Keystone Design Manual & KeyWall PRO Operating Guide From: Keystone Retaining Wall Systems LLC

Retaining walls are an essential landscaping element that can transform sloped terrains into functional and aesthetically pleasing spaces for outdoor living, play, and planting. Beyond their primary role in preventing soil erosion and managing grade changes, these structures introduce design elements that enhance the visual appeal of a landscape. The strategic placement and material selection of retaining walls contribute significantly to the overall ambiance and utility of an outdoor environment. Selecting the appropriate material for a retaining wall is crucial to ensure it complements the existing home and landscape. When this integration is successful, homeowners experience a sense of satisfaction and excitement about their outdoor spaces. This article presents three distinct project profiles that showcase various applications and benefits of retaining walls, offering insights and inspiration for landscape professionals. The first project details the creation of multi-functional areas on a corner lot where a 1950s house was replaced with a larger home. The unique positioning of the new house necessitated the redefinition of yard spaces. The client, with young children, required a level play area. Landscape designer Jody Shilan addressed this by altering the driveway's grade and incorporating a 2-foot-high, 35-foot-long L-shaped dry-laid granite wall. This wall not only retained the slope but also served as seating for children during play, exemplifying the multi-use philosophy. Additionally, two 20-foot-long, 2-foot-high walls with integrated steps were designed for the front walkway, defining the front yard and adding visual interest and formality to the property. A key challenge was the difficulty in shaping the granite, but the choice of material ensured a cohesive look with the house's foundation. The second project, located on a 5-acre hillside in Colorado, focused on carving out usable space and managing drainage for a new home. The property had a significant 15-percent slope towards the house. Paul Fredell, president of Fredell Enterprises, designed retaining walls to divert runoff and create flat areas for a children's play space, a patio, and planting beds. The homeowners selected a neutral brown/gray ledge stone, dry-laid by hand, ensuring a premium finish. A 175-foot-long retaining wall secured the back of the house, while a series of terraced walls in the front facilitated planting and level outdoor areas. A unique feature was a stream-like water element integrated into these walls, falling 8 feet over a 16-foot run. The project faced challenges with local code enforcement regarding slope ratios and wall height, requiring extensive sub-base preparation with crushed-gravel footers. Water seepage during excavation behind the house was managed by backfilling the wall with pea gravel and installing a drainage system. In the third project, the objective was to connect outdoor and indoor living spaces seamlessly. The homeowners desired an expanded backyard living area with dining, sitting, and a small outdoor kitchen, directly accessible from their indoor kitchen and family room. The existing backyard grade was lower than the house's walk-out level, and an old deck with a sunken spa limited entertainment space. Terry McMahon and Amie Armstrong of Borst Landscape and Design proposed replacing the deck with a raised patio using a retaining wall. A 70-foot-long, 4-foot-high dry-laid colonial bluestone wall created a 450-square-foot level patio. Two sets of Karney stone steps provided backyard access. To comply with local codes and soften the patio's appearance, 2-foot-wide planting beds were incorporated between the wall and the patio, eliminating the need for a handrail. A significant challenge was matching the hardscaping material with the red brick clad house, with bluestone being chosen for its aesthetic contrast. The design also had to accommodate existing shade trees, leading to an asymmetrical patio shape and complex construction of linear steps within curved sections, requiring meticulous craftsmanship. The result successfully transformed the backyard into a cohesive and elegant extension of the indoor living areas. #RetainingWalls #LandscapeDesign #Hardscaping #OutdoorLiving #GradeManagement #PatioDesign #DrainageSolutions #StoneMasonry #ConstructionChallenges

Rich Kubica, owner of K-Wall Poured Walls, LLC, has dedicated his career to the concrete foundation and wall industry, following in his father's footsteps who founded Jerry Kubica Foundations in the 1950s. After his father's retirement and the business closure, Rich revived K-Wall in Traverse City, Michigan, in 1992, later inventing the E-Max insulated wall system, now sold by Western Forms. In 2006, Kubica relocated his family and business to Asheville, North Carolina, and began operations in 2007. The economic downturn of 2008 posed significant challenges, leading to the collapse of many concrete wall contractors in the region. However, K-Wall Poured Walls survived by diversifying its services. Kubica's strategy included expanding into footing and wall projects, flatwork, gypsum concrete underlayment applications for multi-family units, decorative concrete, and epoxy floor coating jobs. This diversification allowed the company