:
ft³ (1.547 m³)
Ledgestone
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Center of Gravity is measured from the back of block, excluding stone infill.
4. Actual block volumes and weights may vary.
5. Weights are based upon a concrete density of 143 lb/ft3 (2291kg/m3).
6. Interface Shear knobs are nominally 10" (254mm) diameter by 4" (102 mm) tall.
• R001-A051 (FORM)
• R001-A052 (72 IN EXTENSION)
• R001-A053 (96 IN EXTENSION)
PARTS AND KIT NUMBERS FOR ORDERING
R001-A067
R001-A068
NOTE: A 36 IN TALL RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
R001-A145
R001-A146
R001-A164
BOTTOM DOOR WELDMENT 1
R001-A146
Note: These steps assume that the 72-in (1830-mm) and 96-in (2440mm) door extensions are pre-assembled. If your door extensions are not already one unit, see page 170 for instructions on transitioning the form from 52 in (1320 mm) to 72 in (1830 mm) and page 181 for instructions on transitioning the form from 72 in (1830 mm) to 96 in (2440 mm).
With the form fully open, remove two nuts and washers on the rear of the top door, and one nut/ washer in the rear hollow insert, then remove 52-in (1320-mm) cap from inside of the form. Repeat with bottom door. 1.
2.
Remove two nuts/washers from each ejector screw plate assembly on top and bottom doors.
Slide the form to almost closed (approx. 2 in (50 mm) from closed). With the door segments on the crane above, align the studs for the hollow-core inserts into the rear of the door.
Lower the door segment while seating the flange pins. Close form fully to engage the pins.
Helpful Hint: Use a guide bar to align door segments if needed as shown. If studs still do not align properly, loosen upper two nuts/ washers from hollow insert. Do not remove nuts/washers.
5.
Secure door segments with seven 3/4-in (19-mm) nuts and bolts on both the top and bottom door flange.
Reassemble four ejector screw plate assemblies with two nuts/ washers per bracket.
Install two nuts/washers to the studs at the rear of each door.
Secure all binder clamps starting with the lowest. 6. 7. 8.
Helpful Hint: Binder clamps may need to be adjusted to ensure proper form closure.
Helpful Hint: If the pin and pocket pads at the door seals don’t mate, follow these steps:
• Loosen but do not remove the eight (four on the cap, four on the hollow core insert) nuts and washers from the rear of each door
• Shut the door slowly so the hollow-core inserts can self align.
• Fully close the door and secure binder clamps.
• Re-tighten the eight nuts and washers on the rear of each door.
Form Assembly Option 2 - 72 in (1830 mm) XL Form to 96 in (2440 mm) XL Form
• R001-A051 (FORM)
• R001-A052 (72 IN EXTENSION)
• R001-A053 (96 IN EXTENSION)
PARTS AND KIT NUMBERS FOR ORDERING
R001-A067
R001-A068
NOTE: A 36 IN TALL RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
With the form fully open, remove four nuts/washers on the rear of the top door, and one nut/washer in the rear hollow insert, then remove 72-in (1830-mm) cap from inside of the form. Repeat step 1 with bottom door. 1.
2.
Beginning with bottom door, use a crane to align the 96-in (2440-mm) door segment over the 72-in (1830-mm) door flange.
Align the studs for the hollow-core inserts into the rear of the door.
4.
Lower the door segment while seating the flange pins.
Helpful Hint: Use a guide bar to align door segments if needed as shown. If studs still do not align properly, loosen upper two nuts/ washers from hollow insert. Do not remove nuts/washers.
Secure door segment with seven 3/4-in (19-mm) nuts/bolts on the bottom door flange. 5.
Install two nuts/washers to the studs at the rear of each door.
Repeat Steps 3-6 with the top door. 7.
XL Block
Shut form doors slowly and secure all binder clamps starting with the lowest.
Helpful Hint: Binder clamps may need to be adjusted to ensure proper form closure.
Helpful Hint: If the pin and pocket pads at the door seals don’t mate, follow these steps:
• Loosen but do not remove the eight (four on the cap, four on the hollow core insert) nuts and washers from the rear of each door
• Shut the door slowly so the hollow-core inserts can self align.
• Fully close the door and secure binder clamps.
• Re-tighten the eight nuts and washers on the rear of each door.
Production Notes
See page xxvii in the Appendix for 96-in (2440-mm) rebar reinforcement cage specifications.
Proper rebar reinforcement cages are a safety critical requirement to protect against crack propagation transferring through the thin-walled sections of the precast modular block. Safety Note:
FREESTANDING FORMS
Freestanding Forms
Overview
General Production
Straight Middle Block
Variable Radius Middle Block
Straight Bottom Block
Variable Radius Bottom Block
Straight Top Block
Variable Radius Top Block
Corner Middle Block
90 Degree Corner Block
Corner Bottom Block
Corner Top Block
Half Corner Middle Block
Half Corner Bottom Block
Half Corner Top Block
Straight Garden Top Block
Variable Radius Garden Top Block
Corner Garden Top Block
Half Corner Garden Top Block
Force Protection Middle Block
Force Protection Bottom Block
Force Protection Top Block
Freestanding Hollow-Core Block
Freestanding Half Hollow-Core Block
Freestanding Corner Hollow-Core Block
Freestanding Half Corner Hollow-Core Block
9 in (230 mm) Tall Corner Block
9 in (230 mm) Tall Garden Block
9 in (230 mm) Tall Two-Sided Block
The standard Redi-Rock Freestanding form consists of a base and four hinged door panels – top, bottom and two sides – that close with binder clamps. The form can be configured with various inserts and molds to create numerous precast modular blocks. Changing the face mold in the freestanding form not only allows you to change the texture of the block, but it can also influence the type of block created.
R003-A009 1 BOTTOM PANEL
R003-A062
R003-A013 1 REMOVEABLE RAILING
General Production
Note: There are instructions specific to producing each Redi-Rock precast modular block throughout this manual. Please be sure to understand both the following general guidelines and the specific instructions before beginning to manufacture a Redi-Rock product.
2. 1.
Set each of the forms as level as practical (level is not critical, however).
To create the texture on the blocks, a rubber face mold is bolted into the form. When installing the mold, set it in place without tightening the bolts and close the form. Use a piece of steel over the bottom two bolts and a pry bar against the rail to shift the mold up or down to achieve a measurement of 46 ⅛ in (1172 mm) from the bottom of the form to the bottom of the lip on the mold. Tighten the top two bolts. Double check the measurement and tighten the bottom two bolts. Repeat on the other side of the form.
Helpful Hint: The video “How to Set Freestanding Block Length” on the RediRock producer secure site walks through this process and provides a good visual representation of this step.
Critical Note: The face mold placement plays a critical role in the correct length of freestanding blocks. Check this measurement frequently to make sure the mold has not shifted and that freestanding blocks are being poured within dimensional tolerance.
Critical Note: Many of the face molds are reversible to increase the texture variations; however, the Limestone texture is not reversible. Be sure to install the face mold so that the thicker portion of the rubber is at the top of the form.
3.
Scrape residual concrete from steel and rubber parts after each demolding operation. Concrete build-up will deform rubber molds and impact product quality.
Pay close attention to:
• Surfaces where steel contacts rubber
• The underside of the knob formers – this is critical for proper knob size and maintaining alignment during wall installation
• Around the loop holders before closing forms so debris does not fall onto the face mold.
4.
Apply a thin layer of release agent to the form surfaces. Over-applying release agent will adversely affect the finished product. Excess release agent can pool in the face mold, causing the surface to flake, spall off, or create bug holes.
Pay attention to hard to reach areas:
• Undersides of inserts
• Underside of knob formers
• Around and inside loop holders
For a list of appropriate release agents visit the secure site or call your business consultant.
5.
Place the lifting insert into the loop holder.
Commercially available lifting inserts are offered by a number of manufacturers, and Redi-Rock producers have elected to use a variety of lifting inserts to safely handle Redi-Rock blocks.
Two inserts which are made from galvanized, A36 steel are shown here.
Critical Note: To aid in demolding Freestanding blocks, another recessed lifting insert will need to be placed in the end of the block after pouring.
Helpful Hint: The rubber face mold should be free of debris before pouring blocks. Compressed air can be helpful if used safely.
Helpful Hint: Spraying the exterior surfaces of the forms will aid in cleaning but can also make them slippery.
Helpful Hint: Depending on what lifting insert you choose to utilize, various loop holders are available to hold the insert in place. See page vi in the Appendix for a full breakdown of available options.
Manufactured by: American Step Company
https://www.americanstep.com/ 830 East Broadway PO Box 137 Griffen, GA 30224-0137
Safety Notes: For Step 5
Manufactured by: A.L. Patterson
https://www.alpsupply.com/ (800) 332-7090
300 Ben Fairless Drive Fairless Hills, PA 19030
• The Redi-Rock Licensed Manufacturer is responsible for safe lifting and handling of all concrete products created in Redi-Rock forms. The use of lifting inserts and associated hardware shall be in accordance with the printed safe lifting practices and procedures, as published by the manufacturer.
• The National Precast Concrete Association (NPCA) publishes the NPCA Quality Control Manual for Precast and Prestressed Concrete Plants. The manual provides guidance to help assure production of quality precast products, and includes many recommendations which are applicable to Redi-Rock Manufacturers. The section of this manual which addresses lifting inserts allows the use of smooth bars made of steel conforming to ASTM A36 for lifting inserts and apparatus (Commentary to Section 2.3.1). The manual also recommends that embedded steel shapes which will be exposed to moisture or other corrosive environments be galvanized (Commentary to Section 2.3.2).
• Wire rope lifting loops are not recommended due to accelerated corrosion potential that adversely affects block durability and safety.
• Blocks must be poured with concrete in accordance with ASTM C94. ASTM C94 specifies that mixing water shall be potable water. Do not use admixtures containing chlorides because Redi-Rock blocks contain metal embedments.
• Redi-Rock Manufacturers should obtain testing data which demonstrates the capacity of the lifting inserts exceeds the weight of the blocks with a factor of safety of 4 or greater. The capacity of the inserts should be checked when the blocks are in a green condition when they are stripped from the forms and in subsequent handling and setting conditions. For commercially available inserts, this test data should be available from the lifting insert manufacturer. If commercially available inserts are not used, the Redi-Rock Manufacturer should perform a testing program to demonstrate that the inserts are appropriate, meet all applicable specifications, and have a lifting capacity which will provide a minimum factor of safety of 4 or greater.
6.
When closing the forms, close the side panels first, bottom panel second, and top panel third. Be sure to check the position of the lifting insert as the panel closes. Latch form binders.
1.
Fill forms to the specified depth to produce blocks that conform to published dimensions and tolerances.
2. Pour
Helpful Hint: Depending on your concrete mix, you may need to vibrate concrete during or after pouring to get the desired finished product.
Pour concrete to here
3 4
Finish the end of the block with a trowel, and place a recessed lifting insert to aid with demolding.
Critical Note: If lifting inserts are not fully recessed into the end of the block, they will interfere with block placement in the field.
Full Corner Mold Side View
Half
3.
Coding and dating blocks is easily done by scribing into fresh concrete on the end of the block at this time.
Demolding
Safety Note:
Allow blocks to cure properly before lifting out of form. Proper cure times vary according to weather, concrete mix, and curing conditions. Lifting inserts typically have minimum concrete strength requirements to develop necessary lifting capacity.
1.
To open the form, unlock and unhook the binders.
2.
Use a pry bar to aid in opening the forms. Do not hammer on forms.
Helpful Hint: The appropriate pry point for Freestanding forms will vary depending on what generation form they are. Older forms will have a tab halfway down the side panel to use as a leverage point. Newer forms are designed with a notch towards the top of the panel for the pry bar placement.
Helpful Hint: Do not allow panels to slam open hard on rails. Protecting the form from unnecessary wear and tear will help to prolong the life of your investment.
3.
To carefully lift the blocks out of the form, hook on to the recessed lifting insert on the end of the block. Lift vertically to clear the form before moving, and be careful that blocks do not swing and tear edges of the face mold.
Safety Note:
The concrete blocks are heavy – refer to the specific information from the Block Library to determine requirements for safe lifting of each product. Always use load-rated chains, cables and hooks. A Lifting Load Safety sheet can be found on page xix of the Appendix.
4.
To transition the blocks for storage, gently roll the block from its end to the bottom.
5.
It is recommended to break away concrete flashing at form seams and lift hook. This step makes wall installation easier and safe work for your customer.
Storage
1.
Moving the blocks into inventory can be done with a chain and hook or a lift/clamp.
Safety Note:
The height of the stacks of blocks will be determined by your specific location and safety standards.
Critical Note: Once the block has been lifted, do not attempt to set it back in face mold. Serious damage may occur to the mold.
Helpful Hint: Some manufacturers prefer to inventory freestanding blocks on pallets to make moving them around the yard easier. It is also recommended to stack like blocks together.
Maintenance
Binder Adjustments
Binder tension loosens over time. When the forms are really easy to close or more flashing is appearing on blocks, it’s time to adjust the binders. Tension can be increased by tightening the nuts on the binder. Check regularly, and adjust as required.
Face Mold Position
FORM INSTALLATIO
Rubber/Polyurethane Mold Storage Worn
Redi-Rock molds are sensitive to ultraviolet exposure. Do not store in direct sunlight.
Protect all edges/lips of the mold from warping or deforming during storage.
Hinges
If hinges are worn, consult RediRock for options.
Frequently check the block length measurement for freestanding forms to ensure the face mold position hasn’t shifted for full length blocks. If the measurement is out of tolerance from 46 ⅛ in (1172 mm), loosen the bolts for the face mold, readjust the mold height with a pry bar and steel over the bottom bolts, then tighten. Repeat on both sides.
Helpful Hint: The video “How to Set Freestanding Block Length” on the Redi-Rock producer secure site walks through this process and provides a good visual representation of this step.
BATTER
Straight Middle Block
FREESTANDING BLOCKS
Block Library
Freestanding Straight Middle blocks are textured on two sides and have many uses, such as barriers, parapet walls, seat walls, signs, etc.
F-SM STRAIGHT MIDDLE
Face Texture:
F-SB STRAIGHT BOTTOM
Kingstone / Ledgestone
F-SG STRAIGHT GARDEN
KNOBS @ 23 (584) OC, TYP.
Kingstone / Ledgestone Kingstone / Ledgestone
Kingstone / Ledgestone
24
• RR FS FORM
• R003-A071 (FLAT BASE)
• R003-A100 (FILLER PLATE)
• R003-A101 FS GROOVE FORMER 40IN STANDARD OR R003-A102 FS FULL GROOVE FORMER 46IN
• TWO R002-A104 (10IN KNOB FORMERS)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
NOTE: TWO 18IN FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH
Form Assembly
1.
Install the filler plates (R003-A100) in the top and bottom door panels near the base of the form using the existing holes.
ORIENTATION IN FORM
2.
Position the flat base insert (R003-A071) in the bottom of the form, centering it with the filler plates on the top and bottom door panels. Bolt in place.
Helpful Hint: Make sure the center holes in the flat base are aligned toward the top panel of the door. These will be used with variable radius inserts and force protection inserts.
3.
Install the groove former (R003-A047).
4.
Install two 18-in (457-mm) face molds on the side panel doors.
Critical Note: Many of the face molds are reversible to increase the texture variations; however, the Limestone texture is not reversible. Be sure to install the face mold so that the thicker portion of the rubber is toward the top of the block.
Helpful Hint: The video “How to Set Freestanding Block Length” on the RediRock producer secure site walks through this process and provides a good visual representation of this step. Instructions are also found on page 194.
5.
Install the knob formers (R003-A155) and lifting insert if they are not already installed.
Helpful Hint: Depending on what lifting insert you choose to utilize, various loop holders are available to hold the insert in place. See page vi in the Appendix for a full breakdown of available options.
Production Notes
Prep
1.
With the block being poured vertically, make sure to apply release agent on the undersides of surfaces in the face mold to facilitate demolding and prevent unneeded wear and tear on the face mold.
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
Use a pry bar to aid in opening the forms. Do not hammer on forms.
Helpful Hint: The appropriate pry point for freestanding forms will vary depending on what generation form they are. Older forms will have a tab halfway down the side panel to use as a leverage point. Newer forms are designed with a notch towards the top of the panel for the pry bar placement.
Helpful Hint: Do not allow panels to slam open hard on rails. Protecting the form from unnecessary wear and tear will help to prolong the life of your investment.
Full Corner Mold Side View Side
Half Corner
Full Face Mold Side View
Freestanding
Variable Radius Middle Block
PARTS LIST
FREESTANDING BLOCKS
PART NUMBER
Freestanding Variable Radius Middle blocks are textured on two sides, and the recesses at the end of the blocks make it easier to cut blocks to turn a radius.
Block Library
F-VM STRAIGHT MIDDLE
F-VM VARIABLE RADIUS MIDDLE
Face Texture:
Face Texture:
Block Weight: Block Volume:
RECESS OPTIONAL
OPTIONAL GROOVE EXTENTION
/ Limestone
DESCRIPTION QTY
4"X12" END INSERT FOR TOP OF FORM 1
R003-A052 4"x12" END INSERT FOR BOTTOM OF FORM 1
R003-A087
Kingstone / Ledgestone
F-VG VARIABLE RADIUS GARDEN TOP
COMPATIBLE OPTIONS (FL1)
PART NUMBER QTY DESCRIPTION
/ Limestone Kingstone / Ledgestone
/ Limestone
Kingstone / Ledgestone
R002-A108 A/R LOOP HOLDER #1 R002-A155 A/R LIFTEYE FORM #1
12 (305) x 4 (101) END RECESS
FACE TEXTURE VARIES
24 (610) ± LEDGESTONE COBBLESTONE
23 (584) ± LIMESTONE
FACE TEXTURE VARIES
24 (610) ± LEDGESTONE COBBLESTONE
23 (584) ± LIMESTONE
F-VB VARIABLE RADIUS BOTTOM
Kingstone / Ledgestone
F-VT VARIABLE RADIUS TOP
Kingstone / Ledgestone
Notes: FL1) COMPATIBLE OPTIONS MUST BE SELECTED SEPARATELY AND ARE NOT INCLUDED IN THIS AS 2) GRAY COMPONENTS FOR REFERENCE ONLY
REVISION HISTORY REV ECO NUMBER DESCRIPTION DATE APPROVED A NA INITIAL RELEASE 12/09/2021 L RADOY
• R003-A102 FS FULL GROOVE FORMER 46IN OR R003-A101 FS GROOVE FORMER 40IN STANDARD WITH TWO R003-A050 FS GROOVE FORMER EXTENSIONS
• TWO R002-A104 (10IN KNOB FORMERS)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE PARTS AND KIT NUMBERS FOR ORDERING
BOTTOM BLOCK
BOTTOM BLOCK
BOTTOM BLOCK
Form Assembly
1.
Install the 46-in (1168-mm) groove former on the bottom panel; OR install the groove former extensions to the standard 40-in (1016-mm) groove former.
2.
Remove the flat base from the form. The 4x12 bottom insert (R003-A087) bolts to the flat base, then reinstall the base and insert in the form, centering with the filler plates.
3.
Helpful Hint: The top variable radius insert is placed on top of the poured concrete in the form, so it is not actually installed prior to pouring the blocks.
Helpful Hint: it is recommended to use a full length groove former with the variable radius inserts. Some manufacturers do choose to pour it with a shorter groove former; however, this creates excess concrete near the groove that a contractor will need to work around in the field.
If the face mold is not already installed, see page 188 for installation instructions, as it is the same as with the straight middle block.
Production Notes
Pour
1.
Pour concrete to the bottom lip of the face mold.
2.
Place the top variable radius insert with lifting hook into the top of the block until the steel bar hits the top edge of the form. Clean up excess concrete.
Demolding
1.
Remove the top insert from the form.
2.
Then, demold the block as usual using the lifting hook in the end of the block.
Maintenance, Tips & Tricks
Tips
1.
Variable Radius Middle blocks are used to create curved freestanding walls. The recesses in the ends of the block make cutting concrete in the field easier. Blocks can be poured with one or two recesses; and curves can be created with one or two saw cuts per joint.
One saw cut per joint.
Two saw cuts per joint for tighter radius curves.
