C1/SfB

Ff2

July 1999

concrete paving
A COMPLETE RANGE

O F PAV I N G P R O D U C T S

TO S U I T YO U R N E E D S
2
contents

introduction 3

cobblesett 4

castlestone 8

paving flags 12

technical information 16

3
introduction
Roadstone are the leading manufacturer and supplier of concrete paving products in Ireland.
We pride ourselves on offering you quality paving which is sure to enhance all residential,
commercial, industrial and public applications alike. Concrete paving is attractive, versatile,
and durable. It is quick and easy to install, cost effective and easily maintained. Recent
years have seen its use in Ireland increase dramatically and it is now the most popular form
of hard landscaping in keeping with best European tradition.

An extensive range of shapes, sizes, textures, colours and accessories, manufactured to the
highest standards, offer total flexibility of design. Whatever your paving needs, we believe
we have a solution that is affordable, elegant and quite simply the best.

CASTLESTONE paving block distinguishes itself by the fact that it has an ‘Old World’
appearance and is particularly suitable for town and village renewal schemes and the
renovation of period buildings, where it is
important to maintain the character of the
buildings and their surroundings. It is equally
suitable for modern design.

Our brand COBBLESETT has a wide range

of applications including residential, shopping
centres, garage forecourts, town and village
improvement schemes, and heavy duty
storage areas. Available in a selection of 6
colours, these paving bricks manage to
combine hard wearing practicality with a
touch of class. They bring an added value
and an aesthetic dimension to all
developments.

Exposed aggregate paving FLAGS can

bring great character and warmth of colour
to your garden patio. They are carefully
manufactured from specially selected
natural aggregates, and can be combined
with plain or patterned flags, or paviors,
to create an individual design option to
complement any plan.

Roadstone now have two manufacturing plants - one at Belgard Co. Dublin, the other at
Castleconnell Co. Limerick. Our concrete paving is manufactured under the independent
NSAI registered quality system - ISO 9002 in accordance with B.S. 6217: Part 1:1986.

Roadstone is a company within the CRH Group who offer you an expert advisory service
on product choice, design, application and installation.

We invite you to call to a Roadstone Paving Centre and have a look around.

5
 Commercial development using Tan cobblesett
with Terracotta and Natural designs mirroring
roof detail feature.

Natural cobblesett with Charcoal Grey spots and border blending

the old with new.

cobblesett
Residential driveway using Multi-colou

Garage forecourt with Charcoal Grey cobblesett incorporating Terracotta border.

6
 Retail industrial park, with panels in Natural and Charcoal Grey cobblesett, using
a strong Terracotta border.

cobblesett in herringbone pattern.

Residential driveway laid with Charcoal Grey and

Tan cobblesett

Circular detail in Natural cobblesett at Dublin Port.

7
 Railway station platform
(note the use of tactile paving at platform edge for the visually impaired). Co-ordinating water channel block and kerb with
supporting soldier course available in all colours.

Detached house with driveway finished in Charcoal Grey and Terracotta border, also using kerb block feature to good effect.

Natural cobblesett at Waterford Port incorporating a

company logo in Black with special White on a
Terracotta backdrop in herringbone pattern.

Terracotta and Charcoal Grey cobblesett

with Terracotta border and matching
Terracotta kerb block.
8
 Cobblesett Paviors & Accessories

cobblesett

dimensions cobblesett

details, dimensions & colours

all dimensions height 60 and 80mm
are in mm. 50 units per sq. metre

kerb blocks MK

kerb blocks can be laid to

provide either a low splay or
high splay or a bull nose profile.

kerb corner units AB AE AA AD

internal and external angle units

are available for use with kerb
block in low splay and high
splay format

MK - AB - MK MK - AE - MK MK - AA - MK MK - AD - MK

External Angle Internal Angle External Angle Internal Angle

channel block

dished channel blocks for

drainage are available providing
a modular fit with paving and
kerb units. Weight of unit is
6.5kg five units per linear
metre.

NATURAL CHARCOAL GREY TERRACOTTA

HEATHER TAN MULTI-COLOUR

9
Creative use of standard castlestone kerb unit to get from one level to another.

castlestone
Town square using castlestone in three sizes and colours.

Office courtyard in Castlestone. (note the

Roadstone display area.

