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pavingmodern meth ds of

MACHINE INSTALLATION OF

CONCRETE PAVING BLOCKS

Uniclass L534:L212December 2006

methods_of_paving 20/12/06 16:37 Page 2

Machine laying principlesBasically, a hydraulically operatedclamping system is used to lift a‘cluster’ of concrete paving blocks,about 1 square metre in area andalready in the required laying pattern.Clamps can be fitted to a variety of siteequipment or form an integral part of adedicated machine designed for goodsite manoeuvrability. While the machinedoes all the work, there is sometimesan operative guiding the cluster intoplace, as well as the machine driver.

There are various shapes available, aswell as standard rectangular blocks invarious patterns, including herringbonewhich some manufacturers offer readyfor machine laying. The speed of layingdepends very much on site organisation,travel distances, machine types andother factors. But 1,500 square metresor more per day is easily achievable –contrasting with no more than 50square metres per person for manuallaying. Productivity is comparable withasphalting operations. The ability todeploy a block laying machine and crewat short notice to meet ‘just in time’demands on sizeable projects is a majorbenefit. But there are also benefits inusing the technology on modest sizedprojects, as well as larger schemes.

Faster installation means earliercompletion and less operational down-time of the paved area – not forgettingthat block paving can be usedimmediately after completion withoutcuring times. But machine installationalso makes it easier to consistentlyachieve accuracy and uniform jointwidths as machine laying is less tiringon operatives. To maximise theefficiencies of mechanical laying,installers are examining all the othersite processes, such as mechanisingother operations including laying and

screeding the laying course, anddelivering blocks close to the laying face– as shown here in some of theexample photos.

Modern methodsof pavingConcrete block paving meets today’s ‘Modern Methods of Construction’ requirementsfor fully engineered, prefabricated products and the increasing use of efficient, fullymechanised site processes adds to this. In Germany and some other countries,machine laying has been the norm for many years and is used on even the smallestjobs. Here in the UK, the proportion installed mechanically is growing rapidly,particularly as more forward-thinking contractors invest in readily-availableequipment. Opposite are just three recent examples of machine laid concrete blockpaving projects.

I N T E RPAVE : MODERN ME THODS O F PAV I NG

Machine based screeding equipment speeds up the layingcourse preparation.

The laying course can also be placed particularly efficientlywith a paver machine. A sonic sensor (on the left of thephoto) controls the screed box to ensure a constantthickness.

A hydraulically operated clamping system is used to lift a‘cluster’ of blocks already in the required laying pattern.

Banks of plate vibrators can be used for compaction.

For even greater efficiency, machine-mounted jointingmaterial spreading and (as shown here) compactionequipment can be used.

There is even machine-mounted equipment available forbrushing in jointing material.

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I N T E RPAVE : MODERN ME THODS O F PAV I NG

The ability to deploy a block layingmachine and crew at short notice tomeet ‘just in time’ demands is a majorbenefit – demonstrated by a recentlycompleted airport project.

The new aircraft ‘Parking Pan’ atNewquay Cornwall International Airportforms an essential component in thisbusy airport’s expansion plans.Designed to meet the needs of moreflights and larger aircraft, such as theBoeing 737 and 767, the Parking Panwas the final phase of current airport

expansion andneeded to beready to meetoperators’ strictschedules. The3,500m2 area wasinstalled in just 10 days maximising the capabilities ofmachine installed concrete block pavingtechniques. Fast, efficient mechanisedblock laying means earlier completionand less operational down-time of thepaved area.

This replacement of unsightly asphaltand insitu concrete with machine laidconcrete block paving offers anotherexample of the capabilities of thetechnology to minimise operational‘down time’ in critical applications.

Some 7,000m2 was laid in sectionswithout disruption to bus servicesbecause block paving can be usedimmediately after completion withoutthe curing times demanded by someother materials. Also, the ability forblock paving to be lifted and re-laidwithout scarring was demonstratedwhen additional barrier work wasrequired after paving completion. Theblocks were removed, barriers installedand the blocks replaced without theunsightly reinstatement associated withother formless paving materials.

Mechanised techniques enabled tightdeadlines demanded by the NEC’s eventschedule to be comfortably met. The project involved transformation of57,000m2 of car parking from an uneven loose compacted aggregate to a high quality, consistent concrete block surface.

Two different contractors worked intandem to achieve the challenging 12-week construction period for theNEC’s N10, 11 and 12 car parks. Up tofour block laying machines were in useat any one time achieving some of thefastest installation rates ever completedin the UK, with up to 2,000m2 beinginstalled per day. Coordination and

mechanisation of all the constructionprocesses – not just block laying - wasessential for this impressiveperformance to be achieved (as shownin some of the photos opposite).

Sustainability was also important withblock deliveries on re-useable palletsand approved recycling contractors withon-site equipment for shrink-wrapdisposal.

National Exhibition Centre Car Parks

Newquay Cornwall International Airport

Orpington Bus Depot

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