FACE TEXTURE VARIES
Straight Bottom Block
Freestanding Straight Bottom blocks are textured on two sides and are used at the bottom of freestanding walls.
F-SB STRAIGHT BOTTOM
F-SB STRAIGHT BOTTOM F-ST STRAIGHT TOP
Face Texture:
Cobble / Limestone
Kingstone / Ledgestone
24 (610) ± LEDGESTONE
COBBLESTONE 23 (584) ± LIMESTONE FACE TEXTURE VARIES
Block
Face Texture:
Block Weight: Block Volume:
KNOBS @ 23 (584) OC, TYP.
Cobble / Limestone
Kingstone / Ledgestone
Face Texture:
Block Weight: Block Volume:
(254)
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Architectural faces on the blocks have varying texture.
4. Actual block volumes and weights may vary.
Cobble / Limestone
Kingstone / Ledgestone
24 (610) ± LEDGESTONE
COBBLESTONE
(584) ± LIMESTONE
5. (2291 kg/m3).
BOTTOM
6. 6" (152 mm) diameter vertical semi-clyindrical voids at the ends of the block for mechanical tie-down are available, refer to Force Protection blocks for additional information.
7. Knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knobs are available.
• RR FS FORM
• R003-A071 (FLAT BASE)
• R003-A100 (FILLER PLATE)
• TWO R002-A104 (10IN KNOB FORMERS)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
Form Assembly
1.
Remove the groove former from the form. Holes in the form can be plugged using bolts.
2.
The remainder of the set up is the same as the Freestanding Straight Middle block. See page 195 for instructions.
Straight Bottom Block
RECESS OPTIONAL
Freestanding
12 (305) x 4 (101) END RECESS
RECESS OPTIONAL
(457)
Variable Radius Bottom Block
OPTIONAL GROOVE EXTENTION
FACE TEXTURE VARIES
OPTIONAL GROOVE EXTENTION
8(1172)
Freestanding Variable Radius Bottom blocks are used at the bottom of freestanding walls with curves.
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Variable radius feature can be cast on only one end, coordinate.
OPTIONAL GROOVE EXTENTION
Kingstone / Ledgestone
/ Limestone
23 (584) ± LIMESTONE
Kingstone / Ledgestone
RECESS OPTIONAL
LIFTING INSERT OR TEXTURED TOP SURFACE, OPTIONAL
FACE TEXTURE VARIES
FACE TEXTURE VARIES
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE
4. Architectural faces on the blocks have varying texture. 5. Actual block volumes and weights may vary. 6. Weights are based upon a concrete density of 143 lb/ft3 (2291 kg ). 7. Knobs are typically 10" (254
• RR FS FORM
• R003-A087 (BOTTOM VARIABLE RADIUS INSERT)
• R003-A052 (TOP VARIABLE RADIUS INSERT)
• TWO R002-A104 (10IN KNOB FORMERS)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
BOTTOM BLOCK
BOTTOM BLOCK
Form Assembly
1.
Remove the groove former and extensions from the form. Holes in the form can be plugged using bolts.
2.
The remainder of the set up is the same as the Variable Radius Middle block. See page 199 for instructions.
Production Notes
Pour 1.
Pour concrete to the bottom lip of the face mold.
2.
Place the top variable radius insert with lifting hook into the top of the block until the steel bar hits the top edge of the form. Clean up excess concrete.
Demolding
1.
Remove the top insert from the form.
2.
Then, demold the block as usual using the lifting hook.
Storage
1.
To stack freestanding bottom blocks in the yard, use a spacer, such as a block of 4-in (100-mm) tall wood, to stack the blocks level.
Kingstone / Ledgestone
Straight Top Block
noted otherwise. manufacturer.
Freestanding Straight Top blocks are textured on two sides and typically used at the top of freestanding walls when a cap will be placed on the wall.
5. Weights are based upon a concrete density of 143 lb/ft3 (2291 kg/m3). 6. 6" (152 mm) diameter vertical semi-clyindrical voids at the ends of the block for mechanical tie-down are available, refer to Force Protection blocks for additional information.
7. Knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knobs are available.
• RR FS FORM
• R003-A071 (FLAT BASE)
• R003-A100 (FILLER PLATE)
• R003-A101 FS GROOVE FORMER 40IN STANDARD OR R003-A102 FS FULL GROOVE FORMER 46IN
• TWO R002-A095 (KNOB COVERS)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
R003-A047
Form Assembly
1.
Remove the knob formers and install the knob covers. All other setup is the same as the freestanding straight middle. See page 195 for instructions.
Maintenance, Tips & Tricks
Tips 1.
If a customer won’t be using a cap on top of the wall and desires a texture on top of the block, a textured top panel (R003-A111) exists to create this option. The top panel of the form would be removed, and the textured top panel would be installed. After the door panels have been switched, install the textured top panel rubber (R003-A113) into the door.
(FL2)
R003-A112 A/R TEXTURE TOP POLY INSERT FOR CORNERS R003-A113 A/R TESTURE TOP POLY INSERT STANDARD
GRAY COMPONENTS
Helpful Hint: If blocks with no hook are necessary, a probst lift, clamp or nylon slings will need to be used for storage and placement.
Freestanding Variable Radius Top blocks are textured on two sides and are used at the top of curved walls where the recesses at the end of the blocks make it easier to cut blocks to turn a radius.
Face
F-VT VARIABLE RADIUS TOP
Face Texture:
Kingstone / Ledgestone
• RR FS FORM
• R003-A087 (BOTTOM VARIABLE RADIUS INSERT)
• R003-A052 (TOP VARIABLE RADIUS INSERT)
• R003-A102 FS FULL GROOVE FORMER 46IN OR R003-A101 FS GROOVE FORMER 40IN STANDARD WITH TWO R003-A050 FS GROOVE FORMER EXTENSIONS
• TWO R002-A095 (KNOB COVERS)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
MIDDLE BLOCK
R003-A087
Form Assembly
1.
Set up is the same as for the Variable Radius Middle block, except the knobs are removed and the covers are installed. See page 199 for additional form assembly instructions.
Production Notes
Pour
1.
Pour concrete to the bottom lip of the face mold.
2.
Place the top variable radius insert with lifting hook into the top of the block until the steel bar hits the top edge of the form. Clean up excess concrete.
Demolding
1.
Remove the top insert from the form.
2.
Then, demold the block as usual using the lifting hook.
Corner Middle Block
Freestanding Corner Middle blocks are textured on three sides and are used at the beginning and ends of freestanding or retaining walls, as well as in 90 degree corners for retaining walls.
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
Form Assembly
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Install the freestanding corner mold centered in the base of the form.
4.
If the knobs and groove former are not installed, install now.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
The spreader lever is helpful when demolding Freestanding Corner Middle blocks. Use the 41-in (1041-mm) position on the spreader lever to help hold doors open when pulling corner blocks out of forms.
Critical Note: If you open the spreader lever all of the way before lifting most of the weight of the blocks off of the mold with a fork lift or overhead crane, you will tear the corners of the molds. If this happens, the mold will still make good blocks, but extra caution will be needed in keeping the tear clean when closing the mold.
LIFTING INSERT,
90 Degree Corner Block
FACE TEXTURE VARIES
23 (584) ± LIMESTONE FACE TEXTURE VARIES LIFTING INSERT, OPTIONAL
24 (610) ± LEDGESTONE COBBLESTONE
FACE TEXTURE VARIES
Freestanding 90 Degree Corner blocks are used for turning outside 90 degree corners in retaining wall applications.
F-90C 90 DEGREE CORNER
Face Texture:
Cobble / Limestone
Block Weight: 1330 lb (600 kg)
F-90C 90 DEGREE CORNER
Block Volume:
Face Texture:
Block Weight: Block Volume:
4x6x2 (102x152x51) OVAL KNOBS @ 23 (584) OC, TYP.
ft³ (0.26 m³)
Cobble / Limestone Kingstone / Ledgestone
Kingstone / Ledgestone
lb (600 kg)
ft³ (0.26 m³)
13 (330) WIDE GROOVE NEAR END OF BLOCK
CORNER BLOCKS TEXTURED ON THREE FACES OPTIONAL 6 (152) DIAMETER KNOB IN LIEU OF OVAL KNOB THIS LOCATION
FACE TEXTURE VARIES
FACE TEXTURE VARIES
TOP BLOCK HAS NO SHEAR KNOBS AND A TEXTURED TOP SURFACE.
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE
1. Units for dimensions are inches (mm), typical unless noted otherwise.
Actual block volumes and weights may vary.
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE FACE TEXTURE VARIES
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering. 3. Architectural faces on the blocks have varying texture.
Weights are based upon a concrete density of 143 lb/ft (2291 kg ).
• RR FS FORM
• R003-A122 (FS 13IN GROOVE FORMER)
• TWO R002-A104 (10IN KNOB FORMERS)
• TWO R003-A155 (4X6 OVAL KNOB INSERTS)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
Form Assembly
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Remove the standard 40-in (1016-mm) or 46-in (1168-mm) groove former and install the 13-in (330-mm) groove former (R003-A122) with the 13-in (330-mm) end toward the top of the form.
4.
Install the freestanding corner mold centered in the base of the form.
5.
Install the 4x6 knob inserts (R003-A155) into the 10-in (254-mm) knob formers (R003-A155), then install the knob formers in the form.
Critical Note: Do not over tighten so as to deform rubber.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
Continued
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
The spreader lever is helpful when demolding 90 Degree Corner blocks. Use the 41-in (1041-mm) position on the spreader lever to help hold doors open when pulling corner blocks out of forms.
Critical Note: If you open the spreader lever all of the way before lifting most of the weight of the blocks off of the mold with a fork lift or overhead crane, you will tear the corners of the molds. If this happens, the mold will still make good blocks, but extra caution will be needed in keeping the tear clean when closing the mold.
Maintenance, Tips & Tricks
1.
Freestanding 90 Degree Corner Blocks are used in retaining wall applications with a 90 degree outside corner.
CORNER BLOCKS TEXTURED ON THREE FACES
Corner Bottom Block
Freestanding Corner Bottom blocks are textured on three sides and are used at the bottom course at the beginning and ends of freestanding or retaining walls, as well as in 90 degree corners for retaining walls.
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Architectural faces on the blocks have varying texture.
4. Actual block volumes and weights may vary. 5. Weights are based upon a concrete density of 143 lb/ft3 (2291 kg ). 6. Knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knobs are available.
Cobble / Limestone Kingstone / Ledgestone
Cobble / Limestone Kingstone / Ledgestone
• RR FS FORM
• TWO R002-A104 (10IN KNOB FORMERS)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
Form Assembly
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Install the freestanding corner mold centered in the base of the form.
4.
Remove the groove former.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Side View
Full Corner Mold
Full Corner Mold
Side View
Pour concrete to here (Bottom lip of mold)
Demolding
1.
The spreader lever is helpful when demolding Freestanding Corner Bottom blocks. Use the 41-in (1041-mm) position on the spreader lever to help hold doors open when pulling corner blocks out of forms.
Critical Note: If you open the spreader lever all of the way before lifting most of the weight of the blocks off of the mold with a fork lift or overhead crane, you will tear the corners of the molds. If this happens, the mold will still make good blocks, but extra caution will be needed in keeping the tear clean when closing the mold.
Corner Top Block
Freestanding Corner Top blocks are textured on three sides and are used at the top of walls for the beginning and ends of freestanding or retaining walls, as well as in 90 degree corners for retaining walls.
F-CT CORNER TOP
Face Texture:
Cobble / Limestone
Kingstone / Ledgestone
• RR FS FORM
• R003-A101 (FS GROOVE FORMER 40IN STANDARD)
• TWO R002-A095 (KNOB COVERS)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
R002-A095
Form Assembly
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Install the freestanding corner mold centered in the base of the form.
4.
If the groove former (R003-A047) is not installed, install now.
5.
Remove the knob formers if installed and install the knob covers (R002-A095).
Production Notes
Pour 1.
Pour the concrete to the bottom lip of the mold. Continued
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
The spreader lever is helpful when demolding Freestanding Corner
Top blocks. Use the 41-in (1041-mm) position on the spreader lever to help hold doors open when pulling corner blocks out of forms.
Critical Note: If you open the spreader lever all of the way before lifting most of the weight of the blocks off of the mold with a fork lift or overhead crane, you will tear the corners of the molds. If this happens, the mold will still make good blocks, but extra caution will be needed in keeping the tear clean when closing the mold.
Maintenance, Tips & Tricks
Tips 1.
If a customer won’t be using a cap on top of the wall and desires a texture on top of the block, a textured top panel (R003-A111) exists to create this option. The top panel of the form would be removed, and the textured top panel would be installed. After the door panels have been switched, install the corner textured top panel rubber (R003-A112) into the door.
Helpful Hint: If blocks with no hook are necessary, a probst lift, clamp or nylon slings will need to be used for storage and placement.
BONDED
Block Library
Half Corner Middle Block
Freestanding Half Corner Middle blocks are textured on three sides and are used at the beginning and ends of freestanding or retaining walls.
• TWO LOOP HOLDERS (ONE FOR KNOB FORMER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
NOTE: ONE FREESTANDING HALF CORNER FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
HALF CORNER MIDDLE - OPT 1
HALF CORNER MIDDLE - OPT 1
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Install the freestanding half corner mold centered in the base of the form.
4.
If the groove former (R003-A047) is not installed, install now.
5.
Install the loop holder into the one 10-in (254-mm) knob former (R003-A155), then install the knob former in the bottom knob position of the form.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
The spreader lever is helpful when demolding Freestanding Half Corner Middle blocks. Use the 48-in (1219mm) position on the spreader lever to help hold doors open when pulling half corner blocks out of forms.
Critical Note: If you open the spreader lever all of the way before lifting most of the weight of the blocks off of the mold with a fork lift or overhead crane, you will tear the corners of the molds. If this happens, the mold will still make good blocks, but extra caution will be needed in keeping the tear clean when closing the mold.
Half Corner Middle Block
Form Assembly Option 2 - Half Freestanding Form
• R003-A091 HALF FS FORM
• R003-A094 (HALF GROOVE FORMER)
• R002-A104 (10IN KNOB FORMER)
• TWO LOOP HOLDERS (ONE FOR KNOB FORMER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
R002-A110 A/R
R002-A152 A/R LOOP HOLDER #6
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Install the freestanding half corner mold centered in the base of the form.
4.
If the half groove former (R003-A094) is not installed, install now.
5.
Install the loop holder into the one 10-in (254-mm) knob former (R003-A155), then install the knob former in the form.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Half Corner Middle Block
Half Corner Mold Side View
Form Assembly Option 3 - Half Door
• RR FS FORM
• R003-A107 (FS HALF PANEL)
• R003-A101 (FS GROOVE FORMER 40IN STANDARD)
• R002-A104 (10IN KNOB FORMER)
• TWO LOOP HOLDERS (ONE FOR KNOB FORMER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Remove one side panel, and install the half panel (R003-A107).
R003-A047
R003-A107
R003-A155
4.
Install the freestanding half corner mold centered in the base of the form.
5.
If the groove former (R003-A047) is not installed, install now.
6.
Install the loop holder into the 10-in (254-mm) knob former (R003-A155), then install the knob former in the bottom knob position of the form.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Helpful Hint: The half panel makes finishing the half blocks in a freestanding form much easier due to additional access to the block.
Half Corner Middle Block
FACE TEXTURE VARIES
Freestanding
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE
Half Corner Bottom Block
Freestanding Half Corner Bottom blocks are textured on three sides and are used in the bottom course at the beginning and ends of freestanding or retaining walls.
F-HCB HALF CORNER BOTTOM F-HCT HALF CORNER
Face Texture:
Cobble / Limestone Kingstone / Ledgestone
Face Texture:
/
F-HCB HALF CORNER BOTTOM
Face Texture:
Block Weight:
Block Volume:
Cobble / Limestone
Block Weight:
Block Volume:
Kingstone / Ledgestone
10 (254) DIAMETER x 4 (101) HIGH KNOB, TYPICAL. 6 (152) DIAMETER KNOB AVAILABLE.
FACE TEXTURE VARIES
FACE TEXTURE VARIES
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Architectural faces on the blocks have varying texture.
4. Actual block volumes and weights
5. Weights are based upon a concrete
6. Knobs are typically 10" (254mm) Smaller knobs are available.
Cobble
Form Assembly Option 1 - Freestanding Form
• RR FS FORM
• R002-A104 (10IN KNOB FORMER)
• TWO LOOP HOLDERS (ONE FOR KNOB FORMER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE PARTS AND KIT NUMBERS
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels,
If the groove former is installed, remove it now.
4.
Install the freestanding half corner mold centered in the base of the form.
5.
Install the loop holder into the one 10-in (254-mm) knob former (R003-A155), then install the knob former in the bottom knob position of the form.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
The spreader lever is helpful when demolding Freestanding Half Corner Middle blocks. Use the 48-in (1219mm) position on the spreader lever to help hold doors open when pulling half corner blocks out of forms.
Critical Note: If you open the spreader lever all of the way before lifting most of the weight of the blocks off of the mold with a fork lift or overhead crane, you will tear the corners of the molds. If this happens, the mold will still make good blocks, but extra caution will be needed in keeping the tear clean when closing the mold.
Form Assembly Option 2 - Half Freestanding Form
• R003-A091 HALF FS FORM
• R002-A104 (10IN KNOB FORMER)
• TWO LOOP HOLDERS (ONE FOR KNOB FORMER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
If the half groove former (R003-A094) is installed, remove it now.
4.
Install the freestanding half corner mold centered in the base of the form.
5.
Install the loop holder into the one 10-in (254-mm) knob former (R003-A155), then install the knob former in the form.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Half Corner Bottom Block
Side View
Half Corner Mold
Pour concrete to here
Half Corner Mold Side View
Pour concrete to here (bottom lip of mold)
Form Assembly Option 3 - Half Door
• RR FS FORM
• R003-A107 (FS HALF PANEL)
• R002-A104 (10IN KNOB FORMER)
• TWO LOOP HOLDERS (ONE FOR KNOB FORMER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK
HALF CORNER BOTTOM - OPT 3
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
HALF CORNER BOTTOM - OPT 3
2.
CORNER BOTTOM - OPT 3
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Remove one side panel, and install the half panel (R003-A107).
R003-A107
R003-A155
If the groove former is installed, remove it now.
5.
Install the freestanding half corner mold centered in the base of the form.
6.
Install the loop holder into the one 10-in (254-mm) knob former (R003-A155), then install the knob former in the bottom knob position of the form.
Production Notes
Pour 1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Helpful Hint: The half panel makes finishing the half blocks in a Freestanding Form much easier due to additional access to the block.
Half Corner Bottom Block
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE
Freestanding
FACE TEXTURE VARIES
Half Corner Top Block
BOTTOM F-HCT HALF CORNER TOP
Kingstone / Ledgestone
TEXTURE VARIES
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE
Freestanding Half Corner Top blocks are textured on three sides and are used on the top course at the beginning and ends of freestanding or retaining walls.
Face Texture:
Cobble / Limestone Kingstone / Ledgestone
4.9 ft3 (0.14m3) 700 lb (320 kg)
F-HCT HALF CORNER TOP
Face Texture:
Block Weight: Block Volume:
lb (290 kg)
ft3 (0.13m3)
Cobble / Limestone
lb (290 kg)
ft3 (0.13m3)
Kingstone / Ledgestone Block
DIAMETER x 4 (101) HIGH TYPICAL. 6 (152) DIAMETER AVAILABLE.
5. Weights are based upon a concrete density of 143 lb/ft3 (2291 kg ).
6. Knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knobs are available.
Form Assembly Option 1 - Freestanding Form
• RR FS FORM
• R003-A101 (FS GROOVE FORMER 40IN STANDARD)
• R002-A095 (KNOB COVER)
• TWO LOOP HOLDERS (ONE FOR KNOB COVER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
NOTE: ONE FREESTANDING HALF CORNER FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
HALF CORNER TOP - OPT 1
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Install the freestanding half corner mold centered in the base of the form.
4.
If the groove former (R003-A047) is not installed, install now.
5.
Install the loop holder into the knob cover (R002-A095), then install the knob cover on the bottom knob position of the form. Drilling knob cover will be required.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
The spreader lever is helpful when demolding Freestanding Half Corner Top blocks. Use the 48-in (1219-mm) position on the spreader lever to help hold doors open when pulling half corner blocks out of forms.