10
 Double soldier course of castlestone in
broken bond with semi-circular detail.

Castlestone with standard kerb unit demonstrating

flexibility of design options.

creative use of multi-level kerb stones.)

Civic office using single size castlestone in Natural colour grids with Terracotta
cobblesett borders

11
 Celtic cross design using castlestone at ancient historic tourist attraction.

The flexibility of castlestone demonstrated in a garden feature, Natural colour

combined with Charcoal Grey.

Modern streetscape created by local authority at busy junction

with planters used to good effect.

Private residential driveway using castlestone in two sizes randomly

in a broken bond pattern.

12
 Castlestone Paviors & Kerb Block
castlestone

details, dimensions & colours

dimensions

all dimensions
are in mm.

160
240 160 160 120 160 80 160
80 60
80 60 80 60 80 60

No per M2 26 39 52 78

castlestone kerb
120
typical installation

160

240

Natural Heather

Charcoal grey Tan

13
Exposed aggregate flags, Fastnet (green granite) with Achill (green and cream shingle)
mixed to contrast.

paving flags
Typical garden feature using roman circles and squares.

Aran (cream shingle) 600 mm x 400 mm rang

14
 600 mm Exposed aggregate flags in two finishes in private patio scene.

Shopping mall, Kilkenny, 400 range granite flags with

clay cobblesetts in two colours.

Entrance to commercial development, showing comprehensive use of paving flags over a

e in idyllic sea front setting.
large area, and combining the use of cobblesett paviors.

15
 Paving Flags

400 Range

details & dimensions colours

dimensions 400 range

400mm x 400mm - 6.25 flags per m2 chamfered arris on all 400 range flags excluding liscannor and riven
400mm x 600mm - 4.20 flags per m2

liscannor flag
type exposed aggregate roman square roman circle plain
& riven

50mm thick

finish / colour see colours 17 kg see colours 17 kg see colours 17 kg see colours 17 kg see colours 17 kg

63mm thick

finish / colour see colours 22 kg

50mm thick

finish / colour see colours 26 kg

see colours 26 kg

600 Range

dimensions 600 range

sharp arris on all 600 range.
600 x 600 - 2.78 flags per m2

Type Exposed aggregate Plain

50mm
thick

finish / colour Natural 50 kg

63mm
thick

finish / colour See colours 50 kg Natural 50 kg

Important

Roadstone are not responsible for the naturally The information given in this brochure is correct to the
occurring phenomenon of efflorescence nor the best of our knowledge but customers and specifiers
normal colour variation in colour or texture inherent must satisfy themselves as to the suitability of any
in concrete products. particular product, specification or design detail for
a specific application.

16
These are guide colours only samples should
be inspected for exact colour and texture.

details & dimensions colours

Dalkey Tuskar Skellig Fastnet
(Granite) (Red Granite) (Red / White Granite) (Green Granite)

Roadstone supply a wide range of

exposed aggregate flags in a vairety of finishes,
sizes and thickness.

Clare Tuskar
(Green / White Granite). (Bright Natural Stone)

Aran Valentia Erris Achill

(Creem Shingle) (Red Sandstone) (Natural Stone) (Green / Cream)

Terracotta Natural Tan

FIVE TYPES OF FLAGS ARE AVAILABLE IN THESE COLOURS

Plain Flags (Smooth finish)
Patterned (Roman circles & squares)
Textured (Liscannor & Riven)

Charcoal Grey Heather

17
 Technical Information

Introduction
Precast concrete paving products form an aesthetically pleasing and The purpose of this technical section is to give some back-up
durable wearing surface. Over the years, their use in Ireland has information and guidelines to Specifiers and Builders on the correct
increased dramatically. design, use and installation of these products. By designing these
products on a module we have ensured that our Flags, Paviors
Roadstone have always been to the forefront in high quality concrete
and Accessories are compatible in size with each other. This gives
paving. In keeping with the changing market trends we have a
specifiers and users a flexibility in design, which is unavailable
complete range.
elsewhere in the market.

Sub-Base Pavior s

Interlocking Paviors
40mm Sand Base (compacted)
Sub-base
Sub-grade

Site Preparation
All vegetable matter and loose material should be cleared form the site area, and the site excavated to the required depth.
Dig out any soft spots and fill with suitable well tampered material.

