Installation Guide - Grass

Suregreen Truckgrid-Max Installation Guide – Grass Finish
Our Heaviest Duty Permeable Paver

Truckgrid-Max porous plastic pavers provide an effective solution to a wide range of trafficking needs where a structured, free-draining and grassed surface is required. Traffic types include pedestrians, bicycles, cars, vans, but Truckgrid-Max is especially suitable for regular trafficking by heavier weight vehicles such as dustcarts, dray lorries, HGVs and forklifts.

Applications include:

  • Industrial yards
  • Forklift loading bays
  • HGV loading bays
  • Emergency access routes for emergency vehicles
  • A busy business forecourt.

Manufactured from fully recycled plastics, Truckgrid-Max porous pavers have been designed to meet the demands and loadings imposed across a wide range of end requirements and site conditions. To ensure Truckgrid Max operates at its optimum working condition over a long period of time (which could be 20 years or more), they need to be installed correctly as per our guidelines described below.

All Truckgrid Max plastic paver installations will have some basic requirements to the construction profile. Some components to the profile will need to be designed to meet the needs of the client, but the elementary building blocks are the same. Please see our design guidelines for further information.


Installation steps

Prior to any work on site, it is highly advisable that a site survey – even if only a rudimentary one – is completed. Ask questions such as:

  • Will the site drain naturally?
  • What slopes - if any - need to be allowed for?
  • What type of surface conditions and what type of soils are on site?
  • Is the type of soil on the surface the same 200 - 400mm under the surface (will draining water be trapped on a non-porous layer?)

You will also need to consider the type of edge retention system or kerb that the Truckgrid-Max porous plastic pavers will require. This should be as substantial as 150mm x 150mm concrete road kerbs due to possible heavyweight lateral loadings. Please refer to our design guide or get in touch with us for any technical advice.


There are four basic layers to any construction profile.

1) The sub-grade

The sub-grade is at the bottom of the profile. This is the layer after removal of the existing soils. This soil is removed to the required depth which has been calculated based on the type and frequency of traffic and the ability of the existing soils to handle imposed loadings. The sub-grade could be as little as 100mm or as much as 500mm below the existing surface. It is advisable that the sub-grade is compacted (by roller or any other method) and an even working surface created.


2) The sub-base layer

On top of the sub-grade, a sub-base layer needs to be installed. The depth of this layer should be pre-determined (please see our design guidelines). This sub-base layer needs to be stable and porous. The sub-base ideally needs to be composed of a free-draining, sharp angular fill material (angular stone or aggregate), 95% of which the particle size is of a mixed nature between 5mm to 45mm (MOT type3 or similar) with reduced fine content which would produce a stable and porous sub-base/hard-core after compaction. MOT type 1/crushed concrete would be generally unsuitable because of the high fine content, leading to minimal porosity and permeability. The sub-base needs to be compacted to the required depth.

At the bottom and the top of the sub-base, a geotextile separation layer needs to be installed. The geotextile will stabilise the sub-base by separating/filtering, and this will limit fine material migration into the sub-base while still being permeable and allowing water to infiltrate. The fines - if allowed in - would cause eventual deformation/dipping of the top surface and drainage issues. On top of the bottom layer of geotextile, a 20KN geogrid can be applied to reduce the depth of sub-base used and also reduce the amount of spill caused by works (please see our design guidelines for guidance). Not all sites will benefit from using a geogrid, mainly due to economies of scale. Please contact our technical team for further direction.


3) The bedding layer

For a grass finish, the bedding layer needs to be free-draining, uniform, level and well-compacted, comprising of a 20mm-thick bedding layer of clean coarse grit sand. Do not exceed the recommended bedding layer thickness. This bedding layer may require compaction using a vibrator plate or roller and must be smooth and level to allow an even surface for Truckgrid-Max porous pavers to be laid onto.


4) Laying Truckgrid-Max

Truckgrid-Max should be laid from above onto the prepared bedding layer, working from one corner laying adjacent paving grids into their connectors. The pavers can be cut on-site using a handsaw, jig-saw or other mechanical saws to match site/client requirements, shapes and obstacles.


5) Filling the pavers

Once installed, fill the paver cells to just below the top of the Truckgrid Max with a free-draining soil such as rootzone. This type of soil mix will encourage rapid grass growth, aid drainage and be structurally sound within the Truckgrid Max cells. It is very important not to fill to the top or overfill the cells, as this will lead to over-compaction during use and the grass cover will degrade.  A single pass with a light vibrating plate machine or roller may be used to firmly bed the pavers and settle the rootzone.

The Truckgrid-Max filled cells can then be seeded using a hard-working grass seed mix, then fertilised and watered if necessary. It is strongly advised that the grass is allowed to become fully established and has been cut a couple of times before the Truckgrid-Max is trafficked, otherwise there is a risk of damage to the tender growing grass.

Please get in touch with us for specific technical guidance if you require trafficking and movements on the Truckgrid-Max before the grass has grown.


Notes on rootzone

In our experience, using a soil fill of 60/40 root-zone will enable you to achieve the best long-term results and optimum working conditions for the Truckgrid-Max pavers. Rootzone is a blend of semi-rounded sands of a selected grain size mix and sandy soils. Rootzone is used on most modern sports pitches, golf courses and for horticultural uses. It has good drainage, encourages rapid grass growth and has a good load-bearing capacity.

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