Construction of Interlocking Concrete Pavements

Adequate compaction of the soil subgrade and aggregate base materials are essential to the long-term performance of interlocking concrete pavements.

Purpose

Tinterlocking concrete pavements. The bulletin reviews

the steps in constructing an

pavement structure is com

units 23/81/8 in.

Standard Specification for Solid Interlocking Concrete Paving Units

abrasion resistance tests.

Precast Concrete Pavers

2

saline solution.

Job Planning

P

Layout

I

Figure 1. Excavation of the soil subgrade.

2

Excavating, Drainage and Compacting the Soil Subgrade

D

pavement perimeter to remove excess water in the

with screens to prevent animal ingress. Drainage is

Figure 2. Compacting the soil subgrade.

Table 1. Guide to the Application of Compaction Equipment to Various Soils (Courtesy of Vibromax 2000 Co.)

Table 2. Geotextile Physical Property Requirements1

< 50% geotextile elongation / > 50% geotextile elongation 2, 3

NON-COHESIVE

Sand100% 75% 50% 75% 100%

Percent Mix Sand & Clay

COHESIVE

Clay

Normal Range Testing Recommended

Static Rollers

Rammers* (Jumping Jacks) & Sheeps Foot Rollers

Reversible Plates

Reversible Plate with Extension Plates

Vibratory Rollers

Static Rollers

Forward Plates

*Rammers work very well in sand if confined, as around abutments, foundations, etc.

SurvivabilityLevel

GrabStrength

ASTM D 4632(lbs)

PunctureRestistance

ASTM D 4833(lbs)

Trapezoid TearStrength

ASTM D 4533(lbs)

High 270/180 100/75 100/75 Medium 180/115 70/40 70/40

Additional Requirements Test Methods

Apparent Opening Size (AOS) ASTM D 4751 <50% soil passing a No. 200 (75 µm) sieve, AOS <0.6 mm. >50% soil passing a No. 200 (75 µm) sieve, AOS < 0.3 mm.

Permeability ASTM D 4491 k of the fabric >k of the soil (permittivity times the nominal geotextile thickness).

Ultraviolet Degradation ASTM D 4355 At 150 hours exposure, 70% strength retained for all cases.

Geotextile Acceptance ASTM D 47591 Values shown are minimum roll average values. Strength values are in the weaker principle direction.2 Elongation as determined by ASTM D 4632.3 The values of geotextile elongation do not imply the allowable consolidation properties of the subgrade soil. These must be deterrmined by separate investigation.

Recommeded Overlaps Soil Overlap Strength (CBR) Unsewn (in.) Less than 1 ---- 1-2 38 2-3 30 3 & above 24

3

Applying Geotextiles (Optional)

AASHTO Guide Specification and Test Procedures for Geotextiles

Spreading and Compacting the Sub-base and/or Base Aggregates

S

aggregate base shown in Table 3.

Figure 3. Application of the geotextile under aggregate base.

Table 3. Grading Reqirements for Dense Graded Material Sieve Size

(Square Openings)

Design Range(a)

%PassingBases Subbases

Job Mix Tolerance%Passing

Bases Subbases

2 in. (50 mm) 100 100 –2 –311/2 in. (37.5 mm) 95-100 90-100 ±5 ±53/4 in. (19 mm) 70-89 — ±8 —3/8 in. (9.5 mm) 50-70 — ±8 —No. 4 (4.75 mm) 35-55 30-60 ±8 ±10No. 30 (600 µm) 12-55 — ±5 —No. 200 (75 µm) 0-8(b) 1-12(b) ±3 ±5

(a) Job mix formula should be selected with due regard to availability of materials in the area of the project. Job mix tolerances may permit acceptance of test results outside the design range.

(b) Determine by wet sieving. Where frost and free moisture are indicative of site conditions, a lower percentage passing the No. 200 (75 µm) sieve shall be specified.

