GB2049015A

GB2049015A - Insulated building component

Info

Publication number: GB2049015A
Application number: GB8012891A
Authority: GB
Original assignee: CCG ROOFING CONTRACTORS Ltd
Current assignee: CCG ROOFING CONTRACTORS Ltd
Priority date: 1979-04-18
Filing date: 1980-04-18
Publication date: 1980-12-17

Abstract

A tile for use in the construction of flat roofs and pedestrian walkways comprises spaced outer skins (1, 2) which are precast from glass- reinforced cement or asbestos cement and are held in spaced relation while a non-absorbent, heat-insulating foam (3) of vermin- and rot-proof material is injected into, fills the space between and adheres to the skins to form a heat-insulating core. <IMAGE>

Description

SPECIFICATION Building component This invention relates to building components and is concerned with the provision of a tile for use in the construction of flat roofs and pedestrian walkways which is highly resistant both to wear and to the passage of heat.

To this end, a tile in accordance with the invention, comprises spaced outer skins of a hard cementitious material and heat-insulated core of foamed synthetic plastics material which fills the space between and adheres to the skins.

In the accompanying drawings: Figure 1 to 8 are fragmentary perspective views of different forms of tile constructed in accordance with the invention; Figures 9A, 9B and 9C are a plan, side elevation and end elevation respectively of a tile constructed in the manner shown in any one of Figs. 1 to 8 and additionally formed with rebated edges and a frog on its underside; Figure 10 is a fragmentary perspective view of a tile of irregular section; and Figures 11 to 13 are fragmentary views showing the manner in which tiles of irregular section are employed at the junction with a brick wall, at the edge of a roof and at a kerb respectively.

In a preferred method of producing a tile in accordance with the invention outer skins 1 and 2 are precast from glass-reinforced cement or asbestos cement and are held in spaced relation while a non-absorbent heat-insulating foam 3 of vermin and rot-proof synthetic plastics material is injected into and fills the space between them.

The outer skin 1 which will be uppermost in use is preferably formed, during manufacture, with a non-slip surface 4 which may also bear a definite pattern, as illustrated in Figs. 1 and 2 and the outer surface of the lowermost skin 2 is preferably formed during manufacture with a frog 5(Figs. 9B and 9C). The edges of a finished tile are preferably formed with rebates 9 (Figs. 9A, 9B and 9C) to facilitate interlocking of adjacent tiles when laid.

A colouring matter may be incorporated into the skins 1, 2 during manufacture and mineral chips or other broken or granular material may be applied to the upper surface of the finished tile, as shown in Figs. 3 to 8, to enhance its decorative appearance.

The skins 1, 2 may be formed separately and held apart, during injection of the foamed material 3, by spacers 6 of any suitable material and of any suitable form, as shown in Figs. 1 to 7, which spacers become permanently embedded in the core materials 3 and form part of the finished tile or the skins 1, 2 may form the limbs of a substantially U-section casing (Fig. 8), the web portion 7 of which serves both to connect and space the skins apart during the filling process.

The'thickness of a tile may be uniform from one end to the other or may increase from one end to the other to provide a wedge-shaped tile when it is required to create falls on a flat roof.

The skins 1, 2 may be cast in the form of large sheets between which the plastics foam 3 is injected and allowed to set before being cut up to form a plurality of square tiles of the required size.

When tiles of irregular section are required to fulfill special functions at the edges or corners of a roof, kerb or other structure, as shown in Figs. 11 to 13, a hollow casing 8 of each requisite section, as shown, for example, in Fig. 10 is separately moulded from glass-reinforced or asbestos cement and then filled with foamed plastics material 3.

The glass reinforced or asbestos cement is preferably mixed with a cementitious slurry and the mixture vibrated and cast in any suitable manner to form the outer skin or skins of one or more tiles. The foam infill is preferably formed from polyurethane, polyisocyanurate, polystyrene or glass fiber-reinforced synthetic resin which adheres strongly to the inner surfaces of the outer skins or casing to provide a non-combustible tile which is rot and vermin-proof, will not support mould growth and has a chemical resistance broadly similar to that of concrete.

The thermally insulating tiles so formed, which can be used with all types of roof weatherings, are unaffected by-the extremes of climate experienced in the United Kingdom and Continent of Europe and in hot climates assist in protecting roofs from solar gain and in preserving roof weatherings such as asphalt and built-up feit which are susceptible to heat degradation.

