Redi-Rock User Manual

User Manual

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: February 26, 2024

TABLE OF CONTENTS

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

XL Retaining Forms

Overview

General Production

52 in (1320 mm) XL Block

72 in (1830 mm) XL Block

96 in (2440 mm) XL Block

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

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

xxi

xxxiv

xxxvi

xxxix

8 in (203 mm) Core Column

4 in (102 mm) Core Column

Column Cap

Textures

Limestone

Kingstone

Ledgestone

Cobblestone

Smooth

XL

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. 52

9

9 in

28

Tall blocks

Retaining block size options

Freestanding blocks

Accessories

RETAINING FORMS

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

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.

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.

Knob Location

• 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

Setback

• Planter Setback

•

Universal Panel (Discontinued) R002-A007

PARTS LIST DESCRIPTION PART NUMBER QTY FORMED ANGLE R002-0013 1 LOWER SIDE PANEL R002-0021 1 LONG STIFFENER R002-0022 3 SHORT STIFFENER R002-0023 3 UPPER SIDE PANEL R002-0024 1 BOTTOM STIFFENER R002-0025 2 STOP BLOCKS R002-0026 2 CHAIN BINDER ATTACHMENT TUBE WELDMENT R002-A006 1 SPRING BINDER - MODIFIED CLAMP R002-A029 1 1 1 2 2 3 3 4 4 A B B 866) 222 8400 Phon 23 ) 237-9521 Fa d - k T TLE SHEET: RETAINING FORM STANDARD TOP PANEL PART No : R002-A007 1 OF 4 SIZE: B REV: A DRAWN BY DRAWN DATE F LE NAME C NADOLSKY 6 28 2016 R002-A007 am SCALE 1:8 PROPR ETARY AND CONF DENT ALREVISION HISTORY ZONE REV DESCRIPTION DATE APPROVED H PICTORAL UPDATE FOR 41 HC 06/26/20 T RUTHIG Notes: FL 1) Concentr ca y crit cal hru a assoc ated ho es FL 2) Asymme ric Locat on of ho es off of Center ne is Cri ical FL 3) Cr t ca F atness: Surface must have a f atness of ±0 032 R002-0026 R002-0013 PARTS LIST DESCRIPTION PART NUMBER QTY LONG STIFFENER R002-0022 2 BOTTOM STIFFENER R002-0025 1 STOP BLOCKS R002-0026 2 OUTER RIGHT PANEL STIFFENER R002-0050 1 OUTER LEFT PANEL STIFFENER R002-0051 1 LOWER SIDE PANEL R002-0054 1 ANGLE STIFFENER R002-0055 1 BOTTOM STIFFENER R002-0057 1 UPPER SIDE PANEL R002-0081 1 R002-0189 1 R002-0190 1 CHAIN BINDER ATTACHMENT TUBE WELDMENT R002-A006 1 SPRING BINDER - MODIFIED CLAMP R002-A029 1 1 1 2 2 3 3 4 4 A B B 866) 222-8400 Phone (231 237-9521 Fax www ed - ock com TITLE: SHEET: 9IN SETBACK - PANEL PART No : R002-A030 1 OF 6 SIZE: B REV: I DRAWN DATE F LE NAME 6 28/2016 R002-A030 am SCALE: 1/10 PROPR ETARY AND CONF DENTIAL THE NFORMAT ON CONTA NED N H S DRAW NG S SO O O - OC O ANY REPRODUCT ON N PAR OR N WHOLENTERNAT ONAL S PROH B TED REVISION HISTORY ZONE REV DESCRIPTION DATE APPROVED I UPDATED R002-0055 0022 0050 0051 0189 0190 23FEB2021 C NADOLSKY Notes FL 1) Concentricity Cr t cal thru al assoc ated holes FL 2) Asymmetr c Locat on of ho es off of Center ine is Cr tical FL 3) Critica Flatness: Surface Must have a flatness of ±0 032 R002-0026 R002-0055 R002-0022 R00 R002-0026 R002-0054 PARTS LIST DESCRIPTION PART NUMBER QTY FORMED ANGLE R002-0013 1 LOWER SIDE PANEL R002-0021 1 LONG STIFFENER R002-0022 3 SHORT STIFFENER R002-0023 3 UNIVERSAL TOP PANEL R002-0402 1 BOTTOM STIFFENER R002-0025 2 STOP BLOCKS R002-0026 2 CHAIN BINDER ATTACHMENT TUBE WELDMENT R002-A006 1 SPRING BINDER - MODIFIED CLAMP R002-A029 1 3 3 4 4 B REVISION HISTORY ZONE REV DESCRIPTION DATE APPROVED I R002-0013 UPDATED TO 1/4", UPDATED R002-0022 23FEB2021 C NADOLSKY PARTS LIST DESCRIPTION PART NUMBER QTY STEP AP203 5-13x1 5-TR 2 LONG STIFFENER R002-0022 2 BOTTOM STIFFENER R002-0025 1 STOP BLOCKS R002-0026 2 OUTER RIGHT PANEL STIFFENER R002-0050 1 OUTER LEFT PANEL STIFFENER R002-0051 1 LOWER SIDE PANEL R002-0054 1 ANGLE STIFFENER R002-0055 1 BOTTOM STIFFENER R002-0057 1 UPPER SIDE PANEL R002-0060 1 INSIDE LEFT PANEL STIFFENER R002-0189 1 INSIDE RIGHT PANEL STIFFENER R002-0190 1 3 WAY BINDER SPACER R002-0463 2 Modif ed C amp R002-A029 1 3-WAY BINDER R002-A168 1 1 1 2 2 3 3 4 4 A A B B 05481 US 31 SOUTH CHARLEVO X M 49720 866) 222-8400 Phone (231 237-9521 F www red - ock com PROJECT: TITLE: SHEET: RETAINING FORM: 3-WAY TOP PANEL WELDMENT PART No : R002-A018 1 OF 6 SIZE: B REV H DRAWN BY DRAWN DATE F LE NAME C NADOLSKY 6 28 2016 R002-A018 am SCALE: 1/10 PROPR ETARY AND CONF DENT AL SO O O - OC O ANY REPRO UCT ON N P RT O N WHO EREVISION HISTORY ZONE REV DESCRIPTION DATE APPROVED H REPLACED R002-A019 & R002-0056 WITH R002-A168 & R002-0463 12JULY2021 J T KLOSS Notes FL 1) Concentric ty Cr tical thru a l associated ho es FL 2) Asymmetric Locat on of ho es off of Center ne s Cr tica FL 3) Crit ca Flatness: Surface Must have a latness of ±0 032 R002-0026 R002-0055 R002-0022 R002-0050 R002-0025 R002-0190 R002-0189 R002-0051 R002-A029 R002-0022 R002-0054 R002-0060 R002-A168 R002-0463 R002-0057

Can be used to produce:

• Standard 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.

10

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.

10" (254 mm) diameter knob

Installation Instructions: Bolt to top panel of form.

6 ¾ in (171 mm) Knob Insert R002-A159

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

60 in (1520 mm) wide, 9" (230 mm) Setback retaining blocks ......... page xlvii

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.

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

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.

7.

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.

Pour

1.

Fill forms to the specified depth to produce blocks that conform to published dimensions and tolerances.

2.

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.

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.

Storage 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.

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.

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-41T 41" (1030mm) TOP *

R-41HT

Face Texture:

Block Weight:

Block Volume:

Center of Gravity:

28 in (710 mm)

Cobble / Limestone Kingstone / Ledgestone

41 in (1030 mm)

Middle Block

28 in (710 mm) or 41 in (1030 mm) Middle blocks are used in gravity retaining walls.

R-28M 28" (710mm) MIDDLE

13.9" (354 mm) 11.28 ft3 (0.319 m3)

lb (730 kg) 13.4" (340 mm) 10.78 ft3 (0.305 m3) 1540 lb (700 kg)

B

R-28B 28" (710mm) BOTTOM

1.

14.0" (355 mm)

12.19 ft3 (0.345 m3) 1740 lb (790 kg) 13.5" (343 mm) 11.70 ft3 (0.331 m3) 1670 lb (760 kg)

R-28HM 28" (710mm) HALF MIDDLE

R-41M (1030mm) MIDDLE

Kingstone / Ledgestone

Kingstone / Ledgestone Cobble

ft3 (0.148 m3)

lb (340 kg) 13.8" (350 mm)

(364 mm)

710 lb (320 kg)

ft3 (0.141 m3)

R-28HB 28" (710mm) HALF BOTTOM

R-41B 41" (1030mm) BOTTOM

Cobble / Limestone

lb (370 kg)

(364 mm)

Kingstone / Ledgestone

R-41HB

lb (350 kg)

ft3 (0.153 m3)

(352 mm)

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.

Form Assembly

1.

Knob formers (RR-G-KF10-S) 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.

2.

Loop holder is installed. See page vi in the Appendix for loop holder options.

3. Groove former (R002-A011) and face mold are installed.

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.

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.

Critical Note: Top of groove former should be 21 13/16 in (554 mm) from the top of the form.

R-28M 28"

1610 lb (730 kg)

11.28 ft3 (0.319 m3)

13.9" (354 mm)

R-28HM 28" (710mm)

1540 lb (700 kg)

10.78 ft3 (0.305 m3)

13.4" (340 mm)

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

1740 lb (790 kg)

12.19 ft3 (0.345 m3)

14.0" (355 mm)

1670 lb (760 kg)

11.70 ft3 (0.331 m3)

13.5" (343 mm)

750 lb (340 kg)

5.23 ft3 (0.148 m3)

14.3" (364 mm)

710 lb (320 kg)

4.98 ft3 (0.141 m3)

Retaining Forms

13.8" (350 mm)

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.

R-41B 41" (1030mm) BOTTOM

R-28HB 28" (710mm) HALF BOTTOM

810 lb (370 kg)

5.66 ft3 (0.160 m3)

14.3" (364 mm)

R-41HB

Kingstone / Ledgestone

770 lb (350 kg)

5.41 ft3 (0.153 m3)

13.8" (352 mm)

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.

7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102mm) tall. Smaller knob diameters are available.

3. Center of Gravity is measured from the back of block.

PARTS 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.

Bottom Block

Form Assembly

1.

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.

2.

Face mold, knob formers, and loop holder are the same as for middle block set up.

Production Notes

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.

1.

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.

Helpful Hint: If the PC kit is installed, see page 99.

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.

Note: If the two-way or three-way panel are installed, the top insert is different than with the standard panel

Block Library

ft3 (0.229 m3) 1160 lb (530 kg)

ft3 (0.113 m3) 570 lb (260 kg)

(389 mm)

/

365 8(930)

461

R-41M

3518(892)

/

36 5 8(930) 1 8 ( 4 5 7 ) 2) FACE TEXTURE VARIES 4012(1029)± FACE 4012(1029)± 3518(892) 36 5 8(930) 1 8 ( 4 5 7 ) 1 8 ( 4 5 7 ) 461 8 "(1172) FACE TEXTURE VARIES 4012(1029)± FACE TEXTURE FACE RETAINING

Ledgestone PARTS LIST DESCRIPTION QTY PART NUMBER TOP BLOCK WELDMENT 1 R002-A058 .5-13 HEX NUT 2 .5-13-HN 5 FLAT WASHER 2 5-FW 3 3 4 4 A B PROJ TIT PAR DRAW DRAW FILE PROPRIETARY AND CONFIDENTIAL THE NFORMAT ON CONTA NED IN TH S DRAW NG IS THE SOLE PROPERTY OF REDI-ROCK NTERNAT ONAL ANY REPRODUCT ON IN PART OR N WHOLE W THOUT PRIOR WRITTEN CONSENT OF REDI-ROCK NTERNAT ONAL IS PROHIB TED REVISION HISTORY ZONE REV DESCRIPTION DATE APPROVED C Added in loop holder for reference. Added in compatible option table 6/2/2021 G.HEINZ NOTES: FL1) Compatible options must be selected separately and are not included in this assembly 2) GRAY COMPONENTS FOR REFERENCE ONLY R002-A058 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. 28 in (710 mm) 41 in (1030 mm)

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)

COMPATIBLE

(FL1)

COMPATIBLE

(FL1)

FL1)

NOTES:

FL1)

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.

Critical Note: Knob formers may then be reinstalled if desired, but this may promote rust inside.

