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Laying Instructions

It is recommended that Breedon Wayfarer is laid at a finished compacted thickness of 35-40mm. The approximate coverage is 10m2 per tonne.

Wayfarer is a natural material quarried from selected limestone and graded approximately 6mm to fines; the fines content being naturally occurring marl which acts as the self setting agent when the material is watered and rolled to fullest compaction in the manner described below. 

Wayfarer self binding gravel is not free draining and therefore requires a cross fall or camber to shed water from its surface into adequate drainage.

Wayfarer must be laid onto a compacted quarried MOT Type 1 Sub Base clause 803. The depth of which should be of sufficient strength and stability to carry the proposed traffic (we suggest a minimum of 150mm if the ground is good) and also the area concerned should be porous enough to ensure that water is not held directly in or immediately below the Wayfarer. If a weed suppressant membrane is required, this must be installed underneath the Type 1 Sub Base and not in between the Sub Base and Wayfarer.

The Type 1 Sub Base should be laid and compacted with a roller of suitable weight, i.e. minimum 1.5 tonnes. On smaller areas a pedestrian roller may be used, however it is vital that the Wayfarer is rolled sufficiently to achieve fullest compaction prior to water rolling.  The sub base should be laid with cross falls or cambers prior to the application of the Wayfarer surface course.

The Wayfarer should be spread onto the prepared foundation using a flat board or the back of a rake. Do not use the prongs of a rake as this may pull the coarse components of the gravel up to the surface. Spread the material out to a depth of no more than 60mm in order to achieve a finished compacted thickness of 40mm.   

The surface must then be rolled using a roller of similar type to that used for compacting the foundation with the vibratory action of the roller switched on and the area should be continually rolled until fullest compaction is achieved. It is imperative that Wayfarer is laid to a cross fall or camber in order to shed surface water. To give some indication, an adequate fall on a pathway would be 1-55 to 1-60 or we would suggest a 1 in 40 fall for larger areas such as patios or courtyards.    The same gradient should apply when installing the Type 1 Sub Base. After this initial laying to cambers and falls it is probable that occasional coarse areas will be evident where segregation of the Wayfarer may have occurred. At this point, fines can be sieved from the main heap of material and scattered onto these coarse areas, then re-rolled.

Once a uniform appearance has been achieved the second stage can be undertaken. This is the water rolling of Breedon Wayfarer for which the vibratory action of the roller must be switched off.

 

By using a water roller, water is automatically sprayed onto the drum of the roller. The fundamental aim is to have a film of water covering the whole Wayfarer surface and in some instances the water tank on the roller may be insufficient for dispelling enough water onto the drum and additional water may be required, particularly in dry, warm weather. If any gravel is sticking to the drum of the roller this indicates that there is not sufficient water being applied and to rectify this it is advisable that a hose is directed onto the drum of the roller as the material is rolled so that the drum is saturated and there is a flood of water where the drum meets the surface. Never direct a hose directly onto the gravel itself as this will wash out the necessary fines which are required for the material to bind. The object of water rolling this material is to float sufficient fines to the top surface of the Wayfarer to obtain a well-bonded finish.

If there are any lines or grooves in the gravel left by the weight of the roller, a soft wide broom can be used to gently pass over the surface whilst still wet – this will remove any lines and leave a perfect surface finish.

The area should then be allowed to dry out before being opened up to general use, the length of time to allow is dependant on weather conditions, but this can take up to 2 weeks or more.

Because Wayfarer depends entirely on its own binding properties for its stability, it is not practical to lay this material on steep slopes where the angle of fall is steeper than a 1 in 15 gradient. Long continuous fall over sloping ground can be minimised by the formation of deep steps to reduce the risk of ruts occurring through the action of flowing storm water.

On completion, the appearance of Wayfarer Gravel is a very smooth and even finish but over time with weathering and trafficking the surface will scarify, giving a loose dressing of chippings on the surface whilst maintaining a solid base. Should a lasting smooth appearance be required, the loose chippings can be swept from the surface using a soft broom. However, the surface will naturally scarify with use, therefore the sweeping process would need to be repeated when necessary.

Should maintenance work be required it is advisable, in the case of pot holes occurring, to cut out affected areas to a neat edge down to the Sub Base and replace completely with new Wayfarer gravel.

In the event of resurfacing at a later date, the top of the gravel surface should be scarified with a rake to a depth of approximately 25 to 35mm whilst taking care to protect the integrity of the type 1 sub base layer beneath. The loose material discarded and a new layer of Wayfarer laid, rolled and water rolled in accordance with our laying procedure described above.

Individual requirements can be discussed in detail with our sales team.





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