Note: ASTM D 2940 corresponds closely to this National Stone Association developed specification. While local or state highway specifications may be substituted for the design ranges above, the fraction finer than the No. 200 (75 µm) sieve should be maintained.

1993 Guide for the Design of Pavement Structures

1/8

1/8

CPI Tech Spec 4, Structural Design of Interlocking Con-crete Pavement for Roads and Parking Lots or ICPI

3/ 1/2

3/8 in. (

Constructing Edge Restraints

E

Placing and Screeding the Bedding Sand

Figure 4. Base compaction with a vibratory roller.

Figure 5. Density testing of the aggregate base with a nuclear density gauge.

5

ICPI Tech Spec 17—Bedding Sand Selection for Interlocking Concrete Pavements in Vehicular Applications

Placing the Concrete Pavers

C

tions, as these interlocking

Figure 6. Screeding the bedding sand.

Figure 7. Placing the concrete pavers.

Figure 8. Saw cutting pavers.

1/163/16

to enter between each unit. Pavers with spacers are

3/8

rain. This will prevent saturation

3/8 in. (

6

Interlocking Concrete Pavement Institute13921 Park Center Road, Suite 270Herndon, VA 20171Tel: (703) 657-6900Fax: (703) 657-6901

In Canada:P.O. Box 41545 230 Sandalwood ParkwayBrampton, ON L6Z 4R1

1/2

1/8 to 3/8

1/8 to 1/

ICPI Tech Spec 5–Cleaning, Sealing and Joint Sand Stabilization of Interlocking Concrete Pavement

ICPI Tech Spec 9–A Guide Specification for the Construction of Interlocking Concrete Pavement

Tech Spec 9

tions are available at www.icpi.org as well as ICPI Tech

ReferencesFlexible Pavement

Design Guide for Roads and Streets.

Stone Base Construc-tion Handbook, September 1988.

Figure 9. Compacting the pavers and bedding sand.

Figure 10. Spreading and sweeping joint sand. Figure 11. Vibrating sand into the joints.

Figure 12. Excess sand swept from the finished surface will make the pavement ready for traffic.

WARNING: The content of ICPI Tech Spec Technical Bulletins is intended for use only as a guideline. It is NOT intended for use or reliance upon as an industry standard, certification or as a specifica-tion. ICPI makes no promises, representations or warranties of any kind, express or implied, as to the content of the Tech Spec Technical Bulletins and disclaims any liability for damages resulting from the use of Tech Spec Technical Bulletins. Professional assistance should be sought with respect to the design, specifications and construction of each project.

e-mail: ICPI@icpi.orgWeb site: www.icpi.org

TECHNICAL NOTECalStar Paver

calstarproducts.com

Headquarters6851 Mowry Avenue Newark, CA 94560

Manufacturing2825 Four Mile Road Racine, WI 53404

Contactphone 510-793-9500 fax 510-793-9501

Introduction

CalStar pavers are intended to be a low-maintenance product. Occasional cleaning (see CalStar Technical Note “Cleaning Fly

ash pavers. Sealers are not necessary, but can be used to reduce the penetration of water, dirt, oil, and other agents that might soil, stain, or otherwise discolor the pavers.

Certain sealers can intensify the paver color and provide a “wet” look.

Sealing Fly Ash Pavers

See ICPI Tech Spec Number 5, “Cleaning, Sealing and Joint Sand Stabilization of Interlocking Concrete Pavement” for general information on sealing pavers, and basic categories of sealers (available on the CalStar website: www.calstarproducts.com). Please note that, although addressed in these ICPI notes, CalStar does not recommend the use of polymeric sand jointing materials.

Pavers must be thoroughly clean, dry, and free of dirt, debris, and all loose particles, prior to application of a sealer. Clean pavers according to CalStar Technical Note “Cleaning Fly Ash

ot roirp ,gninaelc retfa sruoh 42 rof yrd srevap teL .”srevaPapplying sealer.

