Porcelain Pavers: How Layout & Material Size Affects Cost

White Paper by Steve Lasek

When designing exterior space, at some point budget typically comes into consideration. Designing an outdoor space with a raised paver system is no exception. Additionally, since outdoor space is sometimes considered amenity space, it may be subject to value engineering.

When evaluating material costs for these systems there are two major components:
1. the finish material (paver) and;
2. the setting material (pedestals).

Assuming that all project stakeholders agree on the importance of material quality and do not want to reduce cost by selecting cheaper material, the question usually becomes, “How can cost-savings be achieved without sacrificing material quality?” The answer lies in changing the paver layout and/or size of the paver itself. 

Keeping it simple, imagine a 5,000 square foot (SF) recreational finished roof deck space at a corporate office building. Consider the following two scenarios.

Scenario 1

Paver Size 24″x24″ Nominal Pavers
Layout Running Board
Pedestal Height Averages 5″
Sloped Roof Deck 1/4″ Per foot must be offset in paver installation

Scenario 1 with 24x24 Nominal Porcelain Pavers Running Board

  • Project required 3,000 pedestals
  • At roughly $10/pedestal assembly + $7.00/SF for the paver = total material cost $65,000

In this case, changing the pattern to stacked bond decreased the number of pedestals required:

Paver Size 24″x24″ Nominal Pavers
Layout Stacked Bond
Pedestal Height Averages 5″
Sloped Roof Deck 1/4″ Per foot must be offset in paver installation

Scenario 1 with 24x24 Nominal Porcelain Pavers Stacked Bond Cost

  • Project required 1,950 pedestals
  • At roughly $10/pedestal assembly + $7.00/SF for the paver = total material cost $54,500

This adjustment yields a material savings of $10,500 (16%), without sacrificing material quality and without having to reselect finish material.

Scenario 2

Scenario 2 with 12x48 Nominal Pavers Stacked Bond

Paver Size 12″x48″ Nominal Pavers
Layout Stacked Bond
Pedestal Height Averages 5″
Sloped Roof Deck 1/4″ Per foot must be offset in paver installation
  • Project requires 3,750 pedestals
  • At roughly $10/pedestal assembly + $8.50/SF for the paver = total material cost $80,000

In this case, a wider paver was implemented into a nicer looking 1/2 running bond, decreasing the number of pedestals required:

Scenario 2 with 16x48 Nominal Pavers 1/2 Running Bond

Paver Size 16″x48″ Nominal Pavers
Layout 1/2″ Running Bond
Pedestal Height Averages 5″
Sloped Roof Deck 1/4″ Per foot must be offset in paver installation
  • Project requires 2,750 pedestals
  • At roughly $10/pedestal assembly + $7.50/SF for the paver = total material cost $65,000

This adjustment yields a $15,000 savings (19%).

The Creative Materials team understands that all projects have different requirements. Although numbers in this whitepaper are hypothetical, they factually represent how cost savings can be achieved. Creative Materials regularly consults with architects and designers to determine the best solution to meet specific project needs.

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