GB2183626A - Coloured concrete roof tiles - Google Patents

Coloured concrete roof tiles Download PDF

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Publication number
GB2183626A
GB2183626A GB08628420A GB8628420A GB2183626A GB 2183626 A GB2183626 A GB 2183626A GB 08628420 A GB08628420 A GB 08628420A GB 8628420 A GB8628420 A GB 8628420A GB 2183626 A GB2183626 A GB 2183626A
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GB
United Kingdom
Prior art keywords
sand
iron oxide
tile
colour
finished appearance
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB08628420A
Other versions
GB2183626B (en
GB8628420D0 (en
Inventor
Hans Erich Schulz
Hans-Joachim Buhler
Johann Dietz
Manfred Weisweiler
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Braas GmbH
Original Assignee
Braas GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Braas GmbH filed Critical Braas GmbH
Publication of GB8628420D0 publication Critical patent/GB8628420D0/en
Publication of GB2183626A publication Critical patent/GB2183626A/en
Application granted granted Critical
Publication of GB2183626B publication Critical patent/GB2183626B/en
Expired legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/08Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
    • B28B11/0818Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for roughening, profiling, corrugating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B60VEHICLES IN GENERAL
    • B60HARRANGEMENTS OF HEATING, COOLING, VENTILATING OR OTHER AIR-TREATING DEVICES SPECIALLY ADAPTED FOR PASSENGER OR GOODS SPACES OF VEHICLES
    • B60H1/00Heating, cooling or ventilating [HVAC] devices
    • B60H1/32Cooling devices
    • B60H1/3201Cooling devices using absorption or adsorption
    • B60H1/32011Cooling devices using absorption or adsorption using absorption, e.g. using Li-Br and water

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Aftertreatments Of Artificial And Natural Stones (AREA)
  • Finishing Walls (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

Concrete roof tiles are made by the extrusion press method from a mixture of Portland cement, sand, water and a coloured aggregate material (such as a solid or liquid iron oxide pigment or paint) having a colour corresponding to the desired finished appearance of the tile, in which (a) the sand used either has a natural colour which corresponds to the desired finished appearance of the tile or is pre-treated (e.g. with iron oxide) so that it has the necessary colour, (b) after the shaping step, but before the hot setting step, a setting retarder is applied uniformly to the visible surface of the tiles in an amount corresponding to the desired surface roughness, and (c) after the hot setting step, the unset surface layer of the tiles is removed to form a rough surface. e