Always test the sealer in an inconspicuous area, prior to applying to the entire installation. Apply sealer according to the manufacturer’s recommendations. A hand roller can be used on small areas. For larger areas, low-pressure spray, a power roller, or a squeegee might be more convenient. Be sure to protect all

raew syawlA .ffonur relaes laitnetop morf noitategev ybraenappropriate personal protective equipment, including, but not limited to, gloves, long clothing, and safety glasses.

pavers: • Techniseal EV Protector • Techniseal iN Protector • Techniseal WL4 Protector (provides a “wet” look) • Ot na no tseT .elbatpecca eb yam srelaes reh inconspicuous area to ensure they have satisfactory aesthetic performance.

pils eht egnahc thgim srelaes emos taht deton eb dluohs tI relaes eht htiw kcehC .srevap ratSlaC eht fo ecnatsiser

manufacturer, if this is a concern.

eb ot deen thgim dna etaroireted yllautneve nac srelaeS ot roirp aera eht naelc ylhguorohT .derised os fi ,deilppa-er

reapplication of sealer. See CalStar Technical Note “Cleaning Fly Ash Pavers” for general cleaning information.

thgils ,sdohtem gninaelc dna srelaes lla htiw sA :etoNchanges to the appearance of the pavers might occur as a result of application.

Conclusion

htiw desu eb nac ,deriuqer ro yrassecen ton hguoht ,srelaeSCalStar pavers to reduce the penetration of water, dirt, oil, and other agents that might soil, stain, or otherwise discolor the

a edivorp lliw srevap ratSlaC ,erac reporp htiW .srevap beautiful, long-lasting installation, and deliver both near-term

tseb eht no desab si eton siht ni deniatnoc noitamrofni ehT sekam eton siht elihW .cnI ,stcudorP ratSlaC fo ecneirepxe

recommendations, good construction practices should always be followed. Ultimately, the responsibility to make sound techni-cal judgments resides with the project stakeholders, including the owner, architect, engineer, and installer.

7/13/10

SEALERS

TECHNICAL NOTECalStar Brick

Headquarters6851 Mowry Avenue Newark, CA 94560

Manufacturing2825 Four Mile Road Racine, WI 53404

Contactphone 510-793-9500 fax 510-793-9501

calstarproducts.com

Introduction

Proper installation of pavers of any kind (fly ash, concrete,or clay) is essential for performance of the paving system.CalStar fly ash pavers should be installed following ICPIguidelines, as discussed in ICPI Tech Spec #2 Constructionof Interlocking Concrete Pavements.

Polymeric sands are sold as an alternative to standard sandsfor the final step of paver installation. It is well-known thatpolymeric sands can leave a haze on or moderately discolorpavers. With effort, this haze can be reduced, though not necessarily entirely avoided.

Some manufacturers of polymeric sands sell a polymericsand haze-cleaner. Proprietary haze removers and othermethods of cleaning can contain strong acids. If not applied carefully, and removed quickly, the cleaners themselves can permanently change the surface of thepavers. Thus, both the polymeric sands, and the cleaningmethod used to remove them, can change the surface texture and appearance of the pavers. (For general cleaningguidance, see CalStar Technical Note Cleaning Fly Ash Pavers.)

DO NOT use polymeric sands with CalStar pavers. CalStarpavers possess a distinct, crisp, vibrant aesthetic. Use of polymeric sands can result in a haze on the pavers, and a muting of the colors and textures distinct to CalStar pavers.

Use of standard sands and proper installation techniqueswill provide beautiful, long-lasting paver systems, whichdeliver both near-term and long-term environmental benefits.

The information contained in this note is based on the best experience of CalStar Products, Inc. While this note makes recommendations, good construction practices should always be followed. Ultimately, the responsibility to makesound technical judgments resides with the project stakeholders, including the owner, architect, engineer, and installer.

POLYMERIC JOINTING SANDS