2. 3.

Groove former needs to be bolted to the bottom panel.

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: 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.

28 in (710 mm) 41 in (1030 mm)

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.

Kingstone / Ledgestone

(700 kg)

(0.305 m3)

(340 mm)

Kingstone / Ledgestone

(760 kg)

(0.331 m3)

(343 mm)

R-41M 41" (1030mm) MIDDLE

R-28HM

28" (710mm) HALF MIDDLE

R-41HM 41" (1030mm) HALF MIDDLE

R-28HB

Cobble / Limestone Kingstone / Ledgestone

750 lb (340 kg)

5.23 ft3 (0.148 m3)

14.3" (364 mm)

Kingstone

710 lb (320 kg)

4.98 ft3 (0.141 m3)

13.8" (350 mm)

R-41B 41" (1030mm) BOTTOM

28" (710mm) HALF BOTTOM

R-41HB 41" (1030mm) HALF BOTTOM

Cobble

810 lb (370 kg)

5.66 ft3 (0.160 m3)

14.3" (364 mm)

Kingstone

Cobble / Limestone Kingstone / Ledgestone

770 lb (350 kg)

5.41 ft3 (0.153 m3)

13.8" (352 mm)

Kingstone

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.

4.

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

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)

(FL1)

NOTE:

FL1)

Form Assembly

1.

Knob formers and groove former are the same as for full blocks.

2.

The half block rubber face mold is centered and bolted to the bottom of the form.

3.

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.

(700 kg)

(0.305 m3)

(340 mm)

Kingstone

R-28HM 28" (710mm) HALF MIDDLE

R-41M 41" (1030mm) MIDDLE

Cobble / Limestone

Cobble / Limestone Kingstone / Ledgestone

750 lb (340 kg)

2310 lb (1050 kg)

5.23 ft3 (0.148 m3)

16.14 ft3 (0.457 m3)

14.3" (364 mm)

20.4" (518 mm)

R-41HM 41" (1030mm) HALF MIDDLE

Face Texture:

Cobble / Limestone

Kingstone / Ledgestone Kingstone / Ledgestone

4.98 ft3 (0.141 m3)

19.8" (504

13.8" (350 mm)

Half Bottom Block

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.

R-28HB 28" (710mm) HALF BOTTOM

R-41B 41" (1030mm) BOTTOM

Cobble / Limestone

810 lb (370 kg)

5.66 ft3 (0.160 m3)

R-41HB 41" (1030mm) HALF BOTTOM

Cobble / Limestone Kingstone / Ledgestone

770 lb (350 kg)

5.41 ft3 (0.153 m3)

14.3" (364 mm)

13.8" (352 mm)

710 lb (320 kg) (343 mm) (0.331 m3) (760 kg)

Cobble / Limestone

Half Bottom Block

noted otherwise. manufacturer.

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.

7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102mm) tall. Smaller knob diameters are available.

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.

PARTS AND KIT NUMBERS FOR ORDERING

• 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)

NOTE: FL1)

COMPATIBLE

Form Assembly 1.

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.

TITLE:

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.

Kingstone / Ledgestone

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.

RETAINING BLOCKS

Block Library

R-41T 41" (1030mm) TOP *

Cobble / Limestone Kingstone / Ledgestone

R-41HT 41" (1030mm) HALF TOP *

Half Top Block

(340 mm) (0.305 m3) (700 kg)

R-28HM 28" (710mm) HALF MIDDLE

R-41M 41" (1030mm) MIDDLE

750 lb (340 kg)

5.23 ft3 (0.148 m3)

14.3" (364 mm)

Kingstone / Ledgestone Cobble / Limestone Kingstone / Ledgestone Kingstone

R-41HM 41" (1030mm) HALF MIDDLE

SHEAR

R-28HB

710 lb (320 kg) (343 mm) (0.331 m3) (760 kg)

4.98 ft3 (0.141 m3)

13.8" (350 mm)

noted otherwise. manufacturer.

R-41B 41" (1030mm) BOTTOM

28" (710mm) HALF BOTTOM

810 lb (370 kg)

5.66 ft3 (0.160 m

14.3" (364 mm)

R-41HB 41" (1030mm) HALF BOTTOM

Kingstone /

FACE

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.

1. Units for dimensions are inches (mm), typical unless noted otherwise.

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.

PARTS AND KIT NUMBERS FOR ORDERING

• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM

• R002-A128 (WEDGE)

NOTE: A HALF-BLOCK RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

R002-A127

NOTES:

Compatible

ONLY

in

GRAY

REFERENCE

ONLY

PROJECT:

DRAWN BY:

clay nadolsky 3/4/2021 REVISION HISTORY ZONE REV DESCRIPTION DATE APPROVED A INITIAL RELEASE 16JUNE2021 J T KLOSS

DATE:

TITLE:

PART No : R002-A128

Half Top Block

Form Assembly

1.

The top block insert and groove former are the same as for the full top block. See page 27 for top block assembly instructions.

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.

2. 3. 4.

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.

FREESTANDING BLOCKS

Block Library

Block Library

FREESTANDING

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.

FREESTANDING BLOCKS

R-28SDT

Face

Block Library

Cobble / Limestone

Block Library

9" (230 mm) STEPDOWN TOP

9" (230 mm) STEPDOWN TOP

Kingstone / Ledgestone

Kingstone / Ledgestone

600 lb (270 kg)

4.2 ft3 (0.12 m3)

Cobble

1.

2.

1.

2.

1.

2.

Kingstone / Ledgestone

Kingstone / Ledgestone

500 lb (230 kg) 225 8(575)

3.4 ft3 (0.10 m3)

9" (230 mm) STEPDOWN TOP

9” (230 mm) TALL TOP 9” (230 mm) TALL TOP

Kingstone / Ledgestone Kingstone / Ledgestone

Cobble / Limestone 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.

4.

3.

4.

5.

3.

4.

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/m3).

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

1.

9INCH TOP BLOCK

Remove the face mold and groove former from the form.

2.

Install the 9 in (230 mm) bottom block insert (R002-A139) into the bottom panel using the groove former holes.

Critical 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.

Helpful Hint: If pouring bottom blocks, do not install the groove former.

3.

Install the 9 in (230 mm) tall face mold (R002-A133) into the bottom of the form.

4.

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

Pour

1.

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.

2.

To manufacture a 41-in (1030-mm) block, fill the form full.

Maintenance, Tips & Tricks

Tips

1.

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.

Middle Block

60 in (1520 mm) Middle blocks are used in gravity retaining walls.

RETAINING BLOCKS

Block Library

R-60M 60" (1520mm) MIDDLE

Block

Center of

Kingstone / Ledgestone

Block

Center

Kingstone / 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.

Kingstone / Ledgestone

Kingstone / Ledgestone

1360 lb (620 kg)

ft3 (0.270 m3)

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.

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)

PARTS LIST

RIGHT END PANEL 1

TOP/BOTTOM PANEL

LEFT END PANEL 1 R002-A036

FORK SLOT INSERT CAP

R002-A034

60" MIDDLE WITH FORKSLOTS

R002-A034

R002-A036

PROJECT:

DESCRIPTION QTY PART NUMBER RIGHT END PANEL 1 R002-A033 TOP/BOTTOM PANEL ASSEMBLY 2 R002-A034 LEFT END PANEL 1 R002-A036 FORK SLOT INSERT CAP ASSEMBLY 2 R002-A032 5-13 x 1.5 HEX BOLT 16 5-13x1 5-HB 5-13 HEX NUT 18 .5-13-HN .5 FLAT WASHER 18 5-FW 2 2 3 3 4 4 A B

DRAWN BY:

DRAWN DATE:

FILE NAME: PROPRIETARY AND CONFIDENTIAL THE NFORMAT ON CONTA NED IN THIS DRAWING IS THE SOLE PROPERTY OF RED -ROCK INTERNATIONAL ANY REPRODUCTION N PART OR IN WHOLE WITHOUT PR OR WR TTEN CONSENT OF RED -ROCK INTERNATIONAL IS PROHIBITED

60"

FORM

CONFIDENTIAL

PROJECT:

DRAWN BY:

DRAWN DATE:

gabby heinz 3/4/2021 R002-M004 iam

TITLE: 60" FORM OPTIO

PART No : R002-M004

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.

7.

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.

8.

Once all adjustments are final, tighten all eight bolts very tight with an impact wrench. This will hold everything in place.

9.

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.

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.

Bottom Block

60 in (1520 mm) Bottom blocks are used in the base course in gravity retaining walls.

R-60B 60" (1520mm) BOTTOM

R-60B 60" (1520mm) BOTTOM

60" (1520mm) HALF 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.

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.

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

PROJECT:

DRAWN BY:

TITLE:

PART No :

PROJECT:

Form Assembly

1.

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

1.

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.

Ledgestone

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)

Kingstone / Ledgestone

Face Texture: Cobble / Limestone Kingstone / Ledgestone

Block Weight: 1340 lb (610 kg) 1300 lb (590 kg)

Block

Ledgestone

R-60HB

Kingstone / Ledgestone

PROJECT:

TITLE:

PART No : R002-M002

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

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.

PARTS LIST DESCRIPTION QTY

HALF BLOCK WELDMENT 1 R002-A060

60" HALFBLOCK WELDMENT 1 R002-A062

60" HALF MID

Form Assembly

1.

R002-A060 R002-A062 5-13-HN .5-FW .5-13-HN 5-FW

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.

CONFIDENTIAL

PROJECT:

DRAWN BY:

2.

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.

t 6 R

TITLE: Reta

PART No : R

Half Bottom Block

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.

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.

60" HALF BO

Form Assembly

1.

60" HALF BOTTOM

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

PROJECT:

TITLE:

41

9 in (230 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.

Note: See page 11 in the introduction to this section and page ii in the Appendix for more information on setback options.

Block Library

R-419M

R-419M

R-419B

R-419B

RETAINING

Block Library

Block Library

R-419HM

41" (1030mm) MIDDLE 9" (230mm) SETBACK

Kingstone / Ledgestone Kingstone / Ledgestone

2320 lb (1050 kg)

16.21 ft3 (0.46 m3)

20.2" (514 mm)

Kingstone / Ledgestone

Kingstone / Ledgestone

2250 lb (1020 kg)

15.72 ft3 (0.44 m3)

19.7" (500 mm)

1030 lb (470 kg)

lb (1500 kg)

7.20 ft3 (0.20 m3)

ft3 (0.65 m3)

21.3" (540 mm)

R-419HM

Kingstone / Ledgestone

Kingstone / Ledgestone

1000 lb (450 kg)

3230 lb (1460 kg)

6.96 ft3 (0.20 m3)

22.56 ft3 (0.64 m3)

20.7" (525 mm)

30.3" (770 mm)

R-419HB

Kingstone / Ledgestone

TEXTURE VARIES

4012(1029)±

HALF MIDDLE

41" (1030mm) BOTTOM 9" (230mm) SETBACK

2450 lb (1110 kg)

17.13 ft3 (0.48 m3)

20.6" (523 mm)

SHEAR KNOBS @ 23 (584) OC, TYP.

Kingstone / Ledgestone

2380 lb (1080 kg)

16.63 ft3 (0.47 m3)

20.1" (510 mm)

Block Weight:

Block Volume:

R-419HB

Cobble / Limestone

1090 lb (500 kg)

lb (1550 kg)

7.63 ft3 (0.22 m3)

ft3 (0.68 m3)

Kingstone / Ledgestone

Kingstone / Ledgestone

1060 lb (480 kg)

3360 lb (1520 kg)

7.39 ft3 (0.21 m3)

23.47 ft3 (0.66 m3)

R-609HB

Face Texture: Center of

Face Texture:

Block Weight:

Center of

21.6" (548 mm)

(800 mm)

21.0" (534 mm)

30.9" (786 mm)

5.

6.

Form Assembly Option 1 -

• RR 41IN 9IN SETBACK FORM

• R002-A038 (60 IN KIT)

• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)

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 (RR-GKF10-S) 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.

• RR 41IN 3-WAY FORM

• R002-A038 (60 IN KIT)

• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)

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.

2.

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

NOTE:

IF POURING A 60 IN (1520 MM) 9 IN (230 MM) SETBACK BLOCK AND THE EXTENSION KIT IS NOT ALREADY INSTALLED, SEEPAGE 43 FOR INSTRUCTIONS.

