AU2011274253B2

AU2011274253B2 - A modular vegetating arrangement and media

Info

Publication number: AU2011274253B2
Application number: AU2011274253A
Authority: AU
Inventors: Mark Paul
Original assignee: EX PARROT Pty Ltd
Current assignee: EX-PARROT Pty Ltd
Priority date: 2010-07-02
Filing date: 2011-07-04
Publication date: 2014-08-14
Anticipated expiration: 2031-07-04
Also published as: GB201301840D0; WO2012000063A1; GB2495262B; GB2495262A; AU2011274253A1; NZ606487A

Abstract

A plant growth media is provided. The plant growth media comprises a particulate lightweight carrier material, a particulate cation exchange medium and a binder, for binding together the lightweight carrier material and the cation exchange medium to provide in combination a lightweight conglomerate. A modular vegetating arrangement comprising a containment structure, an outer penetrable layer which can be penetrated by plant growth carried on the containment structure; an inner wicking layer; plant growth media located between the outer penetrable layer and the inner wicking layer, and a barrier layer adjacent the inner wicking layer, is also provided.

Description

WO 2012/000063 PCT/AU2011/000836 A modular vegetating arrangement and media Field of the invention This invention relates to a modular vegetating arrangement, as well as to modules making up the vegetating arrangement, and to the plant growth media used in such 5 modules. Background of the invention Recently, there has been an increasing trend towards "greening" the urban environment. This has been driven by various factors, including environmental concerns related to global warming and the resultant drive towards making existing and 10 new buildings "carbon neutral", With outdoor horizontal surfaces being at a premium in urban environments, there has been greater usage of vertical surfaces and roof areas to establish wall and roof gardens or "green cladding", The resultant mass of soil and foliage can create significant structural challenges. In addition, there are safety issues associated with 15 green cladding, in particular in windy environments where the existence of heavy and dislodgable structures Is potentially hazardous. There are also challenges associated with providing efficient and uniform irrigation throughout the entire green clad area, without adding significantly to the overall load on the system. 20 In addition (or in alternative) to meeting these challenges it would be desirable to provide arrangements that are durable, incorporate recycled components, and/or that are easy to install, establish and maintain. Reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that this prior art forms part of the common 25 general knowledge in Australia or any other jurisdiction or that this prior art could 2 reasonably be expected to be ascertained, understood and regarded as relevant by a person skilled in the art. Summary of the invention According to a first aspect of the invention there is provided a plant growth media 5 comprising: a particulate lightweight carrier material; a particulate cation exchange medium, wherein the carrier material comprises particles of polystyrene foam having an abraded surface; and a binder, for binding together the lightweight carrier material and the cation 10 exchange medium to provide in combination a lightweight conglomerate. The lightweight carrier material may have a porous or abraded surface and a density of less than 1000kg/cubic metre, preferably less than 500kg/cubic metre, more preferably less than 250kg/cubic metre, still more preferably less than 100kg/cubic metre, still more preferably less than 100kg/cubic metre and greater than 15kg/cubic metre, still 15 more preferably less than 50kg/cubic metre and greater than 15kg/cubic metre and still more preferably less than 30kg/cubic metre and greater than 15kg/cubic metre. The lightweight carrier material may further comprise particles selected from a group consisting of polyurethane expanded foam, expanded perlite, charcoal and pumice stone. 20 The cation exchange medium is preferably a clay or clay mix, more preferably a bentonite and still more preferably a low-sodium bentonite. The plant growth media may further include additional material such as one or more of dolomite, gypsum, diatomaceous earth, coral sand, charcoal, peat, bark and slow release fertiliser.

