Concrete Paver Installation

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Project Overview

Concrete paver path installation

Several years ago we created our first test plot for utilizing UltraBaseSystems® panels as the base support system for interlocking concrete pavers. We showed this concept to a top executive of one of the world’s largest paver companies, his response was that nearly 70% of all paver failures are base related. We knew we were on the right track. Where others may have seen a problem, we knew we had a solution.

The following presentation is a commercially-available, interlocking, concrete paver system that was installed over UltraBaseSystems® panels. With no excavation or additional fill added to the job site, this installation was completed in just two days by UltraBaseSystems® President Dave Barlow.

The existing mulch and organics in the area were stripped away and the entire site compacted and leveled.

An 8 oz permeable woven geotextile fabric was installed on the prepared ground ready for panels.

Utilizing a homemade compass, the 14-foot diameter circle was drawn onto the assembled panels in the driveway and cut to shape using a jigsaw. It was much easier to pre-cut the panels in the driveway rather than the heavily-landscaped backyard. The panels were disassembled and moved to the backyard and reassembled over the geotextile fabric. You’ll note that there are a few missing panels; that is a result of my inability to count properly so there was a quick trip back to the shop for a few extra panels.

A thin layer of permeable woven geo-fabric was installed on top of the panels. We used a polypropylene material that would prevent moisture from absorbing into the geo fabric which could result in mold in the sand joints. This thin layer of permeable material is there to prevent the sand filler used between the pavers from washing away. If the pavers had been uneven such as the inconsistencies found in flagstone, then a 1 inch layer of bedding sand would’ve been secreted on top of the geo-fabric and then the pavers installed. This is the same technique used on a compacted rock base but instead the bedding sand is installed on the geo covered panels.

This pre-engineered paver kit made easy work of laying out the concentric rings of the patio. As long as you are able to count and read a tape measure this installation is quite easy. Row after row the ring finally reaches the 14-foot diameter measurement.

The excess geo-fabric is cut away and the commercially-available paver edging is secured in place. This edging prevents the pavers from moving outwards. Prior to the edging being installed, additional sand was packed under the cut panels to firm up the outer edge.

The existing synthetic turf was trimmed and wrapped into the gap that was left between the new UltraBaseSystems® panels and pavers and the existing panels on which the turf is installed. Panels are everywhere in this yard.

Course sand is swept into the joints and watered to lock the pavers in place.

Two coats of sealer are sprayed onto the pavers giving a nice low luster finish while helping stabilize the sand joints.

The end result is a beautiful new patio capable of supporting the load of an automobile and was easily achieved by using this great base technology.

We have added a few additional photographs of this yard to show the versatility of UltraBaseSystems®. From the putting green area to the pet run, the paver fire pit to the landscaping turf, panel base technology transformed this yard into a showplace without the need of heavy equipment or trucks of fill material. The turf is easily attached to the panels using staples which prevent even the smallest sections of turf from moving in the wind or rain.

UltraBaseSystems® panels performed perfectly in my own yard and I’m confident they will pass your test also.