AU2020104137B4 - Rock Armour Sheets And Methods Of Its Manufacture - Google Patents
Rock Armour Sheets And Methods Of Its Manufacture Download PDFInfo
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- AU2020104137B4 AU2020104137B4 AU2020104137A AU2020104137A AU2020104137B4 AU 2020104137 B4 AU2020104137 B4 AU 2020104137B4 AU 2020104137 A AU2020104137 A AU 2020104137A AU 2020104137 A AU2020104137 A AU 2020104137A AU 2020104137 B4 AU2020104137 B4 AU 2020104137B4
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- 239000000463 material Substances 0.000 claims abstract description 81
- 239000004567 concrete Substances 0.000 claims abstract description 79
- 238000009434 installation Methods 0.000 claims abstract description 58
- 239000004816 latex Substances 0.000 claims description 9
- 229920000126 latex Polymers 0.000 claims description 9
- 229920005989 resin Polymers 0.000 claims description 8
- 239000011347 resin Substances 0.000 claims description 8
- 238000005266 casting Methods 0.000 claims description 5
- 229920001971 elastomer Polymers 0.000 claims description 4
- 239000005060 rubber Substances 0.000 claims description 4
- 229920002379 silicone rubber Polymers 0.000 claims description 4
- 239000004945 silicone rubber Substances 0.000 claims description 4
- 230000003628 erosive effect Effects 0.000 description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 7
- 229910052799 carbon Inorganic materials 0.000 description 7
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- 238000013461 design Methods 0.000 description 6
- 230000006870 function Effects 0.000 description 6
- 239000011178 precast concrete Substances 0.000 description 6
- 239000004575 stone Substances 0.000 description 5
- 239000003086 colorant Substances 0.000 description 4
- 238000010276 construction Methods 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 239000011371 regular concrete Substances 0.000 description 3
- 239000012779 reinforcing material Substances 0.000 description 3
- 238000012358 sourcing Methods 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 241000607479 Yersinia pestis Species 0.000 description 2
- 238000013459 approach Methods 0.000 description 2
- 239000010881 fly ash Substances 0.000 description 2
- 229910001385 heavy metal Inorganic materials 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
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- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 244000007853 Sarothamnus scoparius Species 0.000 description 1
- 208000027418 Wounds and injury Diseases 0.000 description 1
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- 239000004927 clay Substances 0.000 description 1
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- Lining And Supports For Tunnels (AREA)
- Road Paving Structures (AREA)
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Abstract
Embodiments of the present disclosure provides a rock armour sheet. The rock armour
sheet includes a base layer comprising a flexible mesh configured to reinforce and
stabilize an installation surface. The rock armour sheet also includes an upper layer
comprising a plurality of moulds formed by pouring a mould material over one or more
natural rocks set into a master pattern and a concrete material filled in the plurality of
moulds to keep the base layer in place. The concrete material may include an eco
friendly concrete material.
Description
[0001] The present disclosure is related to the field of trail building, wall building and erosion control/ rectification products. More particularly, the present disclosure relates to a rock armour sheet and methods of manufacturing the rock armour sheets using an ecofriendly concrete material.
[0002] Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.
[0003] Traditionally, the materials used to rock armour tracks, trails and erosion control works is to use site sourced natural rock from the surrounding environment or imported natural rock if there is short supply. Flag stone and pavement can be used but not frequently used as installing them may require specific skills and places employees in higher risk of injury due to often rugged manual handling tasks, sourcing rock from uneven and steep terrain which is often overgrown with thick vegetation as well as but not limited to loose rock, fallen trees.
[0004] Another method used for trail building includes workers scouring the area they are building the trail in. Then the workers locate suitable rock, collect the rock, cart the rock to the work site and then lay and position the individual rocks to form the tread of the track. The disadvantages to this is that it is very time intensive which increases costs. This also often means only short sections of track can be rock armoured as it is too difficult and costly to source natural rock. Scouring and collecting rock also disturbs the surrounding environment and animal habitat. There may not be adequate supply of natural rock so imported rock is used which can be a biosecurity risk as imported rock can spread invasive pests.