WO 2012/000063 PCT/AU2011/000836 3 The plant growth media Includes as a dry mass 20-95% (preferably 60-90%, more preferably 65-85% and still more preferable 70-80%) lightweight carrier material, 0.1 30% (preferably 0.5-4% by volume of a binder, and 0.1-10% (preferably 0.5-1%) by volume of a clay. 5 The media may be supplemented with further material, proportionately reducing the overall percentage by volume of foam, caffon exchange medium and binder. A proportion of the media greater than 40%, preferably greater than 65% and more preferably greater than 75%, may be relatively inert or resist degradation to the extent that the media has a useful life of greater than 5 years, preferably greater than 10 years 10 and more preferably greater than 20 years. The binder binds together the media in such a way that the relatively high and low density particles, and particles of different sizes, form a lightweight conglomerate having a relatively consistent particle distribution in contrast to a loose mixture in which particles of differing densities and sizes may separate out to form an inconsistent and 15 irregular mixture. The conglomerate may be loosely or tightly bound together depending on the quantity of binder. The particle size range of the expanded polystyrene is typically 55% below 8mm (with an average particle size of I to 2mm) and 45% with a size range from 8 to 200mm (with an average particle size of 12mm). 20 The binder is typically a cement such as an hydraulic cement, and preferably a Portland cement, but may also be a starch, resin or an acrylic-based binder. The media may further include 0.1-2.5% by volume dolomite (such as Brunnings Dolomite supplied by Brunnings Garden Products), 0.1-2.5% by volume gypsum, 0.4 16% by volume slow release fertiliser prills (typically Including Nitrogen, Phosphorus, 25 Potassium and trace elements such as Osmocote) 'TOTAL All Purpose" fertiliser supplied by-Scotts Australia) and 2% by volume charcoal (such as agrichar).

WO 2012/000063 PCT/AU2011/000836 4 According to a second aspect of the invention there is provided a modular vegetating arrangement comprising: a containment structure; an outer penetrable layer which can be penetrated by plant growth carried on the 5 containment structure; an inner wicking layer; plant growth media located between the outer penetrable layer and the inner wicking layer, the plant growth media being a lightweight conglomerate of the type described above; and 10 a barrier layer adjacent the inner wicking layer. Preferably, the barrier layer includes a lightweight semi-rigid panel adjacent the inner wicking layer. The panel may be covered with a waterproof sheet. In a further embodiment of the Invention, there is provided a modular vegetating arrangement comprising a sheet configured into a profile defining a plurality of 15 containment regions, each containment region comprising: a containment structure; an outer penetrable layer which can be penetrated.by plant growth carried on the containment structure; an Inner wicking layer; 20 plant growth media located between the outer penetrable layer and the inner wicking layer, the plant growth media being the lightweight conglomerate of the type described above; and a barrier layer adjacent the inner wicking layer.

WO 2012/000063 PCT/AU2011/000836 5 Brief description of the drawings Figure 1 shows a partially schematic exploded front perspective view of the various components or layers making .up a first embodiment of a vegetating module of the invention; 5 Figure 2 shows a cross sectional top plan view of the vegetating module of Figure 1 in an assembled condition; Figure 3 shows a cross sectional top plan view of a second embodiment of a vegetating module of the invention; Figure 4 shows a cross sectional top plan view of a third embodiment of a vegetating 10 module of the invention; Figure 5 shows a cross sectional top plan view of a fourth embodiment of a vegetating module of the invention; Figure 6 shows a cross sectional top plan view of a fifth embodiment of a vegetating module of the invention; 15 FIgure 7A shows a top plan view of a one of the vegetating modules of Figures 1 to 6 with a drip irrigation package in position; Figure 7B shows a cross sectional view of the drip irrigation package of Figure 7A along lines 7A-7A of Figure 7A; Figures 7C and 7D show a top plan view two further examples of a drip irrigation 20 package to be used with the vegetating modules of the present invention. Figure 8 shows a cross sectional side view of an embodiment of a rooftop module of the invention; Figure 9A shows a cross sectional top plan view of a square tuttular vegetating module of the Invention; WO 2012/000063 PCT/AU2011/000836 6 Figure 9B shows a cross sectional top plan view of a round tubular vegetating module embodiment of the invention, Figure 10 shows a cross sectional side view of a vegetating wall or roof arrangement of the invention made up of a number of vegetating modules, and 5 Figures 11A, 11B and 11C show cross sectional top plan views of various mounting arrangements used to mount various different types of vegetating modules to a vertical structure such as the wall of a building. Figures 12A, 12B and 12C show cross sectional top plan views of single mesh sheets which can be used to form gabions to house vegetating modules of the invention. 10 DelaIled description of the embodiments Referring first to Figure 1, a first embodiment of a vegetating module 10 of the invention is made up of various layers designed to support plant material 11 having a high biodiversity. The layers include an outer gabion 12 formed from a metal or plastic mesh -which is relatively rigid but lightweight. In the particular embodiment, the mesh is 15 formed from aluminium alloy and has a diamond or triangular mesh pattern, with the mesh size typically being 50-200mm, and preferably 80-120mm. The mesh gabioh Includes a front wall 12a, sidewalls 12b and 12c and a rear wall 12d. Top and bottom walls 12e and 12f are also provided. A protective coat 14 of polyester non-woven textile, recycled polyester felt, gravel or tile 20 chip paper or coir (for example 'Regar 200 denier polyester wadding manufactured from recycled PET and supplied by the Tontine Group may be used) is located internally or externally of the mesh. If located externally, a light mesh (such as nylon bird netting), is used to retain the layer in position. Located internally of the protective coat is a 20mm thick polyester wadding 15, suitable for unimpeded plant growth and preferably non 25 woven and recycled such as 'Regal' 200 denier polyester wadding supplied by the Tontine Group.