1. A tile for use in the construction of flat roofs, pedestrian walkways and like structures, said tile comprising spaced outer skins of hard cementitious material and a heat-insulating core of foamed synthetic plastics material which fills the space between and adheres to the skins.

2. A tile according to Claim 1, wherein said hard cementitious material is glass-reinforced cement or asbestos cement.

3. A tile according to Claim 1 or 2, wherein said foamed synthetic plastics material is a nonabsorbant, heat-insulating, vermin- and rot-proof material.

4. A tile according to any one of Claims 1 to 3, wherein that one of the outer skins which will be uppermost in use is formed with a non-slip surface.

5 A tile according to any preceding claim wherein that one of the outer skins which will be uppermost in use is formed with a pattern.

6. A tile according to any preceding claim, wherein that one of the outer skins which will be lowermost in use is formed with a frog.

7. A tile according to any preceding claim wherein the edges of the tile are formed with rebates.

8. A tile according to any preceding claim wherein said skins incorporate a colouring matter 9. A tile according to any preceding claim, the upper surface of which is covered with a layer of mineral chips on other broken granular material.

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. SPECIFICATION Building component This invention relates to building components and is concerned with the provision of a tile for use in the construction of flat roofs and pedestrian walkways which is highly resistant both to wear and to the passage of heat. To this end, a tile in accordance with the invention, comprises spaced outer skins of a hard cementitious material and heat-insulated core of foamed synthetic plastics material which fills the space between and adheres to the skins. In the accompanying drawings: Figure 1 to 8 are fragmentary perspective views of different forms of tile constructed in accordance with the invention; Figures 9A, 9B and 9C are a plan, side elevation and end elevation respectively of a tile constructed in the manner shown in any one of Figs. 1 to 8 and additionally formed with rebated edges and a frog on its underside; Figure 10 is a fragmentary perspective view of a tile of irregular section; and Figures 11 to 13 are fragmentary views showing the manner in which tiles of irregular section are employed at the junction with a brick wall, at the edge of a roof and at a kerb respectively. In a preferred method of producing a tile in accordance with the invention outer skins 1 and 2 are precast from glass-reinforced cement or asbestos cement and are held in spaced relation while a non-absorbent heat-insulating foam 3 of vermin and rot-proof synthetic plastics material is injected into and fills the space between them. The outer skin 1 which will be uppermost in use is preferably formed, during manufacture, with a non-slip surface 4 which may also bear a definite pattern, as illustrated in Figs. 1 and 2 and the outer surface of the lowermost skin 2 is preferably formed during manufacture with a frog 5(Figs. 9B and 9C). The edges of a finished tile are preferably formed with rebates 9 (Figs. 9A, 9B and 9C) to facilitate interlocking of adjacent tiles when laid. A colouring matter may be incorporated into the skins 1, 2 during manufacture and mineral chips or other broken or granular material may be applied to the upper surface of the finished tile, as shown in Figs. 3 to 8, to enhance its decorative appearance. The skins 1, 2 may be formed separately and held apart, during injection of the foamed material 3, by spacers 6 of any suitable material and of any suitable form, as shown in Figs. 1 to 7, which spacers become permanently embedded in the core materials 3 and form part of the finished tile or the skins 1, 2 may form the limbs of a substantially U-section casing (Fig. 8), the web portion 7 of which serves both to connect and space the skins apart during the filling process. The'thickness of a tile may be uniform from one end to the other or may increase from one end to the other to provide a wedge-shaped tile when it is required to create falls on a flat roof. The skins 1, 2 may be cast in the form of large sheets between which the plastics foam 3 is injected and allowed to set before being cut up to form a plurality of square tiles of the required size. When tiles of irregular section are required to fulfill special functions at the edges or corners of a roof, kerb or other structure, as shown in Figs. 11 to 13, a hollow casing 8 of each requisite section, as shown, for example, in Fig. 10 is separately moulded from glass-reinforced or asbestos cement and then filled with foamed plastics material 3. The glass reinforced or asbestos cement is preferably mixed with a cementitious slurry and the mixture vibrated and cast in any suitable manner to form the outer skin or skins of one or more tiles. The foam infill is preferably formed from polyurethane, polyisocyanurate, polystyrene or glass fiber-reinforced synthetic resin which adheres strongly to the inner surfaces of the outer skins or casing to provide a non-combustible tile which is rot and vermin-proof, will not support mould growth and has a chemical resistance broadly similar to that of concrete. The thermally insulating tiles so formed, which can be used with all types of roof weatherings, are unaffected by-the extremes of climate experienced in the United Kingdom and Continent of Europe and in hot climates assist in protecting roofs from solar gain and in preserving roof weatherings such as asphalt and built-up feit which are susceptible to heat degradation. CLAIMS

