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The Proof is in the Plaza
5 minute read
Since its introduction in 2011, Plaza has revolutionised urban design by providing a cost-effective, low-carbon alternative to natural stone paving. Created to fill a crucial gap in the market for public realm and commercial projects, Plaza excels in both aesthetics and performance.
By 2023, Plaza accounted for nearly 40% of AG’s paving specifications, underscoring its enduring popularity and versatility.
The product line has consistently evolved, featuring enhancements in formulation and new format options. Recent data from Plaza’s independently verified Environmental Product Declaration (EPD) confirmed it as the lowest carbon premium paving range available, cementing its status as a benchmark for innovation in the industry.
Plaza’s Evolution
Innovation, one of AG’s core company values, is evident not only in the creation of new products but also in the continuous improvement of our existing lineup. Our commitment to Research and Development ensures that we are always pushing the boundaries of what’s possible. This dedication is exemplified by Plaza’s most recent reformulation, led by Michael Davies, Head of Innovation + Carbon Reduction at AG.
Starting in 2021, a 15-month journey began to reengineer Plaza, optimising its composition to reduce cement content and, consequently, its embodied carbon. By incorporating locally sourced aggregates, supplementary cementitious materials (SCMs), recycled materials, and availing of AG’s advanced concrete technology, Enduur 1, we achieved a 25% reduction in the product line’s embodied carbon while enhancing its strength and durability.
Plaza’s Formulation
Face Mix
- Premium UK-sourced Granite and Quartz aggregates
- Supplementary Cementitious Materials* (SCMs)
- Pigment (dependent on colour finish)
- Recycled Materials*
- Cement
Base Mix
- Aggregates from AG’s sand pit in Pomeroy + quarry in Fivemiletown
- Supplementary Cementitious Materials* (SCMs)
- Cement
* Byproduct of another industry’s production process
Plaza’s Portfolio
Over the years, Plaza’s product line has grown in response to its widespread popularity, now featuring a diverse range of formats tailored to meet the demands of various projects. Covering traffic loads from Category 3 to Category 5 in accordance with the BS 7533-101 standard, Plaza’s portfolio has become a preferred choice among architects and specifiers.
This diverse range demonstrates our dedication to adapting to customer requirements and improving design versatility. To meet rising demand we recently added a new paving block size, 300mm x 200mm x 80mm, to our Plaza collection. This size extends our paving block offering within the product line and is perfect for Category 5: Heavy Vehicle Traffic projects as the dimensions of the paver minimises surface movement.
Plaza’s Production Process
Manufactured at our MASA factory within AG’s Toome production facility, Plaza undergoes a precise three-day production cycle, utilising 100% renewable energy and 90% harvested rainwater.
Step 1
The process begins with the creation of two distinct mixes using exclusively UK sourced: the Base Mix and the Face Mix. Once made, these mixes are pressed together through a combination of vibration and compaction to form the final product.
Step 2
The Face Mix then undergoes a two-step, computer-controlled water-etching process while the product is still wet. First, high-pressure water is applied to the surface, exposing the premium granite and quartz aggregates as well as creating Plaza’s distinctive textured finish. Then, the product is rinsed to remove any loose cementitious material.
Step 3
Following this, the products are cured in a state-of-the-art curing chamber for 24 hours. This controlled curing environment significantly reduces the likelihood of efflorescence, ensuring the final product’s durability and aesthetic appeal.
Watch the Process
Granite Looks with UK Roots
Plaza’s face mix is meticulously blended to create eight richly pigmented hues that authentically replicate natural stone colourways. Our distinctive water-etched production process ensures at least 90% of the UK sourced granite and quartz aggregates are revealed in the surface layer of each Plaza product.
This process also eliminates the need for additional post-curing processing and is less energy-intensive in comparison to traditional methods like shot blasting or bush hammering, leading to a superior textured finish with a lower environmental impact.
The premium aggregates used in Plaza’s mix are carefully graded to 3mm, ensuring an even distribution throughout the mix. This precise grading not only enhances the visual uniformity of the finished product but also contributes to its strength and durability.