[0005] It is an object of the present invention to overcome or ameliorate the above discussed disadvantages of the prior art, or at least offer a useful alternative. In light of above, there exists a need for improved techniques and products for building trails and erosion mitigation works.
[0006] To address the above-mentioned issues, the present disclosure provides rock armour sheets comprising a base sheet comprising one or more moulds including precast concrete. The concrete used for the rock armour sheets is an eco-friendly concrete, for example WAGNERS EFC concrete, that reduces carbon emissions over regular concrete up to 90%, overall is a better product in this application. The rock armour sheets can be easily installed on any installation surface by placing a plurality of rock armour sheets in a suitable arrangement in accordance with the installation surface. Further, the rock armour sheets are designed to interlock with each other. The rock armour sheets are environment friendly, flexible and are easy to install. Further, as the precast concrete rock armour sheets are made to look like natural rock and the colour of the rock armour sheets may be matched to natural colours of the surrounding environment.
[0007] An object of the present disclosure is to provide a cheaper, easier and more environmentally responsible way to rock armour walking/multi-use tracks, walkways, gully's, abutment batters, bridge approaches, earth access roads while still providing the same function and look as natural rock. The present disclosure provides a rock armour sheet that may be used in track and trail construction, for landscaping to stabilize tracks, for providing erosion control and for design/aesthetics of a trail as well as for creating a more highly technical mountain bike trail.
[0008] An embodiment of the present disclosure provides a rock armour sheet including a base layer comprising a flexible mesh configured to reinforce and stabilize an installation surface. The installation surface may be a surface where the rock armour sheet can be installed. The rock armour sheet also includes an upper layer includes a plurality of moulds that may be formed by pouring a mould material over one or more natural rocks. An example of the mould material may include latex resin. The upper layer also includes a concrete material filled in the plurality of moulds to keep the base layer in place. A non-limiting example of the concrete material includes WAGNERS EFC concrete.
[0009] According to an aspect of the present disclosure, the rock armour sheet includes an interlocking means configured to enable installation of a plurality of rock armour sheets by laying and interlocking the plurality of rock armour sheets with each other onto the installation surface of an installation site.
[0010] According to another aspect of the present disclosure, the base layer further comprises a Tensar geogrid for reinforcing material on the installation surface.
[0011] According to another aspect of the present disclosure, a shape and a size comprising a length, a width, and a thickness of the rock armour sheet is in accordance with the installation surface and the installation site. In some embodiments, the width of the rock armour sheet may be 600 millimetres, the length of the rock armour sheet may be 900 millimetres to 1050 millimetres (mm), and the thickness of the rock armour sheet maybe 50 to 100 millimetres. Insome embodiments, the size of the rock armour sheet is in accordance with the current Parks and Wild life facilities manual.
[0012] According to another aspect of the present disclosure, the concrete material comprises an eco-friendly concrete such as, but not limited to, WAGNERS EFC concrete to reduce carbon emissions. In alternative embodiments, the concrete material may be produced using 10 to 80 MPa (megapascal) conventional concrete mix if engineering design for application requires.
[0013] According to another aspect of the present disclosure, a colour of the at least one of the base layer and the upper layer of the rock armour sheet is customized in accordance with colour of the installation surface and the installation site.
[0014] According to another aspect of the present disclosure, a plurality of voids between the plurality of moulds may be filled with a track surface material.
[0015] Another embodiment of the present disclosure provides a method of manufacturing a rock armour sheet. The method includes: forming a base layer comprising a flexible mesh, wherein the base layer is configured to reinforce and stabilize materials of an installation surface; and forming an upper layer. The upper layer may be formed by: creating a plurality of moulds by pouring a mould material latex resin over one or more natural rocks which are set into a master pattern on a mould layer; and pouring a concrete material into the plurality of moulds to keep the base layer in place. In some embodiments, the plurality of moulds are created by pouring of latex resin over the natural rocks which are set into master pattern on a mould layer of mould material; and pouring a concrete material into the plurality of moulds to keep the base layer in place. In some embodiments, the plurality of moulds can be poured with regular 10 to 80 MPa (megapascal) concrete mix if engineering requirements for a specific task require.