Recommended construction for Roadstone Paved Surfaces

The following are recommendations only. They represent standard good building practice.

Traffic Natural ground Minimum

Classification beneath the paved thickness of Sub-base Wearing
surface sub-base material Course
Frequent Use: Gravels, 150 mm
Up to 2500 commercial vehicles per day. Rocks, etc.
Garage forecourts. Heavy duty industrial storage. Sand (well graded), 150mm
Container terminals. Sandy clay, 220mm
Silty clay, 330mm Roadstone
Heavy clay 550mm blocks laid on a
Clause 804/ 50mm thick sand
Moderate use: Gravels, 150mm
Crushed Rock (0-5mm grain
Up to 350 commercial vehicles per day. Rocks, etc.
size) bed then
Secondary roads. Access to shopping areas. Sand (well graded), 150mm
vibrated to full
Garage forecourts. Heavily trafficked car parks. Sandy clay, 180mm
compaction.
Silty clay, 290mm
Heavy clay 480mm
Occasional use: Gravels, No sub-base
Up to 80 commercial vehicles per day. Rocks, etc.
Minor roads. Car parks (up to 1500 Kg unladen). Sand (well graded), 80mm
Courtyards. Sandy clay, 130mm
Silty clay, 210mm
Heavy clay 370mm

Gravels, No sub-base Granular material.

Pedestrian footways.
Rocks, etc. 100.200mm Hardcore, Hoggin
Private drives. Playgrounds.
Sand (well graded), 300mm (suitably blinded)
Sandy, Silty clay, etc.
Heavy clay
Private paths. No sub-base necessary

18
The sub-base is fully compacted using a vibrator or roller, and the surface blinded with fine material to achieve a smooth and
even surface to within +/- 15mm of the correct levels. Remove any free standing water on the sub-base prior to laying he sand
bed. Where surface water drainage is required minimum cross falls of 19 40 and longitudinal falls of 1 in 75 are recommended.
The appropriate gradient should be built-in during the construction in the sub-base. Contrary to popular belief, water will not
drain through the sand filled joints of the block paving. In all cases, where block paving abuts the channel, the surface of the
paving should be kept 6mm above the edge of the channel to allow for any future settlement. Permanent edge restraints should
be constructed. Roadstone’s Kerb Block is laid on a concrete kerb base as for traditional kerbing, a layer of mortar between the
concrete bed and kerb unit will provide an even foundation. To increase stability, the unit should be haunched to at least half
their height on the back face, ensuring sufficient clearance for the adjacent block paving.

They may be either butt jointed or laid with a mortar joint of approximately 5mm between units. If mortar joints are required they
should be one part cement to four and a half parts sand by volume.

Laying methods
1
Step 1 – Laying Course
A laying bed of coarse washed sand is laid on the sub-base and accurately screeded and
levelled to an uncompacted thickness of 60 mm (one tonne of sand will cover approximately
10m2). The moisture content of the laying course should
be uniformly dry as possible.

The top of the edge restraint can be used as a reference for screeding. For large areas,
accurately aligned 50mm high screed boards are advisable. The laying course should be
approximately 70mm lower than the required profiled level of the paved area to allow the
80mm thick block to vibrate down (or in the case of 50mm blocks 50mm lower). It is important
once the sand bed is formed, it should not be disturbed or stepped on.
2
Step 2 - Surface Course
The laying of blocks can now commence according to the desired pattern, starting from a
corner. The block edges should be laid firmly against the edge restraint and hand tight to each
other (ribs on the blocks ensure correct spacing). The joints between adjoining units should
not exceed 3mm.

It is advisable to lay a substantial area of full blocks prior to in filling gaps with blocks cut on
site using a hydraulic or mechanical splitter. Checks for alignment, squareness and falls should
be carried out at regular intervals.

For efficient operation, position stock piles of blocks on the already paved area, within easy
3
reach of the paver. Avoid bringing blocks or sand over each other
while work is in progress.

Step 3 – Plate Vibrating and Interlock

When the required area is laid the blocks are consolidated down to required levels using a
plate vibrator or "whacker". Do not vibrate within 1m of the unrestrained surface. The blocks
will compact own approximately 20-25% during this operation. The sand is forced into the
joints between the blocks, this sand promotes interlock and is an essential function of
structural performance.

