DIY Network

Cobble Pavers: Design and Excavation From "Rock Solid" episode DROC-110

In this episode of Rock Solid, stone masons Dean Marsico and Derek Stearns test a cobble paver product that has just hit the market. Can they recreate the look of individually set cobblestones for a driveway revamp? They use a system of cobble pavers manufactured on a nylon grid backing for easy installation. The product comes in two thicknesses – a thicker 1-5/8 inch cobble for newly prepared-base applications and a thinner 3/4 inch cobble for overlayment applications. The guys use both here!

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	The cracked asphalt driveway...
	was transformed with cobble pavers...
	giving it an old-world charm.
	Figure A
	Figure B
	Figure C

Materials:

Measuring tape
Shovel
Rebar or sturdy stakes
String
Landscaping rake
Garden hose
Vibratory plate compactor
Multi-snips
Caulk gun
Chisel
Hammer
Diamond blade saw
Wheelbarrow
Dual blade moss foam squeegee head and stick
Mortar mixer (3-1/2 cubic ft. capacity or larger)
Air blower (optional)
Skid steer (optional)
Push broom (optional)
Construction adhesive
Crusher run
Coarse sand
Cobblestones
Epoxy grout mix

Design and Excavation

1. The project begins with design. The existing asphalt driveway (figure A) will be covered with the thin 3/4 inch cobble and the driveway will be expanded ten feet, excavated and the thicker 1-5/8 inch cobble installed on a new sub-base. With the two cobble thicknesses, the seam between the existing driveway overlay and the cobble on the newly prepared-base won’t be detectable! The project will be bordered in charcoal colored cobble and have rustic red cobble for the field (figure B). Once you’ve decided on your colors and design, order your material and have it delivered (figure C)!

Note: Installation of the thin cobble on asphalt or concrete sub-bases is not recommended in areas prone to frost heaves, unless a flexible thin set mortar is applied as a setting material. In addition, asphalt may not be suitable for an overlayment due to undetermined base conditions under the asphalt. Check with your local distributor or the manufacturer to determine what application is best for your project.

2. To create the new driveway area, the ground should be excavated (figure D) six to eight inches and filled with road rock and approximately 3/4 inches of coarse sand for drainage and compaction. Measure and mark the outside edge of your demo line with string tied between two pieces of rebar and dig down six to eight inches for your sub-base (figure E). You can dig using shovels, but a skid steer or similar tool might be worth the rental. It’ll save you time and hours of backbreaking work.

Safety Alert: Before you dig, call your local utilities! They will come out and mark underground utility lines that might be near your dig site. Digging near utility lines could cause serious injury and service outages. You may also need to relocate sprinkler heads and piping prior to digging.

Figure D

Figure E

RESOURCES :

Products:
1. Straight SP-01 (rustic red and charcoal)
2. Thin Straight TS-01 (rustic red and charcoal)
3. 1/2 Circle HC-01 (Rustic Red)
4. Epoxy Grout

Cobble Systems
Toll Free: 877-238-8663
Fax: 407-841-4426
E-mail: info@cobblesystems.com
Website: www.cobblesystems.com

GUESTS :

Tal Shuford
Cobble Systems

Eric Wright
D&W Landscapes, Inc.
Phone: 1-954-914-3952