[0016] According to an aspect of the present disclosure, the method includes providing an interlocking means configured to enable installation of a plurality of rock armour sheets, wherein the plurality of rock armour sheets are laid adjacent to each other on the installation surface of an installation site, further wherein respective interlocking means of two or more of the plurality of rock armour sheets are connected to install the plurality of the rock armour sheets.
[0017] According to another aspect of the present disclosure, the method also includes forming a Tensar geogrid in the base layer for reinforcing material on the installation surface.
[0018] According to another aspect of the present disclosure, the method also includes varying a shape and a size comprising a length, a width, and a thickness of the rock armour sheet in accordance with the installation surface and the installation site. In some embodiments, the width of the rock armour sheet is 600 millimetres, the length of the rock armour sheet is 1050 millimetres, and the thickness of the rock armour sheet is 65 millimetres.
[0019] According to another aspect of the present disclosure, the method also includes filling a plurality of voids between the plurality of moulds with a track surface material.
[0020] Another embodiment of the present disclosure provides a rock armour sheet includes a geogrid, an upper layer, and an interlocking means. The geogrid includes a flexible mesh configured to reinforce and stabilize an installation surface. The upper layer includes a plurality of moulds formed by pouring a mould material over one or more natural rocks set into a master pattern; and a concrete material filled in the plurality of moulds to keep the base layer in place. The interlocking means is configured to enable installation of a plurality of rock armour sheets, wherein the plurality of rock armour sheets are laid adjacent to each other on the installation surface of an installation site, further wherein respective interlocking means of two or more of the plurality of rock armour sheets are connected to install the plurality of the rock armour sheets.
[0021] According to an aspect of the present disclosure, the concrete material comprises an eco-friendly concrete, further wherein the mould material comprising at least one of a latex resin, silicone rubber, and casting rubber, further wherein the geogrid comprising a Tensar geogrid.
[0022] In some embodiments, the rock armour can be manufactured out of standard concrete or eco (environment or earth) friendly concrete. An example of the eco friendly concrete includes Ecoblend concrete, which contains a minimum of 30% cement replacement materials in the form of slag and fly-ash. This blend may reduce C02 emissions of the cement by around 29%, as well as have other advantages such as reduced heavy metal content and water use. Another example of eco-friendly concrete includes Wagners EFC which reduces the greenhouse emissions of the cement portion of the concrete by 80% to 90% compared to standard concrete.
[0023] According to an aspect of the invention, there is provided a rock armour sheet, the rock armour sheet comprising:
a base layer comprising a flexible mesh configured to reinforce and stabilize an installation surface;
an upper layer comprising a plurality of treads configured to keep the base layer in place;
wherein the plurality of treads is formed from a concrete material that is poured into a plurality of moulds configured to abut the base layer, and further wherein the plurality of moulds if formed by pouring a mould material over one or more natural rocks set into a master pattern; and
an interlocking means configured to enable installation of a plurality of rock armour sheets by laying and interlocking the plurality of rock armour sheets with each other onto the installation surface of an installation site.
[0024] According to an embodiment, the flexible mesh comprises a geogrid.
[0025] According to an embodiment, the concrete material comprises an alternative cementitious material or blended concrete, and the mould material comprises at least one of a latex resin, silicone rubber, or casting rubber.
[0026] According to an aspect of the invention, there is provided a method of manufacturing a rock armour sheet, comprising: forming a base layer comprising a flexible mesh, wherein the base layer is configured to reinforce and stabilize materials of an installation surface; and forming an upper layer by: creating a plurality of moulds by pouring a mould material over one or more natural rocks set into a master pattern; removing the one or more natural rocks; abutting the base layer to the plurality of moulds; forming a plurality of treads configured to keep the base layer in place by pouring a concrete material into the plurality of moulds; and removing the plurality of moulds.
[0027] According to an aspect of the invention, there is provided a rock armour sheet comprising:
a geogrid configured to reinforce and stabilize an installation surface;
an upper layer comprising a plurality of treads configured to keep the base layer in place;
wherein the plurality of treads is formed from a concrete material that is poured into a plurality of moulds configured to abut the base layer, and further wherein the plurality of moulds is formed by pouring a mould material over one or more natural rocks set into a master pattern; and
an interlocking means configured to enable installation of a plurality of rock armour sheets, wherein the plurality of rock armour sheets are laid adjacent to each other on the installation surface of an installation site, further wherein respective interlocking means of two or more of the plurality of rock armour sheets are connected to install the plurality of the rock armour sheets.