Critical Note: If you open the spreader lever all of the way before lifting most of the weight of the blocks off of the mold with a fork lift or overhead crane, you will tear the corners of the molds. If this happens, the mold will still make good blocks, but extra caution will be needed in keeping the tear clean when closing the mold.
Half
Maintenance, Tips & Tricks
Tips
1.
If a customer won’t be using a cap on top of the wall and desires a texture on top of the block, a textured top panel (R003-A111) exists to create this option. The top panel of the form would be removed, and the textured top panel would be installed. After the door panels have been switched, install the corner textured top panel rubber (R003-A112) into the door.
Helpful Hint: If blocks with no hook are necessary, a probst lift, clamp or nylon slings will need to be used for storage and placement.
Form Assembly Option 2 - Half Freestanding Form
• R003-A091 HALF FS FORM
• R002-A104 (10IN KNOB FORMER)
• TWO LOOP HOLDERS (ONE FOR KNOB FORMER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE PARTS
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Install the freestanding half corner mold centered in the base of the form.
4.
If the groove former (R003-A094) is not installed, install now.
5.
Install the loop holder into the knob cover (R002-A095), then install the knob cover on the form. Drilling knob cover will be required.
Production Notes
Pour 1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Half Corner Top Block
Side View
Half Corner Mold
Half Corner Mold Side View
Form Assembly Option 3 - Half Door
• RR FS FORM
• R003-A107 (FS HALF PANEL)
• R003-A101 (FS GROOVE FORMER 40IN STANDARD)
• R002-A095 (KNOB COVER)
• TWO LOOP HOLDERS (ONE FOR KNOB FORMER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are
Remove one side panel, and install the half panel (R003-A107).
4.
Install the freestanding half corner mold centered in the base of the form.
5.
If the groove former (R003-A047) is not installed, install now. Drilling knob cover will be required.
6.
Install the loop holder into the knob cover (R002-A095), then install the knob cover on the bottom knob position of the form.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Helpful Hint: The half panel makes finishing the half blocks in a freestanding form much easier due to additional access to the block.
Maintenance, Tips & Tricks
Tips 1.
If a customer won’t be using a cap on top of the wall and desires a texture on top of the block, a textured top panel (R003-A111) exists to create this option. The top panel of the form would be removed, and the textured top panel would be installed. After the door panels have been switched, install the corner textured top panel rubber (R003-A112) into the door.
Helpful Hint: If blocks with no hook are necessary, a probst lift, clamp or nylon slings will need to be used for storage and placement.
Freestanding Straight Garden Top blocks are textured on two sides and have a void in the top of the block to be finished in the field with soil and plantings or poured concrete.
F-SG STRAIGHT GARDEN TOP
Face
R003-A071 FILLER PLATE 2
FREESTANDING FLAT BASE 1
R003-A100
R003-A101
Freestanding 40 IN Groove Former 1
COMPATIBLE OPTIONS
PART NUMBER QTY DESCRIPTION
R002-A105 A/R LOOP HOLDER TYPE #5
R002-A145 A/R LOOP HOLDER TYPE #7
R002-A155 A/R LIFTEYE FORMER TYPE #1
NOTES:
FL1) Compatible options must be selected separately and are not included in th 2) GRAY COMPONENTS ARE FOR REFERENCE ONLY
FL3) Quantity of fasteners is dependent on loop holder and location of loop hold 4) The default position for the various loop holders & their optional configuratio
REVISION HISTORY
REV ECO NUMBER DESCRIPTION DATE APPROVED A ECO-078 Initial Release Liz Radoy
• RR FS FORM
• R003-A071 (FLAT BASE)
• R003-A100 (FILLER PLATE)
R003-A021
R003-A020
Garden Insert 1
Garden Insert Extension 1
5-13 HEX NUT 10 5-13-HN
5 FLAT WASHER 10 5-FW
R003-0377
• R003-A101 FS GROOVE FORMER 40IN STANDARD OR R003-A102 FS FULL GROOVE FORMER 46IN
• R003-A105 (GARDEN INSERT)
.5-13x1.5-CB
R003-A071
R003-A100
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
R003-A101
NOTE: TWO 18IN FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
BOLT PLATE 2
1/2"-13X1 5" CARRIAGE BOLT 4
FREESTANDING FLAT BASE 1
FILLER PLATE 2
Freestanding 40 IN Groove Former 1
COMPATIBLE OPTIONS
PART NUMBER QTY DESCRIPTION
R002-A105 A/R LOOP HOLDER TYPE #5
R002-A145 A/R LOOP HOLDER TYPE #7
R002-A155 A/R LIFTEYE FORMER TYPE #1
NOTES:
FL1) Compatible options must be selected separately and are not included in this assembly 2) GRAY COMPONENTS ARE FOR REFERENCE ONLY
FL3) Quantity of fasteners is dependent on loop holder and location of loop holder 4) The default position for the various loop holders & their optional configurations are on the
Form Assembly
1.
Install the loop holder into the garden insert.
Helpful Hint: When creating the Freestanding Garden Top block, loop holder #5 should be installed according to the drawings below.
2.
Remove the knob formers or knob covers, and install the garden insert into the form.
Helpful Hint: Make sure both pieces of the garden insert (R003-A020 and R003-A021) are bolted together before installing in the form.
Variable Radius Garden Top Block
Freestanding Variable Radius Garden Top blocks are textured on two sides with recesses at the end of the blocks to make it easier to cut blocks to turn a radius, as well as a void in the top of the block to be finished in the field with soil, plantings, or poured concrete.
• R003-A102 (FS FULL GROOVE FORMER 46IN) OR R003-A101 (FS GROOVE FORMER 40IN STANDARD WITH TWO R003-A050 FS GROOVE FORMER EXTENSIONS)
• R003-A105 (GARDEN INSERT)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
MOLDS
R003-A051
LOOP HOLDER
R003-A092
Form Assembly
1.
Install the 46-in (1168-mm) groove former on the bottom panel; OR install the groove former extensions to the standard 40-in (1016-mm) groove former.
2.
Helpful Hint: it is recommended to use a full length groove former with the variable radius inserts. Some manufacturers do choose to pour it with a shorter groove former; however, this creates excess concrete near the groove that a contractor will need to work around in the field.
Remove the flat base (R003-A071) from the form. The 4-in x 12-in (102mm x 305-mm) bottom variable radius garden insert (R003-A092) bolts to the flat base, then reinstall the base and insert in the form, centering with the filler plates (R003-A100).
3.
Install the loop holder into the garden insert.
Helpful Hint: The top variable radius garden insert (R003-A051) is placed on top of the poured concrete in the form, so it is not actually installed prior to pouring the blocks.
Helpful Hint: When creating the Freestanding Garden Top block, the loop holder should be installed according to the drawings below.
4.
Remove the knob formers or knob covers, and install the garden insert into the form.
5.
If the face molds are not already installed, see page 188 for installation instructions.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Place the top variable radius garden insert with lifting hook into the top of the block until the steel bar hits the top edge of the form. Clean up excess concrete.
Demolding
1.
Remove the top variable radius garden insert from the form.
2.
Then, demold the block as usual using the lifting hook in the end of the block.
Helpful Hint: Make sure both pieces of the garden insert (R003-A020 and R003-A021) are bolted together before installing in the form.
Ledgestone
Freestanding
Ledgestone
R003-A021
R003-A020
Corner Garden Top Block
F-CG CORNER GARDEN TOP
Garden Insert 1
Garden Insert Extension 1
.5-13 HEX NUT 10
.5-13-HN .5 FLAT WASHER 10
.5-FW
R003-0377
.5-13x1.5-CB
R003-A071
R003-A100
R003-A101
BOLT PLATE 2
Freestanding Corner Garden Top blocks, which are used at the top of the wall where freestanding or retaining walls start or stop, are textured on three sides and have a void in the top of the block to be finished in the field with soil, plantings, or poured concrete.
Face Texture:
Cobble / Limestone
F-CG CORNER GARDEN TOP
Block Weight:
Face Texture:
Block Volume:
Kingstone / Ledgestone
1/2"-13X1.5" CARRIAGE BOLT 4
FREESTANDING FLAT BASE 1
FILLER PLATE 2
Freestanding 40 IN Groove Former 1
COMPATIBLE OPTIONS
PART NUMBER QTY DESCRIPTION
Cobble / Limestone Kingstone / Ledgestone
R002-A105 A/R LOOP HOLDER TYPE #5
R002-A145 A/R LOOP HOLDER TYPE #7
R002-A155 A/R LIFTEYE FORMER TYPE #1
Face Texture:
Block Weight:
Block Volume:
Cobble / Limestone
NOTES:
FL1) Compatible options must be selected separately and are not included in t 2) GRAY COMPONENTS ARE FOR REFERENCE ONLY
FL3) Quantity of fasteners is dependent on loop holder and location of loop ho 4) The default position for the various loop holders & their optional configurat
Kingstone / Ledgestone
HISTORY
Liz Radoy
• RR FS FORM
• R003-A101 (FS GROOVE FORMER 40IN STANDARD)
• R003-A105 (GARDEN INSERT WITHOUT EXTENSION)
Garden Insert 1 R003-A021
R003-A020
.5-13-HN
Garden Insert Extension 1
.5-13 HEX NUT 10
5 FLAT WASHER 10 5-FW
R003-0377
BOLT PLATE 2
1/2"-13X1.5" CARRIAGE BOLT 4 .5-13x1.5-CB
R003-A071
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
R003-A100
R003-A101
FREESTANDING FLAT BASE 1
FILLER PLATE 2
Freestanding 40 IN Groove Former 1
COMPATIBLE OPTIONS
PART NUMBER QTY DESCRIPTION
R002-A105 A/R LOOP HOLDER TYPE #5
R003-A0
5-13-HN
5-13x1
R003-A071
NOTES:
R002-A145 A/R LOOP HOLDER TYPE #7
R002-A155 A/R LIFTEYE FORMER TYPE #1
FL1) Compatible options must be selected separately and are not included in this assembly. 2) GRAY COMPONENTS ARE FOR REFERENCE ONLY
holder and location of loop holder.
The default position for the various loop holders & their optional configurations are on the following pages.
R003-A066 CORNER MOLD ASSEMBLY NOTE: ONE FREESTANDING CORNER FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
REVISION HISTORY REV ECO NUMBER DESCRIPTION DATE APPROVED A ECO-078 Initial Release Liz Radoy
Initial Release Liz Radoy
FL3) Quantity of fasteners is dependent on loop holder and location of loop holder 4) The default position for the various loop holders & their optional configurations are on the fo
Form Assembly
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Install the freestanding corner mold centered in the base of the form.
4.
Remove the extension from the garden insert (R003-A020), and install the loop holder into the garden insert (R003-A021).
Helpful Hint: When
5.
Remove the knob formers or knob covers, and install the garden insert into the form.
Helpful Hint: Make sure the two pieces of the garden insert are not bolted together and only the larger portion (R003-A021) is installed.
6.
If the groove former (R003-A101) is not installed, install now.
Production Notes
Pour
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Side View
Full Corner Mold
Full Corner Mold Side View
Pour concrete to here (Bottom lip of mold)
Demolding
1.
The spreader lever is helpful when demolding Freestanding Corner Garden Top blocks. Use the 41-in (1041-mm) position on the spreader lever to help hold doors open when pulling corner blocks out of forms.
Critical Note: If you open the spreader lever all of the way before lifting most of the weight of the blocks off of the mold with a fork lift or overhead crane, you will tear the corners of the molds. If this happens, the mold will still make good blocks, but extra caution will be needed in keeping the tear clean when closing the mold.
Half Corner Garden Top Block
Freestanding Half Corner Garden Top blocks are shorter blocks used at the top of the wall where freestanding or retaining walls start or stop, and they are textured on three sides with a void in the top of the block to be finished in the field with soil, plantings, or poured concrete.
• R003-A105 (GARDEN INSERT WITHOUT EXTENSION) OR R003-A103 (HALF (GARDEN INSERT WITHOUT EXTENSION)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
If the groove former (R003-A047) is not installed, install now.
4.
Remove the extension (R003-A020) from the garden insert and install the loop holder into the larger portion of the garden insert (R003-A021).
Helpful Hint: The half garden insert (R003-A099) without the extension (R003-A020) can also be used in this form configuration option.
5.
Remove the knob formers or knob covers, and install the garden insert into the form.
Helpful Hint: When creating the Freestanding Half Corner Garden Top block, the loop holder should be installed according to the drawings below.
Helpful Hint: Make sure the two pieces of the garden insert are not bolted together and only the larger portion (R003-A021 or R003-A099) is installed.
6.
If the groove former (R003-A047) is not installed, install now.
ion Loop Holder Is In the Bottom Position
Production Notes
Pour 1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
The spreader lever is helpful when demolding Freestanding Corner Garden Top blocks. Use the 48-in (1219-mm) position on the spreader lever to help hold doors open when pulling corner blocks out of forms.
Critical Note: If you open the spreader lever all of the way before lifting most of the weight of the blocks off of the mold with a fork lift or overhead crane, you will tear the corners of the molds. If this happens, the mold will still make good blocks, but extra caution will be needed in keeping the tear clean when closing the mold.
Half Corner Mold
Form Assembly Option 2 - Half Freestanding Form
• R003-A091 (HALF FS FORM)
• R003-A094 (HALF GROOVE FORMER)
• R003-A103 (HALF GARDEN INSERT WITHOUT EXTENSION)
• TWO LOOP HOLDERS (ONE FOR KNOB COVER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
Install the freestanding half corner mold centered in the base of the form.
4.
Remove the extension (R003-A020) from the half garden insert (R003-A099) and install the loop holder into the garden insert.
5.
Remove the knob former or knob cover, and install the half garden insert into the form. 6.
If the half groove former (R003-A094) is not installed, install now.
Helpful Hint: Make sure the two pieces of the garden insert are not bolted together and only the larger portion (R003-A099) is installed.
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Half
Form Assembly Option 3 - Half Door
• RR FS FORM
• R003-A107 (FS HALF PANEL)
• R003-A101 (FS GROOVE FORMER 40IN STANDARD)
• R003-A105 (GARDEN INSERT WITHOUT EXTENSION) OR R003-A103 (HALF (GARDEN INSERT WITHOUT EXTENSION)
• TWO LOOP HOLDERS (ONE FOR KNOB FORMER AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
40" Groove Former 1
R003-A071
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Remove one side panel, and install the half panel (R003-A107).
4.
Install the freestanding half corner mold centered in the base of the form.
5.
Remove the extension from the garden insert (R003-A020) and install the loop holder into the garden insert (R003-A021).
Helpful Hint: The half garden insert (R003-A099) without the extension (R003-A020) can also be used in this form configuration option.
Helpful Hint: When creating the Freestanding Half Corner Garden Top block, the loop holder should be installed according to the drawings below.
Half Corner Garden Top Block
Remove the knob formers or knob covers, and install the garden insert into the form.
7.
If the groove former (R003-A047) is not installed, install now.
Production Notes
Pour 1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Helpful Hint: Make sure the two pieces of the garden insert are not bolted together and only the larger portion (R003-A021 or R003-A099) is installed.
Helpful Hint: The half panel makes finishing the half blocks in a freestanding form much easier due to additional access to the block.
R003-A044
R003-A046
Freestanding
6 IN VERT
CONDUIT RETAINER - 3 IN HORIZ
R003-A041 L ROD 1
SPLITTER 1
R003-0107
R003-0338
FILLER BAR 1
Force Protection Middle Block
FREESTANDING BLOCKS
Block Library
Freestanding Force Protection Middle blocks are textured on two sides and used in scenarios where tying the blocks together with additional connectors is specified by an engineer.
COMPATIBLE OPTIONS (FL2)
PART NUMBER QTY
F-FM FORCE PROTECTION MIDDLE
F-FM FORCE PROTECTION MIDDLE
/ Limestone Face
Face
Block
DESCRIPTION
R002-A108 A/R LOOP HOLDER TYPE #1
R002-A155 A/R LIFTEYE FORMER TYPE #1
Kingstone / Ledgestone
/ Limestone
Kingstone / Ledgestone
KNOBS @ 23 (584) OC, TYP.
Cobble / Limestone
10.23 ft3 (0.290 m3)
6 (152) DIAMETER x 18 (457) TALL RECESS EACH END
CAST-IN #4 (#13) REBAR HOOK EACH END
24 (610) ± LEDGESTONE COBBLESTONE
23 (584) ± LIMESTONE
Kingstone / Ledgestone
Notes
LEDGESTONE COBBLESTONE
1) GRAY COMPONENTS ARE FOR REFERENCE ONLY FL2) Compatible options must be selected separately and are not included in
REVISION HISTORY
ZONE REV DESCRIPTION DATE APPROVED A Initial Release 9/8/2021 G HEINZ
FACE TEXTURE VARIES 10 (254) DIAMETER x 4 (102) HIGH, TYPICAL. 6 (152) DIAMETER KNOBS AVAILABLE.
3 (76) DIAMETER HORIZONTAL VOID FULL LENGTH OF BLOCK, TYP.
24 (610) ±
(584) ±
• RR FS FORM
• R003-A071 (FLAT BASE)
• R003-A100 (FILLER PLATE)
• R003-A101 (FS GROOVE FORMER 40IN STANDARD) OR R003-A102 (FS FULL GROOVE FORMER 46IN)
• TWO R002-A104 (10IN KNOB FORMERS)
• R003-A108 (FORCE PROTECTION KIT)
R003-A046
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
2 R003-A039 BOTTOM INSERT 2 R003-A042
LIFTEYE FORMER - 6 IN VERT TUBE 2 R003-A044 CONDUIT RETAINER - 3 IN HORIZ CONDUIT 2 R003-A046 SPLITTER 1 R003-A041 L ROD 1 R003-0107 FILLER BAR 1 R003-0338
NOTE: TWO 18IN FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
Form Assembly
1.
Install the filler plates (R003-A100) in the top and bottom door panels near the base of the form using the existing holes.
2.
The force protection components will be installed on the flat base insert (R003-A071), so if it is installed, remove it from the form. First install the force protection bottom insert (R003-A042) on the corresponding holes of the flat base – this part will slide under the groove former. Next install the lifteye former (R003-A044); the open side of this is positioned toward the bottom insert (R003-A042). Next, install the top insert (R003-A039) against the lifteye former; and finally secure the conduit retainer (R003-A046) through the top insert and base.
3.
Helpful Hint: The holes in the flat base insert are offset, so the force protection kit can only be installed one way.
Position the flat base insert (R003-A071) with the force protection components in the bottom of the form, centering it with the filler plates on the top and bottom door panels. Bolt in place.
4.
Install the groove former (R003-A047) if not already installed.
5.
Install two 18-in (457-mm) face molds on the side panel doors if not already installed. See page 188 for instructions.
6.
Install the knob formers (R003-A155) and lifting insert if they are not already installed.
Production Notes
Prep
1.
With the block being poured vertically, make sure to apply release agent on the undersides of surfaces in the face mold to facilitate demolding and prevent unneeded wear and tear on the face mold.
Critical Note: Be sure to apply release agent on the top portion of the force protection kit before installing it on the form.
2.
Install the force protection hook or engineer-specified reinforcement into the bottom lifteye former (R003-A044) before closing the form.
Helpful Hint: If wall design requires cable through the block, install the 3-in (76mm) conduit now onto the bottom conduit retainer. Continued
3.
Close the form. Install the top portion of the kit to the fully closed form, using the holes provided in the top and bottom panels. The L-shaped pin (R003-0107) slides in and holds the force protection hook or engineer-specified reinforcement into the top insert.
Pour
1.
Pour the concrete to the bottom lip of the mold.
Demolding
1.
Remove the L-shaped pin and the top portion of the kit from the form.
2.
Use a pry bar to aid in opening the forms. Do not hammer on forms.
Helpful Hint: The appropriate pry point for freestanding forms will vary depending on what generation form they are. Older forms will have a tab halfway down the side panel to use as a leverage point. Newer forms are designed with a notch towards the top of the panel for the pry bar placement.
Helpful Hint: Do not allow panels to slam open hard on rails. Protecting the form from unnecessary wear and tear will help to prolong the life of your investment.
