How To Lay a Resin Bound Driveway

While Moli would always recommend hiring a professional to install a resin bound driveway we understand some clients want to understand the process of how to lay resin driveways themselves.

Drawing on years of experience from Moli’s expert installation partners, here’s a basic step-by-step guide on laying a resin bound driveway.

Resin bound applications

Resin bound surfacing is perfect for creating durable, smooth, and permeable surfaces and is suitable for:

• Driveways
• Patios
• Pathways
• Pool surrounds
• Car parks
• Courtyards and more.

We will specifically focus on resin bound gravel driveways but this process can be applied to many other settings with minor adjustments.

Recommended resin bound materials and tools

Before starting you should get together all the materials and equipment. Here’s what you’ll need:

Materials

• UV stable polyurethane resin
• Washed and dried aggregates
• Sand/Binding quartz
• MOT type 3 sub-base
• Open graded tarmac AC10-14 or no fines concrete base
• Catalyst (accelerator for curing in colder temperatures)

Tools

• Forced-action mixer
• Paddle Mixer
• Hover trowel or hand trowels
• Kneeling pad
• Plastic lined wheelbarrow (for transporting the mix)
• Rake/Spazzle or screed sledge
• White spirit/trowel cleaner
• Bag splitter
• PPE
• Small paint brush

Before you install

Before the installation, there are a few things we need to check:

• Is the surface suitable? – At Moli we offer two systems, these are our Transformation and Makeover options. A ‘Transformation’ can be installed anywhere and involves creating a new sub-base and base for the product. A ‘Makeover’ is where we try to use the existing surface. To do this the base needs to be either tarmac or concrete and must be solid, intact and without any major defects.
• What edgings are required? – Resin bound needs to be installed with solid edges around it to ensure longevity. This can be existing stone/brick walls, new block edging or pin kerbs.
• What do you want as an end result? – The two systems offered have slight differences in features and benefits. The transformation option has benefits such as zero weeds and zero puddles because the base can be created to achieve this. The Makeover package relies on the existing surface which will likely be non porous. This means it is very cost-effective and good value for money, however, while it will allow water to drain through the resin bound surface puddles can still occur as the base does not allow water to pass through. As such you may need to consider falls in the surface and creating drainage solutions.

The example below will take you through the transformation system of laying a resin driveway

Preparation

Resin bound does not react well with moisture. It is therefore important to pick a day for the resin install which is dry with a low chance of precipitation. In addition, the reaction between the resin components will not take place below 5c so the temperature on the day also plays a factor.

Before applying a resin bound surface, ensure the area is completely clean and dry, as any moisture or debris can affect the quality of the finish.

It’s important to measure and monitor the ambient temperature, relative humidity, and ground temperature before and during installation. There are more details within step 2 on how to counter those cooler days.

Pre checks before starting

Before starting perform the following checks;

Tools

• Lay out all necessary tools, such as mixers, trowels, and spazzles, to confirm they are in good working order.
• Verify that protective equipment (PPE) like gloves, masks, and goggles are available for the team.

Materials

• Ensure all materials, including resin and aggregates, are on site and meet quality standards.
• Check batch numbers and consistency to ensure uniform colour and texture throughout the mix.
• Confirm that the resin has been stored according to manufacturer guidelines.

Rain

• Ensure there is no rain forecast during and immediately after installation, as moisture can interfere with curing.
• Have a cover or canopy available to protect the surface if rain becomes unexpected.

Surface Checks

• Verify that the surface is clean, dry, and free from contaminants.
• Confirm that the surface temperature is at least 3°C above the dew point to avoid condensation issues.
• Check for any cracks, weak spots, or surface damage that might affect bonding.

Step 1 – Prepare the sub base

A solid base is essential for a resin bound driveway. Follow these steps for optimal base preparation:

1. Dig Out – The area will need to be excavated down to 250-300mm to allow for each layer of the system
2. Lay the MOT Type 3 Sub-Base – Spread an MOT Type 3 sub-base to a depth of 150-200mm, compacting it thoroughly with a plate compactor
3. Edgings – Where necessary block edgings or pin kerbs will need to be concreted in place
4. Lay the Open Grade Tarmac or No Fines Concrete – This layer needs to be approximately 80mm thick and applied over the sub-base. Once compacted well this should leave between 18-20mm for the resin bound layer.
5. Inspection – At this stage, it’s ideal to scrutinise the area and check for any low spots or edgings. Ensure any manholes which have been replaced are at the correct height and get ready for the next stage.

Step 2 – How to mix the resin

The quality of your mix is key to a durable resin bound driveway.

