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How Do You Lay Resin Bound Gravel?

July 21, 2022

Resin bound gravel over the last few years have become increasingly popular both for commercial and residential buildings. Homeowners and real estate developers have made it a flooring system of choice as a result of its many advantages. They are used for driveway and footpath surfaces.

The popularity of resin bound gravels is enhanced thanks to its permeability, low-maintenance requirement, durability and weight bearing properties.

Resin bound gravels are made using a mixture of washed and kiln-dried decorative aggregate and a specially formulated polyurethane-based resin binder to create a fully permeable surface. Resin bound gravels are created by preparing a base and then applying the binder and aggregate mixture.

The resin bound gravel does not require redressing with sand like the block paving nor does it need resealing as with concrete surface. This is because the gravel is not loose on the surface but is held together by the binder. This is unlike the resin bonded gravel in which the resin mixture is poured on a base and then the gravel scattered across the surface. The resin bound gravel surface is therefore smooth, flat and even. Materials such as crushed glass can be added either in the gavel and resin mix or scattered over the surface during the curing period to make the surface slip resistant. This adds a rougher texture to the surface and also increases grips for both tyres and pedestrians.

Furthermore, the resin bound gravel is fully SUDS compliant as the surface is porous allowing water to permeate through it and soak into the ground. The implication of this is that you do not need a UK Planning Authority permission to install a resin bound gravel.

Resin Bound Gravel Kit

Our resin bound gravel kits come with a high strength aliphatic resin (these are UV stable unlike the aromatic resins) and kiln-dried aggregates to give you the best for your project.

You can trust our highly skilled resin bound gravel installers to give you a high-quality resin bound gravel installation. Our aggregate stones come in different colour blends and textures giving you unlimited design options for your outdoor space.

Each of Our Kit contains;

  • Four 25kg Daltex Gravel
  • One 6.25kg Daltex C52 Sand (there is also an option of crushed glass)
  • One 7.5kg Gravel Binder Resin UVR

How To Lay Resin Bound Gravel

Typically, there are three stages to laying the resin surface which are;

  • Preparing the base
  • Mixing the resin
  • Laying the Resin Bound Gravel

However, in this guide, we give you a more detailed installation procedure.

PREPARE THE BASE

This is perhaps the most important part of the project. This is because if the base is not prepared or laid on an unprepared damp or irregular base, there is a high risk that the surface will crack and the driveway may also sink or swell. Also, the surface may have dark patches while the resin may react with the moisture underneath and begin to foam.

It is therefore important that the base is well prepared and in the right weather conditions for the overall success of the installation.

Here are the processes involved in preparing the base;

Removal of Existing Surface

If there is an existing surface such as block-paved, concrete or tarmac surface, this can be excavated especially if it is not suitable enough to be used as a base. The blocks removed from a block paved surface can be recycled and used as edging around the installation.

Excavating The Area

After removing the surface, the area will be excavated to an appropriate depth for the installation. Our installers will be able to give you professional advice on the depth to be excavated depending on the ground type and the intended use of the driveway (number of cars or weight the surface will carry). We recommend a minimum excavation depth of 220mm.

Installing Perimeter Edging

An appropriate load bearing edging should be installed to provide a solid edge around the installation. Materials which can be used include kerbstones, plastic lumber or block-paving bricks.

Laying Of the Hardcore Base

After installing the perimeter edging, a MoT type 3 base layer should be laid. We recommend a minimum depth of 150mm for laying the hardcore. However, factors to take into consideration while laying the hardcore include sub-grade stability and intended use for the surface.

The hardcore base is compacted using a roller or vibro-plate (whacker) to ensure consolidation of the base.

Lay Geotextile Membrane And Sand Bedding Layer

The next step will be to spread an appropriate permeable geotextile membrane across the surface of the base. The weight of the membrane should not be less than 110g/m2 while any joins should have an overlap of 100mm and secured in place using plastic fixing pegs or galvanized steel U-Pins.