Maintenance, Tips & Tricks
Tips
1.
The connection between blocks will be specified per the engineer’s design for the wall. Commonly, a J-bolt and clip are used to connect the blocks.
Helpful Hint: See page xxxvi in the Appendix for more information on J-bolts and clips. Continued
FACE TEXTURE VARIES
Force Protection Bottom Block
VARIES
Freestanding Force Protection Bottom blocks are textured on two sides and used at the bottom of walls where tying the blocks together with additional connectors is specified by an engineer.
F-FB FORCE PROTECTION BOTTOM
F-FB FORCE PROTECTION BOTTOM
Face Texture:
Face Texture:
Block
KNOBS @
Cobble / Limestone
Cobble / Limestone
Kingstone / Ledgestone
24 (610) ± LEDGESTONE
COBBLESTONE 23 (584) ± LIMESTONE FACE TEXTURE VARIES
FACE TEXTURE VARIES
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Architectural faces on the blocks have varying texture.
4. Actual block volumes and weights may vary. 5. Weights are based upon a concrete density of 143 lb/ft (2291 kg/m3). 6. Knobs are typically 10" (254mm) diameter by 4" (102 mm) tall. Smaller knobs are available.
• RR FS FORM
• R003-A071 (FLAT BASE)
• R003-A100 (FILLER PLATE)
PARTS AND KIT NUMBERS FOR ORDERING
R003-A042 LIFTEYE FORMER - 6 IN VERT TUBE 2 R003-A044 CONDUIT RETAINER - 3 IN HORIZ CONDUIT 2 R003-A046
• TWO R002-A104 (10IN KNOB FORMERS)
• R003-A108 (FORCE PROTECTION KIT)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
2
R003-A039 BOTTOM INSERT 2 R003-A042
LIFTEYE FORMER - 6 IN VERT TUBE 2 R003-A044
CONDUIT RETAINER - 3 IN HORIZ CONDUIT 2 R003-A046 SPLITTER 1 R003-A041 L ROD 1 R003-0107 FILLER BAR 1 R003-0338 5-13 HEX
COMPATIBLE OPTIONS (FL2)
QTY DESCRIPTION R002-A108 A/R LOOP HOLDER TYPE #1 R002-A155 A/R LIFTEYE FORMER TYPE #1
6 5-13-HN 5
6 5-FW
COMPATIBLE OPTIONS (FL2) PART NUMBER DESCRIPTION R002-A108
NOTE: TWO 18IN FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
REVISION HISTORY ZONE REV DESCRIPTION A Initial Release Notes 1) GRAY COMPONENTS ARE FOR REFERENCE ONL FL2) Compatible options must be selected separate
Form Assembly
1.
Install the filler plates (R003-A100) in the top and bottom door panels near the base of the form using the existing holes.
2.
The force protection components will be installed on the flat base insert (R003-A071), so if it is installed, remove it from the form. First install the force protection bottom insert (R003-A042) on the corresponding holes of the flat base – this part will slide under the groove former. Next install the lifteye former (R003-A044); the open side of this is positioned toward the bottom insert (R003-A042). Next, install the top insert (R003-A039) against the lifteye former; and finally secure the conduit retainer (R003-A046) through the top insert and base.
3.
Helpful Hint: The holes in the flat base insert are offset, so the force protection kit can only be installed one way.
Position the flat base insert (R003-A071) with the force protection components in the bottom of the form, centering it with the filler plates on the top and bottom door panels. Bolt in place.
If the groove former is installed, remove it.
5.
Install two 18-in (457-mm) face molds on the side panel doors if not already installed. See page 188 for instructions.
6.
Install the knob formers (R003-A155) and lifting insert if they are not already installed.
Production Notes
Prep
1.
With the block being poured vertically, make sure to apply release agent on the undersides of surfaces in the face mold to facilitate demolding and prevent unneeded wear and tear on the face mold.
Critical Note: Be sure to apply release agent on the top portion of the force protection kit before installing it on the form.
2.
Install the force protection hook or engineer-specified reinforcement into the bottom lifteye former (R003-A044) before closing the form.
Helpful Hint: If wall design requires cable through the block, install the 3-in (76mm) conduit now onto the bottom conduit retainer. Continued
3.
Close the form. Install the top portion of the kit to the fully closed form, using the holes provided in the top and bottom panels. The L-shaped pin (R003-0107) slides in and holds the force protection hook or engineer-specified reinforcement into the top insert.
Pour
1.
Pour the concrete to the bottom lip of the mold.
Demolding
1.
Remove the L-shaped pin and the top portion of the kit from the form.
2.
Use a pry bar to aid in opening the forms. Do not hammer on forms.
Helpful Hint: The appropriate pry point for freestanding forms will vary depending on what generation form they are. Older forms will have a tab halfway down the side panel to use as a leverage point. Newer forms are designed with a notch towards the top of the panel for the pry bar placement.
Maintenance, Tips & Tricks
Tips
1.
The connection between blocks will be specified per the engineer’s design for the wall. Commonly, a J-bolt and clip are used to connect the blocks. See page xxxvi for this construction detail.
Helpful Hint: Do not allow panels to slam open hard on rails. Protecting the form from unnecessary wear and tear will help to prolong the life of your investment.
Helpful Hint: See page xxxvi in the Appendix for more information on J-bolts and clips.
Force Protection Top Block
Freestanding Force Protection Top blocks are textured on two sides used at the top of walls in scenarios where tying the blocks together with additional connectors is specified by an engineer.
F-FT FORCE PROTECTION TOP
F-FT FORCE PROTECTION TOP
Face
• RR FS FORM
• R003-A071 (FLAT BASE)
• R003-A100 (FILLER PLATE)
• TWO R002-A095 (KNOB COVERS)
• R003-A108 (FORCE PROTECTION KIT)
R003-A039 BOTTOM INSERT 2
R003-A042
R003-A046
R003-A041
• R003-A101 (FS GROOVE FORMER 40IN STANDARD) OR R003-A102 (FS FULL GROOVE FORMER 46IN)
R003-0338
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
QTY PART NUMBER TOP INSERT 2 R003-A039 BOTTOM INSERT 2 R003-A042 LIFTEYE FORMER - 6 IN VERT TUBE 2 R003-A044 CONDUIT RETAINER - 3 IN HORIZ CONDUIT 2 R003-A046 SPLITTER 1 R003-A041 L ROD 1 R003-0107 FILLER BAR 1 R003-0338 5-13 HEX NUT 6 5-13-HN 5
QTY DESCRIPTION
R002-A108 A/R LOOP HOLDER TYPE #1
R002-A155 A/R LIFTEYE FORMER TYPE #1
Form Assembly
1.
Install the filler plates (R003-A100) in the top and bottom door panels near the base of the form using the existing holes.
2.
The force protection components will be installed on the flat base insert (R003-A071), so if it is installed, remove it from the form. First install the force protection bottom insert (R003-A042) on the corresponding holes of the flat base – this part will slide under the groove former. Next install the lifteye former (R003-A044); the open side of this is positioned toward the bottom insert (R003-A042). Next, install the top insert (R003-A039) against the lifteye former; and finally secure the conduit retainer (R003-A046) through the top insert and base.
3.
Helpful Hint: The holes in the flat base insert are offset, so the force protection kit can only be installed one way.
Position the flat base insert (R003-A071) with the force protection components in the bottom of the form, centering it with the filler plates on the top and bottom door panels. Bolt in place.
Install the groove former (R003-A047) if not already installed. 5.
Install two 18-in (457-mm) face molds on the side panel doors if not already installed. See page 188 for instructions.
6.
If the knob formers (R003-A155) are installed, remove them and install the knob covers (R002-A095). 7.
Install the lifting insert if not already installed.
Production Notes
Prep
1.
With the block being poured vertically, make sure to apply release agent on the undersides of surfaces in the face mold to facilitate demolding and prevent unneeded wear and tear on the face mold.
Critical Note: Be sure to apply release agent on the top portion of the force protection kit before installing it on the form.
2.
Install the force protection hook or engineer-specified reinforcement into the bottom lifteye former (R003-A044) before closing the form.
Helpful Hint: If wall design requires cable through the block, install the 3-in (76mm) conduit now onto the bottom conduit retainer.
3.
Close the form. Install the top portion of the kit to the fully closed form, using the holes provided in the top and bottom panels. The L-shaped pin (R003-0107) slides in and holds the force protection hook or engineer-specified reinforcement into the top insert.
Pour
1.
Pour the concrete to the bottom lip of the mold.
Demolding
1.
Remove the L-shaped pin and the top portion of the kit from the form.
2.
Use a pry bar to aid in opening the forms. Do not hammer on forms.
Helpful Hint: The appropriate pry point for freestanding forms will vary depending on what generation form they are. Older forms will have a tab halfway down the side panel to use as a leverage point. Newer forms are designed with a notch towards the top of the panel for the pry bar placement.
Maintenance, Tips & Tricks
Tips
1.
The connection between blocks will be specified per the engineer’s design for the wall. Commonly, a J-bolt and clip are used to connect the blocks. See page xxxvi for this construction detail.
Helpful Hint: Do not allow panels to slam open hard on rails. Protecting the form from unnecessary wear and tear will help to prolong the life of your investment.
Helpful Hint: See page xxxvi in the Appendix for more information on J-bolts and clips.
Hollow-Core Block
Block Library
Freestanding Hollow-Core blocks have rebar alignment features and a hollowcore to allow for concrete reinforcement in the field for barrier, water retention, cantilever, or cast-in-place wall applications.
F-HC HOLLOW-CORE
F-HC HOLLOW-CORE
Face Texture:
Face Texture:
Block Weight:
Block Volume:
Cobble / Limestone
Cobble / Limestone
F-HHC HALF HOLLOW-CORE
Face Texture:
Block
Cobble / Limestone
F-CHC CORNER HOLLOW-CORE
Face Texture:
Kingstone / Ledgestone
Cobble / Limestone
R003-A029 A/R REBAR ALIGNMENT VOID INSERT C
Block Weight:
Block Volume:
HALF CORNER HOLLOW-CORE
Kingstone / Ledgestone
Kingstone / Ledgestone
Kingstone / Ledgestone
Kingstone / Ledgestone
• RR FS FORM
• R003-A082 (FS HOLLOW-CORE KIT)
• R003-A071 (FLAT BASE)
• R003-A100 (FILLER PLATES)
• TWO R002-A095 (KNOB COVERS)
R003-A028
R003-A079
R003-A080
HOLLOW-CORE INSERT - LOWER 1
HOLLOW-CORE INSERT - UPPER 1
HOLLOW-CORE INSERT - CORNER 2 R003-A081
Hollow-Core
Form Assembly
1.
Install flat base insert (R003-A071) and two filler plates (R003-A100) at the bottom of the form. Remove any bolts that will interfere with the hollow-core inserts.
2.
Bolt together the two pieces of the hollow-core bottom insert (R003-A079 and R003-A081).
3.
Remove the groove former, and install the entire hollow-core bottom insert (R003-A079 and R003-A081). Do not tighten bolts.
4.
Bolt together the two pieces of the hollow-core top insert (R003-A080 and R003-A081).
5.
Remove knob formers or knob covers if installed, then install the entire hollow-core upper insert (R003-A080 and R003-A081) through the knob cover holes. Install the knob covers, but do not tighten bolts.
6.
Install the top rebar alignment insert (R003-A026) and the bottom rebar alignment insert (R003-A028). Make sure to align the nubs on the rubber inserts with the holes in the steel inserts. Continued
7.
Install face molds. Ensure that molds are positioned so that the distance from the base insert to the edge of the texture face is 46 ⅛ in (1172 mm). See page 194 for additional instructions.
Helpful Hint: When installing Ledgestone 5, ensure that the mold is oriented with texture ribbing nearest top side of the form to avoid potentially breaking blocks.
8.
Close the form. Tighten all insert bolts.
9.
Measure the width of the form opening. Ensure that the block height opening is within 18 in +/- 1/16 in (457 mm +/- 1.5 mm).
Production Notes
Prep
1.
Remove the top and bottom rebar alignment inserts and spray with release agent. Spray the rest of the form with release agent.
Helpful Hint: Applying oil to the contact surfaces between the rubber inserts and steel inserts, as well as the end surfaces of the rebar alignment inserts and groove forming features, will aid in proper release of the inserts and help prevent buildup of concrete between the inserts. Continued
Hollow-Core
2.
Reinstall the rubber inserts, ensuring they are seated tight between both steel inserts when the form is closed. Failure to do so will result in out of tolerance blocks and/or inserts embedded in the block.
Pour
1.
Pour the concrete to the bottom lip of the mold.
Helpful Hint: If you’re using internal vibration when pouring, adjust the method and duration for the reduced concrete volume of freestanding hollow-core blocks.
Demolding
1.
Before demolding, ensure concrete has cured to proper strength. With less concrete volume, the block will crack easier if not sufficiently cured.
2.
Most commonly, manufacturers use a nylon strap to remove Freestanding Hollow-Core blocks from the form. Then, two nylon straps around the two center beams of concrete are used to move blocks to storage.
3.
During cleaning, pay close attention to the surfaces where the rubber contacts the steel inserts.
Helpful Hint: Failure to clean these surfaces properly will prevent the rubber inserts from installing properly and cause out of tolerance blocks.
Maintenance, Tips & Tricks
Maintenance
1.
Regularly check the height measurement with the form doors closed remains 18 in +/- 1/16 in (457 mm +/- 1.5 mm). If the form is out of tolerance, adjust the inserts accordingly.
Hollow-Core Block
Freestanding
FACE TEXTURE VARIES FACE TEXTURE VARIES
Half Hollow-Core Block
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE
Freestanding Half Hollow-Core blocks are used in hollow-core wall applications to maintain the running bond, oftentimes when the wall abuts an existing structure.
F-HHC HALF HOLLOW-CORE
F-HHC HALF HOLLOW-CORE
Face Texture:
Cobble / Limestone
Cobble / Limestone
Kingstone / Ledgestone
Kingstone / Ledgestone
FACE TEXTURE VARIES
FACE TEXTURE VARIES
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE
1. Units for dimensions are inches (mm), typical unless noted otherwise.
2. Confirm block production with licensed Redi-Rock manufacturer.
3. Architectural faces on the blocks have varying texture.
4. Average block weights shown. Actual block volumes and weights may vary.
5. Weights are based upon a concrete density of 143 lb/ft3 (2291 kg ).
F-HCHC HALF CORNER
Form Assembly Option 1 - Freestanding Form
REBAR ALIGNMENT VOID INSERT B 1
R003-A028 HALF HOLLOW-CORE INSERT - LOWER 1
R003-A074 HALF HOLLOW-CORE INSERT - UPPER 1
• RR FS FORM
• R003-A071 (FLAT BASE)
• R003-A100 (FILLER PLATES)
• TWO R002-A095 (KNOB COVERS)
NOTE: TWO 18IN HALF FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
base
R003-A076 HOLLOW-CORE INSERT - CORNER 2
R003-A081
• R003-A082 (FS HOLLOW-CORE KIT) OR R003-A078 (HALF HOLLOWCORE KIT)
R002-A095 FREESTANDING FLAT BASE 1
R003-A100
R003-A071 FILLER PLATE 2
OPTIONS
R003-A029 A/R REBAR ALIGNMENT VOID INSERT C
2.
Bolt together the two pieces of the hollow-core bottom insert (R003-A079 or R003-A074 and R003-A081).
3.
Remove the groove former, and install the entire hollow-core bottom insert (R003-A079 or R003-A074 and R003-A081). Do not tighten bolts.
4.
Bolt together the two pieces of the hollow-core top insert (R003-A080 or R003-A076 and R003-A081).
Helpful Hint: If using the half hollow-core kit the bottom insert will be part R003-A074.
5.
Remove knob formers or knob covers if installed, then install the entire hollow-core upper insert (R003-A080 or R003-A076 and R003-A081) through the knob cover holes. Install the knob covers, but do not tighten bolts.
6.
Install the bottom rebar alignment insert (R003-A028). Make sure to align the nubs on the rubber inserts with the holes in the steel inserts.
7.
Install face molds. Ensure that molds are positioned so that the distance from the base insert to the edge of the texture face is 46 ⅛ in (1172 mm). See page 194 for additional instructions.
Helpful Hint: If using the half hollow-core kit the top insert will be part R003-A076. Continued
Close the form. Tighten all insert bolts.
9.
Measure the width of the form opening. Ensure that the block height opening is within 18 in +/- 1/16 in (457 mm +/- 1.5 mm).
Production Notes
Prep
1.
Remove the bottom rebar alignment inserts and spray with release agent. Spray the rest of the form with release agent.
2.
Reinstall the rubber insert, ensuring they are seated tight between both steel inserts when the form is closed. Failure to do so will result in out of tolerance blocks and/or inserts embedded in the block.
Helpful Hint: Applying oil to the contact surfaces between the rubber inserts and steel inserts, as well as the end surfaces of the rebar alignment inserts and groove forming features, will aid in proper release of the inserts and help prevent buildup of concrete between the inserts.
Pour
1.
Pour the concrete to the bottom lip of the mold.
Helpful Hint: If you’re using internal vibration when pouring, adjust the method and duration for the reduced concrete volume of freestanding hollow-core blocks.
Half
Hollow-Core Block
Demolding
1.
Before demolding, ensure concrete has cured to proper strength. With less concrete volume, the block will crack easier if not sufficiently cured.
2.
Most commonly, manufacturers use a nylon strap to remove Freestanding Hollow-Core Half blocks from the form. They wrap the strap around the center beam of concrete to move the blocks to storage.
3.
During cleaning, pay close attention to the surfaces where the rubber contacts the steel inserts.
Helpful Hint: Failure to clean these surfaces properly will prevent the rubber inserts from installing properly and cause out of tolerance blocks.
Maintenance, Tips & Tricks
Maintenance
1.
Regularly check the height measurement with the form doors closed remains 18 in +/- 1/16 in (457 mm +/- 1.5 mm). If the form is out of tolerance, adjust the inserts accordingly.
Form Assembly Option 2 - Half Freestanding Form
• RR FS HALF FORM
• R003-A078 (HALF HOLLOW-CORE KIT)
• R003-A071 (FLAT BASE)
• R003-A100 (FILLER PLATES)
• R002-A095 (KNOB COVER)
NOTE: TWO 18IN HALF FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE. 1. Install flat base insert (R003-A071) and two filler plates (R003-A100) at the bottom of the form. Remove any bolts that will interfere with the hollow-core inserts.
Bolt together the two pieces of the hollow-core bottom insert (R003-A074 and R003-A081).
3.
Remove the groove former, and install the entire hollow-core bottom insert (R003-A074 and R003-A081). Do not tighten bolts.
4.
Bolt together the two pieces of the hollow-core top insert (R003-A076 and R003-A081).
5.
Remove knob former or knob cover if installed, then install the entire hollow-core upper insert (R003-A076 and R003-A081) through the knob cover holes. Install the knob cover, but do not tighten bolts.
6.
Install the bottom rebar alignment insert (R003-A028). Make sure to align the nubs on the rubber inserts with the holes in the steel inserts.
7.
Install the 18-in (457-mm) half face molds. Ensure that molds are positioned so that the distance from the base insert to the middle lip of the texture is 23 in (584 mm). A portion of the rubber mold will extend beyond the form.
8.
Close the form. Tighten all insert bolts.
Continued
9.
Measure the width of the form opening. Ensure that the block height opening is within 18 in +/- 1/16 in (457 mm +/- 1.5 mm).
Production Notes
Prep 1.
Remove the bottom rebar alignment inserts and spray with release agent. Spray the rest of the form with release agent.
2.
Reinstall the rubber insert, ensuring they are seated tight between both steel inserts when the form is closed. Failure to do so will result in out of tolerance blocks and/or inserts embedded in the block.
Helpful Hint: Applying oil to the contact surfaces between the rubber inserts and steel inserts, as well as the end surfaces of the rebar alignment inserts and groove forming features, will aid in proper release of the inserts and help prevent buildup of concrete between the inserts.
Pour
1.
Pour the concrete to the bottom lip of the mold.
Helpful Hint: If you’re using internal vibration when pouring, adjust the method and duration for the reduced concrete volume of freestanding hollow-core blocks.
Half
Hollow-Core Block
Demolding
1.
