Sudspave 40 – Design & Installation Guidance for Gravel Surfaces

Sudspave® Porous Aggregate Surface

Sudspave is a recycled plastic cellular porous paving solution for use in Sustainable Drainage Systems (SuDS). Sudspave is suitable for a wide range of trafficked applications where a stabilised, free-draining gravel surface is required. Typical applications include: car parks, emergency access, maintenance routes, cycle paths, pedestrian and disabled access. Considerations relating to the movement and attenuation of water within the porous pavement are not covered in this document. This document is intended to be a summary presenting typical solutions. Contact us for site specific advice.

Installation and design guidance for ABG Sudspave 40 porous pavers for permeable gravel surfaces

Installation and design guidance for Sudspave 40 porous pavers for permeable gravel surfaces

Sudspave® installation process

The following generic guidance must be read in conjunction with the specific project specification within the contract documents

1. Install the specified lower filter/separator Bontec NW8 geotextile and subbase stabilisation onto the prepared subgrade formation.

2. Install the specified subbase and edge restraints.

3. Install the upper filter/separator Bontec NW8 geotextile geotextile on top of the subbase.

4. Install the specified bedding layer to a uniform thickness.

5. Ensure an accurate right-angled Sudspave laying pattern by setting-out the site using pins and string-lines. Check the lines regularly for accuracy. Start installing the pre-assembled Sudspave panels (4 units/m²) by placing the webbed face downwards onto the bedding layer. Place the panels with the T-shaped lugs facing in the direction of laying on the two leading edges, with the clip-slots on the reverse-edges.

6. Progress across the site in rows by slotting panels together in a downward motion, ensuring that the 8 self-lock clips-slots engage fully with the T-shaped lugs on adjacent panels.

7. Avoid starting more than 2 new rows of panels prior to completing the row which is in progress. Avoid installing in a diagonal pattern too far ahead of completed rows. Regularly check and adjust the completed leading edge to ensure that it is straight. It is recommended that protective gloves are worn to avoid abrasions during installation.

8. Individual paver units can be separated if required. Insert the tip of a flatblade screwdriver between each side of T-lug and the slotted paver-face in turn. Gently twist the blade to dislocate each clip-lock & lug, whilst lifting the slotted unit up and apart. Do not force clips open or pull pavers apart as this will break clips.

9. Sudspave can be cut to fit around curves or obstacles using a hand-saw or disc-saw. Using cut-pieces which do not have integral T-lugs & clips should be avoided wherever possible. However, if use of small pieces is unavoidable, these must be securely attached to adjacent panels using strong cable-ties or appropriate screws.

10. Installation of parking bay/line marker inserts is best done prior to filling cells. Push markers into the round cells until they click and lock into place. Rotate slightly to fit if required.

11. Fill the cells with the specified aggregate, so that the final level is to the top of the cells. If placing pavers and filling the cells simultaneously, it is important to keep bulk materials and vehicles away from the leading edge to avoid distortion. Do not drive vehicles on the installed panels until cells are filled with aggregate. Do not over-fill or surcharge the cells unless specified by the designer.

12. After initial settlement and trafficking, aggregate may need topping up.

13. A routine management and maintenance programme, to keep the surface in good condition and free of debris and weed growth, will help to sustain the porosity, quality and longevity of the system.


  • Advice on subgrade CBR% strengths, ground conditions and construction over weak ground is available.
  • Maximum subbase particle size should match minimum subbase thickness, but must not exceed 75mm diameter. For subbase thicknesses of around 100mm, a minimum 37.5mm particle size should be adopted to allow effective installation of the grid.
  • Typical paving edge restraint solutions include: concrete, timber, railway sleepers, steel and heavy-duty plastic.
  • The subbase may be overlaid by an Bontec NW8 geotextile to provide enhanced water treatment function if required.
  • To provide a stable bedding layer for Sudspave, the bedding layer must not be sand.
  • The maximum advised gradient for vehicular trafficked applications is generally 12% (1:8) 7°. For Disabled access applications, a maximum of 8% (1:12) 5° is suggested.
  • All stated dimensions & weights are nominal and in accordance with manufacturing +/- tolerances.
  • The recommendations in this document are only suitable for use with our products.