1. Combine Resin Components – Our Aliphatic Polyurethane resin is a 2-part system. Part A is a polyol and this is in a larger bucket. The Part B is a HDI Trimer. The part b is to be poured into the part a.
2. Add Catalyst – If the temperature outside is between 5-15c catalyst must be added to ensure the correct curing time. To ensure keeping the working time per kit to 40 minutes and the correct cure rate here is the ratio of catalyst based on weather. 5-8c add 3ml of catalyst, 9-12c add 2ml of catalyst, and finally for temperatures between 13-15c add just 1ml of catalyst.
3. Mix Thoroughly – Using your paddle mixer insert this into the bucket and mix on a medium speed for 90 seconds. The reaction is exothermic so 90 seconds is important to ensure the reaction can begin correctly.

Step 3 – Mixing resin, aggregates and sand

Follow this process to ensure an even, strong mixture:

1. Add Aggregates to Mixer – With the resin ready, add 4 bags of the washed and dried aggregates to the forced action mixer and let it run for 30 seconds to release any excess dust.
2. Add the Resin and Sand – Add the resin mix into the mixer ensuring you get all of it out and into the mixer. Once the resin has been added you can now add the sand/binding quartz. Set a timer for 3 minutes and let the material thoroughly mix ensuring no dry spots within the product. It’s important to mix every batch for the same amount of time and add products in the same order. As little as 30 seconds extra in the mixer can mean the colour of it can vary from batch to batch.
3. Stop the Mixer – Once you have hit three minutes you can then open the chute and allow the material to fall into your wheelbarrow underneath. Ensure all of the batch is removed from the mixer to avoid contaminating the next mix.

Step 4 – Moving the mix to the work area

Transporting and spreading the mix effectively is essential for a smooth surface.

1. Transport in Small Batches – Use your wheelbarrow to move material from the mixer to the driveway.
2. Pick your starting point – remember once you lay the resin it’s not possible to walk on it for at least four hours. As such plan where should be laid first and last to work your way around the site. An example on a driveway would often be starting at the garage and working your way to the driveway entrance/exit.
3. Don’t Stop – Sadly to install the driveway without any join lines it’s necessary to not stop once you’ve started the first mix of resin bound. Assign roles on site such as “Trowel”, “Mix” and “Wheelbarrow”. Even the most accomplished three person team can only lay between 150-250m2 per day. More people may be needed on-site to ensure the perfect finish and longevity of the driveway.

Step 5 – Laying the resin bound driveway by trowel

Achieving a smooth, durable finish requires precision and patience.

1. Spread the Resin Mixture Evenly – Tip the material out of your wheelbarrow in the space you want that batch to be laid then use your rake/spazzle or a screed sledge to spread the material out ensuring a level surface of approximately 20-25mm thick.
2. Smooth with Trowel – Then using your hand trowels or a hover trowel compact the surface down to 18-20mm and smooth out. Take your time and keep standing back to inspect and look for any trowel marks on the surface.
3. Work in Small Sections – Resin bound working time is around 40 minutes per kit, as such focus on getting each mix fully compacted and smooth before getting the next onto the surface.
4. “Fluffy Edges” – As you approach the last of each batch the temptation is to thin/feather this down, don’t! Instead, create a mound/peak at the end of the mix you are working on. Then when the next mix goes down blend the two with your trowel. This will help knit multiple kits together seamlessly.
5. Check for Consistency – As you work take the time to scrutinise every batch and ensure the surface doesn’t dip anywhere and the correct depth is being achieved.
6. Spread Rate – Each kit of resin and aggregates should cover between 3.2-3.5m2. Make sure this is the area you are covering with each mix to guarantee the depths are correct and that you won’t run short of material. Tip – It can help to use some line marking spray paint to mark out every 3.5m2 on the surface.

Tip: Keep the trowel clean and well-lubricated to avoid it sticking and dragging across the surface. Use your white spirits or trowel lubricant.

Step 6 – Finishing touches and completion checks

Before calling the job complete, review these final steps to ensure a professional result:

1. Inspect the Surface – Inspection should be happening throughout the installation, however a final look over the surface may show things that can be fixed if accessible.
2. Protect the Area – Typically, resin bound surfacing takes 4-6 hours to cure enough for light foot traffic and up to 48 hours for vehicles. Barrier tape will help alert delivery drivers or similar from walking on the surface and leaving footprints.

In summary

Thank you for reading Moli’s guide to laying resin bound surfaces. Whether you’re considering a DIY installation or seeking professional expertise, we hope this breakdown has clarified each step.

If you have any questions, please don’t hesitate to reach out. Moli is always happy to offer a quote for resin bound systems, including driveways, patios, and pathways.

An instant free online quotation tool is also available which can give you a price for the supply and installation of your dream resin bound driveway.