to maintain operations when housing construction, and consequently poured wall demand, declined. As the economy gradually recovered and competitors re-emerged, Kubica identified a growing market for precast walls, particularly in the mountainous Asheville area. Several factors influenced his decision to incorporate precast walls into his offerings. The limited availability of ready-mix concrete in the region presented a logistical challenge. Additionally, the heavily engineered walls required in Western North Carolina, due to the terrain, led to thick walls, substantial footings, and extensive rebar, significantly increasing the cost of traditional poured wall foundations to the point where they were deemed too expensive for typical homeowners. A crucial development was the 2012 IRC Code Book, which, for the first time, recognized precast walls, moving them from a proprietary product status to a widely accepted construction method. Another significant driver for adopting precast walls was the increasing difficulty in finding skilled and dedicated labor for the demanding work of pouring concrete walls. Kubica noted a shift in work ethic among younger generations compared to his own experiences. Precast walls offer a less labor-intensive solution, as they are manufactured in a factory setting under controlled conditions. Installation primarily involves a crane and minimal manual labor, making the process more attractive to both experienced and new workers. This approach reduces physical strain and streamlines the construction timeline. Kubica partnered with Ron Ward, CEO of Structura Technologies, to develop the MonoKast Precast Wall system. While precast walls had been observed for two decades, their timing was not previously optimal due to lack of code recognition, proprietary status, and higher costs compared to traditional methods. However, advancements now allow for the use of 70 percent less concrete in precast walls, making them a more efficient and cost-effective option. The MonoKast system is manufactured at K-Wall’s facility in Fletcher, North Carolina, and delivered to job sites. These walls are set using a crane on a crushed stone footing, adhering to 2012 IRC building codes. Once installed, they are insulated, studded, and ready for finishing without requiring additional framing. The stud cavities can accommodate insulation to enhance R-values, and MonoKast walls can be integrated with traditional cast-in-place walls to create hybrid foundations. The MonoKast wall profile features a 10-inch wide header beam at the top and a 10-inch wide footing beam at the bottom, both 3.5 inches thick with solid concrete and reinforced steel. The concrete shell is 2 inches thick, fiber-reinforced, and meets 5,000 psi code compliance. Precast concrete offers benefits such as faster construction times, reduced costs, and versatility. Kubica highlighted an instance where 180 lineal feet of MonoKast wall was set in 3.5 hours. He emphasizes that precast walls are not a threat to poured wall contractors but rather an opportunity for diversification and offering a comprehensive service to builders. He views the addition of precast walls as an evolution, allowing contractors to provide a "one-stop shop" solution for foundation and wall construction, ultimately meeting modern building and energy codes, reducing material volume, and opening new revenue streams while maintaining the core business of poured concrete walls. #ConcreteConstruction #PrecastWalls #PouredWalls #FoundationContractor #ConstructionDiversification #MonoKastSystem #BuildingCodes #LaborEfficiency #ConstructionTechnology

Bryce Hollingsworth has built a successful masonry business by transforming his passion for stonework into a career through extensive training and real-world experience, specializing in dry-stone walling—the technique of constructing stone walls without mortar. Early in his career, while working as a laborer for a landscaper, Bryce discovered his aptitude and interest in outdoor trades. This initial exposure allowed him to explore various tasks, quickly identifying his preference for stonework. Consequently, he pursued roles with specialized landscaping companies, first leading a crew that focused on stonework and later joining a company exclusively dedicated to stone installations. This period solidified his conviction that working with stone was his true calling. Driven to enhance his skills, Bryce enrolled in certification courses at The Stone Trust in Vermont. Seeking further mastery, he traveled to Australia to apprentice with Geoff Duggan, a renowned master craftsman. This apprenticeship proved to be a pivotal experience, as it provided him with critical, real-time feedback that he previously lacked due to often working alone. Bryce credits this training with helping him refine his techniques, eliminate inefficient practices, and reinforce fundamental skills, leading to a significant improvement in his walling proficiency. Following his training in Australia, Bryce continued his education at the Dry Stone Conservancy in Kentucky. The subsequent year, he embarked on another hands-on training journey to Ireland. This trip expanded his expertise by teaching him to work with diverse stone types and various construction styles, further broadening his capabilities in dry-stone masonry. With this comprehensive international