Understanding Sub-Base Options for Resin Bound Installations: Concrete, Asphalt, and Mesh N Go
Choosing the right sub-base is one of the most critical factors in ensuring a durable, high-performing resin-bound surface. Whether you’re working on a driveway, patio, or path, the choice of sub-base can significantly impact the longevity, permeability, and overall success of the installation.
At Resco, we offer three main sub-base options for resin-bound surfaces: Concrete, Tarmac, and the innovative Mesh N Go system. Each has its unique strengths and is suited to different project requirements. In this blog post, we’ll explore these three options in detail, discussing when and why each should be used, and how they contribute to a successful resin-bound installation.
1. Asphalt (Tarmac) Sub-Base
Flexibility and Permeability
An asphalt sub-base offers a flexible and permeable solution for resin-bound surfaces. Asphalt, particularly when using an open-graded binder course, allows water to flow through the resin-bound layer and into the sub-base, making it an excellent choice for areas requiring good drainage.
Key Requirements
- Bitumen Penetration Grade: Use an asphalt with a bitumen binder that has a pen value no higher than 100/150. For machine-laid applications, a harder bitumen grade, such as 70/100 pen, is preferred to ensure durability.
- Depth: Ensure the asphalt is compacted to a depth of at least 100mm. Proper compaction is crucial to prevent future deformation or cracking.
- Edge Restraint: Asphalt requires full edge restraint to keep the resin-bound surface in place and prevent movement over time.
Drainage Considerations
The Resco Resin Bound System works well with asphalt because of its porous nature. When used over an open-graded binder course, asphalt eliminates the need for an additional drainage system. Water can easily flow through the resin-bound surface into the sub-base, reducing the risk of water pooling and erosion.
When to Use Asphalt:
- Suitable for driveways, patios, or paths in residential or commercial areas where permeability is essential.
- Recommended for installations in areas with frequent rainfall or where efficient water drainage is necessary.
2. Concrete Sub-Base
Strength and Stability
A concrete sub-base is one of the most commonly used foundations for resin-bound surfaces due to its strength and long-lasting stability. Concrete is ideal for high-traffic areas like driveways and commercial spaces where heavy loads and frequent use are common.
Key Requirements
- Depth: Concrete should be laid to a minimum depth of 100mm to provide adequate strength and support.
- C35 Strength: The concrete must meet a minimum design strength of C35 and have a compressive strength of 25N/mm², as per BS 8500-2:2015 standards.
- Joint Reinforcement: To prevent cracking, especially in larger installations, ensure that open bay joints are reinforced with steel mesh and repair mortar.
Drainage Considerations
Concrete is non-permeable, so proper drainage must be incorporated into the design. This usually involves creating falls or slopes that direct water toward drains or outflow areas. Without proper drainage, water can pool on the surface, leading to damage over time.
When to Use Concrete:
- Ideal for driveways, heavy traffic areas, or commercial installations where strength is a priority.
- Suitable for installations that require a stable, non-flexible foundation.
3. Mesh N Go Sub-Base
Lightweight and Flexible
The Mesh N Go system is an innovative, lightweight alternative to traditional concrete or asphalt sub-bases. This mesh system offers flexibility and is particularly useful in areas where excavation depth is limited or where traditional sub-bases may be impractical due to soil conditions.
Key Requirements
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Build-Up Layers: The recommended base build-up for Mesh N Go includes several key layers:
- 15mm Resin Bound Surface – The resin-bound layer should be a minimum of 15mm thick to ensure durability, following the manufacturer’s recommended mix design using a 7.5kg binder.
- 2mm Bullmesh – The Resin Bull Mesh N Go system includes a 2mm mesh layer that provides structural support to the resin-bound surface, allowing for a thinner build-up while maintaining strength.
- 10mm Grano Dust – Apply a 10mm layer of Grano dust to provide a smooth, even surface for the mesh system to sit on.
- 100mm Type 3 Sub-Base – Depending on the ground conditions, lay a compacted Type 3 granular sub-base to a minimum depth of 100mm to provide additional support.
- Bullbase 3mm – A 3mm layer of Bullbase helps create a level foundation.
- Subgrade Soil – The base of the system, typically compacted soil, should be stable and prepared to support the overall structure.
Drainage Considerations
The Mesh N Go system allows for excellent drainage, as water can easily flow through the resin-bound surface and the mesh layers. This system also reduces the risk of water retention and surface deformation over time.
When to Use Mesh N Go:
- Ideal for paths and patios, especially where excavation is limited or where soil conditions are poor.
- Suitable for light traffic areas such as pedestrian walkways, garden paths, or low-traffic patios.
- Offers a more eco-friendly solution by reducing the need for deep excavation and traditional aggregate sub-bases.
Comparison of Sub-Base Options
| Sub-Base | Strength | Permeability | Ideal For | Installation Depth | Drainage |
|---|---|---|---|---|---|
| Concrete | High | Non-permeable | Driveways, high-traffic areas | Minimum 100mm | Requires drainage system |
| Asphalt | Moderate | Permeable | Driveways, patios, paths | Minimum 100mm | No additional drainage required |
| Mesh N Go | Moderate | Permeable | Patios, paths, light traffic | Build-up with mesh, grano dust, Type 3 | No additional drainage required |
Conclusion
Choosing the right sub-base for your resin-bound installation is essential for ensuring the long-term durability and performance of the surface. Each of the three options—Concrete, Asphalt, and the Mesh N Go system—has its unique benefits and applications.
- Use concrete for high-traffic, heavy-load areas where strength and stability are the primary concerns.
- Opt for asphalt in areas where flexibility and permeability are essential, especially in regions with frequent rainfall.
- Consider the Mesh N Go system for patios and paths where excavation depth is limited, offering a flexible and lightweight solution.
At Resco, we provide the products and expertise to ensure your resin-bound installation is a success, regardless of which sub-base you choose. For more information on our full range of products, including the Resco Ultimate UVR Resin Bound Binder and Resin Bull Mesh N Go, visit our website or contact our team for expert advice.