GB2360959A

GB2360959A - Profiled structural elements or surfaces

Info

Publication number: GB2360959A
Application number: GB0031732A
Authority: GB
Inventors: De Sande Antonius Van
Original assignee: SANDE ANTONIUS VAN DE
Current assignee: SANDE ANTONIUS VAN DE
Priority date: 1999-12-28
Filing date: 2000-12-28
Publication date: 2001-10-10
Also published as: NL1013971C1; DE10050133A1; GB0031732D0; FR2802852A3; BE1013464A6; FR2802852B3

Abstract

Profiled structural elements or surfaces wherein the strength of a base or foundation layer (1) determines the strength of the whole has a surface layer (5) which is produced and profiled during manufacture of the element. The layer (1) could be a concrete mix comprising gravel or aggregate (3) in a sand/cement matrix 4 but the mix could be a hardenable synthetic resin or a combination of resin and cement or concrete. The surface layer (5) may be a coloured or non-coloured material which may be applied by spreading or dusting or laying or rubbing the material onto the top surface of the element 1. A top coating of mould release (7) may be applied. Prior to hardening of the layer (5) a plate (8) carrying a mat (9) is pressed onto the surface to produce the required indented surface profile. The mat (9) and plate (8) has communicating channels (10), (11) and (12) through which air may be removed. As an alternative a roller (13) with air vents (14) and a profiled surface may be used.

Description

1 Title:

2360959 Manufacture of shaped cast elements.

This invention relates to the manufacture of shaped cast elements using hardenable or settable powdered or granular materials such as concrete, cement or synthetic materials such as hardenable resin compositions.

This invention also relates to the restoration and recycling of existing or prefabricated constructional elements by re-manufacturing the surface thereof.

According to one aspect this invention provides slabs for constructing paths or roadways formed from a base element, being concrete for example, with aggregates in a cement/sand matrix. During hardening of the element top surface layer is formed by the application of a screeding which forms a hard dense surface layer to which a top coating of a mould release agent is applied.

is Prior to curing or hardening of the layer a plate carrying a mat is pressed onto the surface to produce the required indented surface profile. The mat and plate have communicating channels through which air may be removed.

Broadly according to this invention there is provided a process for the production of profiled structural elements or surfaces wherein the strength of a base or foundation layer determines the strength of the whole, characterised in that a surface finishing layer is applied to the element, said layer being produced and profiled during manufacture of the element.

In this invention a press member is provided with a profiled surface which is forced onto the soft surface layer applied to a slab or the like in order to imprint the surface with a required pattern. The soft surface layer may 1 comprise a hardenable top layer, possibly coloured.

Although it may be clear that the invention in question relates to impressing all kinds of products, the following description will relate to the manufacturing process for prefabricated profiled concrete slabs, that are used for laying out pavements, patios, roads, terraces and walls, including acoustic walls, retaining walls, building elements, ceilings etc.

The invention, besides the working procedure, also relates to the fitting of air vents to pressure applying mats.

The present invention focuses on providing automated or non-automated lo prefabricated impervious surfaces to avoid organic growth, so that there will be little need for maintenance.

The joints between the slabs are sealed with the known technically environmentally resistant substances, after which it is possible to put on a water-resistant layer.

By providing the bottom layer with the necessary loading power, road subsidence caused by heavy transport can be avoided, so that repairing will no longer be necessary.

The structures can be diverse, such as in the shape of a tile, paving stone, rocks, boulders etc. In addition, finishes based on individual design, such as logos or combinations of the above mentioned alternatives are possible.

The surface does not need to be level, so that slanting or spherical surfaces for water drainage are possible. The colour, shade, hardness, protection against wear and density of the top layer depend on the chosen top layer materials.

3 The present invention also relates to a mobile machine, possibly provided with a profiling tool, to travel in one pass over a profiled road or profiled part of the terrain being constructed.