WO 2012/000063 PCT/AU2011/000836 7 The innermost layer is constituted by loosely bound plant growth media 18 which has as a major component bound recycled expanded polystyrene particles. Various formulations of the bound growth media 18 will be described further on in this specification. 5 A polyester or viscose wicking layer 20, such as Bidim@ "A14 supplied by Geofabrics Australasia, is provided rearwardly of and directly adjacent the plant growth media 18 and is also in direct contact with a drip irrigation package 22 which is located in a removable and accessible configuration above the module. A semi-rigid expanded polystyrene sheet 24, which may range in thickness from 10 10 50mm but in the present embodiment Is 15 mm thick, is provided adjacent and rearwardly of the wicking layer. This is covered by a covering 26 comprising either a permeable woven polypropylene or nylon fabric, or alternatively a waterproof vinyl or polyurethane pond liner. The layers 24 and 26 provide a barrier on the building/wall side of the wicking layer. 15 The rear wall 12d of the mesh gabion 12 is located directly rearwardly of the semi-rigid expanded polystyrene sheet 26. A further component of the vegetating arrangement is a plantroom illustrated schematically at 28. This includes a nutrient tank, a power and water supply, an irrigation controller, a backflow prevention arrangement Including various solenoid 20 operated valves, and arrangements of filters and low volume dosers. The plantroom may also'include pumps for recycling water (including rainwater, grey water and black water) and/or increasing water pressure. Referring now to Figure 2, the vegetating module 30 is shown made up of the various layers illustrated in Figure 1. For the sake of clarity, the mesh gabion 12 is not shown. 25 In Figure 3, a double-sided module 32 is shown. This is conigured for double-sided planting, with plant growth media 18a and 18b being located on either side of an Internally positioned expanded polystyrene foam slieet 24, opposite sides of which are WO 2012/000063 PCT/AU2011/000836 8 covered with a viscose or polyester wicking layer. With additional structural reinforcing modifications, this embodiment can be used to provide a "green column". Referring now to Figure 4. a "wetland" vegetating module 34 is shown which is similar to the module 30 of Figure 2, save that the covering 26 includes a waterproof vinyl or 5 polyurethane pondliner 26 is used to confine a larger or more constant water supply completely within the module. In Figure 5, a vegetating module 36 is shown in which the plant growth media 18c is made up of a fully bound sheet. The other layers are similar to that of Figures 2 and 4, save that establishment of plants is achieved by a layer of paper 38 impregnated with 10 seed or spores. Alternatively, the seed or spores may be spray coated onto the front face of the bound plant growth media 18c. Referring now to Figure 6, a vegetating module 40 is shown having a 50:50 arrangement of bound and loose plant growth media. A pyramidal array of plant growth media 42 having additional binder to form a solid sheet is alternated with pockets 44 of 15 more loosely bound media. This arrangement combines the advantages of ease of planting associated with more loosely bound media with the structural rigidity provided by the more fully bound portions 44. Referring now to Figure 7A, a drip irrigation package 22 is shown. This includes three parallel drip irrigation pipes or lines 46, preferably of 16mm diameter flexible plastic 20 tubing, connected to a manifold 48, preferably of 19mm diameter flexible plastic tubing, which is in turn coupled to a swing arm 50, preferably of 13mm diameter flexible plastic tubing fitted with an inlet 52 for connection with the rest of the irrigation system, preferably comprising 19mm diameter flexible polypropylene (PP) plastic tubing. The swing arm 50 is able to pivot freely at elbow 54 to provide for easy installation and 25 access for service. As can be seen in Figure 7B, each of the irrigation pipes or lines 46 is covered with an inner layer of viscose material, such as 80gsm non woven 70% viscose/30% polyester material supplied by Asia Pacific Brands, and two outer layers of non-woven polyester 9 58 and 60, bidim@ "A14" supplied by Geofabrics Australasia. These layers serve to retain moisture and spread it evenly across each module and to minimise root and plant invasion into the irrigation lines 46. Figure 7C shows an alternative arrangement for the drip irrigation package, wherein the 5 swing arm 50 is coupled to larger diameter pipe 53 that substantially traverses the largest dimension of the module. The larger diameter pipe 53 is connected to narrower pipes or lines 46 which are attached to the larger diameter pipe 53 in a comb arrangement. The narrower pipes 46 are generally parallel to one another and lie along the shorter dimension of the module. 