and domestic training under his belt, Bryce felt prepared to establish his own company, Stone Bear Mason, LLC. During the initial phase of his business, work consistency was a challenge. To mitigate this, Bryce frequently subcontracted with other wallers and masons, demonstrating a willingness to travel extensively to gain varied practical experience. He emphasizes that working with different professionals provided exponential growth in his skills, as each collaboration introduced new perspectives and techniques that differed from his own established methods. While Bryce's business is now thriving and keeps him fully engaged, he remains open to traveling for specific projects that offer unique opportunities for learning and application of his specialized craft, reflecting his ongoing commitment to skill development and passion for dry-stone walling. #DryStoneWalling #Masonry #Stonework #Craftsmanship #CareerDevelopment #SkillBuilding #Entrepreneurship #KeepCraftAlive #HomeImprovement

Key-Link Fencing & Railing has introduced its new Chesapeake Series, a deckboard rail product designed to meet growing homeowner demand for enhanced outdoor living spaces. The Chesapeake series has received positive feedback from customers since its recent rollout. Jeremiah Hershberger, Key-Link's product manager, highlights that the increasing average size of decks and homeowners' desire to entertain outdoors were key drivers for the development of this product. The Chesapeake series aims to provide a functional and aesthetically pleasing solution that allows guests to move freely and place food or drinks, thereby making outdoor spaces more conducive to entertaining. The design also allows for aesthetic matching with existing decking materials. The development of the Chesapeake Series stemmed from Key-Link's commitment to quality, unique designs, and ease of installation, all core tenets of their brand. While a previous bracket set was available, the company sought to innovate and redefine the concept of drink rail. Product performance and quality were paramount in the design process. The Chesapeake's design specifically addresses ease of installation, featuring a profile tailored for deckboard integration. This includes recessed channels and pre-drilled holes for screws, with all necessary hardware (except the deckboard itself) included in the boxed section. This comprehensive packaging simplifies the installation process for contractors, who can cut the railing to size, install it, lay the deckboard on top, and fasten it securely. This approach ensures that the Chesapeake Series aligns with Key-Link's reputation for user-friendly products and superior craftsmanship. Key-Link's continued innovation in railing systems reflects a broader trend in home design, where outdoor spaces are becoming increasingly important extensions of the living area. The demand for functional yet stylish outdoor amenities, such as drink rails, underscores a shift towards more integrated and versatile home environments. The Chesapeake Series, with its focus on both practical utility and aesthetic appeal, caters to these evolving homeowner preferences. The product's thoughtful design not only simplifies installation for professionals but also enhances the overall user experience, making outdoor entertaining more convenient and enjoyable. This strategic product development underscores Key-Link's responsiveness to market trends and its dedication to providing high-quality solutions for the building materials industry. #KeyLinkFencing #ChesapeakeSeries #DeckboardRail #OutdoorLiving #HomeImprovement #ProductInnovation #EasyInstallation #BuildingMaterials #HomeDesign #OutdoorEntertaining

The re-evaluation of traditional architectural styles and materials, sparked by initiatives like the Building Beautiful Commission and the ban on combustible cladding, is leading architects to reconsider the use of stone in construction. Historically, stone was fundamental in creating structural solid masonry walls, offering a sense of safety and security in buildings. However, its usage evolved over the last seven decades, moving away from solid wall construction, with modern applications typically involving stone cladding panels fixed to steel or concrete frames. This shift presents challenges, especially for indigenous stones like softer limestones, which are often unsuitable for thin cladding sections due to their susceptibility to weathering and frost when saturated, making them less ideal for rainscreen cladding systems. Further complicating the use of traditional stone construction methods was the 2010 update to Part L of the Building Regulations. This update significantly increased the focus on mitigating cold bridging at critical junctions such as wall/floor connections and around windows and doors. Consequently, the conventional use of solid stone elements became problematic, necessitating the introduction of thermal break layers. This requirement directly conflicts with stone's inherent reliance on thickness for structural integrity; splitting a stone element to insert a thermal break can compromise its stability. Areas demanding particular attention in detailing include window reveals, sills, lintels, balconies, parapets, and the interfaces between walls, floors, and roofs. In contrast, internal applications of stone, such as floor and