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.

2.

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.

Production Notes

Prep

1.

Double check that the loop holder is in the correct location for 9 in (230 mm) Setback blocks.

Storage

1.

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.

R-609M

41 in (1030 mm) 60 in (1520 mm)

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.

FULL MIDDLE

R-609HM

SHEAR

16.63 ft3 (0.47 m3)

20.1" (510 mm)

Block Library

R-609B

R-609B

Face Texture:

Block Weight:

Block Volume:

Center of Gravity:

Cobble / Limestone

2380 lb (1080 kg) 21.6" (548 mm)

7.63 ft3 (0.22 m3) 1090 lb

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

3430 lb (1550 kg)

23.97 ft3 (0.68 m3)

31.5" (800 mm)

60" (1520mm) BOTTOM 9" (230mm)

3360 lb (1520 kg)

23.47 ft3 (0.66 m3)

30.9" (786 mm)

R-609HB

Face Texture:

Block Weight:

Block Volume:

Center of Gravity:

FULL 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.

2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.

5.

7. Interface Shear knobs are typically 10" (254mm) diameter by 4" (102 mm) tall.

3. Center of Gravity is measured from the back of block.

4. Actual block volumes and weights may vary.

Shear mm) tall.

Form Assembly Option 1 - Two-Way Panel

PARTS AND KIT NUMBERS FOR ORDERING

• RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM

• R002-A038 (60 IN KIT)

• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)

NOTE:

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.

1.

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.

2.

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.

PARTS AND KIT NUMBERS FOR ORDERING

• RR 41IN 3-WAY FORM

• R002-A038 (60 IN KIT)

• R002-A122 (OPTIONAL FORKSLOT ADAPTERS)

NOTE:

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.

1.

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.

2.

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.

Kingstone

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.

R-609M

(1030mm) MIDDLE 9" (230mm) SETBACK

R-419HM

Kingstone / Ledgestone

(1030mm)

R-609B

5-FW 5-13-HN 5-FW

HALF MIDDLE

R-609HM

PROJECT:

DRAWN BY:

DRAWN DATE:

truthig PROPRIETARY AND CONFIDENTIAL THE NFORMAT ON CONTAINED N THIS DRAW NG IS THE SOLE PROPERTY OF REDI-ROCK INTERNAT ONAL ANY REPRODUCTION IN PART OR IN WHOLE WITHOUT PRIOR WR TTEN CONSENT OF REDI-ROCK NTERNATIONAL IS PROHIBITED

Kingstone / Ledgestone

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.

iam

TITLE: SHEET:

R-609HB

PARTS AND KIT NUMBERS FOR ORDERING

• 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

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.

PROJECT:

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

1.

Production is the same as for the standard half middle block.

Helpful Hint: See page 31 for 41-in (1030-mm) set up and page 50 for the 60-in (1520-mm) set up instructions.

Kingstone / Ledgestone

(510 mm) (0.47 m3) (1080 kg)

41 in (1030 mm) 60 in (1520 mm)

9 in (230 mm)

Setback Half Bottom Block

R002-A062

R002-A126

The 9 in (230 mm) Setback Half Bottom blocks are used to maintain a running bond in the bottom course of large batter walls.

8(213) 1 8 ( 4 5 7 ) 2213 16(579) FACE TEXTURE VARIES 60(1524)± 1 8 ( 4 5 7 ) SHEAR KNOBS @ 23 (584) OC, TYP.

Note: See page 11 in the introduction to this section and page ii in the Appendix for more information on setback options.

FULL MIDDLE

41” (1030 mm) HALF BOTTOM 9” (230 mm) SETBACK

Face

HALF MIDDLE

Cobble 4012(1029)±

/

1090 lb (500 kg)

60" (1520mm) BOTTOM 9" (230mm) SETBACK

3430 lb (1550 kg)

7.63 ft3 (0.22 m3)

21.6" (548 mm)

R-419HB

Kingstone / Ledgestone

Kingstone / Ledgestone

1060 lb (480 kg)

7.39 ft3 (0.21 m3)

21.0" (534 mm)

60” (1520 mm) HALF BOTTOM 9” (230 mm) SETBACK

1400 lb (640 kg)

9.80 ft3 (0.28 m3)

34.2" (869 mm)

R-609B R-609HB

Kingstone / Ledgestone

1370 lb (620 kg)

9.55 ft3 (0.27 m3)

33.6" (854 mm)

Cobble / Limestone Cobble / Limestone Block Weight: Face Texture: Center of Gravity: Block Weight: Block Volume: Face Texture: 545 8(1387) 313 8(797) 1 8 ( 4 5 7 ) 461 8(1172) FACE TEXTURE VARIES 60(1524)± 1 8 ( 4 5 7 ) 545 8(1387) 313 8(797) 1 8 ( 4 5 7 ) 461 8(1172) FACE TEXTURE VARIES 60(1524)± 1 8 ( 4 5 7 ) 545 8(1387) 83 8(213) 1 8 ( 4 5 7 ) 2213 16(579) FACE TEXTURE VARIES 60(1524)± 1 8 ( 4 5 7 ) 545 8(1387)

5-FW 5-13-HN

HALF BOTTOM

FULL BOTTOM

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.

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.

5-13-HN

5-FW

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" (102 mm) tall.

PARTS AND KIT NUMBERS FOR ORDERING

• 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

60" HALF BO

NOTE:

F3WAY 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.

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 34 for 41-in (1030-mm) set up and page 52 for the 60-in (1520-mm) set up instructions.

Production Notes

1.

Production is the same as for the standard half middle block.

Helpful Hint: See page 34 for 41-in (1030-mm) set up and page 52 for the 60-in (1520-mm) set up instructions.

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-41HPL

R-41PL 41" (1030mm) PLANTER

•

•

Form Assembly Option 1 - Three-Way Panel

COMPATIBLE

COMPATIBLE

FL1)

1.

See diagram for planter setback knob former and cover positions.

PLANTER POSITION

KF = Knob Former

B = “B” Style Knob Covers

D = “D” Style Knob Covers

Note Loop Holder position.

PARTS LIST

QTY DESCRIPTION

2.

20 1/2"-13 HEX NUT

16 1/2"-13 x 1 5" CARRIAGE BOLT

The planter block insert (R002-A174) is bolted through the outside holes in the D knob covers.

2 1/2" FLAT WASHER

2

2 Groove former is bolted to the bottom panel.

R002-A059

3.

.5-FW 5-13-HN

4.

Loop holder is bolted to a planter block insert in the center pair of holes.

RR-G-KF10-S

5-13-HN

R002-A020

R002-A024

.5-13x1.5-CB

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

•

•

• R002-A101 (INSERT)

FL1)

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.

A

4.

R002-A059 RR-G-KF10-S 5-13-HN 5-13x1 5-CB 5-FW 5-13-HN

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.

Storage

4 4

Loop holder is bolted to the planter block insert in the center pair of holes.

Production Notes 2 2

B TITLE: PART No : R002-M007

Critical Note: Do not over tighten so as to deform rubber.

3 3

UNIVERSAL PANEL PLANTER BLOCK

PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTA NED IN TH S DRAWING S THE SOLE PROPERTY OF REDI-ROCK NTERNAT ONAL ANY REPRODUCT ON N PART OR IN WHOLE W THOUT PR OR WRITTEN CONSENT OF REDI-ROCK INTERNATIONAL S PROH B TED

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.

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.

41

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.

Face

Block

Center

Cobble

Block

Center

ROVED HEINZ

• RR 41IN 3-WAY FORM

• R002-A174 (INSERT)

• R002-A163 (WEDGE)

PARTS AND KIT NUMBERS FOR ORDERING

R002-A131 .5-13-HN .5-FW

PROJECT:

DRAWN BY: DRAWN DATE:

gabby heinz 6/2/2021 R002-A163 iam PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF REDI-ROCK INTERNATIONAL ANY REPRODUCTION, IN PART OR IN WHOLE, WITHOUT PRIOR WRITTEN CONSENT OF REDI-ROCK INTERNATIONAL IS PROHIBITED

TITLE:

PART No : R002-A163

Form Assembly

1.

Planter block insert is the same as for full planter block. Use the appropriate insert for your top panel.

2.

Groove former same as for full planter block.

3.

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.

5.

Two loop holders are bolted to planter block insert in outer pairs of holes.

4. 6.

Open holes may be covered with bolts.

Critical Note: Do not over tighten so as to deform rubber.

1

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:

Block Weight:

Block Volume:

Center of Gravity:

Cobble / Limestone

1200 lb (540 kg)

8.38 ft3 (0.24 m3)

17.9" (455 mm)

Kingstone / Ledgestone

1130 lb (510 kg)

7.88 ft3 (0.22 m3)

17.2" (438 mm)

R-MHT MODIFIED HALF TOP

Face Texture:

Block Weight:

Block Volume:

Center of Gravity:

Cobble / Limestone

710 lb (320 kg)

4.95 ft3 (0.14 m3)

20.7" (527 mm)

Kingstone / Ledgestone

640 lb (290 kg)

19.8" (504 mm)

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.

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.

3. Center of Gravity is measured from the back of block.

1. Units for dimensions are inches (mm), typical unless noted otherwise.

4. Actual block volumes and weights may vary.

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).

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.

•

•

COMPATIBLE OPTIONS (FL1)

PARTS LIST

COMPATIBLE OPTIONS (FL1)

PART

R002-A105 A/R

R002-A145 A/R

NOTE: FL1)

NO-RECESS HOLDER

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. 2.

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.

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.

Helpful Hint: To achieve a better center of balance for lifting, you may need to relocate the loop holders.

Pour to here

3518(892)

Modified Half Top Block

MODIFIED HALF TOP

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.

mm) m3) kg)

Face Texture:

Block Weight:

Block Volume:

Center of Gravity:

Face Texture:

Block Weight:

Cobble / Limestone

Ledgestone Kingstone / Ledgestone

710 lb (320 kg)

4.95 ft3 (0.14 m3)

20.7" (527 mm)

640 lb (290 kg)

4.45 ft3 (0.13 m3)

19.8" (504 mm)

Cobble / Limestone

710 lb (320 kg)

640 lb (290 kg)

otherwise. manufacturer.

otherwise. manufacturer.

SPECIALITY BLOCK

Block Volume:

Center of Gravity:

4.95 ft3 (0.14 m3)

20.7" (527 mm)

4.45 ft3 (0.13 m3)

19.8" (504 mm)

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.

•

•

•

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.

Helpful Hint: To achieve a better center of balance for lifting, you may need to relocate the loop holders.

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.

Pour to here

Block Volume:

Center of Gravity:

16.54 ft3 (0.47 m3)

21.0" (533 mm)

16.04 ft3 (0.45 m3)

20.4" (519 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

14.95

Cobble / Limestone 19.7"

Cobble / Limestone

1280 lb (580 kg)

8.96 ft3 (0.25 m3)

1240 lb (560 kg)

8.66 ft3 (0.24 m3)

19.5" (494mm)

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.

15.63 ft3 (0.44 m3)

20.6" (523 mm)

Cobble / Limestone

15.13 ft3 (0.43 m3)

20.0" (509 mm)

7.33 ft3 (0.21 m3)

4.64 ft3 (0.13 m3)

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

• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM

• R002-A186 (SIDE INSERTS)

NOTE: A 42.5 SHORT BLOCK RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE. PARTS LIST

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

Cobble / Limestone

1110 lb (500 kg)

7.77 ft3 (0.22 m3)

13.7" (349mm)

Cobble / Limestone

710 lb (320 kg)

4.94 ft3 (0.14 m3)

13.9" (352mm)

1050 lb (480 kg)

7.33 ft3 (0.21 m3)

13.2" (336mm)

/ Ledgestone

660 lb (300 kg)

4.64 ft3 (0.13 m3)

13.3" (339mm)

PARTS AND KIT NUMBERS FOR ORDERING

• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM

• R002-A183 (SIDE INSERTS)

NOTE: A 42.5 SHORT BLOCK RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

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.

2.

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.

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.

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.

R-28PCT 28" (710mm) PC TOP

Face

Kingstone / Ledgestone

R-41PCT 41" (1030mm) PC TOP

R-41PCT 41" (1030mm) PC TOP

Cobble / Limestone 21.8" (554 mm)

Kingstone / Ledgestone

1560 lb (710 kg)

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.