[0028] Preferred features, embodiments and variations of the invention may be discerned from the following detailed description which provides sufficient information for those skilled in the art to perform the invention. The detailed description is not to be regarded as limiting the scope of the preceding summary of the invention in any way.
[0029] Specific embodiments of the present invention are described, by way of example only, with reference to the accompanying drawings, in which:
[0030] Figure 1 illustrates a schematic view of an exemplary rock armour sheet, in accordance with an embodiment of the present disclosure.
[0031] Figures 2A-2C illustrates a rock armour sheet in different manufacturing stages, in accordance with an embodiment of the present disclosure;
[0032] Figure 3 illustrates a plurality of rock armour sheets installed on a curved alignment, in accordance with an embodiment of the present disclosure; and
[0033] Figure 4 illustrates a plurality of rock armour sheets installed on a straight alignment, in accordance with an embodiment of the present disclosure.
[0034] The present disclosure provides a rock armour sheet comprising precast eco friendly concrete. A rock armour sheet may be easily and quickly installed on a floor for trail building or on a wall. In some embodiments, a size of the rock armour sheet is in accordance with the current Parks and Wild life facilities manual.
[0035] Referring to the Figure 1, the schematic view of an exemplary rock armour sheet 100isshown. The rock armour sheet 100 is flexible rock armour sheet made out of precast concrete for a cost effective and environmentally friendly option for trail building and other purposes. The rock armour sheet 100 can be made to look like natural rock and the colour can be matched to the natural colours of the surrounding environment where the rock armour sheet 100 is to be installed.
[0036] As shown, the rock armour sheet 100 includes a base layer 102, and an upper layer comprising a plurality of treads 104A-104N comprised of concrete material 106. The base layer 102 may include a flexible mesh for reinforcing and stabilizing an installation surface. In some embodiments, a plurality of moulds may be formed by casting pourable latex poly or urethane over one or more natural rocks set into a mould layer master Pattern of a mould material.
[0037] The concrete material 106 is filled in the plurality of moulds to form the plurality of treads 104A-104N. The base layer 102 may abut the plurality of moulds, such that the concrete material 106 at least partially adheres to or encapsulates the base layer 102 in place. Hereinafter, the concrete material 106 may be referred as concrete without change in its meaning. In some embodiments, the concrete material 106 comprises an eco-friendly concrete to reduce carbon emissions. In an example, the concrete material 106 used for the rock armour sheet 100 is WAGNARS eco-friendly concrete (EFC), which reduces carbon emissions and is just as good, and in some cases better than normal concrete. The WAGNERS EFC concrete is an alternate cementitious material that can reduce carbon emissions over regular concrete up to 90%, and hence overall is a better product in this application.
[0038] In some embodiments, a shape and a size comprising a length, a width, and a thickness of the rock armour sheet 100 is in accordance with the installation surface and the installation site. Further, a colour of the at least one of the base layer 102 and the upper layer of the rock armour sheet 100 may be customized in accordance with colour of the installation surface and/or the installation site.
[0039] In some embodiments, a gap between two treads of the plurality of treads 104A 104N is 30 millimetres to 50 millimetres. In some embodiments, the size (or length, width and thickness) of the rock armour sheet 100 is 1050 mm (length), 600mm (width), and 65mm (thickness). In such rock armour sheet 100, a weight of the rock armour sheet 100 is approximately in a range of 42 to 50 kg. The size, weight, and the gap may vary in the rock armour sheet 100 for example, depending on the installation site. Further, the rock armour sheet 100 may be manufactured in any colour or any natural rock colour. Further, the colour may be consistent through the entire thickness of the concrete 106 of the rock armour sheet 100. In some embodiments, there may be a difference of 10 mm in height of the concrete 106.
[0040] In some embodiments, the base layer 102 comprises a geogrid for reinforcing material like soil on the installation surface. In an example, the geogrid is a Geofabrics Australia Tensar Geogrid Biaxial SS30. In some embodiments, the length of the geogrid may be longer than that of the base layer. Further, when the length of the rock armour sheet is 1050 mm, then the length of the geogrid may be 1200 mm.