Plaza’s Profile
Aesthetics are important, but performance is crucial, and Plaza excels in both areas. With the inclusion of Enduur 1, Plaza benefits from enhanced surface colour, reduced efflorescence, increased strength, and improved resistance to wear and tear. This innovation not only extends the product’s longevity and vibrance but also reduces embodied carbon by 70% per percentage of cement replaced. Additionally, it helps prevent moss, algae growth, and deep staining, ensuring that Plaza retains its original look and durability over time. This is reflected in Plaza’s performance metrics (according to hEN 1339:2003):
>75 Low Potential for Slip Unpolished Slip Resistance (USRV)
Plaza boasts an excellent slip-resistance rating of >75, which is more than double the standard requirements for the built environment. This high rating is crucial for ensuring safety by reducing the risk of slips, falls, and accidents. Additionally, it helps mitigate liability issues and potential insurance claims. Its superior slip-resistance makes it particularly well-suited for projects on gradients or areas where safety is a top priority.
Class 4 Abrasion Resistance
Plaza is rated as Class 4 for abrasion resistance. This classification measures a material’s ability to withstand wear and tear, with Class 4 representing the highest tier. This top rating confirms that Plaza will maintain its appearance and performance over many years, ensuring long-lasting durability and minimal maintenance.
Class 3 Frost Resistance
Plaza’s Class 3 frost resistance rating places it at the top of its category, signifying superior durability under freeze-thaw conditions, especially in environments where de-icing salts are used. The Plaza range can effectively withstand freeze-thaw cycles without significant damage, and their surfaces remain intact against mineral salt over time. These high standards of weathering resistance make Plaza an ideal choice for construction projects in cold climates, guaranteeing structural integrity and longevity.
>5Mpa (Class 3) Bending Strength
Plaza is rated high for bending strength across all flagstone sizes and depths. This property measures a material’s ability to resist deformation under load, which is crucial for paving products as it indicates their capacity to endure the stresses and strains experienced during use. With a bending strength exceeding 5 MPa (megapascals), Plaza demonstrates its ability to handle significant stress before failure, ensuring long-term durability and reliability for demanding applications.
>3.6Mpa (High Strength) Tensile Splitting Strength
Plaza’s tensile splitting strength measures 3.6 MPa across all paving block sizes and depths. This strength indicates excellent resistance to tension, contributing to superior crack resistance, load-bearing capability, and overall durability.
Plaza is manufactured to the following standards:
Paving with Purpose
Plaza stands out for its exceptional sustainability credentials, with the entire range earning a BRE Green Guide A Rating, and selected depths achieving BREEAM A ratings*. Our commitment to reducing environmental impact is further highlighted by Plaza’s recently published and independently verified EPD, which identifies it as the lowest carbon premium paving range on the market. With an embodied carbon measurement of 179 GWP Total A1-A3 kgCO2e per m³, Plaza’s carbon footprint is significantly lower than that of granite, natural stone alternatives, and competitor products.
By integrating Endurr 1 alongside sustainable practices, Plaza offers a greener solution for commercial paving projects. This extends to the installation process: unlike granite, which requires a concrete base and mortar joints—both resource-intensive and carbon-heavy—Plaza can be laid using an unbound method. This approach not only conserves materials but also reduces excavation time and costs. For pedestrian applications (Category 3), AG’s 50mm Plaza only requires a 30mm layer of sharp sand over a 40mm MOT1 aggregate layer, compared to granite’s 100mm concrete bed with 6-10mm mortar joints to comply with BS 7533-101 standards. Thus, Plaza not only minimises environmental impact but also offers cost-effective and efficient installation benefits.
*Achieved with 50-60mm thickness; A+ Rating possible with a prepared recycled sub-base according to the Green Guide to Specification 4th edition 2009.
*According to the UK Governments Statistics on Construction Waste website, 93% of the product is reused on site while the remaining 7% is transported 50km to a waste processing site for landfilling. This study has informed the assumptions made in relation to end of life calculations. Data Source here.
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EPD’s
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Resources
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