Heading 1 Heading Connex 1 150 & 200 - Boral

Heading 1

MARCH 2017

BORAL BLOCKSBuild something great™

Heading 1

MARCH 2017

BORAL RETAINING WALLSBuild something great™

BORAL RETAINING WALLSBuild something great™

INNOVATIVE DRY STACK SYSTEM 2017

ConnexTM 150 & 200

Connex™ 150 & Connex-T 150

Stretcher Unit13.8kg (approx)

The Connex™ 150 Stretcher is the main unit, as it stretches between end blocks and corner blocks.

Corner and End Unit10.8kg (approx)

The Connex™ 150 Corner and End unit can be used for either left or right hand corners as well as a full end block.

150 End Unit6.2kg (approx)

The Connex™ 150 End unit is used at ends and openings.

Connex™ 200 & Connex-T 200

Stretcher Unit16.0kg (approx)

The Connex™ 200 Stretcher is the main unit. It is called a ‘stretcher’ as it stretches between end blocks and corner blocks.

Corner and End Unit16.0kg (approx)

The Connex™ 200 Corner and End unit can be used for either left or right hand corners as well as a full end block.

200 Half Unit9.0kg (approx)

The Connex™ 200 Half unit is used as an end block, allowing the wall lengths to be built in multiples of 200mm. It is also used on each 2nd course at window and door openings, alternating with the Connex™ 200 End and Corner Units.

Connex™ Mortarless Masonry Block System

16kg (approx)The Connex Stretcher is the main unit. It iscalled a ‘stretcher’ as itstretches between endblocks and corner blocks.

200 400

200

Stretcher Unit

16kg (approx)The Connex End andCorner unit can be usedfor either left or righthand corners as well asa full end block.

200 400

200

End and Corner Unit

Components

9kg (approx)The Connex Half unit, used as an end blockallows wall lengths to be built in multiples of200mm. It is also used on each 2nd course atwindow and dooropenings, alternatingwith the Connex Endand Corner units.

200 200

200

Half Unit

Int roducing Connex™

The Boral Connex Block System introduces a dry mortarless wall system that when core-filled and reinforced is suitable for loadbearing, blade and retaining walls.

The Boral Connex Block can also be used for non-loadbearing walls when partially core-filled and reinforced.

The Boral Connex Block System comprisesof three modular components which keytogether eliminating the need for mortaredjoints above the first course.

Advantages• The system is quick and easy to install• Can be laid quicker than a standard

block wall• Minimal need for mortar• Reduced wet waste on site• A DIY alternative• Simple modular system – only three

components required• Four hour fire rated (240/240/240)• High acoustic performance

BOR12404_Connex_AW 30/5/07 5:21 PM Page 1

Stretcher Unit13.8kg (approx)The Connex™ 150 Stretcher is the main unit, as it stretches between end blocks and corner blocks.

150 400

200

Corner and End Unit10.8kg (approx)The Connex™ 150 Corner and End unit can be used for either left or right hand corners as well as a full end block.

150 350

200

Connex™ 150 Components

150 End Unit6.2kg (approx)The Connex™ 150 End unit is used at endsand openings.

150 150

200

Connex™ Mortarless Masonry Block System :Typical Details

Connex™ Blocks Additional Information

For technical assistance:

Call Specifier Line on 1300 360 255Visit www.boral.com.au/mdg

ADELAIDEMain North Road,Pooraka SA 5095 Tel (08) 8262 3529Fax (08) 8260 3011

MELBOURNE17-47 Turner Street,Port Melbourne VIC 3207 Tel (03) 9681 9722Fax (03) 9681 9766

Orders, product samples and sales enquiries

03/07

Connex™ 150 Design Guidelines

Base Dimensions

Wall Height Steel Details Level Backfill Sloping Backfill max 1:4

Total Reinforcement Base Heel Base Heelheight V-bars width depth width depth (mm) (mm) (mm) (mm) (mm)H B D B D

800 N12 at 400 600 500 800 500

1000 N12 at 400 800 500 1000 500

1200 N12 at 400 1000 500 1200 600

For higher walls please refer to the Boral Masonry Design Guide.

Section through Retaining Wall

250

N16@400

150

D

450

B

450 min. lap

H = 800 to 1200

Longitudinal reinforcement N12@400cts. commencing from top course. Omit on top of clean-out course.

