Blog of AATILE LIMITD

Posted By Claire on August 14, 2012

Step 1: Purchase Materials

Cobble Systems features cast cobblestones connected to cast-in grids to make handling and application easy. Cobblestone patterns and color options are available. The calculation of square-foot ground coverage is necessary before ordering from the nearest dealer.

The two-part epoxy grout mixture from EcoSystems is permeable when mixed with silica sand, allowing water to pass through the grout rather than running off into unwanted areas. Silica sand is available at local home improvement centers or block and brick masonry retailers. Bedding sand may not be used as epoxy joint sand. Only clean, dry silica sand may be used. This sand is often called medium-grade or coarse-grade sandblasting sand. Some contractors refer to it as #22 sand.

Step 2: Prep Patio Site

Grade is a term often used by contractors to indicate the slope of the land from one point to another. Grade stakes, driven into the ground, along with a 6′ level and string line can be used to keep the grade consistent, either flat or slightly uphill/downhill. A laser level with tripod, which can be rented for about $50 per day, is a more advanced and accurate method for determining grade.

Builder’s Tip: Dirt, crush and run, stone dust: Most DIYers have had little experience with these building materials. Do not let 18 tons of gravel be an intimidator. Call the local sand and gravel yard. They will answer clarifying questions, provide square-footage coverage and thickness data, give prices per ton and deliver to the DIY site.

Purchasing Information: Not all sand and gravel prices are identical. Delivery distances, location of the rock quarry, types of gravel and quantities of load are all variables that affect costs.

Step 3: Lay Stones

Lay the sheets of stone down on the prepared base. The sheets link together, providing a continuous application over the prescribed area. Once a sheet of stone is laid down, it may be walked on gently. Continue laying the sheets of stone until the entire area is covered.

Builder’s Tip: If a fan design is desired, lay stone sheets outside of the perimeter boundary. The rough edges can be trimmed away, leaving a smooth edge

Step 5: Run the Compactor Over the Stone Surface

To set the stones into the base of stone dust, run the vibrating compactor over the entire stone surface. The compactor will compress the stone into the dust, stabilizing the sheets.

Step 6: Trim the Edge

If a fan design is laid, trim the sharp edge. First, using a marking pen or pencil, draw the cut line on the stone. Then rent a portable concrete cut-off saw (about $50 per day) to cut the line where drawn.

Make certain the saw blade cuts entirely through the stones. Now, take the snips and cut the cast-in grid cord to remove the excess stones on the outside of the perimeter.

Safety Tip: Using a portable concrete cut-off saw is dangerous. Use caution and follow the directions provided by the rental center. Wear heavy boots and safety glasses.

Step 7: Apply Edge Mortar

To secure the stone perimeter in place, mix up some Type S mortar and trowel an outside edge frame around the perimeter. This will keep the stones from slipping and stabilize the area.

Step 8: Grout the Joints

Empty a bag of silica sand into a small rental mortar mixer (about $45 per day). Add the two-part EcoSystems grout, then add the recommended amount of water. Mix for three minutes. Wet the stones with a light hand sprayer. Empty the mixed grout onto the stones and squeegee the sand and epoxy grout mixture around to cover the joints between the stones.

Builder’s Tip: On a hot day, the stones will warm up and the water spray will evaporate. Keep spraying as needed prior to application of grout.

The sanded grout joints will set up by themselves. No pressure is needed to compress the sanded joints.

Step 9: Clean and Finish

Use a push broom to sweep the excess grout from atop the stones. Sweep the stone-covered area clean. Allow the grout to set for 48 hours prior to placing heavy objects on the stones.

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