If you ever demolished a house then you know exactly what tremendous amount of debris has to be transported. Therefore, it is wise to find ways to save money on transportation and reuse some materials.
You can save the cost of transporting debris and build something useful for your household if you reuse broken concrete. Laying down the broken concrete as asymmetrical flagstone pavers you can create strong and durable patios, walkways or driveways. However, due to its irregular shape and thickness, you will have to dig deeper than regular flagstone installation.
Steps to take:
1) Plans, Measures and Excavations
a) Measure the area your future driveway or patio. Draw its shape on a piece of paper. Using wooden stakes and string outline your project.
b) To calculate exactly the thickness of the excavation take in consideration the thickness of the concrete waste (urbanite) plus the thickness of a gravel layer (4 to 6 inches) and the bedding sand (1 inch).
c) Make sure your project has a sufficient slope for a good drainage.
2) Build the Base and Bed of Your Project
a) First, make sure that your project is level. Lay down a wooden board with a level on top and check to see if the area is even. If it is necessary, remove soil to level the area. Make sure the area is enough slope for a proper drainage.
b) Start your base, spreading a half of the layer of gravel (2 or 3 inches). Compact the gravel layer.
c) Add the other half of gravel layer (2 or 3 inches). Compact the second half as well.
d) Next, spread a layer of coarse construction sand (1 inch), compact it and rake it. Thus, you will create a fine bedding layer where you supposed to lay down the concrete pieces.
3) Place the Concrete “Flagstones”
a) Start laying down the concrete pieces with their smooth surface up.
b) Start from the outer edges filling the area with the big concrete pieces and interleaves with small ones.
c) Choose carefully your pieces depending on the shape and type of your project. For example, choose round concrete pieces, which can help you to create a curve for your driveway.
d) When you need it, use a chisel and a hammer to shape a concrete piece. Wear protection gear: gloves, goggles, breathing mask.
e) Use a rubber or wooden mallet to even a piece with the other ones.
4) Lock the Concrete in Place
a) Make sure your concrete “flagstones” are even.
b) Spread coarse sand over your project and sweep it into the spaces between the concrete pieces.
c) This interlocking sand will act as a binder creating a strong surface.
d) Walk many times over until every piece is settled.
5) Finish Your Project
Using iron sulfate you can change the color of the concrete surface creating an interesting brownish, earthy nuance.