Surcharge or sloping backfill (1 in 4 max.)

N12@400 cts

V Bars

SL72 Fabric

Optional capping

We reserve the right tochange the details in thispublication without notice.For a full set of Terms andConditions of Sale pleasecontact your nearest BoralMasonry sales office.

Front CoverBanks Road, Castle Hill NSW

™Connex™ is a registeredtrademark of Boral MasonryLimited. © Boral Masonry AllRights Reserved 2007.Boral Masonry LimitedABN 13 000 223 718

SizesContact your nearest Boral Masonry sales office for the full range ofConnex™ sizes available in your state. Not all sizes are available inall regions. Custom Connex™ sizes are available, however minimumorder quantities apply.

Colour and Texture VariationsThe supply of raw materials can vary over time. In addition,variation can occur between product types and production batches.


150 400

200


150 350

200



150 150

200








03/07


Base Dimensions



800 N12 at 400 600 500 800 500

1000 N12 at 400 800 500 1000 500

1200 N12 at 400 1000 500 1200 600



250

N16@400

150

D

450

B

450 min. lap

H = 800 to 1200



N12@400 cts

V Bars

SL72 Fabric

Optional capping







150 400

200


150 350

200



150 150

200








03/07


Base Dimensions



800 N12 at 400 600 500 800 500

1000 N12 at 400 800 500 1000 500

1200 N12 at 400 1000 500 1200 600



250

N16@400

150

D

450

B

450 min. lap

H = 800 to 1200



N12@400 cts

V Bars

SL72 Fabric

Optional capping








200 400

200

Stretcher Unit


200 400

200

End and Corner Unit

Components


200 200

200

Half Unit











200 400

200

Stretcher Unit


200 400

200

End and Corner Unit

Components


200 200

200

Half Unit









When reinforced and core-filled, Connex™ is ideal for load-bearing basement walls, blade walls and boundary retaining walls.

Connex™ can also be used for non-loadbearing masonry when partially reinforced and surface bonded.

Introducing Connex™The Boral Connex™ Block system introduces a dry mortarless wall system that when core-filled and reinforced is suitable for load bearing, blade and retaining walls.

The Boral Connex™ Block can also be used for non-loadbearing walls when partially core-filled and reinforced.

The Boral Connex™ Block System comprises of two ranges of block sytems consisting of three modular components that key together, thereby eliminating the need for mortared joints above the first course.

Advantages• The system is quick and easy to install.

• Can be laid quicker than standard blocks.

• First course is fully mortared, second course onwards is dry stacked.

• Reduced wet waste on site.

• A DIY alternative.

• Simple modular system - only three unit profiles per system.

• Connex™ 150 is three hour fire rated while the Connex™ 200 is four hour fire rated (240/240/240).

Colour Swatches

CHARCOAL OYSTER CLOUD

MARCH 2017

Heading 1

PlanningCheck with your local council before commencement. Generally, they require reinforced walls and footings to be designed by a suitably qualified engineer.

DesignWall heights should be in multiples of 200mm to avoid cutting blocks. Lengths for Connex™ 150 should be in odd 200mm increments, e.g. 1300; 1500 etc.

Estimating• There are 12.5 full Connex™ blocks

per m2.

• There are 5 courses per vertical metre.

• There are 2.5 Half units per vertical metre at ends and openings.

• There are 2.5 Full end units per vertical metre of ends and openings.

• There are 5 Corner units per vertical metre at corners.

• One cubic metre of concrete grout fills 93 Connex™ blocks (7.44m2).

ConstructionWhere starter bars are required (retaining walls), the first starter bar is 75mm in from all ends and corners for Connex™ 150, and 100mm in from all ends and corners for Connex™ 200.

The 2nd starter bar is 275mm from the 1st bar for Connex™ 150 (See Fig 1) and 300mm from the 1st bar for Connex™ 200 (See Figure 2).

Other starter bars are spaced at 400mm or 200mm as required by the engineer.

A clean-out course is not required as there will be no mortar droppings, however the cores must be kept clear – of rubbish.

The first course of Connex™ is laid with nibs on top, in a bed of conventional mortar as footings and floor slabs are seldom perfectly level.