Cobble / Limestone

lb

1520 lb (690 kg)

10.62 ft3 (0.301 m3)

14.2" (360 mm)

14.2" (360 mm)

R-28PCT 40(1016) 1 3 ( 3 3 0 ) 1 8 ( 4 5 7 ) 461 8(1172) FACE TEXTURE VARIES 225 8(575)

1.

2.

28" (710mm) PC TOP 40(1016) 1 8 ( 4 5 7 ) 1 8 ( 4 5 7 ) 461 8(1172) FACE TEXTURE VARIES 28(711)±

28(711)±

28" (710mm) PC MIDDLE R-41PCM 41" (1030mm) PC MIDDLE

Kingstone / Ledgestone

Cobble / Limestone

Cobble

kg) 13.6"

1450 lb (660 kg)

2170 lb (990 kg)

10.12

10.12 ft3 (0.287 m3)

15.2 ft3 (0.43 m3)

mm)

13.6" (346 mm)

SHEAR

TEXTURE VARIES 4012(1029)± 4012(1029)±

20.6" (522 mm)

OPTIONS

R-28PCB 28" (710mm) PC BOTTOM

Kingstone

Ledgestone

1620 lb (740 kg) 13.7" (349 mm)

1 8 ( 4 5 7 ) 461 8(1172)

FACE TEXTURE VARIES

FACE TEXTURE VARIES

2. Block production varies with each licensed Redi-Rock manufacturer. Confirm availability before Specifying or Ordering.

3.

3.

4.

Center of Gravity is measured from the back of block.

4. Actual block volumes and weights may vary.

Kingstone /

Ledgestone

Kingstone / Ledgestone Kingstone / Ledgestone

14.69 ft3 (0.42 m3)

PC

Weights are based upon a concrete density of 143 lb/ft3 (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.

INCLUDED

IN THIS ASSEMBLY

PARTS AND KIT NUMBERS FOR ORDERING

• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM

• R002-A055 (MIDDLE PC KIT)

ARE

Form Assembly

Remove all existing inserts from the top panel in the standard retaining form. Leave the bottom groove former and fork slot attachments.

Mark holes on the panel with paint or marker.

Helpful Hint: Some holes may fit existing holes on the panel.

Helpful Hint: A MAG drill is recommended.

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.

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.

6.

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.

7.

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.

Welds

Bolts

8.

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: Do not overtighten rubber insert or it will deform.

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.

9.

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.

10.

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.

11.

Replace 10 in (254 mm) knob formers.

12.

Center drill template #1 (R002-0359) on bottom panel.

13.

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.

14.

Mark holes on the panel with paint or marker.

15.

Drill 3/4-in (19-mm) diameter holes.

16.

Bolt the PC bottom panel insert (R002-A045) in place.

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.

Critical Note: Do not overtighten rubber insert or it will deform.

Critical Note: This plate is required.

Helpful Hint: Some holes may fit existing holes on the panel.

Helpful Hint: A MAG drill is recommended.

Production Notes

Prep

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 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).

3.

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.

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.

R-28PCM 28" (710mm) PC MIDDLE R-41PCM 41" (1030mm) PC MIDDLE

R-28PCM 28" (710mm) PC MIDDLE R-41PCM 41" (1030mm) PC MIDDLE

Cobble / Limestone

Cobble / Limestone

1520 lb (690 kg)

10.62 ft3 (0.301 m3)

1450 lb (660 kg)

10.12 ft3 (0.287 m3)

15.2 ft3 (0.43 m3) 2170 lb (990 kg)

14.2" (360

14.2" (360 mm)

13.6" (346 mm)

Cobble / Limestone 20.6" (522 mm)

lb (950 kg)

14.69 ft3 (0.42 m3)

(508 mm)

SHEAR KNOBS @ 23 (584) OC, TYP

SHEAR KNOBS @ 23 (584) OC, TYP

SHEAR KNOBS @ 23 (584) OC, TYP.

SHEAR KNOBS @ 23 (584) OC, TYP.

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.

VARIES

R-28PCB 28" (710mm) PC BOTTOM

R-28PCB 28" (710mm) PC BOTTOM

Face

Cobble / Limestone

11.34 ft3 (0.321 m3)

14.2" (362 mm)

Kingstone / Ledgestone Kingstone / Ledgestone Kingstone / Ledgestone

1620 lb (740 kg) 13.7" (349 mm) 10.85 ft3 (0.307 m3) 1550 lb (700 kg)

10.85 ft3 (0.307 m3) 1550 lb (700 kg)

13.7" (349 mm)

FACE TEXTURE VARIES

FACE TEXTURE VARIES

(1030mm) PC BOTTOM

R-41PCB 41" (1030mm) PC BOTTOM

/ Ledgestone

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.

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).

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.

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.

PARTS AND KIT NUMBERS FOR ORDERING

• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM

• R002-A173 (BOTTOM PC KIT)

R002-A050 R002-A043

R002-A053

R002-0130

R002-A051

IF PRESENT IN FORM

Form Assembly

Remove all existing inserts from the top panel in the standard retaining form. Leave the bottom groove former and fork slot attachments.

Mark holes on the panel with paint or marker.

Helpful Hint: Some holes may fit existing holes on the panel.

Helpful Hint: A MAG drill is recommended.

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.

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.

6. 7.

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.

Welds

Bolts

8.

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: Do not overtighten rubber insert or it will deform.

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.

9.

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.

10.

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.

11.

Replace 10 in (254 mm) knob formers.

12.

Center drill template #1 (R002-0359) on bottom panel.

13.

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.

14.

Mark holes on the panel with paint or marker.

15.

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.

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.

Critical Note: This plate is required.

18.

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.

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 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).

3.

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.

Demolding

1. 1. 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.

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

R-28PCT 28" (710mm) PC TOP

Kingstone / Ledgestone

R-41PCT 41" (1030mm) PC TOP

R-41PCT 41" (1030mm) PC TOP

Kingstone / Ledgestone

TOP

TOP BLOCK CENTER INSERT

COMPATIBLE OPTIONS (FL1)

Cobble / Limestone

Cobble / Limestone

1520 lb (690 kg)

1520 lb (690 kg)

10.62 ft3 (0.301 m3)

10.62 ft3 (0.301 m3)

14.2" (360 mm)

14.2" (360 mm)

Kingstone / Ledgestone

Kingstone

1450 lb (660 kg)

1450 lb (660 kg)

10.12 ft3 (0.287 m3)

10.12 ft3 (0.287 m3)

13.6" (346 mm)

13.6" (346 mm)

R-28PCB 28" (710mm) PC BOTTOM

NOTE:

FL1)

FL2)

Cobble

Cobble / Limestone

11.34 ft3 (0.321 m

14.2" (362 mm)

3) GRAY

FACE

ARE FOR

Cobble / Limestone

Cobble / Limestone

lb (950 kg)

20.6" (522 mm)

20.6" (522 mm)

15.2 ft3 (0.43 m3) 2170 lb (990 kg) 20.0" (508 mm)

Kingstone

IF

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.

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).

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.

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.

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)

Form Assembly

1.

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.

2.

Center drill template #2 (R002-0358) on the outside of the top block insert.

3.

Mark holes on insert with paint or marker.

4.

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.

8.

Cut a slot between the existing center solid loop holder holes.

9.

Place new rubber loop holder over new slotted hole. Mark the location of the two new side holes with a pencil.

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.

Note: Holes are offset towards the bottom of the Insert/front of block.

10.

Bolt Loop Holder #5 on the bottom of the top block insert.

11.

Use a forklift to place the modified top block insert into the form and bolt it in place.

12.

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.

13.

Center drill template #1 (R002-0359) on bottom panel.

14.

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.

15.

Mark holes on the panel with paint or marker.

16.

Drill 3/4-in (19-mm) diameter holes.

17.

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.

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.

Critical

Production Notes

Prep

1.

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

Pour 1. 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.

Block Volume:

Center of Gravity:

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-28M

R-1AT 1-AT MIDDLE 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.

• 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)

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)

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

Prep

1.

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

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

Legacy Geo 1 Insert

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.

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

R-AM ANCHOR MIDDLE

R-ST SHORT

PARTS AND

• RR 41IN STANDARD FORM, RR 41IN 9IN SETBACK FORM OR RR 41IN 3-WAY FORM

• R002-A180 (ANCHOR

Form Assembly

1.

41 in (1030

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-AB ANCHOR BOTTOM

Block

Cobble

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.

41 in (1030 mm)

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 Library

R-41HC 41" (1030mm) HOLLOW-CORE Face

R-41HC 41" (1030mm) HOLLOW-CORE

/ Limestone Kingstone / Ledgestone

Cobble / Limestone

lb (780 kg)

(558 mm)

SHEAR KNOBS @

/ Ledgestone

(540 mm)

FACE TEXTURE VARIES 4012(1029)±

STANDARD PARTS LIST

10" XL KNOB FORMER 2 R001-0386

PC - MOUNTING PLATE - TOP PANEL

Top Door Insert, 41" Retaining H.C. 1 R002-A068

Side Door Insert, 41" Retaining H C 2 R002-A073

Groove Former, 41" Retaining H C 1 R002-A074

Bottom Door Insert, 41" Retaining H.C. 1 R002-A081

LOOP HOLDER #5 NO-RECESS HOLDER 1 R002-A105

NOTES:

NOTES:

FL1)

Top

Top

Side

Side

Groove

Bottom Door Insert, 41" Retaining H C

Bottom Door Insert, 41" Retaining H C

LOOP

.5

.5-13

R002-A068 R002-A105 R002-0130

R002-A073

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

options must be selected seperately and are not included in this as

kit is configurable on Standard & Universal type retaining forms only

R001-0386

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.

3

**CRITICAL LENGTH FOR ASSEMBLY*

PROJECT:

DRAWN BY:

DRAWN

TITLE: 41IN HC - S

PART No :

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.

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.

6.

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.

7.

Fully weld PC plate (R002-0130) to top door as per locations indicated in red.

8.

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.

10.

Install 10 in XL knob former (R001-0386).

Critical Note: Install knobs properly as shown to prevent die-lock condition.

11.

After knobs are installed, secure the top insert (R002-A068) to the panel.

12.

Reinstall all existing carriage (plug) bolts to top panel except for holes indicated in picture.

13.

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.

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.

15.

Using center punch, mark six hole center locations given per template #3, then remove it from the bottom panel.

16.

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.

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.

20.

Using center punch, mark six hole center locations given per template #2, then remove it from the door panel.

21.

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.

22.

Place supplied side door insert (R002-A073) into side door panel and secure.

23.

Repeat steps 19 - 22 on other side panel.

•

STANDARD PARTS LIST

PC - MOUNTING PLATE - TOP PANEL

R002-0130 10" 3-WAY KNOB FORMER; HOLLOW CORE

Top Door Insert, 41" Retaining H.C.

Side Door Insert, 41" Retaining H C 2 R002-A073

Groover Former, 41" Retaining H.C.

Bottom Door Insert, 41" Retaining H C

LOOP HOLDER #5 NO-RECESS HOLDER

R002-A081

R002-A105

5-FW

5-13x1 5-CB

.5-13x1.5-HB

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

5 FLAT WASHER

.5-13 HEX NUT

5-13 x 1 5 CARRIAGE BOLT

.5-13 x 1.5 HEX BOLT

only

PROJECT:

DRAWN

FILE NAME:

TITLE: 41IN HC KIT

PART No : R002-A114

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.

5.

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.

6.

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.

8.

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.

9.

Place supplied top insert (R002-A068) with loop holder into door as shown. Do not secure insert to door at this step.

10.

Install the 10 in 3-way Knob Former (R002-0254).

Critical Note: Install knobs properly as shown to prevent die-lock condition.

11.

After the knobs are installed, secure the top insert to the top panel.

12.

Reinstall all existing carriage (plug) bolts to top panel except for holes indicated in picture.

13.

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.

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.

15.

Using center punch, mark six hole center locations given per template #3, then remove it from the bottom panel.

16.

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.

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.

20.

Using center punch, mark six hole center locations given per template #2, then remove it from the door panel.

21.

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.

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

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.

2.

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).

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

Overview

PLATE 1 2 R001-A029

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.