The purpose of this is to suppress the growth of weeds, prevent sand wash out and separate the build-up layers.

The sand bedding layer to be laid thereafter should be done at a depth of 10mm (recommended- this may however vary). The surface should be made completely even and level using a spirit measure. Thereafter, it can be compacted lightly using a wacker plate.

The essence of the sand bedding layer is to smooth out any undulation which may be present in the hardcore base.

Laying A Solid Base

A Suitable solid base should be laid after the bedding layer of sand. This solid base can be tarmac, concrete or X-Grid® ground reinforcement grid type.

The X-Grid® is recommended as it doesn’t need curing unlike concrete and tarmac meaning that there is no time lag between laying the reinforcement layer and floating the resin. The recommended depth for the different solid base options are;

Tarmac – above 50mm depth

Concrete - above 80mm depth

For the X-Grid, the grid should be filled with chippings of maximum 20mm diameter. Excess dust should also be removed from stone. The gravel requirement (in kg) is calculated by multiplying the installation area by 72.

We also recommend a light compaction of the grid using a wacker plate.

MIXING RESIN BOUND BINDER & AGGREGATES

After preparing the base, the aggregate materials should be split into complete mixes so as not to make mistakes and also to save time.

The formula for material separation and mixing is as follows;

  1. 75% 2-5mm Gravel + 25% 1-3mm Gravel OR
  2. 50% 2-5mm Gravel + 50% 1-3mm Gravel

You can also add 5% coarse sand or crushed glass to any of the above mixing formulas.

We recommend storing the bags in a dry location and avoid moisture getting to the aggregate mix as this will have a negative impact on the final structure.

Thereafter,

Mix the Resin binder and the chosen stone aggregates in a separate bucket thoroughly with a drill and a paddle. This should be done until the mix is uniform in colour. There should be no dry stone in the mix.

Laying the Resin Bound Gravel

After mixing, trowel the mix onto the prepared surface and leave to cure for about 4 hours depending on the temperature. At times, an accelerator may be added into the resin mix to quicken the curing process. The surface should be left undisturbed during the curing process to avoid disturbing the aggregate

Before the curing stars, (usually between 10-30mins depending on the resin used and the weather condition. Curing starts quicker in warmer periods.), ensure that the resin is evenly distributed on the surface. You can use a squeegee or shovel to evenly distribute the resin bound mixture and then use a plasterer's float to float out the material. Time is of essence here so that you can be done with distributing and leveling the resin before the curing starts (especially during warmer periods).

To help with the floating process, you can lightly spray water over your float every 30-40 seconds.

Resin Bound Gravel Cost

The cost of your resin bound gravel is determined by a number of factors which include;

  • The weather condition during the installation
  • Size of the driveway
  • Location of the driveway
  • Topography of the ground
  • Excavation requirement
  • Edging requirement
  • Type of aggregate stones
  • Complexity of design
  • Choice of resin
  • Other logistics

You can fill out our free online enquiry form to get a no obligation quote from us.

Resin Bound Gravel Installers

At Yourresindriveway, you have the best resin bound gravel installers in the UK. Our resin driveways Liverpool installers and in the rest of the UK are some of the highly skilled professionals in the installation industry.

With over three decades of experience in the driveway installation, you can expect nothing but the best for your outdoor space.

Reasons why you should choose us;

  • Our materials are of the highest quality, sourced from the best locations in UK and Europe
  • Our aggregates come in variety of blends which gives you unlimited design options
  • Our resins are UV resistant
  • We have some of the best skilled professionals in the industry who will give you expert designs and installations
  • With over 30 years of experience in the industry, you can be sure to get the best from us
  • Our installations come with a 15year warranty
  • Fully licensed and insured company with a Public Liability Insurance covered up to £3m

Contact us through our phone numbers or fill out our online enquiry form to get started.

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