[0041] In some embodiments, the rock armour sheet 100 includes the geogrid and a plurality of moulds filled with a concrete material comprising an ecofriendly concrete material.
[0042] In some embodiments, the rock armour sheet 100 includes an interlocking means configured to enable installation of a plurality of rock armour sheet 100 by laying and interlocking the plurality of rock armour sheet 100 with each other onto the installation surface of the installation site.
[0043] The rock armour sheet 100 may be used to strengthen track surface across a seepage area. Further, the rock armour sheet 100 may be used to strengthen a steep section of track leading into a creek crossing. Further, the rock armour sheet 100 is designed to conform to Australian Standards (e.g. AS 2156-2001) and approved by Queensland Parks and Wildlife Service to meet their facilities manual design criteria. In some embodiments, the rock armour sheet 100 is can be designed or customised to conform to other countries standards too. Further, the rock armour sheet 100 may provide additional environmental benefits and structural integrity over naturally sourced and laid site material.
[0044] Figures 2A-2C illustrates different stages 200A-200C of manufacturing a rock armour sheet 202, in accordance with an embodiment of the present disclosure. A method of manufacturing the rock armour sheet may include forming a base layer comprising a flexible mesh.
[0045] At stage 200A, a plurality of moulds 204 may be created by pouring a mould material over one or more natural rocks 206 that are set into a master pattern as shown in the Figure 2A. In some embodiments, the plurality of moulds 204 may be formed by using or pressing one or more natural rocks 206 on a mould layer of the mould material. The non-limiting examples of the mould material may include latex resin, silicone rubber, casting rubbers, and so forth.
[0046] Then at stage 200B, the rocks 206 are removed, and the plurality of moulds 204 are formed as shown in the Figure 2B. The real rocks 206 are used to shape the plurality of moulds 204. In some embodiments, the moulds 204 may be formed without using the real rocks 206.
[0047] Then at stage 200C, the base layer, comprising the geogrid, is positioned abutting the plurality of moulds 204. A concrete material 208 is poured into the plurality of moulds 204 to keep the base layer in place. In some embodiments, the geogrid may be longer than length of the base layer. In some embodiments, the concrete material 208 comprises an eco-friendly concrete to reduce carbon emissions. The rock armour sheet 202 is ready once the concrete material 208 has dried completely and the plurality of moulds 204 is removed. The rock armour sheet 202 may be easily packaged and delivered to an installation site. A plurality of rock armour sheet 202 then may be installed on an installation surface.
[0048] As shown in the Figure 2C, in some embodiments, a colour of the rock armour sheet 202 can be matched to suit the installation site specific colours. For example, to match natural site rock that may be used in conjunction with the rock armour sheet(s) 202 so it blends in with the surrounding environment. A base colour may be consistent through the entire thickness of the concrete material 208, therefore the colour remains throughout the life of the step unit.
[0049] Further, in some embodiments, a plurality of voids between the plurality of treads 104A-104N are filled with a track surface material. The track surface material may comprise a precast concrete material or any other suitable material. This may produce a natural finish, effectively blending the sheets in with the natural surrounds.
[0050] In some embodiments, the rock armour sheet 202 may include a bottom layer of concrete. For example, the rock armour sheet 202 may include may include a 15mm bottom layer of concrete. In alternative embodiments, the rock armour sheet 202 may not include the bottom layer of concrete. This may reduce freight costs as well as labour costs due to quicker and easier installation.
[0051] Further, a surface finish of the rock armour sheet 202 may be non-slip, and/or natural stone texture similar to "rough broom" concrete finish. The rock armour sheet 202 may be used for providing a cheaper, easier and more environmentally responsible way to rock armour walking/multi-use tracks, walkways, gully's, abutment batters, bridge approaches, earth access roads while still providing the same function and look as natural rock.
