A New Option in Exterior Paving

New-to-U.S. structural porcelain pavers are naturals for elevated decks, rooftops and plazas
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Porcelain and Other Types of Pavers

Structural porcelain pavers offer an ideal paving solution where durability, frost resistance , scratch resistance , stain resistance and low maintenance are important.

Porcelain pavers can be used in areas subject to high foot traffic and where tables and chairs will be used such as outdoor restaurants and bars.

Photo by Sam Yee

Porcelain pavers can be used in areas subject to high foot traffic and where tables and chairs will be used such as outdoor restaurants and bars.

Hard Wearing and Scratch Resistant. Porcelain is an exceptionally dense and hard material which resists scratching and marking by most objects. Pavers can be used in areas subject to high foot traffic and where tables and chairs will be used such as outdoor restaurants and bars.

Frostproof. Since water cannot penetrate the interior of porcelain pavers, they do not experience freeze/thaw cracking, making them suitable for the most severe climatic zones.

Mold and Mildew Resistant. The non-porous surface and body of porcelain stoneware discourages the growth of mold and mildew and can be easily washed off with water.

Slip Resistant. With a textured surface and ultra-low porosity that encourages quick draining and drying, porcelain pavers easily meet most slip resistant requirements for both home use or public spaces.

Fade Resistant. Because colored pigments are effectively baked into the pavers at a temperature of over 1,200 degrees, becoming part of the overall composition, porcelain pavers do not suffer from fading due to the sun.

Non-porous. Unlike most natural stone and other paving materials including concrete, and wood, porcelain pavers are essentially non-porous, typically rated as less than 0.1 percent water absorption. This prevents penetration by liquids, oils or chemicals and minimizes staining . Porcelain pavers are also resistant to weak acids and bases.

Low Maintenance. Porcelain pavers do not require sealers or protective coatings to be applied to seal the surface. Normally debris and organic matter, such as grass, soil, leaves and the like, can be removed by washing with water from time to time.

Fireproof. Porcelain tiles are completely fireproof so provide an ideal alternative to traditional wood decks, especially for rooftop decks where strict fire regulations may apply.

Because porcelain tiles are fireproof they provide an ideal alternative to wood decking.

Photo courtesy of Kronos Ceramiche

Because porcelain tiles are fireproof they provide an ideal alternative to wood decking.

Stronger than Natural Stone. For the equivalent thickness, porcelain is harder and stronger than most natural stone.

High Load Bearing. Structural porcelain pavers are much tougher, denser and stronger than standard ceramic tiles so can be laid on adjustable height pedestals supported only on each corner for exterior raised flooring and rooftop decks.

Lighter than Stone or Concrete. Porcelain pavers are lighter than both concrete and most natural stone such as granite, making them easier to transport and install than more traditional paving products.

Porcelain Paver Characteristics

The most common structural porcelain paver size is 24 inches x 24 inches x ¾ inch thick, although some manufacturers make other sizes, including larger formats such as 48 x 24 inches and 48 inches x 16 inches.

The manufacturing process of porcelain pavers involves molding, pressing and firing at very high temperatures which may result in slight dimensional variation between individual pavers. Consequently, the majority of porcelain pavers are rectified after production, meaning that they have been machined to precise dimensions on all four sides. The rectification process also places a slight bevel on the edge of the pavers.

Typical specifications include the following:

Water absorption: ISO10543-3 <0.1%
Breaking Strength: ISO10543-4 >2500 lbf
Static load capacity EN12825 center >1800 lbf
side center >1100 lbf
diagonal >1500 lbf
Resistance to abrasion ISO10543-6 <145mm2
Static coefficient of friction ASTM C1028-2007 >0.7 dry/>0.7 wet

In terms of installation requirements, structural porcelain pavers have a wide latitude and can be laid on adjustable pedestals for elevated flooring and roof decks; dry laid on compacted sand, gravel or existing concrete surfaces without requiring thinset or grout. When installed over existing concrete, low height support pads, either plastic or rubber, are placed under each corner of the pavers to prevent any rocking due to irregularities of the surface. Fine height adjustment can be achieved if necessary by inserting rubber shims between the paver and the support pads. Structural porcelain pavers can also be used for vehicular applications when laid in a mortar bed on correctly prepared concrete foundations.

Elevated Deck Applications

The primary consideration for elevated deck applications is that the pavers specified must be durable, have sufficient structural strength for the required application, and have sufficient resistance to wind uplift for the specified location.

In elevated decks, pavers are placed over fixed or adjustable height supports, which essentially creates a ‘floating’ deck system. Elevated deck systems provide an easy to install and cost-effective method of building a perfectly horizontal deck surface over a sloping or uneven substrate for constructing decks over duct work, service pipes or electrical cabling.

The use of a pedestal paving system for constructing elevated decks has a number of advantages over more conventional construction methods such as wood bearers. Pedestal systems allow more design flexibility and a wider choice of materials, including structural wood tiles, porcelain pavers, natural stone pavers, concrete pavers, wood or composite wood decking. While concrete pavers have been commonly used because of their comparatively low cost, in the last few years, structural porcelain pavers have been increasingly used because of their advantages over concrete pavers in terms of stain resistance, frost resistance, and lighter weight in particular.

A well designed pedestal system will not damage or interfere with existing waterproof membranes, and can overcome issues where permanent structures may not be permitted. With pedestal systems, pavers can be easily lifted as required for maintenance to service pipes, electrical wiring, ducts, or for inspection of the waterproof membrane. The lighter weight of porcelain pavers can be beneficial where the weight loading on a rooftop may be an issue. In rooftop applications , pedestal paver systems may increase occupant comfort, as roof temperatures can be lowered due to the thermal break between the pavers and the roof surface.

An elevated decking system.

Image courtesy of HandyDeck

An elevated decking system.

While one of the most common applications for pedestal systems is for the construction of rooftop decks over waterproof membranes and/or over service pipes and cabling, another important application where pedestal systems are widely used is for creating water features where the raised surface allows water to drain away quickly via the gaps between each paver.

 

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Originally published in May 2015

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