20mm Porcelain Paver Installation Instructions

Porcelain pavers on a gravel/sand bed

• Firstly, ensure there is a min. 2° slope for drainage which must be directed away from any building.

• After defining the area to be excavated, mark the perimeter using marker posts connected by a string. Note that the excavated area should be extended on all sides by approx. 200mm to ensure stability at the outer edges of the paved area.

• Remove the soil inside the marked area using a shovel or excavator. The depth of excavation will depend on several factors including the anticipated loading, the drainage capacity of the soil and the soil conditions in general.

• Using a rake or shovel, level the excavated area and ensure there is at least 2° slope for good drainage.

• Compact the soil with a vibrating compactor.

• A restraining perimeter wall should be installed prior to laying the gravel/sand bed unless it is in direct contact with a footpath, wall or an existing edge that is sufficiently rigid. The perimeter wall should be fixed to the ground with mechanical fixing devices or constructed as a solid barrier using poured concrete.

• Place a sheet of geotextile fabric on top of the compacted soil to prevent the soil from mixing with the gravel.

• Fill the excavated area with 15-20mm stone screenings to a thickness of 200 – 300mm, depending on the planned loading.

• Add a further layer of 10mm gravel to a thickness between 100- 200mm.

• Compact the two layers and then level ensuring there is a slope of approximately 2°.

• Place a sheet of geotextile fabric on top of the compacted gravel to prevent the gravel from mixing with the sand.

• Fill the area with paving sand to a thickness of between 20-25mm and compact with a vibrating compactor.

• Level the surface by sliding a wood or steel board placed on two parallel runners across the entire area, again ensuring there is a slope of approximately 2°.

• Taking care not to disturb the sand bed, lay the paving slabs using 3mm spacers. Do not butt joint

• Carefully tap the pavers with a rubber mallet to ensure they are not rocking on the sand bed and that they are level with each other. Fill the joints with polymeric sand that is suitable for use with porcelain tiles.

Porcelain pavers on grass

• Lay the pavers on the ground to determine the numbers of steps needed for the garden path, making sure the pavers are placed at equal distance from each other.

• The joint width between the pavers should be chosen depending on the appearance required. For stepping stones or pathways, the pavers would be normally laid with open joints with grass in between. However for areas where outdoor furniture will be used, pavers would normally be laid with 3mm joints ensuring the joints are filled with polymeric sand that is suitable for use with porcelain tiles.
  Mark the perimeter of each paver with a spade and then remove the pavers.

• Remove the turf up to a depth of between 50-75mm.
  Fill with a layer of fine 5-10mm gravel and compact the gravel before laying the pavers. If preferred, lay 25mm thick layer of sand to add as a bed for the pavers.

• Carefully lay the pavers so they protrude above ground level by approximately 6-10mm. The pavers must not protrude above the lawn level, to avoid damaging lawn mower blades when cutting the grass.
  Carefully tap the pavers with a rubber mallet to ensure they are bedded properly.

Porcelain pavers for elevated deck applications

• For elevated deck applications, adjustable height pedestal supports offer the easiest and quickest way to construct a perfectly horizontal deck or terrace over sloping or uneven surfaces, avoiding the need to construct extensive supporting substructures of wood or metal beams. Electrical cables and pipes can be hidden under the pavers but easily inspected at any time by simply lifting individual pavers.

• Depending on the width of the pavers, pedestals are either placed directly under the pavers or are used to support an array of hollow steel beams, over which the pavers are laid.

• For instructions on how to install pavers using the pedestal system we recommend following the manufactures’ instructions.

Porcelain pavers on a concrete base

• Verify the concrete substrate is in good condition, is installed in accordance with relevant building codes and reinforced with steel mesh, and is constructed with a 2° slope pitched away from any building.

• Clean the surface of the concrete to ensure good adhesion of the pavers.

• Spread an approved exterior grade thin set mortar over the concrete using the correct sized notched trowel.

• Lay the pavers on the thin set with minimum 3mm joint spacing where the area is not large enough to require expansion joints, or with 5mm spacing where expansion joints are present. All expansion joints should be installed in accordance with Australian Standards and must be located along the joint line of the installed pavers to avoid cracking of the pavers.

• After the thin set has dried, grout the pavers with an approved exterior grade grout.

• Wash the pavers carefully after grouting to remove excess grout.

• A final buffered acid wash will also be required to remove any invisible grout residue.

• If polymeric sand is preferred over grout, we recommend proprietary Tile Sand which is specifically made for porcelain pavers.