1

Preparation

Assess the Area: In order for PathBinder to be most effective, the aggregate needs to be well-graded (meaning it has equal amounts of the different size particles) and contain fine dust.

Measure the pathway: To determine the amount of PathBinder needed. Ensure that the pathway has a proper grade for water drainage.

Gather Materials: Based on the area measurements, purchase the required amount of PathBinder. Also, gather all necessary tools for the installation, including a rototiller, grading rake, compactor, and water source.

2

Installation

Tilling the Surface: Begin by tilling the existing aggregate to the desired depth. This will create a loose base to which the PathBinder can be blended.

3

Applying PathBinder

For a 2-inch depth, use 15 pounds per 100 square feet.

Apply evenly over the measured area using a Dropspreader or equivalent, with strong focus on evenly spreading the PathBinder across the entire surface. Do not install in rain or windy conditions.

4

Mixing PathBinder

Thoroughly mix the PathBinder with the tilled aggregate using a rototiller or a similar mixing method. Ensure the PathBinder is evenly distributed throughout the entire depth of the aggregate.

5

Grading the Pathway

Once the PathBinder is mixed in, use a grading rake to smooth the surface to the desired finish. If necessary, add or remove aggregate to create a slight crown for drainage.

6

Moistening the Surface

Apply water evenly across the surface until moisture penetrates the total depth of the tilled area. This activates the PathBinder and is crucial for the binding process.

7

Compacting the Surface

After the surface water has disappeared and the aggregate is moist throughout, compact the area. Use a small riding roller or power walk-behind roller, depending on the size of the project. Minimum 1 ton roller is recommended.

8

Post-Installation Watering

Do a top down soaking of the material directly after compaction to ensure water permeates the full depth of the installation.

9

Drying Time

Allow the finished surface adequate time to dry completely. The set-up time will vary based on weather conditions—expect a longer drying time in cooler or more humid climates.

Final Touches: Establish a maintenance schedule, including spot repairs as needed. Plan for a general surface repair every 1-3 years, depending on usage and environmental conditions.

Note: Remember that proper preparation and following each step carefully will ensure the longevity and performance of your PathBinder pathway.

New Aggregate Installation

1

Optimal Aggregate Composition

Choose well-graded aggregate with a mixture of different-sized particles and sufficient fines to bind well with PathBinder. The aggregate should be sourced from a reliable supplier to ensure consistency in size and quality.

Use a crushed aggregate with the following sieve analysis for best results with PathBinder:

U.S. Sieve No.                              Percent Passing by Weight

# 3/8"                                           100%

# 4                                                90 - 100%

# 8                                                75 - 80%

# 16                                               55 - 65%

# 30                                              40 - 50%

# 50                                              25 - 35%

# 100                                              15 - 20%

# 200                                             10 - 15%

2

Preparation

Base Preparation: Ensure a minimum 3” compacted layer of DOT recommended crushed granular road base. Pre-soak and compact to 95% Proctor Density before the PathBinder application.

Drainage: Ensure proper drainage to avoid standing water on the surface.

3

Blending

Mixing Ratio: Pre-mix PathBinder with aggregate at the rate of 12 to 15 pounds per ton of aggregate, depending on the usage intensity (lower concentration for less used areas and higher for more intensive traffic). Always perform a dry blend.

Bucket Blending:

Set up a clean area to blend the PathBinder with the aggregate. Ensure that this area is free from contaminants and is a controlled environment to prevent material loss.

Add the PathBinder powder into the center of your aggregate pile by creating a volcano-type top to limit material loss when blending. Follow the recommended ratio of PathBinder to aggregate. Ensure thorough mixing by slowly folding the aggregate material over and over so that the PathBinder is evenly distributed throughout the aggregate. Expect a minimum of 30 minutes of blending for a 10 ton pile.

Mechanical Blending:

Use a mechanical blender like a cement mixer, pug mill, or any paddle blender to create an even mix. Ensure thorough mixing for several cycles until uniformly blended.

4

Installation

Applying the Mixture: Spread the PathBinder and aggregate mixture over the prepared base. Grade it to the required depth (3” for light traffic, 4” for heavier traffic).

Water Activation: Thoroughly water the mixture to activate the PathBinder. Use 25 to 45 gallons of water per ton of material, ensuring full depth saturation.

Compaction: Wait for 6-48 hours until the aggregate is dry enough to be ready for compaction. The surface should be dry enough that the aggregate does not stick to the roller upon compaction.  Use a 1 to 5-ton roller for compaction; avoid vibratory plates to prevent separation.

5

Post-installation

Drying: Allow the surface to dry completely, which may vary with weather conditions.

Inspection: Once dry, the surface should be firm and stable with a natural look. Repair any significant surface irregularities.

6

Maintenance

Regular Care: Remove organic debris by blowing or raking.

Winter Care: If plowing is required, use a rubber baffle on the plow blade or lift the blade slightly off the surface.

Annual Maintenance: Redistribute any excess loose aggregate, water thoroughly, and compact again with a power roller if needed.

By following these detailed steps, you will ensure a stable and durable aggregate surface using PathBinder, suitable for a variety of applications from fire lanes to driveways and parking areas.