Evolution in Base Technology
Save Time. Save Labor. Save Money
23.5 in x 35.5 in = 5.79 sq ft, ¾ in thick, weight = 1.32 lbs each
59.7 cm x 90.2 cm = 0.54 sq m, 19 mm thick, weight = 0.6 kg each
10 units per pack
12 packs per pallet
120 units per pallet
Gator Base is environmentally friendly, engineered to return water to the native soil due to the evacuation channels incorporated in the gator base. It will never leach chemicals or degrade in the native soil for over 100 years.
One Gator Base panel is equivalent to 6˝ of crushed stone. The inter-locking panels distribute all dynamic loads to a very wide area practically eliminating any pressure on the ground.
One Gator Base panel acts like 18˝ of crushed stone as a thermal blanket. It is 3 times more effective than crushed stone as an insulator thus significantly reducing freeze and thaw cycles.Technical Report
Alliance Designer Products Inc. has introduced to the market a revolutionary technology that will save time, labor and money when installing concrete pavers and natural stones.
With the new Gator Base® panel, you can save 6 inches of extra excavation, long hours for installation and the transportation of tons of aggregate.
This technology exhibits the polypropylene memory characteristics and allows the material to retain its original shape. Alliance Designer Products Inc. is now using this technology in their Gator Base® panel for the hardscaping industry.
An exhaustive and serious evaluation was made in collaboration with the Université du Québec’s engineering institute (ETS), in the laboratory of their Pavements and bituminous materials department, in order to characterize compare the Gator Base® panels to a traditional method of paving stone installation with aggregate.
Since the Gator Base® panels have a high thermal resistance (it would take nearly 15.7 inches of 0-3/4” dry stone, compacted to a porosity of 20% to equal the insulation provided by a single layer of Gator Base® panels), it can be assumed that there would be better frost protection with the Gator Base® than with the usual additional 6-inch aggregate base. In this case, similar movement for both of these systems would be observed after freeze-thaw cycles. The system with the Gator Base® panels works best for patios and walking paths made with concrete pavers. The subgrade soil should be compacted to at least 95% of the modified Proctor density; a geotextile fabric is needed on top of the subgrade and bedding sand should be used to ensure a smooth and uniform surface.
The results obtained during the “Bench test” study on a concrete paver system with a granular base (standard 6 inches of aggregate), versus the Gator Base® panel as a base are very interesting. The main reason for using gravel aggregate (crushed gravel) in the traditional method is to allow for water drainage, which prevents frost from heaving your pavers. For proper drainage, each Gator Base® panel is equipped with channels for water evacuation along a 1 degree slope as well as 5 drainage holes per 16 sq. in. Also, every Gator Base® panel (1.32 lbs) will replace 288 lbs of compacted aggregate. When using Flexlock Ultra Polymeric Sand, water will run off the paved surface if a minimum of 1° slope is respected.
Conclusions from results obtained by ÉTS* when comparing Gator Base system versus traditional granular base system.
• Gator Base can replace a traditional granular base.
• Gator Base is equivalent to a traditional granular base under static and dynamic loads.
• There would be much better frost protection with Gator Base system.
*École de technologie supérieure (or ÉTS) is part of the Université de Québec.
STEP 1 • Excavation of the New Gator Base Area
Total excavation will be done as follows - Total depth will be determined by adding the following elements depths: Geo-fabric, compacted bedding sand’s final height (1/2 in [13 mm]), Gator Base (3/4 in [19 mm ]), and paver’s height. • Total excavation width should be 6 in (15 cm) wider on each side than the final paved area. This excavation could be done using a shovel or excavator • Prior to excavating, check with local utility services to ensure digging does not damage underground pipes or wires.
STEP 2 • Levelling and compacting of the subgrade
A • Once excavation is completed, level the excavated area using a rake or shovel. • Ensure a slope of at least 1 degree away from any structure, such as a house.
B • The native soil needs to be prepared and compacted in the same way that one would prepare a traditional base installation, using a hand tamper or plate compactor. • This area should be as smooth as possible to get rid of high or low spots within about 3/8 in (10 mm). • Using a string level (stakes and a string line), tie the string to the stakes to establish level according to which the final slope will be measured (minimum of 1 degree to the desired final paver level). • Once the final level is achieved, proceed to step 3.
STEP 3 • Addition of Geo-Fabric levelling and compacting bedding sand
A • Lay down the geo-fabric and cover the complete excavated area.
B • Spread an even layer of sand to a depth of 3/4 in (19 mm) over the Gator Fabric 4.4. • To obtain a perfect 3/4-in (19 mm) bedding layer, use two 3/4-in (19 mm) pipes with an equal distance of 4 to 6 ft (1.22 to 1.83 m) over the Gator Fabric 4.4 and fill the surrounding area with sand. Using a straight board, level the bedding sand relatively to the pipes. • When removing the pipes, fill in the empty gaps. • Remember that levelling and compacting the bedding sand will be the last step prior to installing the Gator Base.
C • Using a hand compactor and/or plate compactor, compact the 3/4 in (19 mm) of bedding sand until you obtain a final height of 1⁄2 in (13 mm) of compacted bedding sand, that should reflect the final paved surface.
STEP 4 • Installation of the Gator Base
Make sure to install the Gator Base on the extended excavation area (total excavation should be 6 in [15 cm] wider on each side than the final paved area). • Start laying the Gator Base units according to a staggered pattern while ensuring locking of the tongue & groove system. This will guarantee the panels’ stability when the pavers or slabs are laid down. • Trim any visible curves or protruding angles using a utility knife.
STEP 5 • Installation of pavers and Gator Edge
Lay the pavers directly onto the Gator Base according to the selected pattern. • (Adding a second layer 1⁄2” (13 mm) of loose bedding sand on top of the Gator Base is also an accepted method of installation.) • Use a rubber mallet to adjust the pavers. • Make sure the Gator base is 6 in (15 cm) wider on each side than the paved surface. Install Gator Edge on the Gator Base, making sure it rests firmly against the pavers. A Gator Base Anchor screw will be driven into every second hole to maximize lateral support of the Gator Edge.
STEP 6 • Sweeping, Compacting and Blowing of the Flexlock Ultra Polymeric Sand
A • When emptying the Flexlock Ultra polymeric sand bags, spread it onto the dry paved surface. This will avoid segregation and sweeping a mountain of sand. • When sweeping the polymeric sand, spread over a small area before moving onto the next, while making sure to fill in the joints.
B • It is now time to compact the sand into the joints using a hand tamper or plate compactor. Do not use a plate compactor over slabs. Repeat filling and compacting of the paver joints. Finally, sweep the surface with a fine bristle broom and remove all excess sand. • Ensure the sand is 1/8 in (3 mm) lower than the paver chamfers.
C • Finally, use a blower to blow off all sand residue lying on the paved surface. • The combined actions of the sweeping and blowing will help eliminate any hazing effect.
STEP 7 • Watering and Blowing Action
The watering process will activate the polymeric sand’s bonding process, and the sand will harden when dry. A • Set your water spray to “shower” and spray the paved surface for 10 to 15 seconds then wait 3 to 4 minutes. (N.B. Ensure the paved surface does not dry between waterings.)
B • Shower and rinse the paved surface and wait 3 to 4 minutes before repeating the shower and rinse process for a third and final time. However, stop watering when you see a minimal amount of water retention on the paver joints. • If the work is being done on a hot summer day, avoid spraying large areas, as they will dry up faster.
C • Finally, use a blower to remove any excess water remaining on the paver surface. Again, this process eliminates any potential hazing effect.