The mosaic is made in the studio, constructed in pieces of various interlocking shapes that will fit together like a jigsaw puzzle. The pebbles are set, tightly packed, good side down, into a layer of sand in a mould. An industrial strength cementitious grout is poured around the pebbles, and topped with a layer of concrete to a final depth of 7.6 cm (3″). Once the concrete has set, the mould is removed, the sand is washed away, and the mosaic is wrapped in plastic to cure for 28 days. This method ensures a flat surface for walking, and is frost proof.
Once on site, the pieces are laid in a similar fashion to other paving stones. Each piece is numbered and placed according to a plan provided.
The site must be prepared according to its intended usage: pedestrian, light or heavy vehicular traffic. Specs are available on request. There must be a base of crushed stone or concrete, as required. A border of setts to protect the edges should surround each mosaic.
The pieces are transported to the previously prepared site strapped vertically to skids. A member of our team will personally supervise the installation.
For larger mosaics, there should be a base of previously prepared poured concrete. Smaller garden pieces can be placed directly onto a sufficient layer of screenings. It is usually more economical for local tradesmen to do the laying of the mosaic, names available on request.
The joints between the individual pieces of the mosaic will be filled by our team with the same grout that has been used for the casting. This creates a seamless look to the finished piece.
When correctly installed, the mosaic will be very strong and durable. It can be swept with a stiff broom as required, and occasionally cleaned with a cold-water power washer.