When all the paved area has been laid and compacted finally check the alignment and surface
4
irregularity, which should not exceed 6mm from the correct levels of profiles. Should any
surface irregularities be found the blocks in the affected areas should be removed, the sand
bed adjusted and then reinstated to correct levels.

Step 4 – Joint Filling

Fine kiln dried jointing sand should be swept over the surface and then vibrated until all the
joints are filled with sand. Once the sand has completely filled the
joints between the blocks the surface is ready for use. This specific type sand
has a usage rate of 7m2 per 25kg bag.

19
Standards and Specifications
Roadstone Paviors are manufactured under the NSAI registered “Precast Concrete Paviors shall be the registered names
quality system - ISO 9002 and in accordance with B.S. 6717: Cobblesett or Castlestone as manufactured by Roadstone
Part 1: 1993 Specification for paving blocks which stipulates complying to B.S. 6717: 1986 with a durable surface layer.
that the average compressive strength of a sample of 16 paviors They shall be installed as per manufacturer’s instructions”.
should be not less than 49N/mm2 and that the minimum Precast Concrete Paving Flags should be 400x400x50 / 63mm
strength of any one paving block shall not be below 40 N/mm2. or 400x600x50mm or 600x600x50 / 63mm hydraulically
Paviors must be laid in accordance with B.S. 6717: Part 3: pressed with exposed aggregate* finish as manufactured by
1989, Code of practice for laying blocks. Roadstone.
*Substitute plain or patterned as required.

Laying Concrete Paving Flags

For best results we recommend the following procedure: Alternatively, they may be laid with a 6mm nominal joint, with
wooden spacers inserted temporarily to help keep spacing
Excavate to depth required for finished levels and falls over
regular. The joint should then be filled (3:1 mortar paste)
the area to be paved and consolidate the base. Allow an
and compacted to within 2-3 m of the flag surface using a
extra 20 mm of depth below grass level for ease of mowing.
small trowel or bent steel bar. Mortar in wide joints
If any parts of the base are unsuitable, excavate further to a
deteriorates over time, repointing maybe necessary at
firm bed, fill with hardcore and compact.
intervals of a few years. Great care should be taken to avoid
The flags should be laid on either a full bed (30-50 mm thick) dropping mortar on the slab surface. However, in the event
or semi-dry mortar mix (5:1 sand:cement or 3:1 for heavier of this happening, the mortar should be sponged off
traffic), or on a full bed of good quality grit sand. immediately to avoid staining.
The five spot mortar method is another alternative, but is not There are 3 methods for cutting flags to fit smaller spaces.
as strong as other types of bedding.
1 Use of bolster/broad bladed chisel and club hammer.
For ease and speed of laying the 400 range of flags may be
2 A power masonry saw.
laid close jointed (2-3 mm) with the chambered edges giving
extra definition to the joints. The flags can be tampered to 3 A Hydraulic slab splitter.
level using a Pavior’s maul or suitable piece of wood and
The flag should be well supported before cutting, ensure use
dry sand swept between the joints.
of safety gear.

Cobblesett Patterns Pavior s

Laying Patterns
Roadstone paving blocks, Cobblesett and Castlestone Where the surface is required to support vehicular traffic,
can be laid in a variety of patterns. The most popular Paviors must be laid in 45° or 90° Herringbone pattern.
are shown below.

Half Bond 45° Herringbone 90° Herringbone Parquet

(Pedestrian only) (Pedestrian Only)

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 Castlestone Patterns Pavior s
Colour combination suggestions for Castlestone

Mix 1 Mix 2 Mix 3 Mix 4

90% Natural, 80% Natural, 20% Natural, 20% Natural,
10% Charcoal Grey 15% Charcoal Grey 75% Charcoal Grey 60% Charcoal Grey
or visa versa 5% Tan 5% Tan 10% Tan
10% Heather

Edge Restraints Pavior s

Firm edge restraints are essential and should be installed at the perimeter of
the area to be paved to retain construction and prevent lateral movement, or
migration of sub-base. Suitable edge restraints include five options.

Roadstone Kerb Block can be Roadstone Half Batter Kerb Roadstone Cobblesett/
laid three ways – in low splay, Imperial size 3’ x 10" x 5" Castlestone Pavior
high splay or bull nose Metric size 900 x 250 x 125 mm
(see page 11).