[0052] Turning now to Figure 3 where a plurality of rock armour sheets 302A-302D installed on a curved alignment is illustrated, in accordance with an embodiment of the present disclosure. A profile or shape of the rock armour sheets 302A 302D may form the sub-base to the line and level required. The sub-base may be compacted as perjob specification for example, minimum 95% of the Standard compaction. Then, the rock armour sheets 302A-302D may be laid in a preferred pattern arrangement for example, here in the curved alignment. The excess geo grid may be cut or folded under so that it geo grid is not exposed. Then, one or more site rocks may be put around the rock armour sheets 302A-302D. For example, the one or more site rocks may be randomly placed such that the site rocks rubble along sheet edges. In some embodiments, large rocks may be placed at joins of the rock armour sheets 302A-302D to define edges at top of steep bank. In some embodiments, larger rocks may be placed at joins of the rock armour sheets 302A-302D. In some embodiments, toe stones may be installed. Then, fill material (or track fill material) may be placed over sheets approx. 20 mm to 40 mm thick. For example, 300 mm minimum sized site rocks may be buried flush with track finished surface level. In some embodiments, the rock armour sheets 302A-302D may be staggered for example, by 100 mm.
[0053] Thereafter, a vibrating plate compactor may be used to work the fill material into the gaps and joins. Several passes with a vibrating plate and additional fill material may be required to adequately backfill all voids and secure the sheets. In some embodiments, the fill material should be dry so that all voids are easily filled. Wet and/or high clay content material may not always be suitable as the material may bind up and not fill all the voids. Then for completion of installation, the rock armour sheets 302A-302D may be swept to clean without removing material from the joins or voids. In some embodiments, a nominal 10 mm thick layer of fill material may be left over the each of the plurality of rock armour sheets 302A-302D to allow for some initial settlement of the fill material is an option especially if rain is expected prior to the track being opened for use.
[0054] This way the plurality of rock armour sheets 302A-302D may be installed in any alignment or arrangement such as curved alignment, straight alignment, and so forth. Further, the plurality of rock armour sheets 302A-302D may be installed on stairs, a curved surface, a flat or straight surface, a sloped surface, and so forth.
[0055] As shown in the Figure 4, a plurality of rock armour sheets 402A-402D may be installed on a straight alignment. The of rock armour sheets 402A-402D may not be staggered for installing the rock armour sheets 402A-402D in the straight alignment. Further, it may appear out of place to give it a natural rock like look.
[0056] In some embodiments, the disclosed rock armour sheet may comprise interlocking means. Such rock armour sheets may eliminate side movement when used on mountain bike trails and corner or berm construction.
[0057] The disclosed rock armour sheet allows for a magnitude of uses from trail work to erosion mitigation and landscaping. Further, the low surface ground pressure footprint of the rock armour sheet may prove to be a great solution in soft terrain.
[0058] The disclosed rock armour sheet may be made out of precast concrete that looks like natural rock and may be used for trail building purposes. In some embodiments, the rock armour can be manufactured out of standard concrete or Eco (environment or earth) Friendly Concrete. An example of the eco-friendly concrete includes Ecoblend concrete, which contains a minimum of 30% cement replacement materials in the form of slag and fly-ash. This blend may reduce C02 emissions of the cement by around 29%, as well as have other advantages such as reduced heavy metal content and water use. Another example of eco-friendly concrete includes Wagners EFC which reduces the greenhouse emissions of the cement portion of the concrete by 80% to 90% compared to standard concrete.
[0059] The present disclosure discloses a precast concrete rock armour matting (may also be referred as rock armour sheets) that may provide a cheaper, easier and more environmentally responsible way to rock armour walking/multi-use tracks while still providing the same function and look as natural rock. The rock armour sheets may be used in track and trail construction, for landscaping to stabilize tracks, for providing erosion control and for design/aesthetics of a trail as well as for creating a more highly technical mountain bike trail.
[0060] Further, the rock armour sheets can be used along outdoor walking/multi-use trails and tracks. The disclosed rock armour sheets can be used on any terrain suitable for rock armouring. The rock armour sheets may be designed to conform any standards such as Australian Standards (AS 2156-2001) to meet their (or a country's) facilities manual design criteria.
[0061] The function of the disclosed rock armour sheet(s) is the same as natural rock armouring. The function of the rock armour sheet is to stabilize trails by hardening them. The rock armour sheet can stabilize steep trail grades of 20 45% and can also prevent human caused erosion particularly in areas of high traffic. Rock armour sheets may be used to elevate a trail above soft or wet soils.