Before demolding, ensure concrete has cured to proper strength. With less concrete volume, the block will crack easier if not sufficiently cured.
2.
Most commonly, manufacturers use a nylon strap to remove Freestanding Hollow-Core Half blocks from the form. They wrap the strap around the center beam of concrete to move the blocks to storage.
3.
During cleaning, pay close attention to the surfaces where the rubber contacts the steel inserts.
Helpful Hint: Failure to clean these surfaces properly will prevent the rubber inserts from installing properly and cause out of tolerance blocks.
Maintenance, Tips & Tricks
Maintenance
1.
Regularly check the height measurement with the form doors closed remains 18 in +/- 1/16 in (457 mm +/- 1.5 mm). If the form is out of tolerance, adjust the inserts accordingly.
Corner Hollow-Core Block
R002-A095
R003-A029
Freestanding Hollow-Core Corner blocks are used at the beginning and ends of hollow-core wall applications.
Remove flat base insert (R003-A071) and two filler plates (R003-A100) at the bottom of the form. Remove any bolts that will interfere with the hollow-core inserts.
2.
Install the corner mold.
3.
If connected, separate the two pieces of the hollow-core bottom insert (R003-A079 and R003-A081).
4.
Remove the groove former, and install the hollow-core bottom insert (R003-A079). Do not tighten bolts.
5.
If connected, separate the two pieces of the hollow-core top insert (R003-A080 and R003-A081).
6.
Remove knob formers or knob covers if installed, then install the hollow-core upper insert (R003-A080) through the knob cover holes. Install the knob covers, but do not tighten bolts.
7.
Install the top rebar alignment insert (R003-A026) and the corner rebar alignment insert (R003-A029). Make sure to align the nubs on the rubber inserts with the holes in the steel inserts. Continued
8.
Close the form. Tighten all insert bolts.
9.
Measure the width of the form opening. Ensure that the block height opening is within 18" +/- 1/16".
Production Notes Prep
1.
Remove the top and bottom rebar alignment inserts and spray with release agent. Spray the rest of the form with release agent.
2.
Reinstall the rubber inserts, ensuring they are seated tight between both steel inserts when the form is closed. Failure to do so will result in out of tolerance blocks and/or inserts embedded in the block.
Helpful Hint: Applying oil to the contact surfaces between the rubber inserts and steel inserts, as well as the end surfaces of the rebar alignment inserts and groove forming features, will aid in proper release of the inserts and help prevent buildup of concrete between the inserts.
Pour
1.
Pour the concrete to the bottom lip of the mold.
Helpful Hint: If you’re using internal vibration when pouring, adjust the method and duration for the reduced concrete volume of freestanding hollow-core blocks. Continued
Demolding
1.
Before demolding, ensure concrete has cured to proper strength. With less concrete volume, the block will crack easier if not sufficiently cured.
2.
Most commonly, manufacturers use a nylon strap to remove Freestanding Hollow-Core Corner blocks from the form. Then, two nylon straps around the two center beams of concrete are used to move blocks to storage.
3.
During cleaning, pay close attention to the surfaces where the rubber contacts the steel inserts.
Helpful Hint: Failure to clean these surfaces properly will prevent the rubber inserts from installing properly and cause out of tolerance blocks.
24 (610) ± LEDGESTONE
FACE TEXTURE VARIES
FACE TEXTURE VARIES
24 (610) ± LEDGESTONE
Half Corner Hollow-Core Block
COBBLESTONE
23 (584) ± LIMESTONE
Kingstone / Ledgestone
COBBLESTONE
The Freestanding Half Corner Hollow-Core block is used at the beginning and ends, as well as every other course at the corners, of hollow-core wall applications to maintain a running bond.
shown. Actual block volumes and weights may vary. concrete density of 143 lb/ft3 (2291 kg ).
F-HCHC HALF CORNER HOLLOW-CORE
Cobble / Limestone
/ Limestone
FACE TEXTURE VARIES
23 (584) ± LIMESTONE 13(330)
Kingstone / Ledgestone
/ Ledgestone
FACE TEXTURE VARIES
24 (610) ± LEDGESTONE
COBBLESTONE
23 (584) ± LIMESTONE
Form Assembly Option 1 - Freestanding Form
• RR FS FORM
• R003-A082 (FS HOLLOW-CORE KIT) OR R003-A078 (HALF HOLLOWCORE KIT)
• R003-A029 (CORNER REBAR ALIGNMENT INSERT)
• R002-A095 (KNOB COVER)
NOTE: A HALF CORNER MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
1.
Remove flat base insert (R003-A071) and two filler plates (R003-A100) at the bottom of the form if they are installed. Remove any bolts that will interfere with the hollow-core inserts.
2.
Install the half corner mold.
3.
If connected, separate the two pieces of the hollow-core bottom insert (R003-A079 or R003-A074 and R003-A081).
4.
Remove the groove former, and install the larger portion of the hollowcore bottom insert (R003-A079 or R003-A074). Do not tighten bolts.
5.
If connected, separate the two pieces of the hollow-core top insert (R003-A080 or R003-A076 and R003-A081).
Helpful Hint: If using the half hollow-core kit the bottom insert will be part R003-A074.
6.
Remove knob formers or knob covers if installed, then install the larger portion of the hollow-core upper insert (R003-A080 or R003-A076) through the bottom knob cover holes. Install the knob cover, but do not tighten bolts.
Helpful Hint: If using the half hollow-core kit the top insert will be part R003-A076.
Helpful Hint: The upper knob former or knob cover can remain, as it will not interfere with pouring half blocks.
7.
Install the corner rebar alignment insert (R003-A029). Make sure to align the nubs on the rubber inserts with the holes in the steel inserts.
8.
Close the form. Tighten all insert bolts.
9.
Measure the width of the form opening. Ensure that the block height opening is within 18" +/- 1/16".
Production Notes
Prep
1.
Remove the corner rebar alignment inserts and spray with release agent. Spray the rest of the form with release agent.
2.
Reinstall the rubber insert, ensuring they are seated tight between both steel inserts when the form is closed. Failure to do so will result in out of tolerance blocks and/or inserts embedded in the block.
Helpful Hint: Applying oil to the contact surfaces between the rubber inserts and steel inserts, as well as the end surfaces of the rebar alignment inserts and groove forming features, will aid in proper release of the inserts and help prevent buildup of concrete between the inserts.
Pour
1.
Pour the concrete to the bottom lip of the mold.
Helpful Hint: If you’re using internal vibration when pouring, adjust the method and duration for the reduced concrete volume of freestanding hollow-core blocks.
Half
Demolding
1.
Before demolding, ensure concrete has cured to proper strength. With less concrete volume, the block will crack easier if not sufficiently cured.
2.
Most commonly, manufacturers use a nylon strap to remove Freestanding Hollow-Core Half Corner blocks from the form. They wrap the strap around the center beam of concrete to move the blocks to storage.
3.
During cleaning, pay close attention to the surfaces where the rubber contacts the steel inserts.
Helpful Hint: Failure to clean these surfaces properly will prevent the rubber inserts from installing properly and cause out of tolerance blocks.
Maintenance, Tips & Tricks
Maintenance
1.
Regularly check the height measurement with the form doors closed remains 18 in +/- 1/16 in (457 mm +/- 1.5 mm). If the form is out of tolerance, adjust the inserts accordingly.
Form Assembly Option 2 - Half Freestanding Form
• RR FS HALF FORM
• R003-A078 (HALF HOLLOW-CORE KIT)
• R003-A029 (CORNER REBAR ALIGNMENT INSERT)
• R002-A095 (KNOB COVER) PARTS AND
1.
Remove flat base insert (R003-A071) and two filler plates (R003-A100) at the bottom of the form if they are installed. Remove any bolts that will interfere with the hollow-core inserts.
2.
Install the half corner mold.
R003-A074
If connected, separate the two pieces of the hollow-core bottom insert (R003-A074 and R003-A081).
4.
Remove the groove former, and install the larger portion of the hollowcore bottom insert (R003-A074). Do not tighten bolts
5.
If connected, separate the two pieces of the hollow-core top insert (R003-A076 and R003-A081).
Helpful Hint: If using the half hollow-core kit the bottom insert will be part R003-A074.
6.
Remove knob former or knob cover if installed, then install the larger portion of the hollow-core upper insert (R003-A076) through the knob cover holes. Install the knob cover, but do not tighten bolts.
Helpful Hint: If using the half hollow-core kit the top insert will be part R003-A076.
7.
Install the corner rebar alignment insert (R003-A029). Make sure to align the nubs on the rubber inserts with the holes in the steel inserts.
8.
Close the form. Tighten all insert bolts.
Helpful Hint: The upper knob former or knob cover can remain, as it will not interfere with pouring half blocks. Continued
Measure the width of the form opening. Ensure that the block height opening is within 18" +/- 1/16".
Production Notes
Prep
1.
Remove the corner rebar alignment inserts and spray with release agent. Spray the rest of the form with release agent.
2.
Reinstall the rubber insert, ensuring they are seated tight between both steel inserts when the form is closed. Failure to do so will result in out of tolerance blocks and/or inserts embedded in the block.
Helpful Hint: Applying oil to the contact surfaces between the rubber inserts and steel inserts, as well as the end surfaces of the rebar alignment inserts and groove forming features, will aid in proper release of the inserts and help prevent buildup of concrete between the inserts.
Pour
1.
Pour the concrete to the bottom lip of the half corner mold.
Helpful Hint: If you’re using internal vibration when pouring, adjust the method and duration for the reduced concrete volume of freestanding hollow-core blocks.
Half
Demolding
1.
Before demolding, ensure concrete has cured to proper strength. With less concrete volume, the block will crack easier if not sufficiently cured.
2.
Most commonly, manufacturers use a nylon strap to remove Freestanding Hollow-Core Half Corner blocks from the form. They wrap the strap around the center beam of concrete to move the blocks to storage.
3.
During cleaning, pay close attention to the surfaces where the rubber contacts the steel inserts.
Helpful Hint: Failure to clean these surfaces properly will prevent the rubber inserts from installing properly and cause out of tolerance blocks.
Maintenance, Tips & Tricks
Maintenance
1.
Regularly check the height measurement with the form doors closed remains 18 in +/- 1/16 in (457 mm +/- 1.5 mm). If the form is out of tolerance, adjust the inserts accordingly.
Form Assembly Option 3 - Half Panel
• RR FS FORM
• R003-A107 (FS HALF PANEL)
• R003-A082 (FS HOLLOW-CORE KIT) OR R003-A078 (HALF HOLLOWCORE KIT)
• R003-A029 (CORNER REBAR ALIGNMENT INSERT)
• R002-A095 (KNOB COVER)
NOTE: A HALF CORNER MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
1.
FS HALF CORNER HC - OPT 3
Remove flat base insert (R003-A071) and two filler plates (R003-A100) at the bottom of the form if they are installed. Remove any bolts that will interfere with the hollow-core inserts.
2.
Remove one side panel, and install the half panel (R003-A107).
Half
3.
Install the half corner mold.
4.
If connected, separate the two pieces of the hollow-core bottom insert (R003-A079 or R003-A074 and R003-A081).
5.
If using the half hollow-core kit the bottom insert will be part R003-A074.
6.
If connected, separate the two pieces of the hollow-core top insert (R003-A080 or R003-A076 and R003-A081).
Helpful Hint: If using the half hollow-core kit the bottom insert will be part R003-A074.
7.
Remove knob formers or knob covers if installed, then install the larger portion of the hollow-core upper insert (R003-A080 or R003-A076) through the bottom knob cover holes. Install the knob cover, but do not tighten bolts.
Helpful Hint: If using the half hollow-core kit the top insert will be part R003-A076.
8.
Install the corner rebar alignment insert (R003-A029). Make sure to align the nubs on the rubber inserts with the holes in the steel inserts.
Helpful Hint: The upper knob former or knob cover can remain, as it will not interfere with pouring half blocks.
Continued
Close the form. Tighten all insert bolts. 10.
Measure the width of the form opening. Ensure that the block height opening is within 18" +/- 1/16".
Production Notes
Remove the corner rebar alignment inserts and spray with release agent. Spray the rest of the form with release agent.
2.
Reinstall the rubber insert, ensuring they are seated tight between both steel inserts when the form is closed. Failure to do so will result in out of tolerance blocks and/or inserts embedded in the block.
Helpful Hint: Applying oil to the contact surfaces between the rubber inserts and steel inserts, as well as the end surfaces of the rebar alignment inserts and groove forming features, will aid in proper release of the inserts and help prevent buildup of concrete between the inserts.
Pour 1.
Pour the concrete to the bottom lip of the half corner mold.
Helpful Hint: The half panel makes finishing the half blocks in a freestanding form much easier due to additional access to the block.
Helpful Hint: If you’re using internal vibration when pouring, adjust the method and duration for the reduced concrete volume of freestanding hollow-core blocks.
Half
Demolding
1.
Before demolding, ensure concrete has cured to proper strength. With less concrete volume, the block will crack easier if not sufficiently cured.
2.
Most commonly, manufacturers use a nylon strap to remove Freestanding Hollow-Core Half Corner blocks from the form. They wrap the strap around the center beam of concrete to move the blocks to storage.
3.
During cleaning, pay close attention to the surfaces where the rubber contacts the steel inserts.
Helpful Hint: Failure to clean these surfaces properly will prevent the rubber inserts from installing properly and cause out of tolerance blocks.
Maintenance, Tips & Tricks
Maintenance
1.
Regularly check the height measurement with the form doors closed remains 18 in +/- 1/16 in (457 mm +/- 1.5 mm). If the form is out of tolerance, adjust the inserts accordingly.
Tall Corner Block
FREESTANDING BLOCKS
Block Library
Freestanding 9 in (230 mm) Tall Corner blocks are used for stepping down at the end of a retaining or freestanding wall in a 9-in (230-mm) increments rather than an 18-in (457-mm) increments.
F-9SC 9" (230) STEPDOWN CORNER
Face Texture:
Cobble / Limestone Block
F-9TC 9" (230 MM) TALL CORNER
Face Texture:
Cobble / Limestone
F-9SG 9" (230) STEPDOWN GARDEN
Face Texture:
Block Weight: Block Volume:
F-90C 90 DEGREE CORNER
Face Texture:
Block Weight: Block Volume:
/ Limestone
FACE TEXTURE VARIES
24 (610) ± LEDGESTONE
COBBLESTONE 23 (584) ± LIMESTONE
Cobble / Limestone
/ Ledgestone
LEDGESTONE
COBBLESTONE
Tall Corner Block
• RR FS FORM
• R003-A101 (FS GROOVE FORMER 40IN STANDARD) WITH ONE R003-A050 (FS GROOVE FORMER EXTENSION) (OPTIONAL)
• TWO R002-A095 (KNOB COVERS)
• R003-A069 (9IN TALL FS STEEL FILLER PLATE)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
ONE FREESTANDING 9-IN (230-MM) CORNER FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
R003-A068
Form Assembly
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Remove the groove former if it is installed.
Critical Note: Using the groove former in 9-in (230-mm) tall blocks will make the concrete thin and prone to cracking. Also, an alternative way to lift the block will need to be devised, as the standard lifting inserts will not work with the thin concrete.
Helpful Hint: If you want to use the groove former in the block, install the groove former extension onto the groove former. Then install the groove former with one extension onto the 9-in (230-mm) tall steel insert (R003-A068)
4.
Install the 9-in (230-mm) tall steel insert (R003-A068) into the bottom panel of the form using the groove former holes.
5.
Install the 9-in (230-mm) tall freestanding corner mold centered in the base of the form.
6.
If the knob formers are installed, remove now and install the knob covers (R002-A095).
9 in
Tall Corner Block
Production Notes
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
Use a pry bar to aid in opening the forms. Do not hammer on forms.
Helpful Hint: The appropriate pry point for freestanding forms will vary depending on what generation form they are. Older forms will have a tab halfway down the side panel to use as a leverage point. Newer forms are designed with a notch towards the top of the panel for the pry bar placement.
Maintenance, Tips & Tricks
Tips
1.
Redi-Rock does not currently offer a 9 in (230 mm) Tall Half Corner block; however, if this block is needed, the form can be short-poured in the full corner configuration outlined above.
Helpful Hint: Do not allow panels to slam open hard on rails. Protecting the form from unnecessary wear and tear will help to prolong the life of your investment.
Tall Garden Block
Freestanding 9 in (230 mm) Tall Garden blocks are used for stepping down at the end of a retaining or freestanding wall in a 9-in (230-mm) increments rather than an 18-in (457-mm) increments and have a void in the top of the block for soil, plantings, or poured concrete.
F-9SG 9" (230) STEPDOWN GARDEN
Face Texture:
Cobble / Limestone
F-9TG 9" (230 MM) TALL GARDEN
Block
Block
Tall Garden Block
• RR FS FORM
• R003-A096 (9IN TALL GARDEN INSERT)
R003-A084 HALF CORNER FACE MOLD
• R003-A069 (9IN TALL FS STEEL FILLER PLATE)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE
R003-A086 9" CORNER FACE MOLD
R003-A066 CORNER MO NOTE: ONE FREESTANDING 9-IN (230-MM) CORNER FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
9IN TALL GARDEN
R003-A068
R003-A012
R003-A068
Form Assembly
1.
If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.
2.
If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.
3.
Remove the groove former if it is installed.
4.
Install the 9-in (230-mm) tall steel insert (R003-A068) into the bottom panel of the form using the groove former holes.
5.
If knob covers or knob formers are installed, remove from the form. Then install the garden insert (R003-A096) onto the top panel of the form.
6.
Install the 9-in (230-mm) tall freestanding corner mold centered in the base of the form.
Critical Note: Using the groove former in 9-in (230mm) tall blocks with a garden insert is not advised.
9 in
Tall Garden Block
Production Notes
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
Use a pry bar to aid in opening the forms. Do not hammer on forms.
Helpful Hint: The appropriate pry point for freestanding forms will vary depending on what generation form they are. Older forms will have a tab halfway down the side panel to use as a leverage point. Newer forms are designed with a notch towards the top of the panel for the pry bar placement.
Maintenance, Tips & Tricks
Tips
1.
Redi-Rock does not currently offer a 9 in (230 mm) Tall Garden Half Corner block; however, if this block is needed, the form can be shortpoured in the full corner configuration outlined above.
Helpful Hint: Do not allow panels to slam open hard on rails. Protecting the form from unnecessary wear and tear will help to prolong the life of your investment.
Tall Two-Sided Block
Freestanding 9 in (230 mm) Tall Two-Sided blocks are used for adjusting the grade by 9-in (230-mm) increments rather than an 18-in (457-mm) increments when more than one block length is necessary for the grade adjustment.
R003-A068
R003-A070
R003-A048
R003-A100
F-9TT 9" (230 MM) TALL TWO-SIDED
Face Texture:
9 in
Tall
Two-Sided Block
Cobble / Limestone
Kingstone / Ledgestone
• RR FS FORM
• R003-A102 (FS FULL GROOVE FORMER 46IN) OR R003-A101 (FS GROOVE FORMER 40IN STANDARD) WITH ONE R003-A050 (FS GROOVE FORMER EXTENSION) (OPTIONAL)
• R003-A070 (FLAT BASE FOR 9IN TALL BLOCKS)
• R003-A100 (FILLER PLATES)
• TWO R002-A095 (KNOB COVERS)
• R003-A069 (9IN TALL FS STEEL FILLER PLATE)
• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE PARTS AND KIT NUMBERS FOR ORDERING
DESCRIPTION
NOTE: TWO FREESTANDING 9-IN (230-MM) FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.
Form Assembly
1.
If the standard flat base (R003-A071) is installed in the base of the form, it needs to be removed. Then install the flat base for 9-in (230-mm) tall blocks (R003-A070).
2.
If one filler plate (R003-A100) is not installed in R003-A068 and another filler plate (R003-A100) in the top panel, install them now.
3.
Remove the groove former if it is installed.
Critical Note: Using the groove former in 9-in (230-mm) tall blocks will make the concrete thin and prone to cracking. Also, an alternative way to lift the block will need to be devised, as the standard lifting inserts will not work with the thin concrete.
