DIY Network

Cobble Pavers: Grouting From "Rock Solid" episode DROC-110

Nearing completion of the driveway, the guys get to work grouting!

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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

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 foot capacity or larger)
Air blower (optional)
Skid steer (optional)
Push broom (optional)
Construction adhesive
Crusher run
Coarse sand
Cobblestones
Epoxy grout mix

Grouting

1. For this project, the joints in the cobble driveway were filled in with epoxy grout, but they can be filled in with coarse sand, stabilized sand, or fine gravel to suit your taste. If you decide on grouting the cobble, it can be ordered from Cobble Systems with the material for the project. The grout comes in prepackaged kits containing resin, hardener and sand (figure A) – everything you need for the grout save the mixer.

2. Make sure the cobble joints are clean and aren’t in standing water. You should not grout if the temperature is expected to drop below freezing in the next 24 hours or if it is expected to rain within five hours of application.

3. Lightly spray the inside of the concrete mixer with water before starting the first batch (figure B). Empty the grout components – 50 pound bag of sand, part A epoxy, part B epoxy, and water – into the mixer following the manufacturer’s instructions. Start the mixer and run it for five minutes until mixture is well mixed. Once mixed, the grout mixture is workable for about 10-15 minutes – slightly longer if the day is cooler. Don’t mix ahead unless you are working with several people – if you are, you can double or triple the mixture as the size of your mixer allows.

4. Pour the grout mixture into a wheelbarrow (figure C) – lightly coat the wheelbarrow with water before pouring the mixture.

5. Start grouting at the top of the driveway and work your way down (figure D). Prepare the cobble and your dual blade moss foam squeegees by coating them with water before using the grout mixture (figure E). Make sure to insert a wood screw into the squeegee head to secure it to the wooden stick. Spraying the cobble and squeegees ahead of time keeps the grout from sticking to them and puts it in the joints – where it belongs. Rinsing the squeegees throughout the process will keep them free of grout and in top working condition.

6. Pour the grout mixture onto the cobbles and work sections at a time (figure F). When you pour the grout from the wheelbarrow, run your squeegee along the lip to remove excess grout and prevent it from dripping onto the cobble. Push the grout into the joints with medium pressure by running the squeegee on diagonals across the face of the stones (figure G).

7. Once the joints have been filled, run the squeegee across the face of the stones to remove excess sand and grout from the top of the stones. If you have difficulty removing all of the sand with your squeegee, you may lightly spray the face of the stones and run the squeegee across them again. Excess sand should be removed immediately before spreading another batch. Try to stay off of a newly grouted area when spreading another batch – excessive walking on newly grouted areas will weaken the bond between the grout and the stone.

8. Repeat this process until the entire driveway or project area is grouted (figure H). Once you have grouted a section, remain off of it for about five hours. Depending on weather conditions, the cobbles should be okay to walk on in about five hours and drive on after 24 hours.

9. After 24 hours, your driveway is ready to be enjoyed!

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