DIY Network

Cobble Pavers: Preparing Sub-base, Laying Borders From "Rock Solid" episode DROC-110

Have the material (crusher run or road rock and coarse sand) for your new driveway section delivered.

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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
	Figure D
	Figure E
	Figure F
	Figure G
	Figure H
	Figure I
	Figure J

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

Preparing Sub-base and Laying Borders

1. For the new driveway portion, there will be approximately 4-1/2 inches of road rock (figure A) and 3/4 inch of sand (figure B). The goal is to create a surface – which when compacted and covered with the 1-5/8 inch cobble – will match up seamlessly with the 3/4 inch cobble on top of the asphalt surface.

2. If you’re not matching surfaces, you don’t need to worry about matching grades – just create a six inch base course of road rock and coarse sand for drainage. These can be purchased from and delivered by your local quarry or landscaping company.

Note: This is another portion of the project where a skid steer is a useful tool.

3. Evenly spread out the road rock using a skid steer and landscaping rake. If you don’t have a skid steer, just use your landscaping rake (figure C). Once the road rock is evenly spread out and leveled, wet the base and compact it (figure D). Compacting creates an even and solid surface for the cobble to rest on.

4. Repeat this process with the coarse sand. Coarse sand (such as concrete sand) packs well and provides the best drainage. Spread and level the sand with the toothed end of the rake and give it a finish grade with the smooth end of the rake (figure E). Wet the sand and compact it (figure F). With the base for the driveway extension prepared, you can begin laying cobble.

5. If you are installing the thin cobble over an asphalt or concrete driveway, it should match up to the level of the garage floor. Fortunately in this project, there was a garage lip the height of the thin cobble that allowed Dean and Derek to run the cobble into the garage and adjust the height of the garage door to meet the driveway. If you don’t have a garage lip and are installing cobble over an existing driveway, you may need to demo the two feet or so of asphalt or concrete near the garage edge to create a seamless line from the cobble to the garage floor.

6. Laying cobble begins by laying the borders for the entire project. These are the leads and will be the guidelines for the field cobble. In this project, the border is created by cutting 16 inch charcoal grey cobble mats in half lengthwise. Both the thick and thin cobble are used to border the entire project and created a seamless looking driveway. To prepare for the cobble borders, run a line along the outside edge of the driveway by tying a piece of string between pieces of rebar (figure G). This line will be your guide for setting the border cobble and ensures that the border line – the guideline for the entire project – is straight.

7. Begin laying cobble at the highest point of the driveway – in this case the garage area (figure H). Lay the first border at the first corner and install all of your borders from that starting point. The outside edge should be the uncut or "factory" edge. Here are several pointers:

• For the installation of the thin cobble over an existing concrete or asphalt base, run a bead of construction adhesive along the leading edge of cobble (figure I). For the installation of the thick cobble over a six inch base course you don’t need adhesive – just set the thick cobble in the sanded base.

• Adhering the outside edge of the border keeps the field from moving when it is installed. You won’t need to adhere the field, the grout works as an adhesive once it’s applied.

  Note: In areas of the country where there are freeze-thaw conditions, a flexible thinset will be needed to adhere the border and entire field.

• If you are cutting your cobble, cut it ahead of time by flipping the mat over (figure J) and cutting the grid on the back side with multi-snips.

• To install continuous mats, cut the half stones out ahead of time to keep the work moving quickly.

8. If the existing or new driveway flares at the end, the cobble mats will bend to fit the curve, but may create some uneven joint sizes. If a joint is too big on one side, cut out that stone and evenly space it between the adjoining stones.

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