Helpful Hint: If you want to use the groove former in the block, install the 46-in (1168mm) groove former (R003-A102) onto the 9-in (230-mm) tall steel insert (R003-A068). If using the 40-in (1016-mm) groove former with an extension (R003-A049), make sure the extension is installed towards the top of the 9-in tall steel insert.
4.
Install the 9-in (230-mm) tall steel insert (R003-A068) into the bottom panel of the form using the groove former holes.
5.
Install the two 9-in (230-mm) tall freestanding face molds on the form, ensuring they measure 46 ⅛ in (1172 mm) from the bottom of the form to the bottom of the lip on the mold.
6.
If the knob formers are installed, remove now and install the knob covers (R002-A095).
Helpful Hint: See page 188 for more instructions on installing face molds in a freestanding form.
Production Notes
1.
Pour the concrete to the bottom lip of the mold.
2.
Install the recessed lifting insert into the end of the block and double check the level of the concrete has not come up past the bottom lip of the mold.
Demolding
1.
Use a pry bar to aid in opening the forms. Do not hammer on forms.
Helpful Hint: The appropriate pry point for freestanding forms will vary depending on what generation form they are. Older forms will have a tab halfway down the side panel to use as a leverage point. Newer forms are designed with a notch towards the top of the panel for the pry bar placement.
Helpful Hint: Do not allow panels to slam open hard on rails. Protecting the form from unnecessary wear and tear will help to prolong the life of your investment.
CAP FORMS
Cap Forms
General
Two-Sided Cap
Three-Sided Cap
Four-Sided Cap
Three-Sided Half Cap
Cap forms are used to create cap blocks that will sit atop walls. They consist of steel jackets and rubber molds to create the desired texture on two, three, or four sides of the caps plus the top.
R004-0037
R004-A016
R004-A006
R004-A012 R004-A017
R004-A018
General Production
Note: There are instructions specific to producing each Redi-Rock precast modular block throughout this manual. Please be sure to understand both the following general guidelines and the specific instructions before beginning to manufacture a Redi-Rock product.
Prep
1.
Scrape and clean any residual concrete from the steel and rubber parts of the form. Pay close attention to surfaces where the steel contacts the rubber, as concrete build-up will deform the rubber molds.
2.
Apply a thin coat of release agent to both the rubber mat and sides of the cap mold(s).
3.
Ensure the cap platform is on a flat location, and set and center the steel jackets on it.
4.
Lock the form together with the clamps.
Pour 1.
Pour the concrete into the form.
2.
Screed the concrete to the top of the form and smooth the surface.
Helpful Hint: The exposed concrete is actually the bottom of the cap and the surface on which it will sit. Having it level and flat is key to quality installation in the field.
Demolding:
Safety Note
Allow blocks to cure properly before lifting out of form. Proper cure times vary according to weather, concrete mix, and curing conditions.
1.
Roll the form using your preferred lifting device, such as a crane, forklift, skidsteer, etc., that is appropriately rated.
2.
Critical Note: Be sure to lock the lifting device onto the trunions to avoid the form sliding off the device.
Set the form down on a pallet or dunnage. Unlatch the clamps to remove the form from the block.
Helpful Hint: Some manufacturers use wood lath, dunnage, or foam between the caps to create separation for easier handling.
Two-Sided Cap
Two-Sided Caps have texture on the two long sides and top. They are used to finish off the top of retaining or freestanding walls.
A-2SC TWO-SIDED CAP
Form Assembly Option 1:
• R004-A012 (FULL FORM, INCLUDING JACKETS, MOLD, MAT AND PLATFORM)
R004-A011
Form Assembly Option 2:
PARTS AND KIT NUMBERS FOR ORDERING
TO CONVERT A FOUR-SIDED FORM (R004-A018) TO A TWO-SIDED FORM YOU NEED THE FOLLOWING PARTS:
• TWO R004-A001 (STEEL END SHIMS) • TWO R004-A011-TX01 (TEXTURES)
Critical Note: Once a three- or four-sided form has been converted using this method; it is not recommended to go back to producing three- or four-sided caps.
1.
Cut all angle iron from inside of the four-sided steel jacket (R004-A016).
2.
Drill three holes on each short end of the form to allow installation of the steel end shims (R004-A001).
3.
Install steel end shims (R004-A001).
4.
Drill four holes on the long sides to allow installation of the textured rubber (R004-A0011-TX01).
5.
Install textures (R004-A0011-TX01) on long sides.
6.
Set it on the mat, and it’s ready for production.
Two-Sided Cap
Three-Sided Cap
Three-Sided Caps have texture on the three sides – two long sides and one short side – and are used to finish off the top ends of retaining or freestanding walls.
A-3SC THREE-SIDED CAP
R004-A016
R004-A006
Four-Sided Cap
Four-Sided Caps have texture on all four sides and top. They are used when there is a standalone section of wall where the texture is needed and it doesn’t abut anything. Sometimes they are used as steps or when a cap needs to be cut for a radius.
A-4SC FOUR-SIDED CAP
• R004-A018 (FULL FORM, INCLUDING JACKETS, MOLD, MAT AND PLATFORM) PARTS AND KIT NUMBERS FOR ORDERING
Form Assembly
1.
Four-sided cap forms (R002-A018) are shipped ready for production.
Three-Sided Half Cap
Three-Sided Half Caps are used at the start or end of a freestanding or retaining wall to accommodate the running bond.
A-3SHC THREE-SIDED HALF CAP
Three-Sided
AND KIT NUMBERS FOR ORDERING
TO CONVERT THE THREE SIDED CAP (R004-A017) OR FOUR SIDED CAP (R004-A018) FORM TO MAKE A THREE-SIDED HALF-CAP YOU WILL NEED: • R004-A057 (DIVIDER PLATE)
R004-A053
Form Assembly
1.
Install the cap divider plate (R004-A057) in the middle of the cap form (R004-A017 or R004-A018) using clamps or screws. Measure both sides to get it square.
Production Notes
When using the Four-Sided Cap Mold, two Three-Sided Caps can be poured at once because there is texture on both short ends of the form. When using a Three-Sided Cap form, only one side of the form will be poured.
Helpful Hint: The steel is cut to match the texture on the rubber mold, so it will fit better in one orientation than the other. Install properly to get the correct dimension of 24 7/16 in (621 mm).
Three-Sided
Half
Cap
STEP FORMS
Three-Sided 48 in (1219 mm) Step
Three-Sided 72 in (1829 mm)
COMPATIBLE OPTIONS (FL1)
COMPATIBLE PLATFORM (FL2)
Step forms are used to create steps. They consist of steel jackets and rubber molds to create the desired texture on three sides – two short and one long – and the top of the steps.
R004-A054 R004-A079 R004-A087
R004-A052
R004-A048
R004-0121
R004-A080
R004-A066
General Production
Note: There are instructions specific to producing each Redi-Rock precast modular block throughout this manual. Please be sure to understand both the following general guidelines and the specific instructions before beginning to manufacture a Redi-Rock product.
Prep 1.
Ensure the form is in a flat location and level.
2.
Scrape and clean any residual concrete from the steel and rubber parts of the form. Pay close attention to surfaces where the steel contacts the rubber, as concrete build-up will deform the rubber molds.
3.
Install the long pin (R004-A050) to lock the steel back plate in place.
4.
Apply a thin coat of release agent to the rubber mold and steel back plate.
5.
Insert the lifting hook into the loop holder on the steel back plate.
6.
Lock the form closed using the rotating form locks (on form R004-A087 and R004-A079) or the pins (on form R004-A054).
Helpful Hint: When using R004-A054, also install the short pin (R004-A048) in the front of the form.
Pour the concrete into the form.
2.
Screed the concrete to the top of the form and smooth the surface.
Helpful Hint: The exposed concrete is actually the bottom of the step and the surface on which it will sit. Having it level and flat is key to quality installation in the field.
Demolding:
Safety Note
Allow steps to cure properly before lifting out of form. Proper cure times vary according to weather, concrete mix, and curing conditions.
1.
Unlatch the rotating form locks or pins to free the rubber mold from the back plate.
2.
Use the long pin (R004-A050) to pry the back plate from the concrete.
Note: If using R004-A054, also remove the short pin (R004-A048) and the three-sided rubber mold prior to lifting the block.
3.
Use the lifting hook to rotate the step 180 degrees to remove it from the form.
4.
Set the step down on a pallet or dunnage with the texture side up.
Helpful Hint: Some manufacturers use wood lath or foam between the steps to create separation for easier handling.
Three-Sided 48 in (1219 mm) Step
Three-Sided 48 in (1219 mm) Steps are used to create steps in various applications where grade changes are needed. They are textured on three sides – two short and one long – and the top.
A-3S48 THREE-SIDED STEP 48 IN
(FL1)
DESCRIPTION
Form Assembly Option 1:
R004-A089
R004-A088
R004-A089
Form Assembly Option 2:
R004-A047 LOCK BAR 1
R004-A048 RELEASE BAR 1
R004-A052
R004-A050 48" 3-SIDED STEP 7" POLYURETHANE 1
COMPATIBLE OPTIONS (FL1)
PART NUMBER QTY DESCRIPTION
R002-A146 A/R LOOP HOLDER TYPE #4
COMPATIBLE PLATFORM (FL2)
PART NUMBER QTY DESCRIPTION
R004-A074 A/R STEP PLATFORM
NOTE:
Three-Sided 72 in (1829 mm) Step
Three-Sided 72 in (1829 mm) Steps are used to create steps in various applications where grade changes are needed. They are textured on three sides – two short and one long – and the top.
A-3S72 THREE-SIDED STEP 72 IN
R004-A080
R004-A066
TO CONVERT THE THREE SIDED CAP (R004-A017) OR FOUR SIDED CAP (R004-A018) FORM TO MAKE A THREE-SIDED HALF-CAP YOU WILL NEED:
R004-A080
R004-A066
COLUMN FORMS
Column Forms
The column form consists of a platform, a steel jacket, and rubber mold(s), and it’s used to produce columns which are more decorative than structural components of Redi-Rock walls.
NOTES: FL1) COMPATIBLE OPTIONS MUST BE SELECTED SEPARATELY AND ARE NOT INCLUDED IN THIS ASSEMBLY 2) MOLD AND ITS POLY INSERT ARE TO BE PLACED UPSIDE DOWN ONTO THE PLATFORM COMPATIBLE OPTIONS (FL1)
FL1
R004-A024
R004-A034
R004-A025
General Production
Note: There are instructions specific to producing each Redi-Rock precast modular block throughout this manual. Please be sure to understand both the following general guidelines and the specific instructions before beginning to manufacture a Redi-Rock product.
Prep 1.
Apply release agent to all surfaces.
2.
Tighten down steel form clamps.
3.
Be sure to install lifting hooks in loopholders.
4.
Check mold alignment.
Note: If using the 8 in (203 mm) center core, grease the core on the first pours or when columns will sit over the weekend before demolding. Pour 1.
Be sure to install lifting hooks in loopholders.
Helpful Hint: Place handles in rubber mold towards the bottom of the form when preparing to pour. Once the blocks are rolled over during demolding procedure, the handles will then be upright for easy demolding of the rubber off of the poured block.
Helpful Hint: Depending on your concrete mix, you may need to vibrate concrete during or after pouring to get the desired finished product.
Demolding:
Safety Note
Allow columns to cure properly before lifting out of form. Proper cure times vary according to weather, concrete mix, and curing conditions.
1.
Raise form using rollover trunions. Break loose base platform with pry bar. 2.
Raise form and gently roll over. 3.
Lower to the floor. 4.
Remove steel jackets. 5.
Raise block and rubber mold using lift hooks. 6.
Use handles on the rubber mold to spread the mold and lower it to the floor.
Critical Note: Be sure to lock the lifting device onto the trunions to avoid the form sliding off the device.
Some producers choose to palletize columns for easier storage and inventory purposes.
Helpful Hint: Blocks may be handled by lifting hooks or a Probst Lift.
A-COLS COLUMN - SOLID CORE A-CC COLUMN CAP
Block
Solid Core Column
Solid Core Columns are textured on four sides and used as decorative elements. They may have optional fence rail pockets when used in fencing applications.
A-COLS COLUMN - SOLID CORE Block
OPTIONAL FENCE POCKET
COMPATIBLE OPTIONS (FL1) PART NUMBER QTY
R002-A146 A/R
1. Units for dimensions are inches (mm), typical unless noted otherwise. 2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.
3. Actual block volumes and weights may vary.
Weights are based upon a concrete density Weight and volume ranges represents the hole size shown and with no hole.
NOTES: FL1) COMPATIBLE OPTIONS MUST BE SELECTED SEPARATELY AND ARE NOT INCLUDED IN THIS 2) MOLD AND ITS POLY INSERT ARE TO BE PLACED UPSIDE DOWN ONTO THE PLATFORM
Solid
• R004-A032 (FULL FORM)
• OPTIONAL R004-A039 OR R004-A040 - FENCE RAIL POCKET FORMERS
• OPTIONAL R004-A030 KEYWAY FOR COLUMN RAIL POCKET RUBBER INSERT PARTS AND KIT NUMBERS FOR ORDERING
COMPATIBLE OPTIONS (FL1) PART NUMBER QTY DESCRIPTION
R002-A146 A/R Loop Holder #4
R004-A041 A/R Lifteye Former #7
FL1 LOOP HOLDER R004-A025
FL1
R004-A024
R004-A034
R004-A025
Form Assembly
1.
If pouring a Solid Core Column, the form will arrive ready to be poured.
2.
If using fence rail pockets, see illustration for how many keyways and fence rail pockets should be used for end post, line posts, and corner posts.
3.
If using the fence rail pockets with the Limestone or Cobblestone texture, the rubber inserts (R004-A039) need to be placed and locked into the rubber mold using the keyways (R004-A030). Keyways are bolted to the bottom of the platform. To attach the fence rail pockets, loosen the keyway and slide the rail pockets tight to the rubber mold, then re-tighten the keyway. Corner Post
Line Post
Helpful Hint:
The Ledgestone texture does not use keyways for attaching fence rail pockets. The fence rail pockets (R004-A040) bolt directly to the bottom of the form.
Production Notes
Demolding: 1.
If the fence rail pockets have been used, the rubber inserts will need to be removed during the demolding process. 2.
The Ledgestone fence rail pockets will need to be unbolted from the form before the block can be demolded. Then they can be tapped out with a hammer from the column while it is still inverted.
3.
The Limestone and Cobblestone inserts that use keyways can be removed by tapping with a hammer after the column is removed from the form.The keyways do not need to be unbolted from the form.
Critical Note: Be sure not to damage the threads when unbolting the fence rail pockets from the form.
ACCESSORIES (COLUMN BLOCKS)
8 in (203 mm) Core Column
Block Library
A-COL8 COLUMN - 8" (203mm) CORE Block
Columns with 8 in (203 mm) Core are textured on four sides and used as decorative elements. The center core can be used to reduce the overall weight, to run utilities or to tie the column with rebar and poured concrete to a footer or wall. It may also have optional fence rail pockets when used in fencing applications.
• OPTIONAL R004-A039 OR R004-A040 - FENCE RAIL POCKET FORMERS
• OPTIONAL R004-A030 KEYWAY FOR COLUMN RAIL POCKET RUBBER INSERT
Form Assembly
1.
To install the 8 in (203 mm) tapered core into the form, use the hole in the center of the base and tighten it.
2.
If using the fence rail pockets, see instructions on page 377 for form set up.
Production Notes
Pour:
1.
Be sure to apply release agent to the center core before pouring.
Helpful Hint: Occasionally applying grease to the center core will help columns demold easier. Be sure to use if columns will cure over the weekend.
Demolding:
1.
If using the fence rail pockets, see instructions on page 378 for demolding instructions.
8 in
(203 mm)
Core Column
4 in (102 mm) Core Column
A-COL4 COLUMN - 4" (102mm) CORE
Block Weight: Block Volume:
Columns with 4 in (102mm) Core have conduit in the center of the column to facilitate running utilities. They are textured on four sides and may also have the fence rail pockets.
810 lb (370 kg)
5.6 ft3 (0.16 m3)
A-COL4 4 IN CORE COLUMN
4 (102) DIAMETER
A-CC
COLUMN CAP 2.7 ft3 (0.08 m3)
• R004-A032 (FULL FORM)
• R004-A037 (COLUMN CONDUIT RETAINER KIT)
• OPTIONAL R004-A039 OR R004-A040 - FENCE RAIL POCKET FORMERS
• OPTIONAL R004-A030 KEYWAY FOR COLUMN RAIL POCKET RUBBER INSERT
R004-A031
R004-A103
Form Assembly
1.
To install the column conduit retainer kit (R004-A037) in the form bolt the rubber retainer (R004-0082) in the center hole in the bottom of the base. The crossbar piece will be attached in preparation for pouring.
Pour concrete to here
2.
If using the fence rail pockets, see instructions on page 377 for form set up.
Production Notes
Prep:
1.
Apply release agent to all of the parts, including the cross bar.
2.
Slide approximately 17-in (432-mm) piece of PVC pipe onto the rubber retainer.
Close the form. 4.
Insert lifting hooks into the loopholders. 5.
Slide the Conduit Cross Bar Retainer into the PVC and secure using the wing nuts. Pour:
Pour the concrete and finish to the bottom edge of the mold.
Pour concrete to here
Remove the conduit cross bar from the form before demolding the column. 2.
If using the fence rail pockets, see instructions on page 378 for demolding instructions.
(102 mm)
Core Column
A-CC COLUMN CAP
lb (180 kg) Block Weight: Block Volume:
Column Cap
ft3 (0.08 m3)
Column Caps are used on top of columns to create a finished look. They have texture on four sides and the top.
A-CC COLUMN CAP
OPTIONAL 4 (102) DIAMETER
4. Weights are based upon a concrete density of 143 lb/ft ).
5. Weight and volume ranges represents the blocks with the maximum hole size shown and with no hole.
6. Optional fence rail pockets available upon request. Typical pocket size is: 2 (50) wide x 5 (130)
R004-A021 (FULL
R004-A020
R004-0028
R004-A006
Form Assembly
Production Notes
Prep: 1.
If using the Cap Conduit Retainer, be sure to apply release agent to the form and the bar that will sit atop the form. Set a 4-in (102-mm) piece of PVC centered on the rubber mat and use the conduit cap retainer to hold it in place. Pour:
Pour the concrete into the form.
2.
Screed the concrete to the top of the form and smooth the surface.
Helpful Hint: The exposed concrete is actually the bottom of the cap and the surface on which it will sit. Having it level and flat is key to quality installation in the field.
Demolding:
Safety Note
Allow blocks to cure properly before lifting out of form. Proper cure times vary according to weather, concrete mix, and curing conditions.
1.
Roll the form using your preferred lifting device, such as a crane, forklift, skidsteer, etc., that is appropriately rated.
2.
Set the form down on a pallet or dunnage. Unlatch the clamps to remove the form from the block.
Critical Note: Be sure to lock the lifting device onto the trunions to avoid the form sliding off the device.
Helpful Hint: Some manufacturers use wood lath or foam between the caps to create separation for easier handling.