This invention is further described and illustrated with reference to the drawings wherein:- Fig. 1 shows a section through a concrete element manufactured in accordance with this invention; Fig. 2 shows a section of a pressure applying mat for forming the surface pattern; Fig. 3 shows a section of a pressure applying roller for forming the surface pattern; Fig. 4 shows a plan view of several different surface patterns applied to elements.

Referring to the drawings Fig. 1 shows a portion, in section, of a slab element which is produced in the following steps:

a) The element shown comprises a lower slab forming layer 1 with or without a reinforcement mat of steel or fibre material. In an example the material 1 comprises cement or concrete. The concrete mix comprises gravel or aggregate 3 in a sand/cement matrix 4 but the mix could be a hardenable synthetic resin or a combination of resin and cement or concrete. This lower layer provides strength and may include supports, channels, reinforcement, connection element or formations for interlocking purposes, as example.

b) After production of the element 1, a coloured or non-coloured hardening 4 top surface layer 5 is applied. This may be applied by spreading, dusting, laying or rubbing the material onto the top surface of element 1. The material 6 may be a pulverised layer and provides a dense wear resisting surface to protect the top surface 5 against abrasion.

c) After a short drying period a fine powdered mould release substance 7 is applied to the surface of the layer 6. This material 7 may be a coloured material which, together with the colour of the layer 6 forms the final required colour. The mould release substance 7 could be a customary fluid compound.

d) Using a pressure member 8 with air channels 12, as shown in Fig. 2, a lo profiled mat 9 with air communicating ducts 10 and 11 and having the desired surface profile, is pressed against the top layer 5, 6, 7 also possibly impressing on the base layer 1 also. Trapped air may escape through the ducts 10 and 11 and channels 12.

e) The element is then allowed to harden accompanied by a cleaning is operation. Various further procedures are possible such as heating, curing, ageing, glazing and the like finishing processes.

With modifications the process may be used for continuous production, such as for road or pathway construction on site. In this method, as shown in Fig. 3, a roller 13 with air vents 14 and a profiled surface 15 is used. The roller profile 15 may have various shapes. Following profiling after treatments may be applied such as the use of a brush system to remove edges. Such treatments take place during the hardening process. When the starting material is a prefabricated slab, wall or ceiling, as example, then only a pressure layer., so-called press-screed, is applied instead of the surface hardening material 6 of Fig. 1. Other steps will be the same as described.

The final slab is usually referred to in the art as a press-plate even through the method is based on a press-screed procedure.

For used or rejected concrete slabs and the like the press-screed method is well suited as the final result is indistinguishable from a pressplate, that is based on the press-plate method.

The contours of the profiled elements may have any desired form such as round, polygonal, semi-circular, and trapezoid. Various exemplary shapes and imprints are shown in Figs. 4 a) to c).

6

Claims

CLAIMS:

1. A process for the production of profiled structural elements or surfaces wherein the strength of a base or foundation layer determines the strength of the whole, characterised in that a surface finishing layer is applied to the element, said layer being produced and profiled during manufacture of the element.

2. A process in accordance with claim 1, wherein during the formation of a profile or pattern on the surface layer air is excluded.

3. A process in accordance with any preceding claim, wherein the proffling 10 is produced by the application of a mat to the surface layer.

4. A process in accordance with any preceding claim, wherein the surface layer includes colouring material.

5. A process in accordance with any preceding claim, wherein the element comprise a hardenable granular or powdered material such as concrete or cement or a synthetic resin material.

6. A process in accordance with any preceding claim, carried out on preformed elements or surfaces.

7. A process in accordance with any preceding claim, wherein the element has a flat rounded or other profiled surface.

8. A process for manufacturing slabs for constructing paths or roadways, in which process a base element is formed, being concrete for example, with aggregates in a cement/sand matrix, during hardening of the element a top surface layer is formed by the application of a screeding which forms a hard dense surface layer to which a top coating of a mould release agent is applied, prior to curing or hardening of the layer, a plate carrying a mat is pressed onto 7 the surface to produce the required indented surface profile, the mat and plate have communicating channels through which air may be removed.

9. A process in accordance with any preceding claim, as described herein and exemplified.