The following courses are dry-stacked. Check each course is plumb and level. Use tile wedges to adjust, inserting them from inside the core.

Grout-fill Connex™ blocks with 20MPa concrete with a maximum aggregate size of 7mm and a minimum quantity of 300kg cement per cubic metre.

Walls over 1.5m high should be filled to half way, allowing half an hour before returning to start to fill the remainder. This is to give the first part of the pour enough time to firm, reducing the amount of hydrostatic pressure at the bottom of the cores.

FireThe Connex™ 150 system can achieve a 180 minute Fire Resistance Level (FRL), while the Connex™ 200 system can achieve the highest Fire Resistance Level (FRL) required by the Building Code of Australia (BCA): 240/240/240.

The BCA allows FRLs for building elements of masonry to be determined through accordance with AS3700, the Masonry Structures code.

When reinforced and core-filled, the Connex™ system achieves a 240 (Srf < 36) / 180 / 180 FRL from the following:

The 240-minute Structural Adequacy FRL is achieved when these blocks are reinforced and the Slenderness ratio (Srf) of the wall is less than or equal to 36 as per Table 6.1 of AS3700.

A typical basement wall of 3.6m high has an Srf of 15 from Formula 6.3.2.2(2) which is less than half the maximum allowed.

For Connex™ 150 the 180-minute Integrity FRL is achieved as per Clause 6.4.2 which requires the other 2 FRLs to reach the integrity FRL. The 180-minute Insulation FRL is as per AS3700:2001, Table 6.3 which requires 150mm of concrete masonry material.

The Connex™ 150 block has 150mm of material when grout-filled.

For Connex™ 200 the 240-minute Integrity FRL is achieved as per Clause 6.4.2 which requires the other 2 FRLs to reach 240 minutes.

The 240-minute Insulation FRL is as per AS3700:2001, Table 6.3 which requires 180mm of concrete masonry material. The Connex™ 200 block has 200mm of material when grout-filled.

StrengthThe minimum characteristic unconfined compressive strength (ƒ’uc) of Connex™ masonry units is 15MPa when tested as per AS4456.4:2003.

Sound RatingThe sound rating required for corridor/unit walls and stair/unit walls by the BCA is Rw 50.

Mass Law calculations and similar tests show this can be achieved with the addition of 10mm of render to each face of the Connex™ block.

A party wall that divides a wet area from a habitable room in another unit requires Rw+Ctr>50 and an impact rating. A stud wall, (no wall ties 20mm clear of the masonry with Tontine TSB6 and 13mm plasterboard or 6mm villaboard fixed to the studs) can be added to achieve the impact rating and 28mm furring channels with Tontine TSB3 and 13mm plasterboard on the other side can achieve the Rw+Ctr>50 sound rating.

ConnexTM 150 & 200

100 300 100300200 or 400 as per engineer

100300

300100

200 or 400

Chip lug away to fit against corner unit


Connex™ is a dry–stack masonry system

When reinforced and core-filled, Connex is ideal for load-bearing basement walls, blade walls and boundary retaining walls.

Connex can also be used for non load-bearing masonry when partially reinforced and surface bonded.

Fire

The Connex system can achieve the highest Fire ResistanceLevel (FRL) required by the Building Code of Australia (BCA):240/240/240

The BCA allows FRLs for building elements of masonry to bedetermined through accordance with AS3700, the MasonryStructures code.

When reinforced and core-filled, Connex system achieves a 240 (Srf < 36) / 240 / 240 FRL from the following:

The 240-minute Structural Adequacy FRL is achieved whenthese blocks are reinforced and the Slenderness ratio (Srf) ofthe wall is less than or equal to 36 as per Table 6.1

A typical basement wall of 3.6m high has an Srf of 15 fromFormula 6.3.2.2(2) which is less than half the maximum allowed.

The 240-minute Integrity FRL is achieved as per Clause 6.4.2which requires the other 2 FRLs to reach 240-minutes.

The 240-minute Insulation FRL is as per AS3700:2001, Table 6.3which requires 180mm of concrete masonry material. TheConnex block has 200mm of material.

Strength

The minimum characteristic unconfined compressive strength(ƒ’uc) of Connex masonry units is 15MPa when tested as perAS4456.4:2003.