8. A tile according to any preceding claim wherein said skins incorporate a colouring matter

9. A tile according to any preceding claim, the upper surface of which is covered with a layer of mineral chips on other broken granular material.

10. A tile according to any preceding claim, incorporating at least one spacer extending between the skins.

11. A tile according to Claim 10, wherein said spacer comprises the web-portion of a U-section casing, the limbs of which form said skins.

12. A tile according to any preceding claim, of uniform thickness.

13. A tile according to any one of Claims 1 to 11, the thickness of which increases from one end to the other.

14. A tile according to any one of Claims 1 to 9, of irregular section, in which said skins form integral parts of a hollow casing which is filled with said foamed synthetic plastics material.

1 5. A tile according to any preceding claim, wherein said foamed synthetic plastics material is polyurethane, polyisocyanurate, polystyrene or a glass fibre-reinforced synthetic resin which adheres strongly tq said outer skins or casing.

1 6. A method of producing a tile for use in the construction of flat roofs, pedestrian walkways and like structures comprising holding two outer skins of hard cementitious material in predetermined spaced relation and filling the space between them with a foamed synthetic plastics material which adheres to the skins and forms a heat-insulating core.

17. A method according to Claim 16, including the step of pre-casting said outer skins from glassreinforced cement or asbestos cement.

18. A method according to Claim 16 or 17, in which the space between said outer skins is filled by injecting a non-absorbent heat-insulating foam of vermin- and rot-proof synthetic plastics material.

19. A method according to any one of Claims 1 6 to 18, wherein the outer skin which will be uppermost in use is formed, during manufacture, with 'a non-slip surface.

20. A method according to Claim 19, wherein a pattern is applied to said non-slip surface during manufacture.

21. A method according to any one of Claims 1 6 to 20, wherein the outer skins which will be lowermost in use is formed during manufacture with a frog.

22. A method according to any one of Claims 16 to 21, wherein a colouring matter is incorporated in said skins during manufacture.

23. A method according to any one of Claims 16 to 22, wherein mineral chips or other broken or granular material is applied to the upper surface of the finished tile.

24. A method according to any one of Claims 1 6 to 23, wherein rebates are formed in the edges of the finished tile.

25. A method according to any one of Claims 1 6 to 24, wherein said outer skins are formed separately and held apart during injection of the foamed material, by at least one spacer which becomes permanently embedded in the core material and forms part of the finished tile.

26. A method according to any one of Claims 1 6 to 24, wherein the two skins are formed as integral limbs of a U-section casing, the web portion of which serves both to connect and space the skins apart during filling.

27. A method according to any one of Claims 1 6 to 25, wherein the outer skins are cast in the form of large sheets, the plastics foam is injected between said sheets and allowed to set and the sandwich so created is cut into a plurality of square tiles of the required size.

28. A method according to any one of Claims 1 6 to 24, of forming a tile of irregular section, said method comprising moulding a continuous casing of the required section from glass-reinforced or asbestos cement and filling said casing with foamed plastics material.

29. A method according to any one of Claims 1 6 to 28, wherein each outer skin or casing is formed by casting from a vibrated mixture of glass reinforced or asbestos cement and a cementitious slurry.

30. A method of producing a tile for use in the construction of flat roofs, pedestrian walkways and like structures, substantially as hereinbefore described.

31. A tile produced by the method claimed in any one of Claims 1 6 to 30.

32. A tile for use in the construction of flat roofs, pedestrian walkways and like structures, substantially as hereinbefore described with reference to or shown in any one of Figs. 1 to 13 of the accompanying drawings.

33. A flat roof or pedestrian walkway incorporating tiles as claimed in any one of Claims 1 to 15,31 or 32.