Description

SPECIFICATION Method of making coloured concrete roof tiles This invention is concerned with a method of making coloured concrete roof tiles.
Concrete roof tiles are today produced virtually ex clusivelyandthroughouttheworld by the extrusion press method. The extrusion press method for producing concrete rooftiles is well known (see, forexample, Beton-stein-Zeitung, 10/1959, pages 413 to 419) and does not have to be described here in detail.
As a result of the method, a thin cement extrusion skin approximately 0.5 mm thick isformed on the surface of the tiles. The following surface refinement methods have become known for such concrete roof tiles, namely: (a) The cement extrusion skin is left so thatthe concrete roof has a relatively smooth surface.
Experience has shown, however, that this untreated cement extrusion layer weathers away over a period of approximately 10 to 20 years. In this process, light-coloured grains of sand become visible on thetile surface and the surface becomes rough and a so-called pepper and salt structure results. The visual appearanceofthetiieschangesinthecourse of the weathering period. If some of the weathered concrete roof tiles on a roof area have to be replaced by new concrete roof tiles with a smooth surface, differences in the visual appearance of the tiles cannot be avoided and an undesirable impression is produced.
(b) Treatment of the concrete roof tile surface with acid after hot setting, preferably with 3 to 10% aqueous hydrochloric acid.
Although the treatment of concrete roof tiles with acid reduces the tendency to effloresce, an undesired change in the appearance of the tile surface in the course ofthe weathering period - exactly as described under (a) - cannot be avoided.
(c) Asu bsequent application of a slurry of cement or sand and cement to the concrete rooftilesurface.
Cement slurries, including slurries containing sup erfinesand aggregates, are known toform, as a rule, a glossy surface layer during the setting process.
Over the weathering period, the tile surface increasingly acquires a more mat appearance. In addition, depending on its thickness, such a slurry weathers away in a certain period,forexample, after about 10 years, throughout its entire thickness. The erosion process described above under (a) then sets in with a further alteration as mentioned in the appearance.
(d) A subsequent application of polymers or of a slurry comprising clear lacquer or paint or of glossy surface coatings and the liketo the concrete roof tile surface.
The types of polymer used at presentfor coating concrete rooftile surfaces (acrylates, styrene acrylates, vinyl acrylates, etc.) have only limited durability to weathering. Observations have shown that such polymer coatings are weathered away com pletely after about 15 5 years. After complete erosion of the polymer coating, the weathering mechanism referred to under (a) and which is detrimental to the visual appearance then occurs.
(e) An additional application of coloured sand granulates to the slurry already applied to the concrete rooftile surface.
Acoloured sand granulate applied to a cement slurry after the latter has been applied is also not re sistantto weathering. Asa result of limited adhesion to the base material, the coloured sand granulate is completely eroded inthecourse oftime. Thevisual appearance of the tile surface alters simply as a result of the loss of granulates. The cement slurry becomes visible and after exposure, weathering as described above under (c) then occurs.
In short, the concrete roof tile surfaces obtainable with all these methods are insufficiently resistant to a change of appearance due to weathering.
We have now developed a method of forming a coloured surface on such concrete rooftiles which retains a substantially constant appearance when subjected to weathering.
According to the present invention, there is provided a method of making concrete rooftiles bythe extrusion press method from a mixture of Portland cement, sand, water and a coloured aggregate material having a colour corresponding to the desired finished appearance ofthetile, in which (a) the sand used either has a natural colourwhich substantially corresponds to the desired finished appearance of the tile or, where such finished appearance is a red or reddish brown colour shade, contains upto about 1% by weight of iron oxide and has been subjected to a firing process so that its col ouration substantially correspondsto such finished appearance, (b) after the shaping step, but beforethe hot setting step, a setting retarder is applied uniformlyto thevisibiesurface ofthetiles in an amountcorresponding to the desired surface roughness, and (c) after the hot setting step, the unset surface layer ofthetiles is removed to form a rough surface.
In the initial mixture used in this method, it is pre ferred thatthe sand should have a particle size upto about4 mm and it is also preferred that the ii-iix' should contain from 3to 3.8 parts by weight of sand and from 0.35 to 0.45 parts by weight of water per part by weight of Portland cement.
The combination of measures according to the invention, namely the colouration of the dry concrete mixture with a coloured aggregate material, the use of a coloured sand to produce the concrete mixture, and the application of a setting retarderto produce a definite surface roughness, ensures thatthe visual colour appearance of the tile surface does not change as a resultofweathering period, i.e. it retains a constant appearance. With the method according tothe invention, it is possibleto obtain deliberately a particularsurface roughness. The appearance ofthe tile surface may be varied from case to case, but is always controllable and the chosen appearance s re tainedafterweathering.Thegraining 'thes-d used in a particular case is visible atthetiie surfaca in addition to the ground mass which determines the colour shade and because the sand grains protrude to a small extent from the beddng plane, the appcafl ance of a naturally rough surface is obtained. The degree of roughness can be adjusted by the quantity of setting retarder used; afterthe hot setting step, the surface roughness becomes visible after removal of the unset material. The material removal is preferably effected by washing with water supplied under high pressure.
Because the setting retarder acts to a relatively great depth which can, however, be adjusted by modifying agents, such as protein or cellulose addit- ives, and can be limited, it is ensured that even after sand particles have been washed out or eroded as a consequence of weathering of the tile surface, neither the visual colour nor the visual structure, that is the rough appearance, is changed. In other words, even after a certain erosion of sand and parts ofthe coloured cement extrusion layer, no alteration will occur in the appearance ofthe tile surface once it is fixed because the same layer structure is always present.
A method of producing concrete tiles with a surface simulating that of natural sandstone is described in German Offenlegungsschrift 2,812,496. In this method, a layer consisting of a mixture of concrete, quartz sand and paintwhich corresponds to the desired sandstone surface is first introduced into a mould. Afurther mixture of lower quality sand, chippings orgravel is applied to said layer. The entire mould is then bedded down and compacted byshaking on a vibrator. After removal and setting ofthe concrete tile slabs, the sandstone surface ofthetile slabs is passed through a metal granule blasting device or sand blasting device in orderto blastthesur- face ofthetiles uniformly.