TEXTURES
Limestone
Full Face Molds
R002-A085-LM01
R002-A085-LM03
R002-A193-LM01
Half Face Mold
Corner Face Molds
R003-A066- LM01
R002-A085-LM02
R002-A085-LM04
Other Available Options
R002-A187-LM01
Short Block Face Mold
R003-A084-LM01
Half Corner Mold
R003-A086-LM01 9 in (230 mm) Corner Face Mold
Kingstone
Full Face Molds
R002-A085-KS01
R002-A085-KS04
R002-A085-KS07
R002-A085-KS02
R002-A085-KS05
R002-A085-KS08
R002-A085-KS03
R002-A085-KS06
R002-A193-KS01
Half Face Mold
Corner Face Molds
R003-A066-KS01
R003-A084-KS01
Half Corner Mold
Other Available Options
R003-A086-KS01
9 in (230 mm) Corner Face Mold
Textures
Ledgestone
Full Face Molds
R002-A085-LD01
R002-A085-LD04
R002-A085-LD07
R002-A085-LD10
Corner Face Molds
R003-A066-LD01
Other Available Options
R003-A086-LD01 9 in (230 mm) Corner Face Mold
R002-A085-LD02
R002-A085-LD05
R002-A085-LD08
R002-A187-LD01 / LD02 Short Block Face Mold
R003-A066-LD02
R002-A085-LD03
R002-A085-LD06
R002-A085-LD09
R002-A193-LD01 Half Face Mold
R003-A084-LD01 Half Corner Mold
Cobblestone
Full Face Molds
R002-A085-CB01
R002-A193-CB01
Half Face Mold
Corner Face Molds
R002-A193-LD01
R002-A085-CB02
Other Available Options
R002-A187-CB01
Short Block Face Mold
R003-A084-CB01
Half Corner Mold
R003-A086-CB01 9 in (230 mm) Corner Face Mold
Textures
Smooth
Full Face Molds
SM01
Corner Face Molds
R003-A066-SM01
R002-A193-SM02
Half Face Mold
R003-A084-SM01
Half Corner Mold
Ledgestone
R001-A050-LD01
R001-A050-LD05
R001-A050-LD02
R001-A050-LD06
Cobblestone
R001-A050-CB01
R001-A050-CB02
R001-A050-LD03
R001-A050-LD07
R001-A050-LD04
R001-A050-LD08
R001-A050-CB03
R001-A050-CB04
R001-A050-LM01
R001-A050-LM02
R001-A050-KS01
R001-A050-KS02
Textures
Limestone
Kingstone
APPENDIX
18" (457 mm) HIGH RETAINING BLOCKS
Block Setback Options
Block Setback Options
The block-to-block setback available with Redi-Rock is controlled by the size and location of the shear knobs (domes) cast into the blocks. While the 10" (254 mm) diameter knob and the 1 5/8" (41 mm) setback position is the most common configuration, Redi-Rock has three different knob sizes and three different locations available.
The block-to-block setback available with Redi-Rock is controlled by the size and location of the shear knobs (domes) cast into the blocks. While the 10” (254 mm) diameter knob and the 1 5/8” (41 mm) setback position is the most common configuration, Redi-Rock has three different knob sizes and three different locations available.
Move blocks forward during installation to engage shear knobs (Typical)
Zero (0°) setback (Specialty)
Available with:
· 28" (710 mm) blocks, 41" (1030 mm) blocks, and 60" (1520 mm) blocks · 28" (710 mm) PC blocks (shown here) and 41" (1030 mm) PC blocks
Move blocks forward during installation to engage shear knobs (Typical)
Block Setback Options
Redi-Rock has two options for large batter retaining walls. Both options are created by relocating the knob so that it is further back in the RediRock blocks compared to our smaller batter walls (5° and less). There are two knob locations further back in the block which create the 9” (230 mm) setback block and the planter block. Blocks made with knobs in either of these locations almost exclusively use 10” (254 mm) diameter knobs.
Redi-Rock has two options for large batter retaining walls. Both options are created by relocating the knob so that it is further back in the Redi-Rock blocks compared to our smaller batter walls (5° and less). There are two knob locations further back in the block which create the 9" (230 mm) setback block and the planter block. Blocks made with knobs in either of these locations almost exclusively use 10" (254 mm) diameter knobs.
9" (230 mm) Setback Blocks
Move blocks forward during installation to engage shear knobs (Typical) Setback = 9 3 8" (238 mm) (27.5° batter angle on
Available with: · 41" (1030 mm) blocks (shown here) and 60" (1520 mm) blocks · Not available in PC blocks
Planter Blocks
Move blocks forward during installation to engage shear knobs (Typical)
36" (914 mm) HIGH RETAINING BLOCKS
Block Setback
The block-to-block setback available with 36" (914 mm) high RediRock XL hollow-core retaining blocks is controlled by the location of the shear knobs cast into the blocks. The 3 1/4" (83 mm) setback between courses creates a 5° batter angle on the back of the wall which is consistent with the batter angle created by 18" (457 mm) high RediRock blocks with 10" (254 mm) shear knobs.
The block-to-block setback available with 36" (914 mm) high Redi-Rock XL hollow-core retaining blocks is controlled by the location of the shear knobs cast into the blocks. The 3 1/4" (83 mm) setback between courses creates a 5° batter angle on the back of the wall which is consistent with the batter angle created by 18" (457 mm) high Redi-Rock blocks with 10" (254 mm) shear knobs.
36" (914 mm) High XL Hollow-Core Retaining Blocks
5 8" (422 mm)
4" (102 mm)
10" (254 mm) shear knob
Setback = 314" (83 mm) (5° Batter Angle on Wall)
(914 mm)
7" (178 mm)
3 8" (340 mm)
The relative knob and groove configuration, and resulting setback, are consistent between the 52" (1320 mm), 72" (1830 mm), and 96" (2440 mm) XL hollow-core retaining blocks.
Move blocks forward during installation to engage shear knobs (typical)
36"
Face Textured
1-AT Geogrid Connection
The 1-AT geogrid connection is a legacy component of the Redi-Rock system.
The 1-AT geogrid connection relies on a sheet of geogrid wrapping around a 7/16 in x 40 in (1.6 mm x 1016 mm) fiberglass rod that is placed in the groove of a 1-AT block. Another block is then placed on top of it to sandwich the geogrid and rod between the two blocks. A minimum of 3 feet (915 mm) of anchored tail is required, and the main reinforcement length of geogrid will be determined by the design.
Reach out to Redi-Rock for more information on purchasing fiberglass rods for use in walls that are utilizing the 1-AT blocks and geogrid connection.
Loop Holders & Lifteye Formers
Redi-Rock offers a number of different options to hold lifting inserts when pouring Redi-Rock blocks. While inserts made from galvanized, A36 steel are the most common type utilized, options are also available for 5/16-in (8-mm) steel cable and 1/2-in (13-mm) rebar.
Loop Holders - 3/8 in Steel Lifting Inserts
Please specify which hook you are using at the time of your order.
The following loop holders are sized to hold a 3/8-in (9.5-mm) solid loop with a maximum outside diameter bend in the top of the insert of 2 1⁄2 in to 2 5/8 in (63.5 mm to 66.7 mm). Commercially available lifting inserts are offered by a number of manufacturers, and Redi-Rock producers have elected to use a variety of lifting inserts to safely handle Redi-Rock blocks. Two examples are below.
Manufactured by: American Step Company https://www.americanstep.com/ 830 East Broadway PO Box 137 Griffen, GA 30224-0137
Manufactured by: A.L. Patterson https://www.alpsupply.com/ (800) 332-7090 300 Ben Fairless Drive Fairless Hills, PA 19030
3/8” Solid Loop Lifter
3/8” R Anchor
Loop Holder #1
R002-A108-AST and R002-A108-ALP
Loop Holder #1 is used on the door panels of most Redi-Rock forms.
Loop Holder #2
R002-A110-AST and R002-A110-ALP
Loop Holder #2 is installed in the 10-in (254-mm) diameter knobs and is primarily used in half blocks.
Loop Holder #3
R002-A154-AST and R002-A154-ALP
Loop Holder #3 is typically placed in the exposed concrete on the top end of freestanding and retaining forms when a recessed hook is desired. (Note: This is the same part as Loop Holder #1 with a steel bar for prying.)
Loop Holder #4
R002-A146
Loop Holder #4 is typically used in column blocks.
Loop Holder #5
R002-A105-AST and R002-A105-ALP
Loop Holder #5 is typically used on retaining top blocks, retaining 41 in (1030 mm) hollow-core blocks, retaining planter blocks, and freestanding garden blocks where a recess is not desired. The loop holder is mounted on the inside of the form insert and is only accessible when the form insert is removed. A slot is notched in the insert to allow the solid loop to be inserted into the holder. (Note: existing form inserts can be modified to use Loop Holder #5 by cutting a slot and drilling new bolt holes as needed.)
Loop Holder #6
Loop Holder #6 is used within 6-in (152-mm) knob formers.
Loop Holders - 1/2 in or 7/16 in Steel Lifting Inserts
Please specify which hook you are using at the time of your order.
The following loop holders are sized to hold a 1/2 in (13 mm) or 7/16 in (11 mm) solid loop. Commercially available lifting inserts are offered by a number of manufacturers, and Redi-Rock producers have elected to use a variety of lifting inserts to safely handle Redi-Rock blocks. Two examples are below.
1/2" Solid Loop Lifter 7/16" R Anchor
Manufactured by: American Step Company americanstep.com
Item Number: 500-975"
1 / 2
Description: Solid Loop Lifter, Ø1/2" X 9 3/4", A36 Steel, Epoxy coated per ASTM A 934
Manufactured by: A.L. Patterson
Website: alpsupply.com
Item Number: LRA7169G
Description: R-Anchor, Ø 7/16" X 9", Hot Dip Galvanized
Loop
Loop Holders - Steel Cable
A few loop holders are also made in a variation to accommodate 5/16in (8-mm) steel cable.
Loop Holder #7
Loop Holder #7 is used on the door panels of most Redi-Rock forms.
Loop Holder #2
R002-A110-CLP
ALPATTERSON 3/8" DIA LIFT HOOK
AMERICAN STEP 3/8" DIA LIFT HOOK
Loop Holder #2 is installed in the 10-in (254-mm) diameter knobs and is primarily used in half blocks.
Polytek
Loop Holder #8
R002-A200-CLP
Loop Holder #8 is typically placed in the exposed concrete on the top end of freestanding and retaining forms when a recessed hook is desired. (Note: This is the same part as Loop Holder #7 with a steel bar for prying.)
Lifteye Formers - Steel Bar
Lifteye formers are available for manufacturers using 1/2-in (13-mm) steel bar as lifting inserts.
Lifteye Former #1
R002-A155
Used for most retaining and freestanding blocks.
Lifteye Former #2
Used for retaining planter blocks.
Lifteye Former #4
R002-A162
Lifteye Former #4 is installed in the 10-in (254-mm) diameter knobs and is primarily used in half blocks.
Lifteye Former #5
R002-A150
Lifteye Former #5 is typically placed in the exposed concrete on the top end of freestanding and retaining forms when a recessed hook is desired.
Lifteye Former #6
R002-A151
Used for 6-in (152-mm) diameter knob formers.
Lifteye Former #7
R002-A196
Used for the step form.
POLYURETHANE - SIDE 1 Lifteye Former #8
R004-A041
Used for column knob formers.
Lifting Load Safety Sheet
Do you know the load you are applying to your lifters and chains? This chart demonstrates the load multipliers and loads at varying degrees of rigging. A shallow angle between the two lifters can actually apply a load greater than the structure being lifted. Angle
A & B Load Multiplier
Angle A Angle B
Block C
Block C in this example = 3,400 pounds
In this example the load multiplier is 1.138 which make the lifters carry a load of 1,936 lbs. per lifter.
C in this example = 3,400 pounds
Lifter
Lifter
Block C
Block
XL Rebar Cages
All Redi-Rock XL Hollow-Core Retaining blocks, including R-5236HC, R-7236HC, and R-9636HC, require steel reinforcement cages. This is a safety critical requirement to protect against crack propagation transferring through thin-walled sections of the precast modular blocks (PMBs).
Follow the specifications below for constructing reinforcement cages. All rebar used for constructing reinforcement cages in Redi-Rock XL blocks is #4 (½ inch) grade 60 minimum and must meet ASTM A615. All rebar intersections must be tied.
The plastic bar wheels used are 3-in (75-mm) cover (ALP-PWWB3 or equivalent) and 2-in (50-mm) cover (ALP-PWWB2 or equivalent).
See the following pages for reinforcement details.
Recommended Tools: Jig fixture (see page xxix in the Appendix for design), rebar tie wire tool
CRITICAL NOTE: All 32-in (812.8 mm) cut length bars must be inside the stirrups. Bars attached to the outside of the frame will significantly reduce the strength of the PMBs.
Construction of Reinforcement Cage for R-9636HC
Put the two stirrups on the channels of the jig fixture.
Place two cut length bars on each end of the jig fixture. Tie all bar intersections as needed.
Slide remaining internal cut length bars into jig inside stirrups. Tie all bar intersections as needed.
Tie cut length rebar crosses at the top and bottom of the cage. The intersection of the two sticks should be centered between the stirrups.
Attach required spacers and position per drawing.
6.
Remove completed reinforcement cage from the jig fixture.
#4 bent hoop, bent as shown (typ. of 2) (continuous bar, overlap 12" (305 mm) min., back end)
5/8" (450 mm)
#4 vertical bars, 32" (813 mm) long, all inside cage (typ. of 10)
6" (150 mm) dia. rebar spacer (typ. of 4)
4" (100 mm) dia. rebar spacer (typ. of 8)
#4 diagonal bars, 32" (813 mm) long (typ. of 2) (crossed, inside cage)
#4 diagonal bars, 32" (813 mm) long (typ. of 2) (crossed, inside cage)
Notes:
1. All bar shall comply with ASTM A615, Grade 60 (13 mm, 420 MPa).
2. Tie all bar intersections.
3. Maintain concrete cover of no less than 1 inch (25 mm) over all reinforcing steel. Actual cover varies.
Jig Fixture for Reinforcing Steel Cage
R001-A170
R001-A170
Tools for Demolding Freestanding Blocks
Reach out to your business consultant for more information on the following tools used to facilitate demolding freestanding blocks.
Air Stripper
The freestanding air stripper is used to ease the demolding of Freestanding Straight Top, Middle, or Bottom blocks.
AIR STRIPPER MATES WITH 2XX SLOTS ON DOOR STIFFENERS
AIR STRIPPER MATES WITH 2X SLOTS ON DOOR STIFFENERS
Spreader Lever
The freestanding spreader lever is used to keep the form doors open when lifting corner and half corner blocks out of the form.
J-Bolts and Clips
J-bolts and clips are commonly used in freestanding force protection applications to connect the blocks together as specified by an engineer.
J-Bolts and Clips
12-in (305-mm) J-bolt, Clip & Nut Kit
R003-A123
The 12-in (305-mm) j-bolt is most commonly used. It connects freestanding blocks to each other or to standard retaining blocks.
J-BOLT, CLIP, AND NUT KI
16-in (406-mm) J-bolt, Clip & Nut Kit
R003-A124
The 16-in (406-mm) j-bolt is used when connecting a freestanding block to a Positive Connection (PC) block. The extra length helps accommodate the different lifting hook placement in a PC block.
PRODUCT DATA SHEETS
Product Data Sheets
Redi-Rock 28" (710mm) Retaining Blocks
Redi-Rock 28" (710 mm) Retaining Blocks
The Redi-Rock 28” (710mm) Retaining wall blocks are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended for use in the construction of dry-stacked modular retaining wall systems. The block units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock Retaining wall products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
DIMENSIONAL PROPERTIES
DIMENSIONS (1)
HEIGHT (FRONT OF BLOCK)
HEIGHT (BACK OF BLOCK)
LENGTH (FRONT OF BLOCK) LENGTH (BACK OF BLOCK)
CONCRETE VOLUME
SHIPPING/HANDLING WEIGHT (2)
(1) All dimensions are inches (mm) (2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft 3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES (2)
FREEZE THAW EXPOSURE
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(10) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the
weight of the cementitious materials. TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (10)
Redi-Rock 28" (710mm) Retaining Blocks
Redi-Rock 28" (710 mm) Retaining Blocks
DESIGN PROPERTIES
HORIZONTAL SETBACK / WALL FACE BATTER OPTIONS
10 inch (254 mm) KNOB
7 1 2 inch (190 mm) KNOB
6 3 4 inch (171 mm) KNOB
(12)
1 5 8 inch (41 mm) PER BLOCK COURSE (5.2° BATTER)
8 inch (10 mm) PER BLOCK COURSE (1.2° BATTER)
SETBACK (NO BATTER) (11)
INFILLED UNIT WEIGHT FOR WALL STABILITY CALCULATIONS (13)
LIMESTONE / COBBLESTONE BLOCKS
LEDGESTONE BLOCKS
MINIMUM CONSTRUCTION RADIUS (14)
CONCAVE CURVE
CONVEX CURVE
(11) Special consideration should be given to the design of vertical retaining walls subject to active lateral earth pressure. (12) Values based on full scale testing performed in October 2011. Copies of the full test reports are available at www.redi-rock.com. (13) The infilled unit weights shown here are based on an assumed concrete unit weight of 143 lb/ft3 (2291 kg/m3) and an assumed soil unit weight of 100 lb/ft3 (1602 kN/m3). They are reference values. Several factors can cause the unit weights of both concrete and infill soil to vary. The designer should use sound engineering judgement when assigning an infilled unit weight value for analysis. (14) The minimum construction radius stated is applicable to both concave and convex curved retaining wall sections. Increases to this minimum radius are required to account for wall batter. Special consideration should be given to block selection, facing batter, and wall height when selecting the minimum radius for the final wall alignment.
HEIGHT (FRONT)
LENGTH (FRONT)
LENGTH (BACK)
HEIGHT (BACK)
WIDTH (FORM LINE TO BACK) WIDTH (FACE TEXTURE)
HEIGHT (FRONT)
LENGTH (FRONT)
LENGTH (BACK)
HEIGHT (BACK)
WIDTH (FORM LINE TO BACK)
Redi-Rock 41" (1030mm) Retaining Blocks
Redi-Rock 41" (1030 mm) Retaining Blocks
The Redi-Rock 41” (1030mm) Retaining wall blocks are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended for use in the construction of dry-stacked modular retaining wall systems. The block units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock Retaining wall products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
DIMENSIONAL PROPERTIES
DIMENSIONS (1)
HEIGHT (FRONT OF BLOCK)
HEIGHT (BACK OF BLOCK)
LENGTH (FRONT OF BLOCK)
LENGTH (BACK OF BLOCK)
18 ± 3 16 (457 ± 5)
13 ± 3 16 (330 ± 5)
HALF TOP
18 ± 3 16 (457 ± 5)
13 ± 3 16 (330 ± 5)
LIMESTONE/COBBLESTONE FACE
FACE CONCRETE VOLUME
SHIPPING/HANDLING WEIGHT (2)
LIMESTONE/COBBLESTONE FACE
LEDGESTONE FACE
(1) All dimensions are inches (mm)
±12.22 ft3 (0.346 m3)
±11.73 ft3 (0.332 m3)
± 1748 lb (793 kg)
± 1677 lb (760 kg)
± 2368 lb (1074 kg) ± 2237 lb (1015 kg)
HALF MIDDLE
±5.38 ft3 (0.15 m3)
±5.14 ft3 (0.15 m3)
HALF MIDDLE
± 770 lb (350 kg)
± 735 lb (333 kg)
(2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft 3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES
(3)
WATER-SOLUBLE CHLORIDE ION (Cl -) CONTENT IN CONCRETE, PERCENT BY WEIGHT OF CEMENT (8)
CHLORIDE
ft3 (0.202 m3) ±6.90 ft3 (0.195 m3)
± 1022 lb (463 kg) ± 987 lb (448 kg)
ALKALI-AGGREGATE REACTIVITY MITIGATION PER ACI 201
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(10) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
(11) Prescriptive limits shown may be waived for concrete mixes that demonstrate excellent freeze/thaw durability in a detailed and current testing program. TOTAL
Redi-Rock 41" (1030mm) Retaining Blocks
Redi-Rock 41" (1030 mm) Retaining Blocks
DESIGN PROPERTIES
HORIZONTAL SETBACK / WALL FACE BATTER OPTIONS
10 inch (254 mm)
7 1 2 inch (190 mm) KNOB
INFILLED UNIT WEIGHT FOR WALL STABILITY CALCULATIONS (14)
LIMESTONE / COBBLESTONE BLOCKS
LEDGESTONE BLOCKS
MINIMUM CONSTRUCTION RADIUS (15)
CONCAVE CURVE
CONVEX CURVE
(12) Special consideration should be given to the design of vertical retaining walls subject to active lateral earth pressure. (13) Values based on full scale testing performed in October 2011. Copies of the full test reports are available at www.redi-rock.com. (14) The infilled unit weights shown here are based on an assumed concrete unit weight of 143 lb/ft3 (2291 kg/m3) and an assumed soil unit weight of 100 lb/ft3 (1602 kg/m3). They are reference values. Several factors can cause the unit weights of both concrete and infill soil to vary. The designer should use sound engineering judgement when assigning an infilled unit weight value for analysis. (15) The minimum construction radius stated is applicable to both concave and convex curved retaining wall sections. Increases to this minimum radius are required to account for wall batter. Special consideration should be given to block selection, facing batter, and wall height when selecting the minimum radius for the final wall alignment.