10 Figure 7D shows yet another arrangement for drip irrigation package, wherein the swing arm 50 is coupled to a central manifold 55 with pipes 46 radiating from the central manifold. Referring now to Figure 8, the application of the vegetating module 40 to a rooftop is shown. The module 40 is positioned on top of a capillary mat, itself above a waterproof 15 roof membrane 62. Drainage cells 64 and 66 are provided on either side of the module 40, and include an expanded polystyrene foam sheet 68 covered by scoria 70 for drainage purposes, but could alternatively incorporate a recycled plastic drainage cell. A layer of nylon "prawn" mesh 72 is passed beneath of the drainage cell 66 and covers the module 40 to provide additional plant and media stability. 20 In Figures 9A and 9B, respective square and tubular vegetating modules 80 and 82 are shown. Each module includes an internal tubular metal or plastic support 84 surrounding by expanded polystyrene foam 86, a viscose or polyester wicking layer 88, growth media 90, polyester wadding 92 and an outer metal or plastic mesh 94. Referring now to Figure 10, a vegetating arrangement 100 is shown made up of 25 vegetating modules 30a, 30b and 30c which are mounted into position to a vertical wall 102 via bracket assemblies 104. The top wall 12e of each gabion is tapered to provide space for main irrigation lines over, and access to, the irrigation packages 22. Further, each point of connection between the irrigation packages 22 and the lines 46 (see Figure 7A, not shown in Figure 10) is positioned above or within a vegetating module I w - 1~ v IV'' 10 30a 30b or 30c so that any leaks or drips can be captured. Felt covered foamed polyethylene backing rods 106 serve as packing strips to fill the gaps between adjacent modules. In Figure 1 1A, a first embodiment of a mounting arrangement 110 is shown. A threaded 5 rod 112 is chem-set into the wall 102, and is fitted with a plastic spacer 114. A fastening cleat 116 engages the outer walls of each mesh gabion module, and secured viaa nut 118. Referring now to Figure 11B, a bracketing arrangement 120 for doubled sided gabion modules 32 is shown. This includes a central support post or column 122 from which 10 support bracket plates 124 extend at intervals corresponding to the top and bottom walls of each gabion. The post 122 is covered by foamed polyethylene backing strips 126 which are covered in felt or another non-woven geofabric. In Figure 11C, a bracketing assembly 128 for a strip facade vegetating module 130 is shown. The bracketing arrangement includes a C-section 132 which is fixed in position 15 via fasting bolts 134, and which also includes a central post 136 from which base support plates 138 extend at intervals. Figure 12A shows a cross section of a single sheet 140 which may be configured to form a series of gabions 141, 143, 145, 146, 148 mounted on vertical wall 102. The single sheet 140 is formed from wire mesh/plastic mesh which is pressed or moulded 20 into a castellated profile. The single sheet 140 forms front wall 12a, sidewalls 12b and 12c of gabion 141. Further sheets of wire mesh or cloth may be used to form back wall 12d, and the top and bottom walls (not shown). The gabions 141, 143 and 145 may enclose vegetation modules as described above. This creates an arrangement of columns of vegetation modules fixed to wall 102. Alternatively, or in addition, a further 25 sheet, or sheets, of wire mesh or cloth 144 may be attached to single sheet 140 to form the front wall 12a of gabions 146 and 148. Gabions 146 and 148 may also be used to enclose vegetation modules and if gabions 141, 143, 145, 146 and 148 are all enclosed, a solid wall of vegetation modules can be formed. Use of the single sheet 140 is advantageous because it allows for a variety of different arrangements to be formed 30 from the one sheet.