This method does not relate to the production of concrete rooftiles and it does not make use ofthe extrusion press method; the use of sand of a parts icular colour is not mentioned. The essential difference is, however, that the roughening step using a sand blast onlyforms the uppermost layer of sand particules in a grain oriented manner. Because of its relatively low bond strength to the concrete layer lying thereunder, the sand particules ofthe uppermost layer are rapidly eroded when subjected to wear or weathering and the cement extrusion layer lying thereunder, along with the iess or barely visible quartz particles, become visible.
The preferred manner of carrying out the method according to the invention is further described in detail below.
Concrete roof tiles are made by the extrusion press method, the details ofwhich are generally known, from a mixture of Portland cement, sand having a particle size of up to about4 mm, and water in the ratio of 3 to 3.8 parts by weight of sand and 0.35 to 0.45 parts by weight of water per part by weight of cement.Acoloured aggregate material isaddedto the mixture in the quantities usual for pigmentation, preferably up to 0.025 parts by weight ofcoloured aggregate material per part by weight ofcement.
Portland cement is used because it meets the established quality requirements and has the appropriate hydraulic setting properties. According to an importantfeature of the invention, a type of sand is used which, according to one alternative, corresponds in its natural colourto the desired visual colour appearance of the finished tile to the greatest possible extent. This applies in particularforyellow, green, grey, brown and black colour shades. For green colour shades, for example, a sand of the rock type diabase green is used, foryellow colour shades yellow quartz or quartzite sand, for grey colour sha- des grey granite sand and for anthracite coloured and black colour shades a sand of the designation diabase grey or dark grey.For concrete roof tiles whose visual colour appearance is intended to have brown shades, a brown quartz sand may, for example, be used and similarlyforcertain reddishbrown colour shadesforwhich, for example, reddish-brown quartz porphyry sand or reddishbrown granite sand may be used.
According to another alternative, for concrete roof tiles whose desired visual colour appearance is a red shade or certain reddish-brown colour shades, a sand is used which contains upto about 1% of iron oxide. The desired red or reddish-brown colour shade is imparted to the sand by a firing process. For this purpose, the sand is fired in a suitable furnace, forexampie at a temperature of upto 600'for45 minutes or at a temperature of up to 500"for60 minutes. In this process the firing time at the given maximum temperature determines the intensity ofthe red colouration.This means that, starting from its naturalcolour,thesandchangescolourduringthe firing process with increasing firing time through reddish-brown shades rightthrough to an intense dark red shade. At any given temperature neo further appreciable increase in the red shade occurs after a certain firing time, that is a certain degree ofsatura- tion is reached. This period of time is specified forthe particularfurnace temperatures specified above as the maximum firing time. This means that the desired red or reddish-brown colour shade forthe desired visual colour appearance of the finished tile can be exactly established by appropriate time and temperature control during the firing process.
The coloured aggregate materials or colourants to be introduced into the concrete mixture can be colour-imparting pigments which are introduced intothe mixture in solid form. These coloured aggregate substances may be solid iron oxide pigments which are colour-determining for the desired visual appearance of concrete roof tiles from yellow through green, brown, red to grey and black shades.
However, in this case, the proportion of water in the concrete mixture must be controlled so as to ensure that the mixture is coloured throughout. Often it is more expedient and simple to use iron oxide use pensions as colourants and to introduce them into the concrete mixture.
After the concrete mixture has been produced from the above-mentioned Portland cement, sand, water and coloured aggregate material components, the tiles are produced by the shaping steps of the extrusion press method which is known per se. In order to obtain the naturally rough surface, after the shaping step, but before the hot setting step, a setting retarder is uniformly applied to the visible surface of the tiles. The quantity of setting retarder per unit area of surface is chosen to obtain the desired surface roughness. Hydroxy carboxylic acids, phosphates or lignin sulphonates may, for example, be used as the setting retarder. The setting retarder is preferably used in aformulationtogetherwith athickening agent, such as, protein or cellulose.The setting retarder may be sprayed on to the tile surface or may be applied by means of brushes. The liquid setting retarderformulation then diffuses more or less deeply into the roof tile. The depth of penetration is determined bythethickening component ofthe formula- tion, for examplethe protein or cellulose. The more thickenerthere is present in the formulation, the less the liquid setting retarder formulation penetrates the tile.
After application of the setting retarder, the tiles are subjected to the hot setting step. This is preferably carried out in a heated oven at approximately 60 Cforatimeof6to8hours.
After hotsetting there is an unsetsurfacelayeron the tiles because of the setting retarder and the unseat surface layer is then removed, preferably by washing with high pressure water.
After the washing step the concrete rooftiles are ready for use; they have a naturally rough surface which is determined by the grains of sand which are visible but only protrude minimally from the surface plane. The desired visual colour appearance of the tiles is produced by the coloured aggregate material and the colour of the sand introduced intothemix- ture.
When the tiles made by the method according to the invention are to be used in a climatiezonewith unfavourable weathering conditions, it may be expedientto subject the tile surface additionally to a treatment with acid subsequent to the washing process and, if necessary, to carry out further surface sealing measures. Such an acid treatment preferably comprises spraying the tile surface with 3 to 5% aqu- eous hydrochloric acid, preferably followed by subsequent rinsing with water. Surface sealing subse quentthereto or coupled with the acid treatment may be carried out by applying suitable impregnating or coating materials. For example, final sealing of the tile surface may be carried out by spraying on an emulsified clear lacquerwhich may optionally be lightlyfilled with a filler, such as calcite, quartz, or talc.
Such an acid treatment serves to minimize or com- pletely avoid concrete efflorescences. Surface sealing prevents weathering effects at least for a certain period oftime. The impregnating or coating mat erials to be used are clear or transparent and do not affect either the visual colour appearance of the tiles or their naturality rough surface structure as obtained by the method according to the invention.