The Redi-Rock 28” (710mm) & 41" (1030mm) Positive Connection retaining wall blocks are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended for constructing dry-stacked modular retaining wall systems. The block units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock Retaining wall products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
DIMENSIONAL
PROPERTIES
DIMENSIONS (1)
HEIGHT (FRONT OF BLOCK)
HEIGHT (BACK OF BLOCK)
LENGTH (FRONT OF BLOCK)
LENGTH (BACK OF BLOCK)
CONCRETE
LIMESTONE/COBBLESTONE FACE
LEDGESTONE FACE
SHIPPING/HANDLING WEIGHT (2)
LIMESTONE/COBBLESTONE FACE
MIDDLE - 28" (710)
BOTTOM - 28" (710)
- 41" (1030) TOP - 41" (1030)
TOP - 28" (710) BOTTOM - 41" (1030)
TOP - 28" (710)
MIDDLE - 28" (710)
BOTTOM - 28" (710)
TOP - 41" (1030)
MIDDLE - 41" (1030)
LEDGESTONE FACE ± 1096 lb (497 kg) ± 1551 lb (703 kg) ± 1447 lb (656 kg)
(1) All dimensions are inches (mm)
(2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft 3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES (3)
MAXIMUM PERCENTAGE OF TOTAL CEMENTITIOUS MATERIALS BY WEIGHT (9, 11) (VERY SEVERE EXPOSURE CLASS ONLY)
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (10)
ALKALI-AGGREGATE REACTIVITY MITIGATION PER ACI 201
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(10) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
(11) Prescriptive limits shown may be waived for concrete mixes that demonstrate excellent freeze/thaw durability in a detailed and current testing program.
INFILLED UNIT WEIGHT FOR WALL STABILITY CALCULATIONS (14)
LIMESTONE / COBBLESTONE BLOCKS
LEDGESTONE BLOCKS
MINIMUM CONSTRUCTION RADIUS (15)
CONCAVE CURVE
CONVEX CURVE
(12) Special consideration should be given to the design of vertical retaining walls subject to active lateral earth pressure.
(13) Values based on full scale testing performed in October 2011. Copies of the full test reports are available at www.redi-rock.com.
(14) The infilled unit weights shown here are based on an assumed concrete unit weight of 143 lb/ft 3 (2291 kg/m 3) and an assumed soil unit weight of 100 lb/ft 3 (1602 kg/m 3). They are reference values. Several factors can cause the unit weights of both concrete and infill soil to vary. The designer should use sound engineering judgement when assigning an infilled unit weight value for analysis.
(15) The minimum construction radius stated is applicable to both concave and convex curved retaining wall sections. Increases to this minimum radius are required to account for wall batter. Special consideration should be given to block selection, facing batter, and wall height when selecting the minimum radius for the final wall alignment.
LENGTH(BACK)
HEIGHT (FRONT)
LENGTH(FRONT)
WIDTH(FORM LINETOBACK) WIDTH (FACE TEXTURE)
LENGTH(BACK)
LENGTH(FRONT) HEIGHT (FRONT)
WIDTH(FORM LINETOBACK) WIDTH (FACE TEXTURE)
Redi-Rock 60" (1520mm) Retaining Blocks
Redi-Rock 60" (1520 mm) Retaining Blocks
The Redi-Rock 60” (1520mm) Retaining wall blocks are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended for constructing dry-stacked modular retaining wall systems. The block units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock Retaining wall products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
DIMENSIONAL PROPERTIES
DIMENSIONS (1)
HEIGHT (FRONT OF BLOCK)
(BACK OF BLOCK)
LENGTH (FRONT OF BLOCK)
LENGTH (BACK OF BLOCK)
SHIPPING/HANDLING WEIGHT (2)
LIMESTONE/COBBLESTONE FACE LEDGESTONE FACE
MIDDLE BOTTOM
3216 lb (1458 kg)
3346 lb (1518 kg)
1364 lb (618 kg) ± 9.34 ft3 (0.264 m3) ± 9.09 ft3 (0.258 m3) ±1335 lb (606 kg) ± 1300 lb (590 kg)
HALF MIDDLE HALF BOTTOM
1397 lb (633 kg)
(1) All dimensions are inches (mm) (2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft 3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES (3)
MAXIMUM WATER-SOLUBLE CHLORIDE ION (Cl -) CONTENT IN CONCRETE, PERCENT BY WEIGHT OF CEMENT (8)
MAXIMUM PERCENTAGE OF TOTAL CEMENTITIOUS MATERIALS BY WEIGHT (9, 11) (VERY SEVERE EXPOSURE CLASS ONLY)
ALKALI-AGGREGATE REACTIVITY MITIGATION PER ACI 201
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(10) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
(11) Prescriptive limits shown may be waived for concrete mixes that demonstrate excellent freeze/thaw durability in a detailed and current testing program.
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (10)
Redi-Rock 60" (1520 mm) Retaining Blocks
Redi-Rock 60" (1520mm) Retaining Blocks
DESIGN PROPERTIES
HORIZONTAL SETBACK / WALL FACE BATTER OPTIONS
10 inch (254 mm) KNOB
7 1 2 inch (190 mm) KNOB
INFILLED UNIT WEIGHT FOR WALL STABILITY CALCULATIONS (14)
LIMESTONE / COBBLESTONE BLOCKS
LEDGESTONE BLOCKS
MINIMUM CONSTRUCTION RADIUS (15)
CONCAVE CURVE
CONVEX CURVE
(12) Special consideration should be given to the design of vertical retaining walls subject to active lateral earth pressure. (13) Values based on full scale testing performed in October 2011. Copies of the full test reports are available at www.redi-rock.com. (14) The infilled unit weights shown here are based on full width units and an assumed concrete unit weight of 143 lb/ft3 (2291 kg/m3) and an assumed soil unit weight of 100 lb/ft3 (1602 kg/m3) They are reference values. Several factors can cause the unit weights of both concrete and infill soil to vary. The designer should use sound engineering judgement when assigning an infilled unit weight value for analysis. (15) The minimum construction radius stated is applicable to both concave and convex curved retaining wall sections. Increases to this minimum radius are required to account for wall batter. Special consideration should be given to block selection, facing batter, and wall height when selecting the minimum radius for the final wall alignment.
The Redi-Rock 60” (1520mm) Retaining wall blocks are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended for constructing dry-stacked modular retaining wall systems. The block units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock Retaining wall products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
(2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft 3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES (3)
± 1366 lb (620 kg)
WATER-SOLUBLE CHLORIDE ION (Cl -) CONTENT IN CONCRETE, PERCENT BY WEIGHT OF CEMENT (8)
CHLORIDE AS Cl - CONCENTRATION IN MIXING
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (10)
ALKALI-AGGREGATE REACTIVITY MITIGATION PER ACI 201
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required. (4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(10) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
(11) Prescriptive limits shown may be waived for concrete mixes that demonstrate excellent freeze/thaw durability in a detailed and current testing program.
The Redi-Rock 60” (1520mm) Retaining wall blocks are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended for constructing dry-stacked modular retaining wall systems. The block units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock Retaining wall products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
DIMENSIONAL PROPERTIES
DIMENSIONS (1)
HEIGHT (FRONT OF BLOCK)
HEIGHT (BACK OF BLOCK)
LENGTH (FRONT OF BLOCK)
LENGTH (BACK OF BLOCK)
5 8 ± 1 2 (1387 ± 13) PLUS ± 5 3 8 (136) FACE TEXTURE
HALF MIDDLE HALF BOTTOM MIDDLE BOTTOM
SHIPPING/HANDLING WEIGHT (2)
LIMESTONE/COBBLESTONE FACE
LEDGESTONE FACE ± 3356 lb (1522 kg) ± 3226 lb (1463 kg)
(2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft 3 (2291 kg/m3). Actual weights will vary.
MAXIMUM PERCENTAGE OF TOTAL CEMENTITIOUS MATERIALS BY WEIGHT (9, 11) (VERY SEVERE EXPOSURE CLASS ONLY)
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (10)
ALKALI-AGGREGATE REACTIVITY MITIGATION PER ACI 201
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(10) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
(11) Prescriptive limits shown may be waived for concrete mixes that demonstrate excellent freeze/thaw durability in a detailed and current testing program.
The Redi-Rock 52” (1,320 mm) XL retaining wall blocks are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended for use in the construction of dry-stacked modular retaining wall systems. The block units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock retaining wall products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
DIMENSIONAL PROPERTIES
DIMENSIONS (1)
HEIGHT (FRONT OF BLOCK)
LENGTH (FRONT OF BLOCK)
LENGTH (BACK OF BLOCK)
WIDTH
CONCRETE VOLUME HEIGHT (BACK OF BLOCK)
LEDGESTONE FACE
SHIPPING/HANDLING WEIGHT (2)
LEDGESTONE FACE
23.29 ft3 (0.660 m3)±
3330 lb (1510 kg)±
(1) All dimensions are inches (mm) (2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES (3)
AIR CONTENT (7)
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (11)
ALKALI-AGGREGATE REACTIVITY MITIGATION per ACI 201
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) Where used in high sulfate environments or where alkali-silica reactivity is an issue, water soluble chloride shall be limited to no more than trace amounts (from impurities in concrete-making components, not intended constituents.)
(10) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(11) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
(12) Prescriptive limits shown may be waived for concrete mixes that demonstrate excellent freeze/thaw durability in a detailed and current testing program.
INFILLED UNIT WEIGHT FOR WALL STABILITY CALCULATIONS (14)
MINIMUM CONSTRUCTION RADIUS (15)
CONCAVE CURVE
CONVEX CURVE
(13) Values based on full scale testing performed in 2017 and 2018. Copies of the full test reports are available at www.redi-rock.com. (14) The infilled unit weights shown here are based on an assumed concrete unit weight of 143 lb/ft3 (2291 kg/m3) and an assumed soil unit weight of 100 lb/ft3 (1602 kN/m3). They are reference values. Several factors can cause the unit weights of both concrete and infill soil to vary. The designer should use sound engineering judgement when assigning an infilled unit weight value for analysis. (15) The minimum construction radius stated is applicable to both concave and convex curved retaining wall sections. Increases to this minimum radius are required to account for wall batter. Special consideration should be given to block selection, facing batter, and wall height when selecting the minimum radius for the final wall alignment.
The Redi-Rock 72” (1,830 mm) XL retaining wall blocks are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended for use in the construction of dry-stacked modular retaining wall systems. The block units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock retaining wall products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
DIMENSIONAL PROPERTIES
DIMENSIONS (1)
HEIGHT (FRONT OF BLOCK)
LENGTH (FRONT OF BLOCK)
LENGTH (BACK OF BLOCK)
WIDTH
CONCRETE VOLUME HEIGHT (BACK OF BLOCK)
LEDGESTONE FACE
SHIPPING/HANDLING WEIGHT (2)
LEDGESTONE FACE
29.10 ft3 (0.824 m3)±
4160 lb (1890 kg)±
(1) All dimensions are inches (mm) (2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES (3)
AIR CONTENT (7)
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (11)
ALKALI-AGGREGATE REACTIVITY MITIGATION per ACI 201
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) Where used in high sulfate environments or where alkali-silica reactivity is an issue, water soluble chloride shall be limited to no more than trace amounts (from impurities in concrete-making components, not intended constituents.)
(10) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(11) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
(12) Prescriptive limits shown may be waived for concrete mixes that demonstrate excellent freeze/thaw durability in a detailed and current testing program.
The Redi-Rock 72” (1,830 mm) XL retaining wall blocks are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended for use in the construction of dry-stacked modular retaining wall systems. The block units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock retaining wall products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
DIMENSIONAL PROPERTIES
DIMENSIONS (1)
HEIGHT (FRONT OF BLOCK)
HEIGHT (BACK OF BLOCK)
LENGTH (FRONT OF BLOCK)
LENGTH (BACK OF BLOCK)
CONCRETE VOLUME
LEDGESTONE FACE
SHIPPING/HANDLING WEIGHT (2)
LEDGESTONE FACE
29.10 ft3 (0.824 m3)±
4160 lb (1890 kg)±
(1) All dimensions are inches (mm) (2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES (3)
AIR CONTENT (7)
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (11)
ALKALI-AGGREGATE REACTIVITY MITIGATION per ACI 201
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) Where used in high sulfate environments or where alkali-silica reactivity is an issue, water soluble chloride shall be limited to no more than trace amounts (from impurities in concrete-making components, not intended constituents.)
(10) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(11) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
(12) Prescriptive limits shown may be waived for concrete mixes that demonstrate excellent freeze/thaw durability in a detailed and current testing program.
The Redi-Rock 96” (2,440 mm) XL retaining wall blocks are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended for use in the construction of dry-stacked modular retaining wall systems. The block units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock retaining wall products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
DIMENSIONAL PROPERTIES
DIMENSIONS (1)
HEIGHT (FRONT OF BLOCK)
LENGTH (FRONT OF BLOCK)
LENGTH (BACK OF BLOCK)
WIDTH
CONCRETE VOLUME HEIGHT (BACK OF BLOCK)
LEDGESTONE FACE
SHIPPING/HANDLING WEIGHT (2)
LEDGESTONE FACE
33.83 ft3 (0.958 m3)±
4840 lb (2190 kg)±
(1) All dimensions are inches (mm) (2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES (3)
AIR CONTENT (7)
(Cl-)
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (11)
ALKALI-AGGREGATE REACTIVITY MITIGATION per ACI 201
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) Where used in high sulfate environments or where alkali-silica reactivity is an issue, water soluble chloride shall be limited to no more than trace amounts (from impurities in concrete-making components, not intended constituents.)
(10) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(11) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
(12) Prescriptive limits shown may be waived for concrete mixes that demonstrate excellent freeze/thaw durability in a detailed and current testing program.
INFILLED UNIT WEIGHT FOR WALL STABILITY CALCULATIONS (14)
MINIMUM CONSTRUCTION RADIUS (15)
CONCAVE CURVE
CONVEX CURVE
(13) Values based on full scale testing performed in 2017 and 2018. Copies of the full test reports are available at www.redi-rock.com. (14) The infilled unit weights shown here are based on an assumed concrete unit weight of 143 lb/ft3 (2291 kg/m3) and an assumed soil unit weight of 100 lb/ft3 (1602 kN/m3). They are reference values. Several factors can cause the unit weights of both concrete and infill soil to vary. The designer should use sound engineering judgement when assigning an infilled unit weight value for analysis. (15) The minimum construction radius stated is applicable to both concave and convex curved retaining wall sections. Increases to this minimum radius are required to account for wall batter. Special consideration should be given to block selection, facing batter, and wall height when selecting the minimum radius for the final wall alignment.
SHEAR KNOBS @ 23 (584) OC, TYP.
WIDTH (FORM LINE TO BACK) LENGTH (FRONT) WIDTH (FACE TEXTURE)
Redi-Rock Freestanding Straight Blocks
Redi-Rock Freestanding Straight Blocks
The Redi-Rock Freestanding wall units are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended to be used exclusively or in combination with dry-stacked modular retaining wall blocks. These units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
DIMENSIONAL PROPERTIES
DIMENSIONS (1)
HEIGHT: 18 ± 3 16 (457 ± 5)
CONCRETE VOLUME
LIMESTONE/COBBLESTONE FACE LEDGESTONE FACE
SHIPPING/HANDLING WEIGHT (2)
LIMESTONE/COBBLESTONE FACE
LEDGESTONE FACE
(1) All dimensions are inches (mm)
(0.244 m3) ± 1523 lb (691 kg) ± 1375 lb (623 kg) ± 1407 lb (638 kg) LENGTH: 46 1 8 ± 1 2 (1172 ± 13)
(2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft 3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES (2)
THAW EXPOSURE CLASS (4)
MAXIMUM WATER-SOLUBLE CHLORIDE ION (Cl -) CONTENT IN CONCRETE, PERCENT BY WEIGHT OF CEMENT (8)
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (10) AIR CONTENT (7)
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(10) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
Redi-Rock Freestanding Variable Radius Blocks
Redi-Rock Freestanding Variable Radius Blocks
The Redi-Rock Freestanding wall units are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended to be used exclusively or in combination with dry-stacked modular retaining wall blocks. These units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
(2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft 3 (2291 kg/m3). Actual weights will vary.
CONCRETE MIX PROPERTIES (2)
THAW EXPOSURE CLASS (4)
MAXIMUM WATER-SOLUBLE CHLORIDE ION (Cl -) CONTENT IN CONCRETE, PERCENT BY WEIGHT OF CEMENT (8) MAXIMUM CHLORIDE AS Cl - CONCENTRATION
AIR CONTENT (7)
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (10)
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required. (4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(10) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
The Redi-Rock Hollow-Core Freestanding wall units are machine-placed, wet-cast, precast modular block units manufactured from first-purpose, non-reconstituted concrete and intended to be used exclusively or in combination with dry-stacked modular retaining wall blocks. These units are manufactured from structural-grade concrete mixes in accordance with ASTM C94 or ASTM C685 that produce a finished unit with excellent resistance to freeze-thaw, deicing chemical exposure, and submerged conditions in both fresh water and salt water applications. All Redi-Rock products are manufactured and distributed through an international network of individually-owned, licensed precast concrete manufacturers.
(1) All dimensions are inches (mm) (2) Weight shown is based on an assumed concrete unit weight of 143 lb/ft3 (2291 kg/m3). Actual weights will vary.
lb (441 kg) ±
HALF CORNER
± 545 lb (247 kg) ±
lb (229 kg) ±
WATER-SOLUBLE CHLORIDE ION (Cl-) CONTENT IN CONCRETE, PERCENT BY WEIGHT OF CEMENT (8,9)
CHLORIDE AS Cl- CONCENTRATION IN MIXING WATER,
MAXIMUM PERCENTAGE OF TOTAL CEMENTITIOUS MATERIALS BY WEIGHT (10) (VERY SEVERE EXPOSURE CLASS ONLY)
TOTAL OF FLY ASH OR OTHER POZZOLANS AND SILICA FUME (11) AIR
(3) Concrete mix properties are in general accordance with ACI 318 durability requirements. Research has shown that concrete manufactured to these standards demonstrates good durability and performance. When these requirements are followed, specific freeze-thaw testing of the concrete is typically NOT required.
(4) Exposure class is as described in ACI 318. “MODERATE” describes concrete that is exposed to freezing and thawing cycles and occasional exposure to moisture. “SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture. “VERY SEVERE” describes concrete that is exposed to freezing and thawing cycles and in continuous contact with moisture and exposed to deicing chemicals. Exposure class should be specified by owner/purchaser prior to order placement. Longer lead times may be required for block units manufactured for “severe” and “very severe” exposure classes.
(5) Test method ASTM C39.
(6) Defined in ASTM C33 Table 3 Limits for Deleterious Substances and Physical Property Requirements of Coarse Aggregate for Concrete.
(7) Test method ASTM C231.
(8) Test method ASTM C1218 at age between 28 and 42 days.
(9) Where used in high sulfate environments or where alkali-silica reactivity is an issue, water soluble chloride shall be limited to no more than trace amounts (from impurities in concrete-making components, not intended constituents.)
(10) The total cementitious material also includes ASTM C150, C595, C845, and C1157 cement. The maximum percentages shall include:
(a) Fly ash or other pozzolans in type IP, blended cement, ASTM C595, or ASTM C1157.
(b) Slag used in the manufacture of an IS blended cement, ASTM C595, or ASTM C1157.
(c) Silica fume, ASTM C1240, present in a blended cement.
(11) Fly ash or other pozzolans and silica fume shall constitute no more than 25 and 10 percent, respectively, of the total weight of the cementitious materials.
NOTES:
Thank you for choosing Redi-Rock International to help you make precast modular blocks. This user manual, used in conjunction with the Producer Secure Site, is intended to assist you in the manufacturing process.
This manual outlines general practices and procedures, but each manufacturer is responsible for creating a site-specific safety plan for their facility, as scenarios and situations vary across locations. If you need to set up a company safety program, we recommend visiting www.osha.gov or calling 1-800-321-OSHA (6742) to find safety-training materials specific to your company.
All manufacturers should abide by all federal, state, and local safety regulations.