wall tiling, fire surrounds, and even the internal leaf of a wall (provided it is thermally isolated to prevent condensation), are considerably simpler to implement. A key concern with external stone detailing is its weight and irregular nature compared to manufactured masonry like bricks and blocks. For cavity walls, external stone must be adequately tied to the internal skin to meet structural design codes. The precise design, placement, and installation of brackets and ties are crucial for ensuring wall strength and stability, alongside maintaining thermal isolation between the outer and inner leaves. The substantial loads imposed by stone panels often necessitate robust metal brackets for support against gravity, lateral forces, and wind. These metal components, however, can act as cold bridges to the main structure. Fortunately, contemporary solutions include proprietary products that leverage the structural strength and low thermal conductivity of fibre-reinforced resins, offering support without the thermal transmission associated with metal. The irregular coursing of stone, even in 150mm thick sections, also poses challenges for compliance with Building Regulations regarding wall tie spacing, particularly the requirement for 300mm vertical centers. To address this, the National House Building Council has provided updated guidance, allowing for wall ties in such situations to be spaced at 450mm centers, provided they are installed in pairs within the same bed joint and within 225mm of an opening or joint. Therefore, integrating stone into contemporary construction is feasible, but it requires architects to exercise heightened care in detailing and a thorough understanding of stone's unique material properties to ensure compliance with modern building regulations and performance standards. Additional guidance is available, such as 'Natural Stone Masonry in Modern Scottish Construction' from the Scottish Stone Liaison Group, which can be accessed free online. #BuildingRegulations #StoneConstruction #ArchitecturalMaterials #ThermalPerformance #CladdingSystems #CavityWalls #StructuralDesign #MaterialProperties #HistoricArchitecture #SustainableBuilding

Building a non-load-bearing interior wall is a practical home improvement project that can add privacy, reduce noise, and create distinct spaces within a home. This project can typically be completed over a weekend for an estimated cost of $155 to $205, even for individuals with intermediate DIY skills. The construction involves basic materials such as two-by-fours for framing and drywall sheets for the surface. Before starting, it is crucial to check local building codes and permit requirements, as many municipalities mandate permits even for non-load-bearing wall construction. The necessary equipment includes a framing hammer, speed square, circular saw, cordless drill, step ladder, laser level or plumb bob, electric miter saw, tape measure, carpenter's pencil, drywall knife, painting supplies, and potentially a powder-actuated nailer for concrete floors. Materials required are nine 8-foot two-by-fours, two drywall sheets, 2-1/2-inch galvanized nails, 1-1/4-inch coarse-thread drywall screws, drywall joint compound, paper drywall tape, drywall primer, interior paint, and an optional pressure-treated two-by-four for concrete floors. The process begins by locating the wall. For wooden floor systems, the wall should be perpendicular to or directly on top of floor joists or beams. On concrete floors, any point is suitable. Next, stud locations are marked on the top and bottom plates, typically 16 inches apart on-center. The bottom plate is then fastened to the floor, using nails for wood floors and a powder-actuated nail gun for pressure-treated wood on concrete. The top plate is installed directly above the bottom plate, ensuring alignment with a laser level, and nailed into ceiling joists. Vertical studs are then measured and cut to fit precisely between the top and bottom plates. It's advisable to cut studs slightly long and trim if necessary. These studs are then toenailed into their corresponding positions, ensuring they are plumb using a laser line. Once the framing is complete, drywall sheets are hung horizontally on the studs using drywall screws. For walls longer than 8 feet, drywall ends should be staggered to avoid four corners meeting at one point. After hanging, screw holes are filled with joint compound, and drywall seams are finished by embedding paper joint tape in joint compound, covering it with another layer, and sanding smooth once dry. The final step involves rolling drywall primer onto the surface, allowing it to dry, and then applying two coats of interior paint. An 8-foot section typically requires one gallon of primer and two to three gallons of paint. For more complex projects, such as building a load-bearing wall or if the non-load-bearing wall lacks a solid base, consulting a contractor or carpenter is recommended to ensure structural integrity and proper support. The cheapest way to build an interior wall is by performing the work oneself and using standard materials to avoid labor costs for carpenters and drywall installers. #InteriorWall #DIYHomeImprovement #HomeConstruction #DrywallInstallation #Framing #HomeRenovation #BuildingCodes #PowerTools