Claims (13)

1. A method of making concreterooftilesbythe extrusion press method from a mixture of Portland cement, sand, water and a coloured aggregate material having a colour corresponding to the desired finished appearance ofthetile, in which (a) the sand used either has a natural colourwhich substantially corresponds to the desired finished appearance of the tile or, where such finished appearance is a red or reddish brown colour shade, contains upto about 1% by weight of iron oxide and has been subjected to a firing process so that its col ouration substantially corresponds to such finished appearance.
(b) after the shaping step, but before the hot setting step, a setting retarder is applied uniformly to thevisibiesurfaceofthetilesinan amountcor- responding to the desired surface roughness, and (c) after the hot setting step, the unset surface layer ofthetiles is removed to form a rough surface.
2. A method according to claim 1, in which the unset surface layer is washed off with water supplied under high pressure.
3. A method according to claim 1 or 2, in which, subsequentto the removal of the unset surface layer, an acid treatment oftile surface is carried out.
4. A method according to claim 3, in which the acid treatment comprises spraying the tile with 3 to 5% aqueous hydrochloric acid and then rinsing the surface with water.
5. A method according to claim 3 or4, inwhich, together with or subsequent to the acid treatment, the treated surface is sealed with an impregnating or coating material.
6. A method according to claim 5, in which sealing is effected by spraying an emulsified clear lacquerwhich may, if desired, contain a filler, on to the surface.
7. A method according to claim 6, in which the filler is calcite, quartz flour ortalc.
8. A method according to any of claims 1 to 7, in which the setting retarder is a hydroxy carboxylic acid, a phosphate, or a lignin sulphonate.
9. A method according to claim 8, in which the setting retarder is used in a formuation which additi onallycontainsa protein or cellulose as a thickening agent.
10. A method according to claim 8or9, in which from 6to 14g of liquid setting retarderformulation is sprayed or painted on to the tile surface.
11. A method according to any of claims 1 to 10, in which the coloured aggregate material is a solid iron oxide pigment or a liquid iron oxide paintwhich contains an iron oxide pigment.
12. A method according to claim 11, in which the liquid iron oxide paint is in an amount of 0.5 to 1.5% by weight, with respect to the weight of the cement.
13. A method according to any of claims 1 to 12, in which a natural sand is used which contains upto 1% by weight of iron oxide and the sand is fired ata temperature of up to 500 Cfor about 1 hourorata temperature of up to 600'C for up to 45 minutes.
GB8628420A 1985-11-30 1986-11-27 Method of making coloured concrete roof tiles Expired GB2183626B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
DE19853542369 DE3542369A1 (en) 1985-11-30 1985-11-30 METHOD FOR THE PRODUCTION OF CONCRETE ROOFS WITH A NATURALLY RAW SURFACE