Sound Rating

The highest sound rating required by the BCA is Rw + Ctr 50.This is for party walls between home units.

Mass Law calculations and similar tests show this can beachieved with the addition of 10mm of render to each face ofthe Connex block. If the party wall divides a wet area from ahabitable room in the other unit, a stud wall, (no wall ties)around the wet area, with plumbing between studs can beadded to achieve the required impact rating.

Planning

Check with your local council before commencement. Generally,they require reinforced walls and footings to be designed by asuitably qualified engineer.

Design

Wall heights and lengths should be in multiples of 200mm to avoid cutting.

Estimating

• There are 12.5 full Connex blocks per m2

• There are 5 courses per vertical metre.• There are 2.5 Half units per vertical metre at ends and openings.• There are 2.5 Full end units per vertical metre of ends

and openings.• There are 5 Corner units per vertical metre at corners.• One cubic metre of concrete grout fills 93 Connex blocks (7.44m2)

Construction

Where starter bars are required (retaining walls), the first starterbar is 100mm in from all ends and corners.

The 2nd starter bar is 300mm from the 1st bar. See fig 1.

Other starter bars are spaced at 400mm or 200mm as requiredby the engineer.

A clean-out course is not required as there will be no mortardroppings, however the cores must be kept clear of rubbish.

The first course of Connex is laid with nibs on top, in a bed ofconventional mortar as footings and floor slabs are seldomperfectly level.

The following courses are dry-stacked. Check each course isplumb and level. Use tile wedges to adjust, inserting them frominside the core.

Grout-fill Connex blocks with 20MPa concrete with a maximumaggregate size of 7mm and a minimum quantity of 300kgcement per cubic metre.

Walls over 1.5m high should be filled to half way, allowing halfan hour before returning to start to fill the remainder. This is togive the first part of the pour enough time to firm, reducing theamount of hydrostatic pressure at the bottom of the cores.

Fig 1. Starter bar spacing from ends and corners

Fig 2. Starter bar spacing from Connex™ 200 ends and corners

Connex™150Mortarless Masonry Block System

Innovative dry stack system

Connex™ 150 is a dry–stack masonry systemWhen reinforced and core-filled, Connex™ is ideal for load-bearing basement walls, blade walls and boundary retaining walls.Connex™ can also be used for non load-bearing masonry when partially reinforced and surface bonded.

The 240-minute Structural Adequacy FRL is achieved when theseblocks are reinforced and the Slenderness ratio (Srf) of the wall is less than or equal to 36 as per Table 6.1 of AS3700.

A typical basement wall of 3.6m high has an Srf of 15 from Formula6.3.2.2(2) which is less than half the maximum allowed.

The 180-minute Integrity FRL is achieved as per Clause 6.4.2 whichrequires the other 2 FRLs to reach the integrity FRL.

The 180-minute Insulation FRL is as per AS3700:2001, Table 6.3 which requires 150mm of concrete masonry material. The 150mmConnex™ block has 150mm of material when grout-filled.

StrengthThe minimum characteristic unconfined compressive strength (ƒ’uc) ofConnex™ masonry units is 15MPa when tested as per AS4456.4:2003.

PlanningCheck with your local council before commencement. Generally, theyrequire reinforced walls and footings to be designed by a suitablyqualified engineer.

DesignWall heights should be in multiples of 200mm to avoid cutting.Lengths should be in odd 200mm increments, e.g. 1300; 1500 etc.

Estimating• There are 12.5 full Connex™ blocks per m2.• There are 5 courses per vertical metre.• There are 2.5 Half units per vertical metre at ends and openings.• There are 2.5 Full end units per vertical metre of ends and openings.• There are 5 Corner units per vertical metre at corners.• One cubic metre of concrete grout fills 180 Connex™ blocks (14.4m2).

Fig 1. Starter bar spacing from ends and corners

7575Steel 275

350Blocks 350multiples of 400

275200 or 400 as per engineer

75S

teel Sp

acing

275275

75 150400

1100W

all Leng

th

400150

Blo

ck Leng

ths

200 or 400

Chip lug away to fit against corner unit

FireThe Connex™ system can achieve a 180 minute Fire ResistanceLevel (FRL).

