Solving problems with state of the art resin bound systems

Following the successful resurfacing of the church’s 40+ year-old asphalt car park, both the architect and client were extremely impressed with StoneSet’s ability to completely transform the space without the need for costly demolition and reconstruction.

With the front of the property now revitalised, attention turned to a newly landscaped courtyard located at the rear of the church. Originally specified as decomposed granite to create a natural, permeable aesthetic, it quickly became apparent that while decomposed granite can look impressive when first installed, it often becomes a maintenance challenge over time.

After only a handful of rain events, the surface began to erode and wash out. The fine particles within the decomposed granite compacted together, significantly reducing permeability and preventing water from effectively infiltrating the surface. As erosion progressed, the area became uneven and undulating, creating not only an unsightly appearance but also a potential trip hazard for church visitors.

Removing and disposing of more than two tonnes of recently installed material seemed both wasteful and unnecessary. The challenge therefore became clear: how could a durable, long-term solution be delivered without rendering the previous investment a complete loss, while also avoiding the additional costs associated with excavation and disposal?

The solution was simple, low impact and highly effective.

Rather than removing the existing material, the decomposed granite was re-levelled to approximately 20mm below finished surface levels before StoneSet Premium UVR was installed directly over the top. By incorporating our triple-layered fibreglass reinforcement system, Mesh And Go, beneath the surface, we created a seamless, fully bound stone pavement capable of delivering exceptional tensile strength, flexibility and long-term durability.

Unlike loose aggregate systems, StoneSet’s continuous void structure allows water to rapidly permeate through the surface while simultaneously dispersing it evenly across the underlying decomposed granite layer. This prevents the concentrated water flow responsible for erosion and washout, preserving both the integrity of the surface and the base below.

Even if minor settlement or movement occurs within the underlying material over time, StoneSet’s inherent flexibility, further enhanced by the Mesh And Go reinforcement system, enables the surface to maintain its form and performance without displacement or failure.

The result is a beautiful natural stone finish using our Tan blend, perfectly complementing the heritage character of the church while seamlessly tying into the StoneSet car park installed at the front of the property. The courtyard now delivers the natural appearance originally envisioned, but with vastly improved durability, permeability, safety and long-term performance.

Installation Methodology 

To maximise the long-term strength, durability and performance of the system, installation was completed using the GlidaBull, a specialist resin bound compaction trowel tool developed by experienced resin bound installers specifically for resin bound applications.

Following placement and screeding of the StoneSet Premium UVR mix to the specified depth, the GlidaBull was passed systematically over the surface. The machine’s high-frequency oscillating action compacts the aggregate matrix while simultaneously consolidating the resin-coated stone particles into a dense, uniform and fully bound structure.

This process helps eliminate minor void inconsistencies, ensures optimal aggregate interlock and produces a flatter, more consistent finished surface compared to traditional hand-finishing methods alone. The controlled compaction also assists the resin-bound mix in fully encapsulating and engaging the underlying Mesh And Go reinforcement system.

By ensuring complete integration between the StoneSet surface course and the triple-layer fibreglass mesh, the installation maximises the tensile and flexural performance of the composite pavement structure. This reinforcement provides additional resistance to minor substrate movement and helps distribute stresses throughout the system rather than concentrating them at isolated points.

The result is a highly durable, monolithic resin bound pavement capable of accommodating minor movement within the underlying decomposed granite while maintaining the structural integrity, permeability and visual appeal of the finished surface. Through the combination of StoneSet Premium UVR, Mesh And Go reinforcement and GlidaBull compaction technology, the strongest and most resilient outcome possible was achieved without the need to remove and reconstruct the existing base materials.