Specifying doors for multi-residential projects is a complex task that requires careful consideration of numerous factors beyond aesthetics. Architects and designers must balance performance requirements, building codes, and occupant needs to select appropriate door systems. Key considerations include fire ratings, acoustic performance, security, durability, accessibility, and environmental impact. Fire-rated doors are critical for occupant safety and building compartmentation, necessitating adherence to specific fire resistance levels (FRLs) and Australian Standards. These doors, often including solid core timber or steel constructions, must be properly installed and maintained to ensure their efficacy. Acoustic performance is another vital aspect, particularly in multi-residential settings where noise transfer between units can significantly impact occupant comfort. Doors contribute to the overall sound insulation of a dwelling, and specifying doors with appropriate acoustic ratings (Rw or STC values) can help mitigate noise pollution. Factors like door material, thickness, gasketing, and sealing mechanisms play a crucial role in achieving desired acoustic targets. Balancing fire and acoustic requirements can be challenging, as solutions for one may sometimes compromise the other. Security is paramount in residential buildings, and doors are the primary barrier against unauthorized entry. Specifying doors with robust locking mechanisms, strong frames, and durable materials is essential. Compliance with relevant security standards, such as those related to forced entry resistance, should be a key part of the specification process. The choice of hardware, including hinges, locks, and handles, directly impacts both security and the long-term functionality of the door. Durability is important for longevity and reduced maintenance costs, especially in high-traffic common areas. Doors in multi-residential buildings are subjected to frequent use and potential abuse, making robust materials and construction methods critical. Environmental factors, such as exposure to weather in external applications, also influence durability requirements. Material choices, finishes, and hardware should be selected to withstand anticipated wear and tear. Accessibility must be integrated into door specifications to ensure ease of use for all occupants, including those with disabilities. This involves considerations such as clear opening widths, appropriate door hardware height, and minimum force requirements for opening. Compliance with accessibility standards and regulations, such as the Disability Discrimination Act, is mandatory. The design of door thresholds and clear circulation spaces around doors also contributes to overall accessibility. Furthermore, the article implicitly suggests that material selection, such as timber or steel, influences various performance criteria. Environmental considerations, like the use of sustainably sourced materials and low-VOC finishes, are also gaining importance. The interaction between different building elements and systems means that doors cannot be specified in isolation; they must be considered as part of a larger, integrated design. The long-term performance, maintenance, and lifecycle costs of doors are also significant factors for consideration in multi-residential projects. #DoorSpecification #MultiResidentialProjects #BuildingDesign #FireSafety #AcousticPerformance #BuildingSecurity #Accessibility #SustainableMaterials #ArchitecturalHardware

This article discusses the benefits of using stone wool insulation in open-joint cladding systems, particularly in a renovation project on East 79th Street. The project aimed to address challenges with the existing facade, including aesthetic, durability, and energy efficiency concerns, by implementing a rainscreen system designed to meet Passive House standards. Architects chose stone wool insulation for its superior fire-resilient properties, thermal performance, and moisture resistance, making it suitable for open-joint systems where insulation is often visible. The project utilized both unfaced and matte black fleece-layered rigid stone wool insulation boards. In the East 79th Street renovation, a porcelain tile cladding material with exposed clips was selected for cost-effectiveness and design flexibility. Zoning regulations allowed for a 101.6-mm (4-in.) encroachment, providing space for a high-performance assembly. The stone wool insulation’s matte black layer ensured that it did not detract from the open-joint design where visible. Its inherent moisture resistance and drying properties were crucial for the rainscreen system, which relies on proper drainage and ventilation to prevent water damage. The installation process involved bolting metal framing to the repaired concrete block backing, which was sealed with a liquid-applied membrane. Stone wool boards were then efficiently installed behind the framing. Custom beveled-edge systems were designed around windows to accommodate the new envelope assembly, ensure airtightness, and allow future window replacements. The ease with which stone wool can be cut was beneficial for fitting the material around existing and new window installations with varying details and spacing. The final stage involved attaching non-combustible porcelain tiles using an innovative clip system, contributing to the overall fire-resilient design. Alissa Bucher of