11 The single sheet 140 may be shaped to provide gabions having different profiles. Further examples are shown in Figures 12B and 12C, which show single sheets 152 and 154 which are formed into zigzag and trapezoidal profiles respectively. Single sheet 152 may be used to form triangular prism shaped gabions 160, 162, 164 and 166. 5 Additionally, or alternatively trapezoidal prism shaped gabions 161, 163, 165 may be formed. Alternatively, a selection of the triangular prism gabions and/or trapezoidal prism gabions may be formed. Single sheet 154 may be used to form large trapezoidal prism gabions 170, 172, 174, 176, 178, small trapezoidal prisms 171, 173, 174, 175 and 177, or a combination or selection of these possible gabions. Each of the gabions may 10 be used to house vegetation modules. In Figure 12B, single sheet 152 has a short flat section between each triangular section, the flat section is included to facilitate attachment to the wall 102, however in an alternative embodiment sheet 152 could be formed without the flat sections. Single sheets 140, 152, 154 may alternatively may be rotated by 90 degrees to form 15 rows of vegetation modules fixed to wall 120 (rather than columns as described above). Example 1 Below are set out examples of formulations of 1000 Litres of plant growth media. Unless specified otherwise, all percentages refer to the proportion of each component by volume. 20 The standard mix includes 830 Litres expanded polystyrene foam 83%; 80 Litres of expanded perlite 8%; 20 Litres of Charcoal 2%; 5 Litres of cement 0.5%; 5 litres of clay 0.5% and organic content of 60 Litres 6% including supplements and fertiliser. * 830 Litres (83%) expanded polystyrene foam (recycled from landfill) milled into abraded particles with a high surface area, assisting to wick the water via 25 capillary action within these abraded particles. This ensures even water WO 2012/000063 PCT/AU2011/000836 12 distribution throughout the entire mix. Clay as a cation exchange medium bound to the surface and clogging capillaries give it a high Cation Exchange Capacity (CEC). The particle size range of the expanded polystyrene foam is typically 55% below 8mm and 45% with a size range from 8 to 200mm (with an average 5 particle size of 12mm). * 80 Litres (8%) expanded perlite. * 20 Litres (2%) charcoal * 5 Litres (0.5%) cement, such as Off White Cement supplied by Blue Circle, holding the medium together in a gradient from loose particles (i.e. around 0.5% 10 cement) to solid sheet (i.e. around 25% cement). The cement also binds fines, particularly clays, to the expanded polystyrene foam giving it a high CEC. It also binds the materials, of different densities and sizes, to maintain a uniform mix during handing, storage, transport etc, and prevents leaching. * 5 Litres (0.5%) low sodium bentonite/clay. This can have a CEC up to 100 meq 15 %, thus giving the mix a good nutrient holding capacity. * Water (variable %). This is necessary to get an even distribution of particles and, activate the cement but it is dependent on how moist the components and prior to dry mixing and on what is being used to do the mix. For example when hand mixing small batches first dry in the various size classes then wetting the 20 expanded polystyrene foam can achieve very low water usages (15 Litres/ m3). But mixing in a cement mixer which is faster and more efficient requires larger amounts to allow the mix to "flow" (55 Litres/m 3 ). * 60 Litres organic content (6%) a mixture predominately consisting of coco peat/peat and/or orchid mix/composted bark with minor nutrient ingredients 25 including Osmocote@N, gypsum and/or dolomite. The exact composition of the organic content component can be varied to suit the horticultural requirements of plant species grown Example 2 30 An altemate mix (making approximately 166 Litres) includes the following ingredients, with percentage ranges for volumetric composition in brackets: * 80 Litres sodium potassium aluminium silicate, heat expanded pellets (Perlite); WO 2012/000063 PCT/AU2011/000836 13 - 1 Litre Dolomite * 1 Litre Gypsum; e 4 Litres Osmocote; a 20 Litres Charcoal/ Agrichar; 5 - 40 Litres Coco Peat/Peat; and - 20 Litres Orchid mix / Composted bark It will be understood that the invention disclosed and defined in this specification extends to all alternative combinations of two or more of the Individual features mentioned or evident from the text or drawings. All of these different combinations 10 constitute various aftemative aspects of the invention. As used herein, except where the context requires otherwise the term "comprise" and variations of the term, such as "comprising", "comprises" and "comprised", are not intended to exclude other additives, components or integers.

