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Posted: Thu Feb 10, 2005 4:31 am
by Paverman Dan
Tony I have just completed reading the section on rigid paving. Recently I had two applications brought to my attention that had me scratching my head, and I wanted to get your wisened opinion on them.

1- I was told by a South New Jersey, USA paver contractor that a lot of contractors, as a standard practice, in Southern New Jersey, where the soil is mostly sand, simply pour concrete over the compacted sand, and lay pavers over the dried poured concrete (he did not specify whether bedding sand or masonry adhesive was used as a layer between the pavers and the concrete base).

This of course runs contrary to my ICPI training that states you need a "flexible" pavement with a compacted sub-grade, base (which it appears is called sub-base in the UK), sand etc etc..

2- Today I was presented with a set of drawings for a pedestrian pavement application by a municipal engineer. The cross drawing shows the pavers on 1" of bedding sand on top of . . .concrete, again. The concrete base had some sort of a funky drainage system where there were drains placed vertically from the sand setting bed to a pipe, I think, that drained water out to a perimeter drain of some sort.

I looked at the plans, and said, OK . . . .

My initial thought is this: I sell concrete pavers against poured concrete primarily due to the fact that over time, concrete is going to fail and crack under loads and freeze thaw cycles. Soooo . . . . . if concrete is an acceptable base, then besides design considerations, why sell concrete pavers? And wont the joints in a rigid interlocking pavcement simply crack under loads? Is the material used to fill the joints adequate for transferring horizontal load from paver to paver?

I do know the ICPI has reccomendations for overlaying pavers over existing concrete when you want to cover up ugly concrete with pavers, but I'm talking about totally new applications.

What are your thoughts on these applications as a matter of course, in terms of both structural stability and labor savings?

Thanks, PM Dan :cool:

Posted: Thu Feb 10, 2005 3:27 pm
by Tony McC
Using concrete as a base for block paving is a method used in Britain and in Europe, although, because a base (which consists of a bound material, either cement bound, as in concrete, or bitumen bound, as in what you in the US call Asphalt) is more expensive to supply and lay, it tends to be used only on those projects where the sub-grade is particularly poor, or where commercial traffic would be expected. It's rarely used for residential driveways.

Even with a base, the completed pavement is deemed to be 'flexible' as the pavers are, in effect, loose laid on a bed of sand or grit and jointed with a sand. True rigid paving has the pavers bedded onto a bound material, usually a mortar, with mortared joints.

The difference between base and sub-base in European terminology is that a sub-base is typically a granular material with no binder, while a base (also called a roadbase) is commonly a bound material. It's not quite as simple as that, as there are cement-bound materials used to form sub-bases. In modern pavement design, a base course is a layer that carries a surface course (the layer that is actually trafficked) while a sub-base is a layer beneath a base that is a stengthening or improvement layer. Confusing, innit!

So: although concrete can be used as a base for block pavers, it's the exception, rather than the rule. Any such concrete base is just as prone to freeze-thaw and cracking as any other concrete structure, but, as it is covered by flexible paving, any minor movement is 'accommodated' by the pavers.

In Britain and Ireland, where freeze-thaw isn't an issue, a flexible sub-base is the norm, but in continental Europe, they do sometimes use concrete or bitmac base courses beneath block pavements, but again, this is more commonly used on large commercial projects than on residential driveways.

For your typical residential driveway, whether it's in Wigan or West Viriginia, a granular sub-base is the best option. If anything does go wrong, whether it's natural settlement, freeze-thaw heave or anything else, it's much easier to rectify an unbound sub-base.