Laying Pavers on Existing Concrete Pavement

We are frequently asked if our wet-cast concrete pavers can be laid over an existing concrete slab. Yes, our pavers can be used in either mortar or sand setting beds over a concrete surface. At 8,000 to 10,000 psi (two to three times the strength of cast-in-place "sidewalk" concrete), they make for a durable and long-lasting wearing surface, one of the best in the industry.

However, as with any pavement, from an Interstate Highway to a backyard patio, the performance of that hardscape surface depends on a number of factors. One of the most important dynamic of a well-functioning pavement is the quality of the base course. Problems in a pavement's base course will always show on the surface of the system. In the case of a concrete overlay, we need to be confident of the existing concrete slab's integrity before laying pavers on the slab surface. Any issue with the concrete will cause problems to the paver system and may compromise the durability and weight-load capability of the pavement.

Damaged existing concrete surface

For example, if we have a concrete slab in a backyard patio that was poured over ten years ago and shows no damage, we can be sure that the slab will be a reliable base to lay pavers on. However, if we see a concrete slab, poured only a year ago, that has many cracks, cracks with elevation changes, cracks where the pavement is "pulling apart" or significant spalling, we should remove that slab before laying any pavers to its surface. Otherwise, we might see pavers sinking, rolling, heaving or cracking due to an unreliable base course.

As mentioned, StoneBilt Concepts' slabs can be laid in either mortar or sand setting beds. With any vehicular application (driveway), our slabs must be mortar set. For a detail on a mortar set system, please click here. Note that a mortar system may be laid in pedestrian-only areas as well. Many people enjoy the look of grouted joints that accompany mortar set paving.

Sandstone Light Buff in a mortar set overlay

When laying pavers in a sand setting bed on an existing concrete slab, special attention must be directed to retaining the system. Without a proper edge restraint to maintain both the pavers and the sand, the system will most certainly show problems quickly. The most common edge restraint in this scenario is to mortar set the pavers along the perimeter of the slab. The "field" can then be filled in on a sand bed. A detail for this system can be found here.

If we are confident in a concrete slabs' integrity in that it shows only a low amount of small cracks after several years, we may want to lay geotextile fabric of the cracks if laying a sand set system. The fabric will stop any sand from falling into the cracks, thereby preventing any paver sinking or rolling. The same patio, in a mortar set application, does not merit any attention to the cracks as the mortar will not migrate down the cavity when cured.

StoneBilt Concepts' wet-cast concrete pavers have the look and feel of natural stone at significant price savings. We offer Slate, Sandstone, Limestone, Travertine and Bluestone pavers as well as custom colors, sizes and shapes. For more information, please click here.

Product Spotlight: Circle Packs

Innovation is an important component of how we do business at StoneBilt Concepts. We have several ideas for new products we are continually testing. This summer will see the release of one of those new products in our new paving slab circle pack.

New StoneBilt Concepts Circle Pack , Sandstone Dark Buff

Our circle pack will initially be available in our sandstone texture and our three sandstone colors. The new shapes are very versatile, allowing for various diameter circles ranging from 60" (5") to 132" (11'.) in diameter. The circle packs will be created using center pieces and three different size wedge units. The wedge shaped pieces can also be used to make partial circles and to create 3' wide curvy walkways.

New circle pack used in a curvy walkway

These new paving slabs will continue to provide the high quality, high strength natural stone alternative that our customers have come to expect from StoneBilt Concepts. Initial runs are coming off our production line as we speak. Look for these new circle packs to be widely available some time in June. For information on various size circle pack application please click here.

Project Spotlight: Jackson Street Corridor - Golden, CO

Today's best practices dictate that municipal jurisdictions safely integrate their transportations systems to accommodate vehicular, cycling and pedestrian traffic. The City of Golden, Colorado is no exception. Recently the city embarked on a project to improve the Jackson Street corridor.

From Left to Right; Vehicular Traffic, Cycling Traffic, Pedestrian Traffic, Commercial Parking Area

Jackson Street is a major corridor within the city of Golden for all types of traffic. The Jackson Street Corridor project encompassed ten city blocks with the Golden High School located near the south end of the project and downtown near the north end of the project. The City staff and its task forces were intent upon improving the corridor to accommodate all travelers.

StoneBilt Concepts' ADA Detectable Warning Slabs (DWS) were utilized in the pedestrian traffic areas of the Jackson Street Corridor Project. Detectable Warnings are utilized on walking surfaces to warn of hazards on a circulation path, such as street crossings. Approximately 70 pedestrian street crossings exist on the Jackson Street Corridor project. Since the project is an improvement project, in contrast to a brand new job, a number of retrofit applications needed to take place to accommodate existing conditions.

Radius Detectable Warning Slabs

StoneBilt Concepts' design staff worked in conjunction with City of Golden officials, the consulting engineer and the contractor to efficiently design the placement of the DWS. Many detectable warning surface products are typically cut on-site by the contractor in efforts to retrofit the pieces into place. This is not the case with StoneBilt Concepts' DWS. Instead, the StoneBilt Concepts radius pieces are fabricated at the plant to eliminate that step for the contractor. Furthermore, StoneBilt Concepts will furnish drawings to the city inspectors and contractors to aide the contractor with their installation. "We are very pleased with the project and have received very positive feedback from the community - including the ADA advocates," said Anne Beierle of the City of Golden Public Works Department.

Multiple ADA Accessible Ramps near Golden High School

No matter what the application, if it be standard square pieces, full radius intersections or retrofit spiral radius intersections, StoneBilt Concepts can accommodate all. For more information on StoneBilt Concepts ADA Detectable Warning Slabs please click here.

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