Note: To increase stability, units should be haunched with mortar, to at least half their height on the back face, ensuring sufficient
clearance for the adjacent block paving.

21
 Edge Detailing
When designing a concrete block paved area, careful
consideration should be given to layout and detailing,
so that the area is structurally sound and visually neat.
This can minimise the amount of cutting required on site,
thereby speeding up the laying process.

Where it is necessary to cut blocks beside an edge restraint,

a single, double stretcher or soldier course between the cut Soldier Course
blocks and abutment provides a neat finish.

Single Course Stretcher

Double Course Stretcher
In areas where the above is neither possible or desirable, half
blocks should be inserted within the field to avoid placing less
than one third size blocks against the abutment.

(note dark spots) Incorrect

Note: For simplicity cobblesett designs are shown for detailing issues.

P a v i o r s , M a n h o l e c o v e r s,
Gulleys & Service ducts Pavior s
Roadstone Paviors laid in a stretcher or soldier course can be used to make
a feature of necessary services such as manhole covers, gulleys and service
ducts.

Where a unit has straight sides a row of Roadstone blocks can be laid in
a stretcher course, butted up against the unit. Where this is not possible,
it will be necessary to cut blocks as shown.

Paving blocks can be laid on sand immediately next to the service/ironwork,

but should be mortared into position if there is a possibility of the sand
migrating beneath the unit surround.

Alternatively, recessed units covers can be used, enabling the access point
to remain as unobtrusive as possible.

For best appearance and finish, it is recommended that coloured mortar

to blend with the paving be used where required for in-filling.

22
Good Site Practice & Building Tips
Familisaration with our product range before starting any experienced paving layers. However, a competent DIY
project will ensure a smoother operation and lead to a more enthusiast can achieve a good result with a little reading,
successful job over all. Roadstone recommends the use of advice and hard work.

Equipment:

(1) A Block Cart provides an efficient safe way of shifting paving around a site.

(2) Block Cutter – adjustable for varying thicknesses, ensures fast, clean, accurate cutting.

(3) A Block Extractor removes individual blocks easily.

(4) Alignment Bar for final positioning and alignment of blocks where necessary.

(5) Rubber Hammer for tapping blocks without damage.

(6) A suitable Plate Vibrator for final compaction with two or three passes of the plate.

(7) Personal safety equipment including knee pads, footwear, gloves, goggles, etc.

When planning or ordering decide upon:-

• Sub-Base materials required • Product selection by Type, Size, Thickness & Colour

• Area dimensions • Area of each colour if a mixed design

• Kerbs and channel requirements • Dried sand at a usage rate of 7m2 per 25 kg bag.

• Organise your site well in advance to minimise movement of materials, including stone filled sub-base,
sand, and paving materials.

• Plan your schedule but avoid delivery of materials before they are needed, as they clog-up the site.

• Don’t spread the base course sand before you are ready to screed and lay, as it dries out in hot weather
reducing its performance.

• On delivery it is recommended to cover the sand to keep the moisture content consistent.

• With Paviors, complete the area laid each day including cutting, whacking and sanding.

• The paved area can be used immediately upon completion.

• Dispose of strapping and product shrink wrapping safely.

• Maintain the product area at least annually with a variety of products available.

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 Roadstone Provinces Ltd

Regional Office, Cherrymount, Drogheda, Co. Louth Tel(041) 9837764, Fax(041) 9835011

Regional Office, Two Mile Ditch, Co. Galway Tel(091) 709050, Fax (091) 752199

Regional Office, Bunratty, Co. Clare Tel(061) 709500, Fax (061) 709575

Regional Office, Kilmacow, Co. Kilkenny Tel(051) 895249, Fax (051) 895405

Paving Plant, Gooig, Castleconnell, Co. Limerick Tel(061) 377217, Fax (061) 377 923

Roadstone Dublin Ltd

Paving Plant, Fortunestown, Dublin 24. Tel (01) 404 1200, Fax (01) 404 1356

John A Wood Ltd.,

(Head Office) Carrigrohane Road, Victoria Cross, Cork. Tel (021) 800 100, Fax (021) 542 840

I.S. EN ISO 9002 A company within CRH group.