A New Pour Concrete Overlay for Cumberland City Council
This project is a testament tot what can be achieved when councils, architects and contractors are committed to delivering better outcomes for their communities.
As part of a major upgrade to Granville Park, Cumberland City Council set out to create a bright, engaging and safe playscape for local families. The redevelopment included new amenities, playground equipment and interactive water play areas designed to encourage activity and enjoyment for children of all ages.
The original specification for the 322m2 splash play zone called for two different exposed aggregate concrete finishes to help bring the design to life. During their due diligence process, primary contractor CAI approached StoneSet to explore whether an alternative solution could deliver improved performance and visual outcomes.
Like exposed aggregate, StoneSet provides a natural stone finish. However, that is where the similarities end.
Why StoneSet Was Selected
Unlike exposed aggregate concrete, StoneSet contains no cement and is visually “stone full”, with no exposed concrete mixed between the aggregate. Instead, the stone is bound using StoneSet’s advanced crystal-clear Premium UVR resin system, creating a far more vibrant and natural appearance while allowing the aggregate itself to remain the hero of the design. The installation process also provided significant environmental benefits. Traditional exposed aggregate requires pressure washing after placement to expose the stone, producing concrete slurry that must be managed carefully to prevent contamination of surrounding waterways. StoneSet requires no such process, eliminating this risk entirely.
From a user experience perspective, StoneSet is hand-laid as a seamless, level surface that is significantly more comfortable underfoot than exposed aggregate concrete. This is particularly important in a splash play environment where children are constantly running barefoot across the surface. Despite its smoother feel, the texture and natural voids between the stone still achieve exceptional slip resistance, exceeding a P5 classification.
Durability & Performance
Durability was another key consideration.
While concrete remains one of the world’s most important construction materials, it is inherently rigid and therefore highly susceptible to surface cracking and visual deterioration over time. StoneSet’s unique flexibility allows it to absorb minor movement within the underlying concrete substrate, providing exceptional crack resistance even as thermal expansion and contraction occur throughout the life of the pavement, in particular the supporting concrete base beneath the StoneSet.
Although the project utilised a concrete base rather than a fully permeable pavement structure, StoneSet’s permeability still delivers important performance benefits. Continuous water flow within the splash play area is able to pass through the StoneSet surface before being directed towards drainage infrastructure along the concrete below. This breathable system prevents moisture entrapment beneath the surface, eliminating the risk of delamination and forming part of StoneSet’s 10-year guarantee.
Design Flexibility
One of the architect’s key design features was the incorporation of multiple colours and flowing shapes throughout the splash play area.
To achieve this, surveyors first established the layout on site before 18mm formable aluminium edging was installed along each design line. This allowed the installation team to precisely follow the architectural vision while maintained crisp and consistent transitions between colours. The option was provided to remove the aluminium divisions after installation for a more blended appearance, which appealed to the architects desire for a seamless of a finish as possible.
Superior Jointing
Jointing was another area where the project team sought a superior outcome.
While Australian Standards require numerous saw cuts and expansion joints within concrete pavements, Cumberland City Council was keen to minimise the visual impact of these elements wherever possible. By incorporating fibreglass reinforcement mesh throughout the installation, StoneSet was able ot bridge many of the underlying saw cuts while still reflecting the major structural construction joints. This reduced the visible jointing throughout the splash play area by approximately 50%, creating a cleaner, more visually striking finish without compromising long-term performance.
The willingness of CAI, the project architects and Cumberland City Council to challenge convention and explore innovative alternatives ultimately delivered a superior outcome for the community. The result is a vibrant, safe and highly durable water play environment that not only brings the original design vision to life, but also demonstrates how thoughtful material selection can significantly enhance both the performance and longevity of public spaces.
Installation Methodology
To ensure the finished paving surface achieved the required levels, falls and drainage performance, the concrete d=substrate was poured approximately 18mm below finished surface level with construction jointing incorporated in accordance with Australian Standards. Major construction joints were reflected through the StoneSet system using Aluminium angle and caulked with Sikaflex (Japanese Beige), while existing saw cuts are bridged with fibreglass mesh to assist with load distribution and minimise reflective cracking. Decorative patterns were created using temporary aluminium formable angle. Once the initial stone blend has cured, the formwork was removed and the adjoining blend installed against the exposed edge, creating a seamless transition between colours while maintaining a continuous resin bound surface.