EJECTOR PLATE 2 2 R001-A030

EJECTOR PLATE 3 4 R001-A031

52" DOOR SEAL 1 1 R001-A047

52" DOOR SEAL 2 1 R001-A048

52" BOTTOM DOOR WELDMENT 1 R001-A137

52" TOP DOOR WELDMENT 1 R001-A138

52" TOP DOOR INSERT 1 R001-A149

BOTTOM DOOR INSERT 1 R001-A150

The Redi-Rock XL form is used to manufacture R-5236HC, R-7236HC, and R-9636HC.

GROOVE FORMER 1 R001-A151

52IN CAP 2 R001-A152

FACE MOLD CRADLE 1 R001-A157

DOOR SUPPORT CARRIAGE 2 R001-A160

EJECTOR SCREW WELDMENT 8 R001-A169

LEFT FLAP SEAL WELDMENT 2 R001-A158

RIGHT FLAP SEAL WELDMENT 2 R001-A162

6" V-GROOVE WHEEL 8 STD-0034

6" METAL WHEEL 4 STD-0035

ALLOY STEEL SHOULDER SCREW 8 STD-0103

5-13 HEX NUT 42 5-13-HN

5-13 x 1 5 HEX BOLT 36 5-13x1 5-HB

.5-13 x 2 HEX BOLT 8 .5-13x2-HB

R001-A137

52" TOP DOOR WELDMENT 1 R001-A138

52" TOP DOOR INSERT 1 R001-A149

BOTTOM DOOR INSERT 1 R001-A150

GROOVE FORMER 1 R001-A151

52IN CAP 2 R001-A152

FACE MOLD CRADLE 1 R001-A157

DOOR SUPPORT CARRIAGE 2 R001-A160

EJECTOR SCREW WELDMENT 8 R001-A169

LEFT FLAP SEAL WELDMENT 2 R001-A158

RIGHT FLAP SEAL WELDMENT 2 R001-A162

6" V-GROOVE WHEEL 8 STD-0034

6" METAL

A

5-13 x 4 HEX BOLT 12 5-13x4-HB

5 FLAT WASHER 86 5-FW

75-4 5-HN

75-4 5 HEX NUT 18

75-4 5 x 2 HEX BOLT 18 75-4 5x2-HB

3/8" HEX NUT 8 375-16-HN

FLAT WASHER 8 .375-FW

ALUMINUM BLIND RIVET 1/8" x 375"- 500" 8 125x 375- 500-BR

NOTES:

1) MUST CONFORM TO INSPECTION REQUIREMENTS PER QIS-R001-A000

REVISION HISTORY

PROJECT:

TITLE:

PART No :

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

Facility Size

• 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.

108

64

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.

Floor Flatness Foundation Strength

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.

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).

Release Agent

See page xxi in the Appendix for steel reinforcement specifications. 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.

1/2" Solid Loop Lifter

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

7/16" R Anchor

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

Overview

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.

4.

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.

5.

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.

Pour

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:

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.

3.

Fill form to desired block size.

4.

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.

Exposed Height: 3 in. (76.2 mm)

Edge Distance: 6 in. (152.4 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.

Helpful Hint: Binder clamps may need to be adjusted to ensure proper form closure.

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.

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.

Push doors to fully open position, then retract all ejector screws to pouring position (hand tight).

5.

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.

6.

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.

Storage

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

Maintenance, Tips & Tricks Maintenance

Flap Seals: Each door has a right and a left tapered flap seal. Make sure to select the correct part for replacement.

1.

Remove two 3/8-inch-16 thread nuts from the seal assembly clamped between the door and the carriage.

2.

On interior of carriage, remove face mold flap seal.

Replace old seal with new seal in same slots (tapered surface toward the center of the block).

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

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.

Unfasten shoulder bolt from the ejector pad. Set aside pad. 8.

Helpful Hint: If the Ejector Pad is not seated flush, shift plate vertically and/or horizontally as needed to achieve alignment.

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.

1.

Remove polyurethane seals from the alignment pins on the frame door segment(s).

2.

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.

NOTE: WHEELS INSTALLED WITH GREASE FITTING TOWARDS OUTSIDE OF FORM 2X

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.

6.

Insert and secure nut/bolt/washer in axle of caster.

7.

Use lifting device to remove carriage from stands and place back on frame.

8.

Reinstall two backstop nuts/bolts/washers on frame slots

Lift Hook Holder

In the rear hollow insert of the top door, remove two nuts and washers.

Remove rubber lift hook holder from bolts.

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.

3.

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.

4.

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

RETAINING BLOCKS

52 in (1320 mm) XL Hollow-Core blocks are used in various retaining wall applications.

Block Library

R-5236HC 52" (1320 mm) XL HOLLOW-CORE

R-5236HC 52" (1320

Face Texture: Ledgestone

Block Weight: 3330 lb (1510 kg)

Block

(0.660 m³) Center

(737 mm) Infill

158(41mm)±

158(41mm)±

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.

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.

4

B

• R001-A051 (FORM)

LEFT FLAP ASSEMBLY 2 R001-A008

EJECTOR PLATE 1 2 R001-A029

EJECTOR PLATE 2 2 R001-A030

EJECTOR PLATE 3 4 R001-A031

52" DOOR SEAL 1 1 R001-A047

PARTS AND KIT NUMBERS FOR ORDERING

52" DOOR SEAL 2 1 R001-A048

52" BOTTOM DOOR WELDMENT 1 R001-A137

52" TOP DOOR WELDMENT 1 R001-A138

NOTE: A 36 IN TALL RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

PARTS LIST

DESCRIPTION QTY PART NUMBER

REDI-ROCK NAMEPLATE 2 R001-0202

10" XL KNOB FORMER 2 R001-0386

PUSH PAD 8 R001-0554

RIGHT FLAP ASSEMBLY 2 R001-A007

LEFT FLAP ASSEMBLY 2 R001-A008

EJECTOR PLATE 1 2 R001-A029

EJECTOR PLATE 2 2 R001-A030

EJECTOR PLATE 3 4 R001-A031

52" DOOR SEAL 1 1 R001-A047

52" DOOR SEAL 2 1 R001-A048

52" BOTTOM DOOR WELDMENT 1 R001-A137

52" TOP DOOR WELDMENT 1 R001-A138

52" TOP DOOR INSERT 1 R001-A149

BOTTOM DOOR INSERT 1 R001-A150

GROOVE FORMER 1 R001-A151

52IN CAP 2 R001-A152

FACE MOLD CRADLE 1 R001-A157

DOOR SUPPORT CARRIAGE 2 R001-A160

3

EJECTOR SCREW WELDMENT 8 R001-A169

STD-0034

STD-0035 STD-0103

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

52" TOP DOOR INSERT 1 R001-A149

BOTTOM DOOR INSERT 1 R001-A150

3 4 A

125x 375- 500-B

NOTES:

1) MUST CONFO

ZONE REV

A

GROOVE FORMER 1 R001-A151

52IN CAP 2 R001-A152

FACE MOLD CRADLE 1 R001-A157

DOOR SUPPORT CARRIAGE 2 R001-A160

EJECTOR SCREW WELDMENT 8 R001-A169

6" V-GROOVE WHEEL 8 STD-0034

6" METAL WHEEL 4 STD-0035

ALLOY STEEL SHOULDER SCREW 8 STD-0103

.5-13 HEX NUT 42 .5-13-HN

5-13 x 1 5 HEX BOLT 36 5-13x1 5-HB

5-13 x 2 HEX BOLT 8 5-13x2-HB

.5-13 x 4 HEX BOLT 12 .5-13x4-HB

5 FLAT WASHER 86 5-FW

75-4 5 HEX NUT 18 75-4 5-HN

.75-4.5 x 2 HEX BOLT 18 .75-4.5x2-HB

3/8" HEX NUT 8 375-16-HN

FLAT WASHER 8 375-FW

NOTES:

2

ISTORY DATE APPROVED R001-0114 1-A049 -0039 22FEB2022 C NADOLSKY

PROJECT:

DRAWN BY:

DRAWN DATE:

T RUTHIG 10/13/2017 R001-A051 iam

FILE NAME:

TITLE: 52IN XL RETAINING FORM

PART No : R001-A051

2 2

1

Form Assembly

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.

Production Notes

Prep

1. 1.

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.

Hollow-Core

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 mm) XL HOLLOW-CORE

Face Texture:

Ledgestone

Block Weight: 4160 lb (1890 kg)

R-7236HC 72" (1830 mm) XL Hollow-Core

Block

Volume:

Gravity:

39.9" (1013 mm) Center

ft³ (1.028 m³)

0)±

noted otherwise. manufacturer.

FACE

461 8(1172)

905 8(2302) 96(2440)±

665 8(1692)

• R001-A051 (FORM)

• R001-A052 (72 IN EXTENSION)

NOTE: A 36 IN TALL RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE. PARTS LIST

72"

6

72"

72"

5-13

PARTS LIST DESCRIPTION QTY PART NUMBER 72" DOOR SEAL 1 1 R001-A069 6 FT DOOR SEAL 2 1 R001-A070 72" TOP DOOR WELDMENT 1 R001-A143 72" BOTTOM DOOR WELDMENT 1 R001-A144 72" INSERT 2 R001-A153 72" CAP WELDMENT 2 R001-A156 5-13 HEX NUT 18 5-13-HN 5 FLAT WASHER 18 5-FW 75-4 5 HEX NUT 14 75-4 5-HN 75-4 5 x 2 HEX BOLT 14 75-4 5x2-HB 8 .75-FW

.75-4.5x2-HB 75-FW 75-FW 75-4 5-HN

A

B REVISION HISTORY ZONE REV DESCRIPTION DATE APPROVED B FULLY REVISED 11JUN2021 C NADOLSKY

NOTE: GRAY COMPONENTS ARE SHOWN FOR REFERENCE ONLY

4 4

truth g 10/16/2017 R001-A052 iam R001-A156 5-FW 5-13-HN 5-FW .5-13-HN R001-A153 R001-A14 75-4 5x2-HB 75-4 5-HN

DRAWN BY:

DRAWN DATE:

3 3

TITLE: 72" DOOR EXTENSIONS

PART No : R001-A052

Form Assembly

1.

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.

4.

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.

10.

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.

11.

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.

Production Notes

Prep 1.

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.

158(41mm)±

96 in (2440 mm)

XL Block

158(41mm)±

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)

Infill Volume 54.63 ft³ (1.547 m³)

158(41mm)±

FACE

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)

NOTE: A 36 IN TALL RETAINING FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

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).

1.

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.

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.

Secure door segments with seven 3/4-in (19-mm) nuts and bolts on both the top and bottom door flange.

6.

Reassemble four ejector screw plate assemblies with two nuts/ washers per bracket.

7.

Install two nuts/washers to the studs at the rear of each door.

8.

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.

Form

• R001-A051 (FORM)

• R001-A052 (72 IN EXTENSION)

• R001-A053 (96 IN EXTENSION)

PARTS AND KIT NUMBERS FOR ORDERING

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.

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.

Lower the door segment while seating the flange pins.

4. 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 segment with seven 3/4-in (19-mm) nuts/bolts on the bottom door flange.

6.

Install two nuts/washers to the studs at the rear of each door.

7.

Repeat Steps 3-6 with the top door.

8.

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

Prep 1.

See page xxvii in the Appendix for 96-in (2440-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.

FREESTANDING FORMS

Freestanding Forms

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

Overview

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.

Product Data Sheets

Freestanding

Freestanding

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.

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 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.

46.125

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.

Helpful Hint: The rubber face mold should be free of debris before pouring blocks. Compressed air can be helpful if used safely.

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: 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.

3/8” Solid Loop Lifter

Manufactured by: American Step Company

https://www.americanstep.com/

830 East Broadway PO Box 137 Griffen, GA 30224-0137

Safety Notes: For Step 5

3/8” R Anchor

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.

A

Pour

1.

2 3 4 B

Fill forms to the specified depth to produce blocks that conform to published dimensions and tolerances.

2.

Finish the end of the block with a trowel, and place a recessed lifting insert to aid with demolding.

Pour concrete to here

TITLE: 18IN FACEM PART

No

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

Rubber/Polyurethane Mold Storage

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.

Worn 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.

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:

Face

Block

Cobble / Limestone

Cobble / Limestone

Block Weight:

/ Limestone Kingstone / Ledgestone Block

Volume:

1

8 ( 4 5 7 ) 461 8(1172) FACE TEXTURE VARIES KNOBS @ 23 (584) OC, TYP.

