Under license from Brock International – U.S. Patents Nos. 8,662,787; 8,827,590; and patents pending
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 panel. 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 interlocking panels distribute all dynamic loads to a very wide area practically eliminating any pressure on the ground.
One Gator Base panel acts like 15,7’’ (40cm) 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 30% of time, labor and money when installing concrete pavers, natural stones or porcelain tiles.
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 (40 cm) of 0-3/4” (0-20mm) 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 (15cm) 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 pedestrian applications such as for patios and walking paths made with concrete pavers, natural stone or porcelain tiles . 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 a compacted layer of 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° 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: Geotextile Gator Fabric GF 4,4, 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° to the desired final paver level). • Once the final level is achieved, proceed to step 3.
STEP 3 • Addition of geotextile (non-woven Gator Fabric GF 4,4) levelling and compacting the sand
A • Lay down the geotextile non-woven Gator Fabric GF 4,4 and cover the complete excavated area and side.
B • Spread an even layer of sand to a depth of 3/4 in (19 mm) over the Gator Fabric GF 4.4. • To obtain a perfect 3/4-in (19 mm) sand 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 GF 4.4 and fill the surrounding area with sand. Using a straight board, level the sand relatively to the pipes. • When removing the pipes, fill in the empty gaps. • Remember that levelling and compacting the sand will be the last step prior to installing the Gator Base. The layer of sand will be compacted to a final thickness ½’’ (13mm). To ensure an easier and better compaction of the sand, hydrate the sand prior the compaction.
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 GATOR MAXX G2 Installation steps (for a new paver surface)
A • Spread GATOR MAXX G2 with hard-bristle broom. Make sure the GATOR MAXX G2 completely fills the joints. Do not use other materials in the joints. Leave a layer of GATOR MAXX G2 on the surface to aid in the vibrating and consolidation of GATOR MAXX G2 into joints.
B • Vibrate the GATOR MAXX G2 into the paver joints using a vibratory plate compactor. A rubber pad is recommended. A roller compactor is best for slab installation. Joints should be filled up to 1/8 inch (3 mm) below the edge or chamfer. It is best to compact in several directions to ensure there are no air gaps or voids in the joints. Repeat steps 1 and 2 to ensure joints are filled and consolidated. Narrow joints require more care to completely fill.
C • Sweep off excess GATOR MAXX G2 from the paved surface, first with a hard-bristle broom, then a soft-bristle broom. Take care to leave the height of the polymeric sand at least 1/8 inch (3 mm) below the edge or chamfer of the paver.