Rogers Partners Architects + Urban Design highlighted that stone wool met multiple project needs, including thermal performance, fire protection, acoustics, and durability, while complementing the unique porcelain tile design. The 101.6 mm of stone wool insulation is expected to ensure the new exterior’s longevity. The article emphasizes that open-joint rainscreens are increasingly popular due to their superior drying potential and aesthetic flexibility. Innovations like black fleece-faced insulation boards eliminate the need to compromise performance for aesthetics. Stone wool's hydrophobic nature means it repels water and resists rot and mold, and any water ingress from weather conditions can easily dry out, making it an ideal choice for such systems. Brendan Van Gool, product marketing manager at Rockwool, is identified as the author. #StoneWoolInsulation #OpenJointCladding #RainscreenSystems #BuildingEnvelope #ThermalPerformance #FireResilience #MoistureResistance #FacadeDesign #ArchitecturalMaterials

HETAS has issued updated information regarding the essential practices for fixing stone fire surrounds, following incidents where surrounds detached from walls, causing significant risk and serious injury. This information was first published in RGE's August 2018 issue. The updated guidance aims to prevent such occurrences by detailing appropriate mechanical fixing methods. The technical committee responsible for the BS 1251 standard, which governs open fire components, revised the 1987 version in 2015 to include new requirements for mechanical fixing. These revisions ensure that fireplace surrounds can adequately support the load of items placed on the mantle and remain securely attached to the wall, even if accidentally pulled. Understanding the type of fire surround is crucial for correct installation, including proper positioning, materials, and fixings. There are three primary types of surrounds: slabbed, cut stone, and boxed section. Slabbed surrounds are single-component structures, usually made from materials like marble, stone, or ceramic tiles on a heat-insulated cement backing. They must have a minimum total thickness of 48mm, with at least 30mm of cement mix for stone and marble, and 40mm for ceramic tile. Cut stone surrounds are multiple-component structures typically made of stone, featuring two vertical legs supporting a horizontal lintel and mantle. Boxed section surrounds are also multiple-component structures, crafted from natural stone or marble, with compartments and a split back panel to accommodate thermal expansion. All types of surrounds should be manufactured in accordance with BS 1251 to allow for appropriate mechanical fixing to the building's structure. If there is uncertainty about a surround's compliance, installers should contact the manufacturer for clarification or seek advice from specialist organizations like Hetas or the Stone Federation of Great Britain. Fixings must be secured directly to the brickwork of the building, necessitating the removal of any plasterboard or other finishing materials to ensure proper bonding. The 'dot dab' adhesive method is explicitly prohibited for affixing surrounds. For slabbed surrounds, manufacturers typically integrate appropriate clip or eyelet-type fixings directly into the product. These usually involve two mechanical fixings on each side of the surround and two more within 300mm of the top, which can be either fixed or swivel types depending on the construction. Cut stone surrounds require more complex, heat-proof bracket fixings appropriate for the backing wall's construction. These must be fixed directly to the chimney breast wall or to another stone structure that is itself mechanically fixed to the breast wall. Manufacturer instructions are essential for specific details on location, type, and bedding joints. Boxed section surrounds incorporate fixing wires on each side, similar to slabbed surrounds, with uppermost fixings within 300mm of the top. The shelf at the top has its own fixing points to secure it to the chimney breast wall, and manufacturer instructions should always be followed, especially considering the size and weight of the shelf overhang. Fixing brackets are generally supplied by the surround manufacturer and are typically made of heat-proof stainless or galvanized steel designed to be fixed into the surround. A critical step before installation is assessing the condition of the chimney breast wall to confirm it can support the surround's weight. Key points for installers include ensuring compliance with BS 1251, referencing manufacturer instructions for fixing types, locations, methodology, and jointing/sealing compounds, and assessing wall and hearth structures for weight capacity. Finally, upon completion, installers must assess and inform occupants of any potential risks, particularly when children or infirm individuals are present. Additional guidance is available from hetas.co.uk and hse.gov.uk/safetybulletins/fireplace-surrounds.htm. Hetas, a not-for-profit organization, offers a Competent Person Scheme for installers, registration for retailers, technicians, and chimney sweeps, and approves appliances and fuels. Further detailed guidance is available for download. #FireSurrounds #HETASTechnicalGuidance #HomeSafety #InstallationStandards #BuildingRegulations #MechanicalFixings #BS1251Standard