8 ( 4 5 7 ) 461 8(1172)

FACE

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.

Block Volume:

(610) ±

LEDGESTONE COBBLESTONE

23

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

• RR FS FORM

• R003-A071 (FLAT BASE)

• R003-A100 (FILLER PLATE)

PARTS AND KIT NUMBERS FOR ORDERING

• 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 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.

ORIENTATION

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 (RR-G-KF10-S) 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.

Variable Radius Middle Block

FREESTANDING BLOCKS

Block Library

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. F-VM

COMPATIBLE OPTIONS (FL1)

RECESS OPTIONAL OPTIONAL

12

Kingstone / Ledgestone Kingstone / Ledgestone Kingstone / Ledgestone Kingstone / Ledgestone

24

Notes: FL1) COMPATIBLE OPTIONS MUST BE SELECTED SEPARATELY AND ARE NOT INCLUDED IN THIS AS 2) GRAY COMPONENTS FOR REFERENCE ONLY

RECESS

RECESS OPTIONAL

18 (457)

1.

3.

FACE

461

13(330)

• RR FS FORM

• R003-A071 (FLAT BASE)

• R003-A100 (FILLER PLATE)

PARTS AND KIT NUMBERS FOR ORDERING

• 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-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 TEXTURE.

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.

Freestanding

Straight Bottom Block

FACE TEXTURE VARIES

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

Face Texture:

Face Texture:

Cobble / Limestone

F-ST STRAIGHT

Cobble / Limestone Kingstone / Ledgestone

Face Texture:

13(330)

24

Block Weight: 1520 lb (690 kg) 1380 lb (630 kg) Block

Cobble / Limestone

Block Weight:

Block Volume:

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.

Block Weight:

Block Volume:

(0.273 m³)

24 (610) ±

5. (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)

• TWO R002-A104 (10IN KNOB FORMERS)

• TWO LOOP HOLDERS (ONE FOR

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 TEXTURE.

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.

KNOBS @ 23 (584) OC, TYP.

RECESS OPTIONAL

Freestanding

18 (457)

13(330)

10(254)

Variable Radius Bottom Block

461 8(1172)

FACE TEXTURE VARIES

18 (457) 461 8(1172)

Freestanding Variable Radius Bottom blocks are used at the bottom of freestanding walls with curves.

F-VB VARIABLE RADIUS BOTTOM

Face Texture:

7 1 2 (190)

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

1380 lb (630 kg)

FACE TEXTURE VARIES

Cobble / Limestone Kingstone / Ledgestone Block

lb (630 kg)

KNOBS @ 23 (584) OC, TYP.

18 (457)

Cobble / Limestone

1240 lb (560 kg)

9.65 ft3 (0.273 m3)

13(330)

F-VB VARIABLE RADIUS BOTTOM F-VT VARIABLE RADIUS TOP

1380 lb (630 kg) 8.66 ft3 (0.245 m3)

461 8(1172)

FACE TEXTURE VARIES

10 (254) DIAMETER x 4 (102) HIGH, TYPICAL. 6 (152) DIAMETER KNOBS AVAILABLE.

RECESS OPTIONAL OPTIONAL GROOVE EXTENTION RECESS OPTIONAL

Cobble / Limestone

1240 lb (560 kg)

8.63 ft3 (0.244 m3)

18 (457)

FACE TEXTURE VARIES

FACE TEXTURE VARIES 13(330)

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. Variable radius feature can be cast on only one end, coordinate.

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

Kingstone / Ledgestone

1090 lb (500 kg)

7.64 ft3 (0.216 m3)

461 8(1172)

FACE TEXTURE VARIES

LIFTING INSERT OR TEXTURED TOP SURFACE, OPTIONAL

13(330)

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 mm) diameter by 4" (102 mm) tall. Smaller knobs are available.

• 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

NOTE: TWO 18IN FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

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

Freestanding

Straight Top Block

13(330)

24 (610) ±

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.

FACE TEXTURE VARIES

F-ST STRAIGHT TOP

F-ST STRAIGHT TOP

Cobble / Limestone

1380 lb (620 kg)

9.61

LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

/ Limestone

(620 kg)

Kingstone / Ledgestone

1230 lb (560 kg)

24 (610) ±

LEDGESTONE

COBBLESTONE

23 (584) ± LIMESTONE

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.

/ Ledgestone

• 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

NOTE:

PROJECT:

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.

COMPATIBLE

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.

13(330)

10(254)

18 (457)

FACE TEXTURE VARIES

(610) ± LEDGESTONE COBBLESTONE (584) ± LIMESTONE

BOTTOM

Kingstone / Ledgestone

(0.245 m3) (560 kg)

DIAMETER x TYPICAL. 6 (152) KNOBS AVAILABLE.

FACE TEXTURE VARIES

(610) ± LEDGESTONE COBBLESTONE (584) ± LIMESTONE

RECESS OPTIONAL

7 1 2 (190)

Variable Radius Top Block

OPTIONAL GROOVE EXTENTION

461 8(1172)

FACE TEXTURE VARIES

13(330)

FACE TEXTURE VARIES

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.

F-VT VARIABLE RADIUS TOP

F-VT VARIABLE RADIUS

Cobble / Limestone

lb (560 kg)

24 (610) ± LEDGESTONE COBBLESTONE 23 (584) ± LIMESTONE

Cobble / Limestone Kingstone / Ledgestone

Kingstone / Ledgestone

1090 lb (500 kg)

7.64 ft3 (0.216 m3)

RECESS OPTIONAL

LIFTING INSERT OR TEXTURED TOP SURFACE, OPTIONAL

18 (457)

OPTIONAL GROOVE EXTENTION

461 8(1172)

FACE TEXTURE VARIES

4.

5.

13(330)

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

PARTS AND KIT NUMBERS FOR ORDERING

• 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

NOTE: TWO 18IN FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK;

VARY

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.

F-CM CORNER MIDDLE

F-CM CORNER MIDDLE

Cobble / Limestone Kingstone / Ledgestone

1360 lb (620 kg)

F-CG CORNER GARDEN TOP

Cobble / Limestone Kingstone / Ledgestone

1070 lb (480 kg)

7.5 ft3 (0.21m3)

13(330)

CORNER BLOCKS TEXTURED ON THREE FACES

18

461

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

F-CB CORNER BOTTOM

Cobble / Limestone Kingstone / Ledgestone

10(254)

18 (457)

461 8(1172)

FACE TEXTURE VARIES

1060 lb (480 kg)

7.4 ft3 (0.21m3)

13(330)

7 1 2 (190)

KNOBS @ 23 (584) OC, TYP.

10 (254) DIAMETER x 4 (101) HIGH, TYPICAL. 6 (152) DIAMETER KNOBS AVAILABLE.

F-CT CORNER TOP

18 (457)

18 (457)

FACE TEXTURE VARIES

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE 23 (584) ± LIMESTONE

4.

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

Cobble / Limestone Kingstone / Ledgestone

lb (600 kg)

(0.26m3)

LIFTING INSERT OR TEXTURED TOP SURFACE, OPTIONAL

461 8(1172)

FACE TEXTURE VARIES

13(330)

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

• RR FS FORM

• R003-A101 (FS GROOVE FORMER 40IN STANDARD)

• 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: ONE FREESTANDING CORNER FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

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.

Freestanding

9 (229)

9 (229)

90 Degree Corner Block

461 8(1172)

FACE TEXTURE VARIES

13(330)

FACE TEXTURE VARIES

461 8(1172)

13(330)

FACE TEXTURE VARIES

F-90C 90 DEGREE CORNER

24 (610) ± LEDGESTONE COBBLESTONE

FACE TEXTURE VARIES

Freestanding 90 Degree Corner blocks are used for turning outside 90 degree corners in retaining wall applications.

Face Texture: Cobble / Limestone Kingstone / Ledgestone

Block Weight:

F-90C 90 DEGREE CORNER

1330 lb (600 kg) 1320 lb (600 kg)

Block Volume: 9.3 ft³ (0.26 m³) 9.2 ft³ (0.26 m³)

Face Texture:

Block Weight:

Block Volume:

9.3 ft3 (0.26m3)

4x6x2 (102x152x51)

OVAL KNOBS @ 23 (584) OC, TYP.

ft3 (0.26m3)

13 (330) WIDE GROOVE NEAR END OF BLOCK

OPTIONAL 6 (152) DIAMETER KNOB IN LIEU OF OVAL KNOB THIS LOCATION

18 (457)

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

461 8(1172)

FACE TEXTURE VARIES

TOP BLOCK HAS NO SHEAR KNOBS AND A TEXTURED TOP SURFACE.

13(330)

CORNER BLOCKS TEXTURED ON THREE FACES

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 ).

PARTS LIST DESCRIPTION QTY PART NUMBER 10" KNOB FORMER 2 RR-G-KF10-S 4"x6"x2" KNOB INSERT 2 R003-A144 Outside Corner Groove Former 13" 1 R003-A122 3 3 4 4 A B PROPR ET THE NFORMAT THE SOLE PROP ANY REPRO W THOUT PRIO NTER 90 DEG CORNER PART NUMBER R002-A108 R002-A155

• RR FS FORM

• R003-A122 (FS 13IN GROOVE FORMER)

R003-A084

• TWO R002-A104 (10IN KNOB FORMERS)

• TWO R003-A144 (4X6 OVAL KNOB INSERTS)

HALF CORNER FACE MOLD R002-A085

• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE

R003-A066 CORNER MOLD ASSEMBLY NOTE: ONE FREESTANDING CORNER FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

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-A144) into the 10-in (254-mm) knob formers (RR-G-KF10-S), then install the knob formers in the form.

Critical

Production Notes

Pour 1.

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

Tips

1.

Freestanding 90 Degree Corner Blocks are used in retaining wall applications with a 90 degree outside corner.

Freestanding

18 (457)

Corner Bottom Block

461 8(1172)

FACE TEXTURE VARIES

F-CB CORNER BOTTOM

Face Texture:

F-CB CORNER BOTTOM

KNOBS @ 23 (584) OC, TYP.

18 (457)

461 8(1172)

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

18 (457) 461 8(1172)

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.

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ±

Cobble / Limestone Kingstone / Ledgestone

lb (680 kg) 1480 lb (670 kg)

F-CT CORNER TOP

Cobble / Limestone Kingstone / Ledgestone Cobble / Limestone Kingstone / Ledgestone

1490 lb (680 kg)

CORNER BLOCKS TEXTURED ON THREE FACES 10.4 ft3 (0.30m3)

1480 lb (670 kg)

ft3 (0.29m3)

ft3 (0.26m3) 1340 lb (610 kg)

FACE TEXTURE VARIES

10 (254) DIAMETER x 4 (101) HIGH, TYPICAL. 6 (152) DIAMETER KNOBS AVAILABLE.

18 (457)

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.

FACE TEXTURE VARIES

4. Actual block volumes and weights may vary.

1330 lb (600 kg)

ft3 (0.26m3)

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.

• 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

PROJECT:

DRAWN BY:

TITLE: FREESTANDING FORM: BASE PART No : R003-M001

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.

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.

13(330)

Freestanding

18 (457)

7 1 2 (190) 10(254)

Corner Top Block

461 8(1172)

FACE TEXTURE VARIES

13(330)

FACE TEXTURE VARIES

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.

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

F-CT CORNER TOP

F-CT CORNER TOP

1330 lb (600 kg) Kingstone

(0.29m3) (670

Cobble / Limestone Kingstone / Ledgestone

1340 lb (610 kg)

9.4 ft3 (0.26m3)

9.3 ft3 (0.26m3)

18 (457)

4.

5.

461 8(1172)

FACE TEXTURE VARIES

LIFTING INSERT OR TEXTURED TOP SURFACE, OPTIONAL

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

• 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

NOTE: ONE FREESTANDING CORNER FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

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.

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.

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. F-HCM

Face

Block Weight:

Face Texture: Block Weight:

Block Volume:

23 (584) ± LIMESTONE

Face

Form Assembly Option 1 - Freestanding Form

PARTS AND KIT NUMBERS FOR ORDERING

• RR FS FORM

• 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

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.

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 (RR-GKF10-S), 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. Side

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

• 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

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.

