How to lay Viblock Concrete Pavers

Viblock pavers are dry cast, so it pays to follow the right laying method from the start. Use the steps below to build a stable base, get a clean finish and help your paving last for years.

Before you start Step by step instructions Sealing your Concrete Pavers Maintenance and care Shopping list Download full PDF guide

What you’ll need

Before you begin, make sure you’ve got everything ready.

Materials:

Viblock pavers. Blend from multiple packs for even colour
Basecourse aggregate. AP20 or GAP20. Use AP40 if you need a thicker sub base
Bedding layer - Dry cast pavers. Clean washed sand about 30 mm thick after compaction
Jointing - Dry cast pavers. Dry jointing sand. Polymeric stabilised sand is OK. Follow its cleanup instructions
Edge restraints. Kerb blocks. Timber. Paver on edge. Concrete haunching
Clean water
Sealer

Tools:

Tape measure and pencil
Pegs and string lines
Spirit level and 3 m straight edge
Plate compactor. Use a rubber or foam mat when compacting over pavers
Shovel, spade, rake and wheelbarrow
Screeding rails. About 25 to 30 mm diameter and 2 to 3 m long
Screed board. About 100 mm by 25 mm and 1.8 m long
Rubber mallet
Steel trowel and pointing tool
Block splitter or a diamond wet saw
Stiff broom and soft broom
Safety gear: Gloves, Safety glasses, Hearing protection, Dust mask

Before you start

Plan drainage and finished height

Set a fall away from buildings
Dry cast - Aim for about 25 mm fall per metre
Keep the finished paving at least 100 mm below the internal floor level of your house

Work out layer thicknesses

Typical patio or path

Basecourse. 100 mm compacted
Bedding layer. 30 mm mortar or sand
Paver thickness. As supplied

Typical residential driveway

Basecourse. 150 mm compacted or more if the ground is weak
Bedding layer. 30 mm
Paver thickness. As supplied

Pro tip: Blend pavers from several pallets as you go. This helps balance natural colour variation for a consistent finish.

Step-by-step laying instructions

Bedding sand with dry sanded joints

Set out
- Mark the area with string lines at finished height
- Allow for basecourse. About 30 mm bedding sand. Paver thickness
Excavate and prepare subgrade
- Remove organics and loose material
- Excavate to suit all layers
- Undercut and replace any soft spots with compacted basecourse
- Shape the subgrade to your planned fall
Basecourse
- Patios and paths. About 100 mm compacted AP20
- Residential driveways. About 150 mm compacted or more if needed
- Compact in thin lifts. Lightly water while compacting
- Bring to exact level and fall. Do not try to level with bedding sand
- Optionally blind with fine crusher dust and compact again for a tight top
Bedding sand
- Place screeding rails about 1 m apart
- Spread clean washed sand between rails
- Screed with your board to about 30 mm thickness after compaction
- Remove rails. Fill and trowel the voids
- Do not walk on screeded sand

Pro tip: On a large job, screed only the area you can lay pavers on the same day. This prevents uneven compaction or moisture changes in the sand.

Lay the pavers
- Start in a corner or along a straight header
- If pavers have spacer lugs, lightly butt them together
- If there are no lugs, keep a 2 to 4 mm gap to stop edge chipping
- On slopes, start at the bottom and work upslope
- Work from the paved area to protect the screeded sand
- Check line and level every few rows

Pro tip: On sloped areas, always start laying at the lowest point and work uphill so rows don’t creep out of alignment.

Edge restraints
- Fit borders such as kerb blocks, paver on edge, timber peg and rail, or concrete haunching
- Borders and restraints should extend at least 50 mm below the bedding sand
- Install restraints before laying except for concrete haunching
- For haunching, remove sand beside the edge course and dig about 50 mm into the basecourse for the haunch. Let it cure before compacting
Jointing and compaction
- Make sure the surface and joints are dry
- Sweep dry jointing sand into all joints until they are full
- If using polymeric stabilised sand, follow the packet for watering and cleanup
- Compact using a plate compactor with a rubber or foam mat
- Do not compact large thin flagstones with a plate compactor. Use a rubber mallet instead
- After the first pass, top up joints. Compact again. Repeat until joints stay full
- Sweep clean
Final check
- Check fall. line. level. and that all joints are full
- Inspect edges and restraints

Finishing and sealing

Decide if sealing is right for your area

Sealing is optional. It helps with cleaning and stain resistance and can enhance colour
It is useful under trees. near BBQs. and in shady areas that grow moss or mould

Clean before sealing

Treat stains now
If needed you can acid wash using about 20 parts water to 1 part Spirit of Salts
Rinse very well and allow to dry completely

Choose the sealer

Penetrating dry look sealer is suitable for dry cast

Apply the sealer

Follow the sealer label. Test a small hidden area first
Apply in the recommended conditions. Clean and dry surface. No rain expected

Pro tip: Sealing helps prevent oil and grease marks and makes future cleaning easier. Reapply every few years depending on traffic and weather.

Maintenance and care

Sweep often to keep dirt and leaves off the surface
Wash with water and a mild cleaner
Replace damaged pavers promptly to prevent shifting.
For moss and mould you can use a chlorine bleach based cleaner. Brush. Then rinse well
Use a water blaster with care. Keep a sensible distance. Do not blast directly into joints
Top up dry sand joints if they settle after rain or heavy use
Let any concrete edge haunching cure for 2 to 3 days before vehicle traffic
Watch for white bloom called efflorescence. It is normal. Good drainage and dry storage help minimise it
Replace any cracked or loose pavers promptly

Pro tip: If you see white powdery patches (efflorescence), don’t worry, it’s normal and will usually fade. Good drainage and dry storage before installation help reduce it.

Note: Product instructions shown here are provided for guidance only and may not reflect current advice. Please refer to the manufacturer’s documentation for most up to date instructions.