Publications (3)

Publication Number Publication Date
GB8628420D0 GB8628420D0 (en) 1986-12-31
GB2183626A true GB2183626A (en) 1987-06-10
GB2183626B GB2183626B (en) 1989-02-22

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ID=6287265

Family Applications (1)

Application Number Title Priority Date Filing Date
GB8628420A Expired GB2183626B (en) 1985-11-30 1986-11-27 Method of making coloured concrete roof tiles

Country Status (7)

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AT (1) AT390607B (en)
DE (1) DE3542369A1 (en)
DK (1) DK161751C (en)
FR (1) FR2590890B1 (en)
GB (1) GB2183626B (en)
IT (1) IT1216404B (en)
NL (1) NL8603019A (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2225780A (en) * 1988-12-08 1990-06-13 Sato Road Co Ltd Cement concrete pavement
US5558708A (en) * 1995-05-11 1996-09-24 C-Cure Corporation System and method for dispersing pigment in cement based compositions
US5846315A (en) * 1995-05-11 1998-12-08 C-Cure Corporation Method for preparing a pigmented dispersing pigment cement composition
US6692565B2 (en) 2000-11-20 2004-02-17 C-Cure Corp. Colored cement
CN103465343A (en) * 2013-08-06 2013-12-25 华南理工大学 Anti-chlorine salt cement-based cushion block and reparation method thereof

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3932573A1 (en) * 1989-09-29 1991-04-11 Nelskamp Dachziegelwerke Gmbh Durable coloured concrete roofing tiles - consist of pigmented portland cement mixes with extruded or rolled on covering of similar cement mix plus specified type of polymer
CN112497448A (en) * 2020-08-31 2021-03-16 光明铁道控股有限公司 Block sleeper secondary bonding surface roughening process for ballastless track

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2812496A1 (en) * 1978-03-22 1979-09-27 Kronimus Betonsteinwerk METHOD FOR PRODUCING CONCRETE STONES WITH A SURFACE CORRESPONDING TO THE NATURAL SANDSTONE SURFACE
JPS59121177A (en) * 1982-12-28 1984-07-13 秩父セメント株式会社 Concrete washing finish
BE900773A (en) * 1984-10-08 1985-02-01 Hayez Pierre Ch Moulding building elements such as wall or covering blocks - using crushed stone and binder, and coating mould bottom with set retarder giving patterned surface

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2225780A (en) * 1988-12-08 1990-06-13 Sato Road Co Ltd Cement concrete pavement
FR2640296A1 (en) * 1988-12-08 1990-06-15 Sato Road Co Ltd PERMEABLE CONCRETE COATING WITH WATER
GB2225780B (en) * 1988-12-08 1992-08-26 Sato Road Co Ltd Cement concrete pavement
US5558708A (en) * 1995-05-11 1996-09-24 C-Cure Corporation System and method for dispersing pigment in cement based compositions
US5846315A (en) * 1995-05-11 1998-12-08 C-Cure Corporation Method for preparing a pigmented dispersing pigment cement composition
US5855665A (en) * 1995-05-11 1999-01-05 C-Cure Corporation System and method for producing a pigmented cement composition
US5951752A (en) * 1995-05-11 1999-09-14 C-Cure Corporation Method of using a coloring composition in a concrete based composition
US6692565B2 (en) 2000-11-20 2004-02-17 C-Cure Corp. Colored cement
CN103465343A (en) * 2013-08-06 2013-12-25 华南理工大学 Anti-chlorine salt cement-based cushion block and reparation method thereof

Also Published As

Publication number Publication date
FR2590890B1 (en) 1992-04-30
GB2183626B (en) 1989-02-22
DK161751B (en) 1991-08-12
DK574286A (en) 1987-05-31
FR2590890A1 (en) 1987-06-05
AT390607B (en) 1990-06-11
DE3542369A1 (en) 1987-06-04
DK161751C (en) 1992-11-02
NL8603019A (en) 1987-06-16
DK574286D0 (en) 1986-11-28
IT8683446A0 (en) 1986-11-28
IT1216404B (en) 1990-02-28
ATA318086A (en) 1989-11-15
DE3542369C2 (en) 1989-06-15
GB8628420D0 (en) 1986-12-31

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732E Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977)
PCNP Patent ceased through non-payment of renewal fee

Effective date: 20001127