[0062] In some embodiments, the rock amour sheet is formed out of the rock moulds. In an example, the rock armour sheet may be made out of concrete material such as, but not limited to, WAGNARS Earth Friendly Concrete (EFC) and a geogrid comprising Tensar geogrid. The geogrid may help a plurality of rock armour sheets to stay together after installation. Further, the rock armour sheets can be used for flag stone paving, stone pitching, raised tread construction, water bars, modular step-down drains, slope retention/retainer mats, erosion scour matting, and so forth.
[0063] According to an embodiment of the present disclosure, a rock armour sheet includes a geogrid, and a plurality of treads formed from an eco-friendly concrete. The geogrid may be a Tensar geogrid. Further, the plurality of moulds, used to form the plurality of treads, may be formed by pouring a mould material such as, but not limited to, latex resin over a number of natural rocks arranged in a master pattern. Once the moulds are set, the rocks are removed, and the ecofriendly concrete material such as, but not limited to, WAGNERS EFC concrete, is filled into the moulds. The eco-friendly concrete may reduce carbon emissions over regular concrete up to 90%, overall is a better product in this application. In alternative embodiments, the concrete material may be produced using 10 to 80 MPa (megapascal) conventional concrete mix if engineering design for application requires.
[0064] The size and shape of the rock armour sheets may vary. The rock armour sheets may be manufactured in different type of colors and by using different type of concrete.
[0065] Further, the rock armour sheet looks like natural rock and can be used and function like natural rock for trail building/rock armoring purposes.
[0066] The rock armour sheet is eco-friendly. It means for using the rock armour sheets, the environment is not disturbed by people or machinery as it would have been by sourcing natural site rock. This may be particularly important when working in environmentally and culturally sensitive areas such as world heritage protected sites.
[0067] The rock armour sheet is a cheaper option as using the rock armour sheet(s) is not as labour intensive as sourcing site rock (i.e. The natural rocks). Further, the rock armour sheet reduces bio security risks. If for example, there are inadequate supplies of site sourced rock or natural rocks, then imported natural rock needs to be used and the imported rock can spread invasive pests. Further, the rock armour sheets may blend in with the natural environment which may in turn improve the users overall experience.
[0068] Further, the rock armour sheet may improve the strength of the trail making it more sustainable and less repairs are required. This is particularly important in areas that endure weather extremes such as in the northern parts of Australia. It is also particularly important with the recent increase in multi day walks in which tracks cover long distances and difficult terrain so getting people and machinery in to complete maintenance is often challenging. Less maintenance also reduces long term costs.
[0069] Using the disclosed rock armour sheets may allow large sections of track to be rock armoured due to the ability for large quantities to be manufactured and supplied easily and quickly. Rock armouring i.e. Installing the rock armour sheets on such large sections of track may not have been a viable option previously due to low supply of natural rock and high costs. Further, the width of the rock armour sheet may be in accordance with the standard width of trails designed for government trail work.
[0070] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term "comprises" and its variations, such as "comprising" and "comprised of' is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.
[0071] Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms.
[0072] Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention.
Claims (5)
1. A rock armour sheet, comprising:
a base layer comprising a flexible mesh configured to reinforce and stabilize an installation surface;
an upper layer comprising a plurality of treads configured to keep the base layer in place;
wherein the plurality of treads is formed from a concrete material that is poured into a plurality of moulds configured to abut the base layer, and further wherein the plurality of moulds is formed by pouring a mould material over one or more natural rocks set into a master pattern; and
an interlocking means configured to enable installation of a plurality of rock armour sheets by laying and interlocking the plurality of rock armour sheets with each other onto the installation surface of an installation site.
2. The rock armour sheet according to claim 1, wherein the flexible mesh comprises a geogrid.
3. The rock armour sheet according to claim 1 or 2, wherein the concrete material comprises an alternative cementitious material or blended concrete and the mould material comprises at least one of a latex resin, silicone rubber, or casting rubber.