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 (RR-GKF10-S), 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.

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)

A

NOTE: ONE FREESTANDING HALF CORNER FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

1.

HALF CORNER MIDDLE - OPT 3

1 1 2 2 3 3 4 4 A A B B TITLE: SHEET: FREESTANDING HALF CORNER FACE MOLD PART No : R003-A084 1 OF 1 SIZE: B REV: C SCALE: 1 / 11 PROPR ETARY AND CONF DENT AL THE NFORMAT ON CONTA NED N TH S DRAW NG S THE SOLE PROPERTY OF RED -ROCK NTERNAT ONAL ANY REPRODUCT ON N PART OR N WHOLE W THOUT PR OR WR TTEN CONSENT OF RED -ROCK NTERNAT ONAL S PROH B TED 2940 Parkview Drive Petoskey MI 49770 info@asterbrands com Te : +1 866 222 8400 X ± 0 063 XX ± 0 032 XXX ± 0 015 Part Tolerance: UOS X ± 1 XX ± 0 5 XXX ± 0 1 Weldment Tolerance: UOS We d Leng h: X ± 0 125 Weld S ze: XX ± 0 063 Pa ts Assembly: XXX ± 0 015 CTQ Critica To Qua ity UOS = Unless Otherwise Spec f ed Un ts in Inches unless otherw se specified R003-A084 HALF CORNER FACE MOLD R003-A086 9" CORNER FACE MOLD D R003-A066 CORNER MOLD ASSEMBLY PARTS LIST DESCRIPTION QTY PART NUMBER 10 KNOB FORMER 1 RR-G-KF10-S 40 GROOVE FORMER 1 R003-A047 HALF PANEL DOOR 1 R003-A107 1 2 3 3 4 4 A A B B 1 SOUTH M 49720 00 Phone 521 Fax ock com 9 PROPRIETARY AND C H SOLE PROPERT O RED -R O C O W THOUT PR OR WR TT N CON O S HALF CORNER MIDDLE - OPT 3 COMPATIBLE OPTIONS PART NUMBER QTY DESCRIPTION R002-A110 A/R LOOP HOLDER #2 R002-A152 A/R LOOP HOLDER #6 LOOP HOLDER R003-A047 R RR-G-KF10-S PARTS LIST DESCRIPTION QTY PART NUMBER 10" KNOB FORMER 1 KF10-S 40" GROOVE FORMER 1 A047 HALF PANEL DOOR 1 A107 1 1 2 2 3 3 4 4 05481 US 31 SOUTH CHARLEVOIX M 49720 (866) 222-8400 Phone (231) 237-9521 Fax www red -rock com PROJECT: TITLE: SHEET: FREESTANDING FORM: BASE FORM PART No : R003-M001 7 OF 19 SIZE: B REV: A DRAWN BY: DRAWN DATE: FILE NAME: gheinz 8/10/2018 R003-M001 iam SCALE: 1 /11 PROPRIETARY AND CONFIDENTIAL THE NFORMAT ON CONTA NED N TH S DRAW NG S THE SOLE PROPERTY OF RED -ROCK NTERNAT ONAL ANY REPRODUCTION N PART OR N WHOLE W THOUT PRIOR WR TTEN CONSENT OF RED -ROCK NTERNAT ONAL S PROHIB TED

2.

4 4

PARTS 2 2

COMPATIBLE OPTIONS PART NUMBER QTY DESCRIPTION R002-A110 A/R LOOP HOLDER #2 R002-A152 A/R LOOP HOLDER #6 LOO

If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.

RR-G-KF10

B PROJECT: TITLE: FREESTANDING FORM: BASE PART No : R003-M001

DRAWN BY: DRAWN DATE: FILE NAME:

gheinz 8/10/2018 R003-M001 iam PROPRIETARY AND CONFIDENTIAL THE NFORMAT ON CONTA NED N THIS DRAW NG S THE SOLE PROPERTY OF REDI-ROCK INTERNATIONAL ANY REPRODUCTION N PART OR N WHOLE W THOUT PR OR WR TTEN CONSENT OF REDI-ROCK INTERNATIONAL S PROHIBITED HALF CORNER MIDDLE - OPT 3

3 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).

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 (RR-GKF10-S), 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.

Freestanding

FACE TEXTURE VARIES

13(330)

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

Face Texture:

Cobble / Limestone Kingstone / Ledgestone

F-HCT HALF CORNER

Face Texture:

Cobble /

F-HCB HALF CORNER BOTTOM

Block Weight:

Block Volume:

Block Weight:

Block Volume:

Face Texture: Cobble / Limestone Kingstone / Ledgestone

Block Weight: 710 lb (320 kg) 700 lb (320 kg)

10 (254) DIAMETER x 4 (101) HIGH KNOB, TYPICAL. 6 (152) DIAMETER KNOB AVAILABLE.

18 (457)

231 16(586)

FACE TEXTURE VARIES

13(330)

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.

18 (457)

640 lb (290

4.5 ft3 (0.13m

231 16(586)

FACE TEXTURE VARIES

4. Actual block volumes and weights

5. Weights are based upon a concrete

6. Knobs are typically 10" (254mm) Smaller knobs are available.

A

Form Assembly Option 1 - Freestanding Form

• RR FS FORM

• R002-A104 (10IN KNOB FORMER)

1.

4 4

2.

PARTS AND KIT NUMBERS FOR ORDERING 2 2

RR-G-KF10-S

DRAWN BY: DRAWN DATE: FILE NAME:

3 3

COMPATIBLE OPTIONS PART NUMBER QTY DESCRIPTION R002-A110 A/R LOOP HOLDER #2 R002-A152 A/R LOOP HOLDER #6 LOOP

B PROJECT: TITLE: FREESTANDING FORM: BASE PART No : R003-M001

gheinz 8/10/2018 R003-M001 iam PROPRIETARY AND CONFIDENTIAL THE NFORMAT ON CONTA NED N THIS DRAW NG S THE SOLE PROPERTY OF REDI-ROCK INTERNATIONAL ANY REPRODUCTION N PART OR N WHOLE W THOUT PR OR WR TTEN CONSENT OF REDI-ROCK INTERNATIONAL S PROHIBITED HALF CORNER BOTTOM - OPT 1

form, it needs

S LIST DESCRIPTION Y 10" KNOB FORMER 1 1 2 2 3 3 05481 US 3 CHARLEVOIX (866) 222-84 (231) 237-9 www redi-r PROJECT: TITLE: SHEET: FREESTANDING FORM: BASE FORM PART No : R003-M001 8 OF 19 SIZE: B REV: A DRAWN BY: DRAWN DATE: FILE NAME: gheinz 8/10/2018 R003-M001 iam SCALE: 1 / 11 PROPRIETARY AND CONFIDENTIAL THE INFORMAT ON CONTA NED N TH S DRAW NG IS THE SOLE PROPERTY OF RED -ROCK NTERNAT ONAL ANY REPRODUCTION N PART OR N WHOLE WITHOUT PRIOR WR TTEN CONSENT OF REDI-ROCK INTERNATIONAL IS PROHIB TED HALF CORNER BOTTOM - OPT 1 COMPATIBLE OPTIONS PART NUMBER QTY DESCRIPTION R002-A110 A/R LOOP HOLDER #2 R002-A152 A/R LOOP HOLDER #6 LOOP HOLDER RR-G-KF10-S PARTS LIST DESCRIPTION QTY T NUMBER 10" KNOB FORMER 1 -S 1 1 2 2 3 3 4 4 A 05481 US 31 SOUTH CHARLEVO X M 49720 (866) 222-8400 Phone (231 237-9521 Fax www redi-rock com PROJECT TITLE: SHEET: FREESTANDING FORM: BASE FORM PART No : R003-M001 8 OF 19 SIZE: B REV: A DRAWN BY: DRAWN DATE: FILE NAME ghe nz 8/10 2018 R003-M001 am SCALE: 1 / 11 PROPR ETARY AND CONFIDENT AL THE NFORMAT ON CONTA NED N TH S DRAW NG S THE SOLE PROPERTY OF RED -ROCK NTERNAT ONAL ANY REPRODUCT ON N PART OR N WHOLE W THOUT PR OR WR TTEN CONSENT OF RED -ROCK NTERNAT ONA S PROH B TED HALF CORNER BOTTOM - OPT 1 COMPATIBLE OPTIONS PART NUMBER QTY DESCRIPTION R002-A110 A/R LOOP HOLDER #2 R002-A152 A/R LOOP HOLDER #6 LOOP HOLDER RR-G-KF10-S Continued 1 1 2 2 3 3 4 4 A A B B TITLE: SHEET: FREESTANDING HALF CORNER FACE MOLD PART No : R003-A084 1 OF 1 SIZE: B REV: C SCALE: 1 / 11 PROPR ETARY AND CONF DENT AL THE NFORMAT ON CONTA NED N TH S DRAW NG S THE SOLE PROPERTY OF RED -ROCK NTERNAT ONAL O UC O O WHOLE W THOUT PR OR WR TTEN CONSENT OF RED -ROCK NTERNAT ONAL S PROH B TED 2940 Parkview Drive Petoskey MI 49770 info@asterbrands com Te : +1 866 222 8400 X ± 0 063 XX ± 0 032 XXX ± 0 015 Part Tolerance: UOS X° ± 1° XX ± 0 5 XXX ± 0 1 Weldment Tolerance: UOS We d Leng h: X ± 0 125 Weld S ze: XX ± 0 063 Pa ts Assembly: XXX ± 0 015 CTQ Critica To Qua ity UOS = Unless Otherwise Spec f ed Un ts in Inches unless otherw se specified R003-A084 HALF CORNER FACE MOLD R003-A086 9" CORNER FACE MOLD R002-A085 18IN FACEMOLD NO BATTER R002-A085 18IN FACEMOLD BATTER R003-A066 CORNER MOLD ASSEMBLY

3.

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 (RR-GKF10-S), 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. Side View

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)

PARTS AND KIT NUMBERS FOR ORDERING

• 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.

If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.

If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.

3.

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 (RR-GKF10-S), 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 Mold

Half Corner Mold

Side View

Form Assembly Option 3 - Half Door

• RR FS FORM

• R003-A107 (FS HALF PANEL)

• R002-A104 (10IN KNOB FORMER)

PARTS AND KIT NUMBERS FOR ORDERING

• 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.

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.

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 (RR-GKF10-S), 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.

24 (610) ± LEDGESTONE

COBBLESTONE

23 (584) ± LIMESTONE

Freestanding

231 16(586)

FACE TEXTURE VARIES

13(330)

Half Corner Top Block

BOTTOM F-HCT HALF CORNER TOP

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.

Kingstone / Ledgestone Cobble / Limestone Kingstone / Ledgestone

700 lb (320 kg)

4.9 ft3 (0.14m3)

Face Texture:

Block Weight:

640 lb (290 kg)

F-HCT HALF CORNER TOP

Block Volume:

4.5 ft3 (0.13m3)

4.4 ft3 (0.13m3) 630 lb (290 kg)

Face Texture: Cobble / Limestone Kingstone / Ledgestone

Block Weight:

Block Volume:

DIAMETER x 4 (101) HIGH TYPICAL. 6 (152) DIAMETER AVAILABLE.

640 lb (290 kg) 630 lb (290 kg)

ft³ (0.13 m³)

ft³ (0.13 m³)

LIFTING INSERT OR TEXTURED TOP SURFACE, OPTIONAL

(330)

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

Half Corner Top Block

typical unless noted otherwise. Redi-Rock manufacturer. Ordering. varying texture.

18 (457) 231 16(586)

FACE TEXTURE VARIES

13(330)

4. Actual block volumes and weights may vary.

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

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

PARTS AND KIT NUMBERS FOR ORDERING

• 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.

If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.

2.

HALF

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. Side View

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.

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.

A

Form Assembly Option 2 - Half Freestanding Form

• R003-A091 HALF FS FORM

• R002-A104 (10IN KNOB FORMER)

1.

4 4

PARTS AND KIT NUMBERS FOR ORDERING 2 2

3 3

R002-A095

PROPRIETARY AND CONFIDENTIAL THE NFORMAT ON CONTA NED N THIS DRAW NG S THE SOLE PROPERTY OF REDI-ROCK INTERNATIONAL ANY REPRODUCTION N PART OR N WHOLE W THOUT PR OR WR TTEN CONSENT OF REDI-ROCK INTERNATIONAL S PROHIBITED

is installed in the base of the form, it needs to be removed.