The Building Code of Australia (BCA) allows FRLs for building elementsof masonry to be determined through accordance with AS3700, theMasonry Structures code.

When reinforced and core-filled, Connex™ system achieves a 240 (Srf < 36) / 180 / 180 FRL from the following:

Sound RatingThe sound rating required for corridor/unit walls and stair/unit wallsby the BCA is Rw 50.

Mass Law calculations and similar tests show this can be achieved withthe addition of 10mm of render to each face of the Connex™ block.

A party wall that divides a wet area from a habitable room in anotherunit requires Rw+Ctr>50 and an impact rating. A stud wall, (no wallties 20mm clear of the masonry with Tontine TSB6 and 13mmplasterboard or 6mm villaboard fixed to the studs) can be added toachieve the impact rating and 28mm furring channels with TontineTSB3 and 13mm plasterboard on the other side can achieve theRw+Ctr>50 sound rating.

ConstructionWhere starter bars are required (retaining walls), the first starter bar is 75mm in from all ends and corners.

The 2nd starter bar is 275mm from the 1st bar. See fig 1.

Other starter bars are spaced at 400mm or 200mm as required bythe engineer.

A clean-out course is not required as there will be no mortardroppings, however the cores must be kept clear of rubbish.

The first course of Connex™ is laid with nibs on top, in a bed ofconventional mortar as footings and floor slabs are seldom perfectly level.

The following courses are dry-stacked. Check each course is plumb andlevel. Use tile wedges to adjust, inserting them from inside the core.

Grout-fill Connex™ blocks with 20MPa concrete with a maximumaggregate size of 7mm and a minimum quantity of 300kg cementper cubic metre.

Walls over 1.5m high should be filled to half way, allowing half an hourbefore returning to start to fill the remainder. This is to give the firstpart of the pour enough time to firm, reducing the amount ofhydrostatic pressure at the bottom of the cores.

Fig 1. Starter bar spacing from Connex™ 150 ends and corners

INNOVATIVE DRY STACK SYSTEM

ConnexTM 150 & 200


Base Dimensions

WallHeight

Steel Details Level BackfillSloping Backfill

max 1:4

Total Height

(mm) HReinforcement V-bars

Base Width

(mm) B

Heel Depth

(mm) D

Base Width

(mm) B

Heel Depth

(mm) D

800 N12 at 400 600 500 800 500

1000 N12 at 400 800 500 1000 500

1200 N12 at 400 1000 500 1200 600

For higher walls please refer to the Boral Masonry Design Guide


Base Dimensions

WallHeight

Steel Details Level BackfillSloping Backfill

max 1:4

Total Height

(mm) H

Reinforcement

V-bars

Heel Width

(mm) W

Base Width

(mm) B

Heel Depth

(mm) D

Base Width

(mm) B

Heel Depth

(mm) D

800 N12 at 400 450 600 500 800 500

1400 N16 at 400 450 1200 500 1400 600

1600 N16 at 400 450 1400 600 1600 700

1800 N16 at 400 450 1600 700 1800 800

2000 N16 at 400 600 1800 700 2000 800

For higher walls please refer to the Boral Masonry Design Guide

Connex™ Mortarless Masonry Block System Typical Details

Sect ion through Retaining Wall

Connex Design Guidelines

Fully Propped Wall

Base dimensionsWall height Steel details Level backfill Sloping Backfill max 1:4

Total Reinforcement Heel Base Heel Base Heelheight V-bars width width depth width depth (mm) (mm) (mm) (mm) (mm) (mm)H W B D B D800 N12 at 400 450 600 500 800 5001400 N16 at 400 450 1200 500 1400 6001600 N16 at 400 450 1400 600 1600 7001800 N16 at 400 450 1600 700 1800 8002000 N16 at 400 600 1800 700 2000 800

Locate the continuousdrain at the bottom of the base

Free draininggranularmaterial

Filter fabric to keep silt out of drainage material


Backfill

Dishdrain

200

WB

D250

600minimumlap

H

SL72 Fabric

N16@400N12@400

Optional capping

Longitudinal reinforcement:N12@400 cts. Omit on top of clean-out course

N16 in top course only

V bars

N12 at 400 cts

200

55mmcover

1000

N16 @400 cts or N12 at 200 cts

N12 @400 cts

2700 max.