4. A method of manufacturing a rock armour sheet, comprising:
forming a base layer comprising a flexible mesh, wherein the base layer is configured to reinforce and stabilize materials of an installation surface; and
forming an upper layer by:
creating a plurality of moulds by pouring a mould material over one or more natural rocks set into a master pattern;
removing the one or more natural rocks;
abutting the base layer to the plurality of moulds;
forming a plurality of treads configured to keep the base layer in place by pouring a concrete material into the plurality of moulds; and
removing the plurality of moulds.
5. A rock armour sheet, comprising:
a geogrid configured to reinforce and stabilize an installation surface;
an upper layer comprising a plurality of treads configured to keep the base layer in place;
wherein the plurality of treads is formed from a concrete material that is poured into a plurality of moulds configured to abut the base layer, and further wherein the plurality of moulds is formed by pouring a mould material over one or more natural rocks set into a master pattern; and
an interlocking means configured to enable installation of a plurality of rock armour sheets, wherein the plurality of rock armour sheets are laid adjacent to each other on the installation surface of an installation site, further wherein respective interlocking means of two or more of the plurality of rock armour sheets are connected to install the plurality of the rock armour sheets.
102
102
104A-104N
106 1/5
Figure 1
200B 200A 206 2/5
204 Figure 2A Figure 2B
200C
208 3/5
Figure 2C
302A 302B 4/5
302C
302D
Figure 3
402A
402B 5/5
402C
402D
Figure 4
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| AU2020104137A AU2020104137C4 (en) | 2019-11-11 | 2020-12-16 | Rock Armour Sheets And Methods Of Its Manufacture |
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| AU2019904247 | 2019-11-11 | ||
| AU2019904247A AU2019904247A0 (en) | 2019-11-11 | Rock Armour Sheets And Methods Of Its Manufacture | |
| AU2020260572A AU2020260572A1 (en) | 2019-11-11 | 2020-10-30 | Rock Armour Sheets And Methods Of Its Manufacture |
| AU2020104137A AU2020104137C4 (en) | 2019-11-11 | 2020-12-16 | Rock Armour Sheets And Methods Of Its Manufacture |
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| US4668451A (en) * | 1985-05-09 | 1987-05-26 | Langson Bruce K | Process of making a full life size artificial rock formation from a natural rock formation surface |
| EP0724039A1 (en) * | 1995-01-25 | 1996-07-31 | Shinko-Kozai Co., Ltd. | Connective paving block |
| US5615971A (en) * | 1993-11-17 | 1997-04-01 | Boeve; Jan A. | Groundcovering element, method for its manufacture and method for the manufacture of a mould to be applied with the manufacturing method |
| KR100583322B1 (en) * | 2002-09-27 | 2006-05-25 | 야와라 구마가이 | The mold frame and the manufacturing methods of a block of an imitated stone made in concrete |
| US20130209170A1 (en) * | 2012-01-09 | 2013-08-15 | Bryce Doman | Modular Decorative Landscape Product and Associated Methods |
| US20190217498A1 (en) * | 2017-05-10 | 2019-07-18 | Riccobene Designs Llc | Articulating composite surface covering mat and method of making |
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2020
- 2020-12-16 AU AU2020104137A patent/AU2020104137C4/en not_active Ceased
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4668451A (en) * | 1985-05-09 | 1987-05-26 | Langson Bruce K | Process of making a full life size artificial rock formation from a natural rock formation surface |
| US5615971A (en) * | 1993-11-17 | 1997-04-01 | Boeve; Jan A. | Groundcovering element, method for its manufacture and method for the manufacture of a mould to be applied with the manufacturing method |
| EP0724039A1 (en) * | 1995-01-25 | 1996-07-31 | Shinko-Kozai Co., Ltd. | Connective paving block |
| KR100583322B1 (en) * | 2002-09-27 | 2006-05-25 | 야와라 구마가이 | The mold frame and the manufacturing methods of a block of an imitated stone made in concrete |
| US20130209170A1 (en) * | 2012-01-09 | 2013-08-15 | Bryce Doman | Modular Decorative Landscape Product and Associated Methods |
| US20190217498A1 (en) * | 2017-05-10 | 2019-07-18 | Riccobene Designs Llc | Articulating composite surface covering mat and method of making |
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| AU2020104137A4 (en) | 2021-03-04 |
| AU2020104137C4 (en) | 2023-03-16 |
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