Laying Instructions

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

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

Wayfarer is a natural material quarried from selected limestone and graded approximately 6mm (1/4”) 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 must be laid onto a compacted quarried MOT Type 1 sub-base to 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 rolled using a roller of suitable weight, i.e. minimum 1.5 tonnes for footways and similar works. By using a heavier roller, this helps achieve maximum compaction with fewer passes, however on smaller areas a pedestrian roller may be used although it is vital that the surface is rolled sufficiently to achieve fullest compaction prior to water rolling. This may take a few more passes over the area. The sub-base should be laid with cross falls or cambers prior to the application of the Wayfarer surface course.

Prior to use it is recommended that the moisture content of the Wayfarer is checked, particularly in prolonged dry conditions or where material has been stored for a period of time before use. When squeezed by hand the material should have enough moisture within in that it should stick together. If the material is dry, we advise that a hose with a fine mist setting is sprayed over the Wayfarer and the heap is turned over sufficiently to replenish lost moisture and to achieve the necessary consistency.

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 will segregate the material. Spread the material out to a depth of approximately 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 - it must NOT be laid flat. To give some indication, an adequate fall would be 1 in 55 for a pathway and a minimum of 1 in 40 for much wider walkways and courtyards. The same gradient should apply when installing the Type 1 sub-base. Please ensure that adequate drainage is installed in proportion to the surface area being laid. If rainfall is not dispelled rapidly this can lead to an ingress of surface water which will prevent the hardening and binding process of the Wayfarer. 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 before being re-rolled.

Once a uniform appearance has been achieved the second stage can be undertaken. This is the water rolling of 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 but in most instances the water tank on the roller may be insufficient for dispelling enough water onto the drum and additional water will be required, this is almost always the case in dry warm weather. If the Wayfarer is sticking to the roller, this indicates that there is insufficient water being applied. To rectify this, it is advisable that a hose is directed onto the drum of the roller as the material is rolled, saturating the drum. There should be a flood of water pushing forward as the drum rolls the surface. Never direct a hose directly onto the Wayfarer 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 gravel to obtain a well-bonded finish.

It is imperative that sufficient water is added to the material during the water rolling process. Failure to float the fines to the Wayfarer surface will result in the re-softening of the material, leading to an unbound finish. Approximately five gallons of water for each tonne of laid material is required to adequately float the marl fines to the Wayfarer surface, which will allow the product to bind and harden. As a visual guide when sufficient water has been applied, the area should have a similar appearance of freshly laid concrete, giving a shiny, glassy finish over the whole surface. Once this has been achieved the binding process can begin.

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 uniform surface finish.

If laying large expanses of Wayfarer, it is important that the whole laying process is completed per section. Newly laid areas can be "butted up" next to previously laid material provided that a neat edge is used. When floating the fines up to the surface in the adjoining sections simply pull a soft broom across the surface as previously advised.

It is important that the area should then be allowed to dry out fully before being opened up to general use. The length of time to allow is dependant on weather conditions, but this can take up to a period of two weeks or more. We would also advise during the drying process that the area is not used. Please note that materials should never be laid in frozen conditions. 

Because Wayfarer depends entirely on its own binding properties for its stability, it is not practical to lay Wayfarer 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, this will reduce the risk of ruts occurring caused by the action of flowing storm water.

On completion, the Wayfarer surface will be very smooth and uniform. Over time, with weathering and trafficking the surface will scarify, giving a light dressing of chippings over the area, whilst maintaining a bound, 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.

Please visit our section on Maintenance for more information.

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

 

 

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