Floor slab reinforcement


N12 at 200 cts

Ag. drain

Vertical reinforcement:N16 @400 cts, central

Tanking to back face of wall e.g. Bituminous coating

Connexblocks

Horizontal reinforcement,N12 at 400 cts



Fully Propped Connex™ 200 Wall

Connex™ Mortarless Masonry Block System Typical Details

Sect ion through Retaining Wall

Connex Design Guidelines

Fully Propped Wall

Base dimensionsWall height Steel details Level backfill Sloping Backfill max 1:4

Total Reinforcement Heel Base Heel Base Heelheight V-bars width width depth width depth (mm) (mm) (mm) (mm) (mm) (mm)H W B D B D800 N12 at 400 450 600 500 800 5001400 N16 at 400 450 1200 500 1400 6001600 N16 at 400 450 1400 600 1600 7001800 N16 at 400 450 1600 700 1800 8002000 N16 at 400 600 1800 700 2000 800

Locate the continuousdrain at the bottom of the base

Free draininggranularmaterial

Filter fabric to keep silt out of drainage material


Backfill

Dishdrain

200

WB

D250

600minimumlap

H

SL72 Fabric

N16@400N12@400

Optional capping

Longitudinal reinforcement:N12@400 cts. Omit on top of clean-out course

N16 in top course only

V bars

N12 at 400 cts

200

55mmcover

1000

N16 @400 cts or N12 at 200 cts

N12 @400 cts

2700 max.



N12 at 200 cts

Ag. drain

Vertical reinforcement:N16 @400 cts, central

Tanking to back face of wall e.g. Bituminous coating

Connexblocks

Horizontal reinforcement,N12 at 400 cts



Section Through Connex™ 200 Retaining Wall


150 400

200


150 350

200



150 150

200








03/07


Base Dimensions



800 N12 at 400 600 500 800 500

1000 N12 at 400 800 500 1000 500

1200 N12 at 400 1000 500 1200 600



250

N16@400

150

D

450

B

450 min. lap

H = 800 to 1200



N12@400 cts

V Bars

SL72 Fabric

Optional capping






Section Through Connex™ 150 Retaining Wall


1. Starter BarsWhere starter bars are required (retaining walls) the bars are positioned as per Figures 1 and 2.

A clean out course is not required as there will be no mortar droppings, however the cores must be kept clear of rubbish.

5. Half Units and Corner/End UnitsHalf units and corner/end units are laid to alternate courses to form an end or opening.

2. First Course

The first course of Connex™ is laid with nibs on top, in a bed of conventional mortar as footings as floor slabs are seldom level.

6. Following Courses

The following courses are dry-stacked. Check each course is plumb and level. Use tile wedges to adjust, inserting them from inside the core.

3. 90° Corners

To form a 90° corner, lay one Connex™ Corner/End unit.

7. Horizontal Reinforcing

Horizontal reinforcing steel bars can be easily positioned into the block recess. After chipping away a recess between the knock-out grooves in the side of the Connex™ unit.

4. Remove Nib

Chip the vertical nib off the end of a Connex™ Stretcher unit to fit flush with the side of the Connex™ Corner/End unit.

8. Grout Fill

Grout fill Connex™ blocks with 20MPa concrete with a maximum aggregate size of 7mm and a minimum quantity of 300kg cement per cubic metre.

ConnexTM 150 & 200INNOVATIVE DRY STACK SYSTEM

For more information contact 1300 134 002 or visit www.boral.com.auShade variations can occur from batch to batch. Colours shown are indicative only and should not be used for final selection. Not all colours are available in every region for each product. Products ordered should be chosen from actual samples current at the time of order and are subject to availability. Photographs in this brochure are only representative of Boral products and the appearance and effect that may be achieved by their use. Samples brochure and displays should be viewed as a guide only. Customers should ensure all delivered products are acceptable, and any concerns about products are made prior to laying. © Copyright Boral Masonry Limited – all rights reserved 2017. Boral, the Boral logo, boral.com.au, Build something great, are trademarks or registered marks of Boral Limited or Boral Masonry Limited in Australia, other countries, or both. BCC_15103 Nov17


ConnexTM 150 & 200

Documents

Heading 1 Heading Connex 1 150 & 200 - Boral