Claims

1. A plant growth media comprising: a particulate lightweight carrier material, wherein the carrier material comprises abraded particles of polystyrene foam; 5 a particulate cation exchange medium; and a binder, for binding together the lightweight carrier material and the cation exchange medium to provide in combination a lightweight conglomerate.

2. The plant growth media of claim 1 wherein the lightweight carrier material has a density of less than 50kg/cubic metre. 10

3. The plant growth media of claim 1 or claim 2 wherein the cation exchange medium is a clay or clay mix.

4. The plant growth media of any one of the preceding claims wherein the cation exchange medium is a bentonite.

5. The plant growth media of any one of the preceding claims wherein the 15 lightweight carrier material constitutes 60-90% of the total dry mass.

6. The plant growth media of any one of the preceding claims wherein the binder constitutes 0.5-4% of the total dry mass.

7. The plant growth media of any one of the preceding claims wherein the abraded particles of polystyrene foam have a particle size range composition of approximately 20 55% below 8mm and 45% with a size range from 8 to 200mm.

8. The plant growth media of any one of the preceding claims wherein the binder comprises at least one of the group consisting of cement, hydraulic cement, Portland cement, starch, resin, acrylic-based binder.

9. The plant growth media of any one of the preceding claims wherein the plant growth 25 media further comprises 0.1-2.5% by volume dolomite. 15

10. The plant growth media of any one of the preceding claims wherein the plant growth media further comprises 0.1-2.5% by volume gypsum.

11. A modular vegetating arrangement comprising: a containment structure; 5 an outer penetrable layer which can be penetrated by plant growth carried on the containment structure; an inner wicking layer; plant growth media located between the outer penetrable layer and the inner wicking layer, the plant growth media being the lightweight conglomerate of any one of 10 the claims 1 to 10; and a barrier layer adjacent the inner wicking layer.

12. The modular vegetating arrangement of claim 11 wherein the barrier layer comprises a lightweight semi-rigid panel adjacent to the inner wicking layer.

13. The modular vegetating arrangement of claim 11 or claim 12 the lightweight semi 15 rigid panel is covered with permeable woven fabric.

14. The modular vegetating arrangement of any one of claims 11-13, wherein the outer penetrable layer is selected from the group consisting of: polyester non-woven textile, recycled polyester felt, gravel paper, tile chip paper, coir.

15. The modular vegetating arrangement of any one of claims 11-14 wherein the inner 20 wicking layer is polyester or viscose.

16. The modular vegetating arrangement of any one of claims 11-15, wherein the containment structure is formed from metal mesh.

17. The modular vegetating arrangement of any one of claims 11-16 further comprising a drip irrigation assembly comprising a drip irrigation line coupled to a connecting arm, 25 wherein the connecting arm is pivotable relative to the drip irrigation line.

18. The modular vegetating arrangement of claim 17 wherein the drip irrigation assembly comprises a plurality of parallel drip irrigation lines. 16

19. A modular vegetating arrangement comprising a sheet configured into a profile defining a plurality of containment regions, each containment region comprising: an outer penetrable layer which can be penetrated by plant growth in the containment region; 5 an inner wicking layer; plant growth media located between the outer penetrable layer and the inner wicking layer, the plant growth media being the lightweight conglomerate of any one of the claims 1 to 10; and a barrier layer adjacent the inner wicking layer. 10

20. The modular vegetating arrangement of claim 19 wherein the single sheet has a profile selected from the group consisting of zigzag, trapezoidal and castellated.