If the filler plates (R003-A100) are installed in the top and bottom panels, they will need to be removed.

TS LIST DESCRIPTION QTY HALF GROOVE FORMER 1 KNOB COVER 1 1 1 2 2 3 3 TITLE: S HALF FREESTANDING FORM PART No : R003-M002 3 S B REV: A SCALE: 1 / 11 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTA NED N THIS DRAWING S THE SOLE PROPERTY OF REDI-ROCK INTERNATIONAL ANY REPRODUCTION IN PART OR IN WHOLE W THOUT PR OR WRITTEN CONSENT OF RED -ROCK INTERNATIONAL IS PROHIBITED 2940 Peto info@ Tel: + HALF CORNER TOP - OPT 2 R002-A095 R003-A094 PARTS LIST DESCRIPTION QTY PART NUMBER HALF GROOVE FORMER 1 R003-A094 KNOB COVER 1 2 2 3 3 4 4 A TITLE: HALF FREESTANDING FORM PART No : R003-M002 REV: A S 1 PROPRIETARY AND CONF DENTIAL THE NFORMAT ON CONTA NED N TH S DRAW NG IS THE SOLE PROPERTY OF RED -ROCK NTERNAT ONAL ANY REPRODUCTION N PART OR N WHOLE W THOUT PR OR WR TTEN CONSENT OF RED -ROCK NTERNAT ONAL S PROH B TED HALF CORNER TOPR002-A095 R003-A094 Continued 1 1 2 2 3 3 4 4 A A B B TITLE: SHEET: FREESTANDING HALF CORNER FACE MOLD PART No : R003-A084 1 OF 1 SIZE: B REV: C SCALE: 1 / 11 PROPR ETARY AND CONF DENT AL THE NFORMAT ON CONTA NED N TH S DRAW NG S THE SOLE PROPERTY OF RED -ROCK NTERNAT ONAL ANY REPRODUCT ON N PART OR N WHOLE W THOUT PR OR WR TTEN CONSENT OF RED -ROCK NTERNAT ONAL S PROH B TED 2940 Parkview Drive Petoskey, MI 49770 info@asterbrands com Te : +1 866 222 8400 X = ± 0 063 XX ± 0 032 XXX ± 0 015 Part Tolerance: UOS X° = ± 1° XX° ± 0 5° XXX° ± 0 1° Weldment Tolerance: UOS We d Leng h: X ± 0 125 Weld S ze: XX ± 0 063 Pa ts Assembly: XXX ± 0 015 CTQ = Critica To Qua ity UOS Unless Otherwise Spec f ed Un ts in Inches unless otherw se specified R003-A084 HALF CORNER FACE MOLD R003-A086 9 CORNER FACE MOLD R002-A085 18IN FACEMOLD NO BATTER R002-A085 18IN FACEMOLD BATTER R003-A066 CORNER MOLD ASSEMBLY

B TITLE: HALF FREESTANDING FORM PART No : R003-M002

HALF CORNE

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.

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)

PARTS R003-A

1.

If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.

HALF 002-A095

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.

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.

Straight Garden Top Block

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

Cobble / Limestone

COMPATIBLE OPTIONS

FACE

Cobble

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)

PARTS AND KIT NUMBERS FOR ORDERING

• R003-A101 FS GROOVE FORMER 40IN STANDARD OR R003-A102

FS FULL GROOVE FORMER 46IN

• R003-A105 (GARDEN INSERT)

• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE

NOTE:

TO PRODUCE THIS

2)

FL3)

4)

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.

END

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. F-VG

Cobble / Limestone

Ledgestone

10(254)

GROOVE EXTENTION

Cobble / Limestone

Kingstone / Ledgestone

Notes:

PARTS LIST DESCRIPTION QTY PART NUMBER 4"x12" End Insert For Garden Block - Top Config 1 R003-A051 4"x12" End Inserts for Garden Block- Bottom Con 1 R003-A092 3 3 4 4 A B REVISION HISTORY REV ECO NUMBER DESCRIPTION DATE APPROVED A NA INITIAL REVIEW 12/09/2021 L RADOY

OPTIONAL OPTIONAL

18

GROOVE EXTENTION

461

24

• RR FS FORM

• R003-A071 (FLAT BASE)

• R003-A100 (FILLER PLATE)

• R003-A092 (BOTTOM VARIABLE RADIUS GARDEN INSERT)

• R003-A051 (TOP VARIABLE RADIUS GARDEN INSERT)

• 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

NOTE:

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.

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.

2.

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).

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.

3.

Install the loop holder into the garden insert.

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

PARTS

R003-A021

Garden Insert Extension 1 R003-A020

.5-13-HN

Corner Garden Top Block

R003-0377

.5-13x1.5-CB

R003-A071

R003-A100

R003-A101

F-CG CORNER GARDEN TOP

.5-13 HEX NUT

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

F-CG CORNER GARDEN TOP

Cobble / Limestone Kingstone / Ledgestone

FREESTANDING FLAT BASE 1

FILLER PLATE 2

Freestanding 40 IN Groove Former 1

COMPATIBLE OPTIONS

BLOCKS

10(254)

13(330)

13(330)

24

FACE

Ledgestone

F-CT CORNER TOP

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

Cobble / Limestone Kingstone / Ledgestone

REVISION HISTORY

Radoy

18

24

• RR FS FORM

PARTS AND KIT NUMBERS FOR ORDERING

• R003-A101 (FS GROOVE FORMER 40IN STANDARD)

• R003-A105 (GARDEN INSERT WITHOUT EXTENSION)

• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE

TEXTURE.

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).

Compatible Option R002-A105 Setups (Loop Holder Type #5)

Helpful Hint: When creating the Freestanding Garden Top block, the loop holder should be installed according to the drawings below.

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.

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.

Freestanding

Half Corner Garden Top Block

CORNER MIDDLE

Limestone Kingstone / Ledgestone

3) kg)

F-HCG HALF CORNER GARDEN TOP

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.

650 lb (300 kg)

4.6 ft3 (0.13m3)

13(330)

Face Texture:

Block Weight:

Cobble / Limestone Kingstone / Ledgestone

F-HCG HALF CORNER GARDEN TOP

Face

CORNER BLOCKS TEXTURED ON THREE FACES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

Limestone Kingstone / Ledgestone

Block Volume:

13(330)

10(254)

18 (457)

231

16(586)

FACE TEXTURE VARIES

Face Texture:

Block Weight:

Block Volume:

13(330)

7 1 2 (190)

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

(254)

x 4 (101) HIGH

18 (457)

13(330)

24 (610) ±

23 (584) ±

Cobble / Limestone Kingstone / Ledgestone

231

16(586)

FACE TEXTURE VARIES

13(330)

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ±

Form Assembly Option 1 - Freestanding Form

PARTS AND KIT NUMBERS FOR ORDERING

• RR FS FORM

• 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 TOP OF BLOCK 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.

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.

Setups

3.

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).

Compatible

Loop

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.

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 Garden Top Block

Form Assembly Option 2 - Half Freestanding Form

PARTS AND KIT

• 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

NOTE: ONE FREESTANDING HALF CORNER FACE MOLD IS NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

If the flat base (R003-A071) is installed in the base of the form, it needs to be removed.

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.

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.

Helpful Hint: Make sure the two pieces of the garden insert are not bolted together and only the larger portion (R003-A099) is installed.

6.

If the half groove former (R003-A094) 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.

Half Corner Mold

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

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.

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.

6.

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.

Freestanding

B

2 R003-A044

2 R003-A046

LIFTEYE FORMER - 6 IN VERT TUBE

CONDUIT RETAINER - 3 IN HORIZ CONDUIT

SPLITTER 1 R003-A041

L ROD 1 R003-0107 FILLER BAR

Force Protection Middle Block

FREESTANDING BLOCKS

Block Library

.5-13 HEX NUT

.5 FLAT WASHER

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

F-FM FORCE PROTECTION MIDDLE

F-FM FORCE PROTECTION MIDDLE

R002-A108 A/R LOOP HOLDER TYPE #1 R002-A155 A/R

F-FT FORCE PROTECTION TOP

FORMER TYPE #1

Kingstone / Ledgestone Kingstone / Ledgestone

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

A

F-FB FORCE PROTECTION BOTTOM

1460 lb (660 kg)

10.23 ft3 (0.290 m3)

KNOBS @ 23 (584) OC, TYP.

FACE TEXTURE VARIES

Kingstone / Ledgestone

Notes

1320 lb (600 kg)

9.23 ft3 (0.261 m3)

.5-FW 4

(530

9.19 ft3 (0.260 m3) 1310 lb (600 kg) 8.19 ft3 (0.232 m3)

LIFTING INSERT OR TEXTURED

TEXTURE

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

10 (254) DIAMETER x 4 (102) HIGH, TYPICAL. 6 (152) DIAMETER KNOBS AVAILABLE.

3 (76) DIAMETER

HORIZONTAL VOID FULL LENGTH OF BLOCK, TYP.

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

A Initial Release 9/8/2021 G HEINZ

• RR FS FORM

• R003-A071 (FLAT BASE)

• R003-A100 (FILLER PLATE)

PARTS AND KIT NUMBERS FOR ORDERING

PARTS LIST

TOP INSERT 2 R003-A039

BOTTOM INSERT 2 R003-A042

• 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)

LIFTEYE FORMER - 6 IN VERT TUBE

CONDUIT RETAINER - 3 IN HORIZ CONDUIT 2 R003-A046

SPLITTER 1 R003-A041

L ROD 1 R003-0107

FILLER

• TWO LOOP HOLDERS (ONE FOR TOP OF BLOCK AND ONE FOR END OF BLOCK); PART NUMBERS VARY BY HOOK STYLE

LIFTEYE

R003-A039

COMPATIBLE OPTIONS (FL2)

NOTE: TWO 18IN FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

ZONE REV

REVISION HISTORY

CT:

N BY:

N DATE:

gabby heinz 8/27/2021 R003-A108 iam

AME:

E: Force Protection Kit

T No : R003-A108

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 (RR-G-KF10-S) 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.

2.

Install the force protection hook or engineer-specified reinforcement into the bottom lifteye former (R003-A044) before closing the form.

Critical Note: Be sure to apply release agent on the top portion of the force protection kit before installing it on 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.

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.

Freestanding

6 (152) DIAMETER x 18 (457) TALL RECESS EACH END

CAST-IN #4 (#13) REBAR HOOK EACH END

461 8(1172)

Force Protection Bottom Block

24 (610) ± LEDGESTONE COBBLESTONE

23 (584) ± LIMESTONE

13(330)

FACE TEXTURE 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:

Cobble / Limestone Block

1460 lb (660 kg)

10.23 ft3 (0.290 m3)

FACE TEXTURE VARIES

24 (610) ± LEDGESTONE

COBBLESTONE

23 (584) ± LIMESTONE

KNOBS @ 23 (584) OC, TYP.

461 8(1172)

FACE TEXTURE VARIES

Cobble / Limestone Kingstone / Ledgestone

1320 lb (600 kg)

9.23 ft3 (0.261 m3)

B

10 (254) DIAMETER x

4 (102) HIGH, TYPICAL. 6 (152) DIAMETER KNOBS AVAILABLE.

3 (76) DIAMETER HORIZONTAL VOID FULL LENGTH OF BLOCK, TYP.

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

PARTS LIST DESCRIPTION

TOP INSERT 2 R003-A039

BOTTOM INSERT 2 R003-A042

LIFTEYE FORMER - 6 IN

• 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

PARTS LIST

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

COMPATIBLE OPTIONS (FL2)

NOTE: TWO 18IN FACE MOLDS ARE NEEDED TO PRODUCE THIS BLOCK; PART NUMBERS VARY WITH TEXTURE.

Notes

1) GRAY COMPONENTS ARE FOR REFERENCE ONL FL2) Compatible options must be selected separate

REVISION HISTORY

ZONE REV DESCRIPTION A Initial Release

R003-A041

R003-A039

CT:

N BY:

N DATE: AME:

R003-0338

R003-A04

gabby heinz 8/27/2021 R003-A108 iam

E: Force Protection Kit

T No : R003-A108

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.

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 (RR-G-KF10-S) 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.

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.