GB2442729A - Stairway formed by cladding a body of settable material - Google Patents

Stairway formed by cladding a body of settable material Download PDF

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Publication number
GB2442729A
GB2442729A GB0619964A GB0619964A GB2442729A GB 2442729 A GB2442729 A GB 2442729A GB 0619964 A GB0619964 A GB 0619964A GB 0619964 A GB0619964 A GB 0619964A GB 2442729 A GB2442729 A GB 2442729A
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GB
United Kingdom
Prior art keywords
stairway
cladding
set body
settable material
reinforcement
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.)
Withdrawn
Application number
GB0619964A
Other versions
GB0619964D0 (en
Inventor
Roger Alfred Bullivant
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.)
Roxbury Ltd
Original Assignee
Roxbury Ltd
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 Roxbury Ltd filed Critical Roxbury Ltd
Priority to GB0619964A priority Critical patent/GB2442729A/en
Publication of GB0619964D0 publication Critical patent/GB0619964D0/en
Priority to EP07253918A priority patent/EP1914053A3/en
Publication of GB2442729A publication Critical patent/GB2442729A/en
Withdrawn legal-status Critical Current

Links

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
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/22Moulds for making units for prefabricated buildings, i.e. units each comprising an important section of at least two limiting planes of a room or space, e.g. cells; Moulds for making prefabricated stair units
    • B28B7/225Moulds for making units for prefabricated buildings, i.e. units each comprising an important section of at least two limiting planes of a room or space, e.g. cells; Moulds for making prefabricated stair units for making stairs or stair units comprising more than one step
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0053Machines or methods for applying the material to surfaces to form a permanent layer thereon to tiles, bricks or the like
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F11/00Stairways, ramps, or like structures; Balustrades; Handrails
    • E04F11/02Stairways; Layouts thereof
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F11/00Stairways, ramps, or like structures; Balustrades; Handrails
    • E04F11/02Stairways; Layouts thereof
    • E04F11/022Stairways; Layouts thereof characterised by the supporting structure
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04FFINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
    • E04F11/00Stairways, ramps, or like structures; Balustrades; Handrails
    • E04F11/02Stairways; Layouts thereof
    • E04F11/104Treads
    • E04F11/116Treads of stone, concrete or like material or with an upper layer of stone or stone like material, e.g. ceramics, concrete; of glass or with an upper layer of glass

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Steps, Ramps, And Handrails (AREA)

Abstract

A stairway 10 is formed from a set body 12 of settable material, e.g. cement or plaster mix, with cladding 14 provided over at least pail of the surface. The cladding may be sheets of material such as wood and may form the steps and risers of the stairway. The cladding may be provided in the form of a mould for receiving the settable material (figs 3 and 4), the cladding being inverted after the material has set to provide a clad surface above the set body. The settable material may contain a thermal insulating material in bead form. Reinforcement 16 may be provided within the set body and may consist of a square mesh of elongate reinforcing members (fig. 5). Recesses 24 may be formed in the back face of the cladding, each receiving a small ridge 26 of material of the body, to provide mechanical engagement or keying.

Description

Stairway The present invention relates to stairways.
Examples of the present invention provide a method of providing a stairway, comprising: providing a set body of settable material, providing cladding over at least part of the surface of the set body to form a stairway of cladding supported by the set body.
The cladding may be provided in the form of a mould for receiving the settable material, the settable material being introduced to the mould, prior to setting. The cladding may be inverted after the settable material is set, to provide a clad surface generally above the set body. At least part of the mould surface may be coated with bonding agent prior to the introduction of the settable material.
The settable material may be a cementitious material The settable material may be a cement mix or a plaster mix or a mixture of these materials.
The settable material may contain thermal insulating material, which may be in bead form and which may be a polymer material. The insulating material may be polystyrene. The cladding may comprise wood.
The stairway may be formed at a first site and transported to a second site for installation in a building The cladding may be provided to form steps of the stairway. The cladding may be provided to form risers of the stairway. The cladding may be provided to cover substantially the whole exposed face of the steps and risers of the stairway.
The cladding may be provided with features providing, in use, mechanical engagement between the cladding and the set body. The features may comprise recesses formed in the cladding and/or the body. The recesses may be grooves. Bonding material may be provided between the surfaces of the cladding and the set body.
The method may further comprise providing reinforcement for the set body. The reinforcement may be provided within the set body. The reinforcement may be provided in the form of reinforcing members. The reinforcing members may be in the form of a mesh. The reinforcing members may be of metal and/or synthetic fibre.
At least a second part of the surface of the set body may be prepared for plastering. At least the or a second part of the surface of the set body is plastered. The second part of the surface may be generally downwardly directed when the stairway is in use Embodiments of the invention provide a stairway comprising: a set body of settable material; and cladding over at least part of the surface of the set body to form a stairway of cladding supported by the set body.
The settable material may be a cementitious material. The settable material may be a cement mix or a plaster mix or a mixture of these materials.
The settable material may contain thermal insulating material, which may be in bead form and which may be a polymer material. The insulating material may be polystyrene. The cladding rriay comprise wood.
The cladding may form the steps of the stairway. The cladding may form the risers of the stairway. The cladding may cover substantially the whole exposed face of the steps and risers. The cladding may be provided with features providing, in use, mechanical engagement between the cladding and the set body. The features may comprise recesses formed in the cladding and/or the body. The recesses may be grooves. Bonding material may be provided between the surfaces of the cladding and the set body The stairway may further comprise reinforcement for the set body The reinforcement may be within the set body. The reinforcement may be provided in the form of reinforcing members The reinforcing members may form a mesh. The reinforcing members may be metal and/or synthetic fibre.
At least a second part of the surface of the set body may be prepared for plastering. At least a second part of the surface of the set body may be plastered. The second part of the surface may be generally downwardly directed, when the stairway is in use.
Examples of the present invention will now be described in more detail, by way of example only, and with reference to the accompanying drawings, in which: Fig. 1 is a perspective view of an embodiment of a stairway according to the invention; Fig. 2 is a section through the stairway of Fig 1, along the line 2-2; Fig. 3 is a perspective view of the cladding of the stairway of Fig. 1, during the manufacturing process; and Figs. 4 to 7 correspond with Fig. 3, showing various stages in the method of manufacture of the stairway of Fig. 1.
Figs. 1 and 2 illustrate a stairway 10. The stairway 10 includes a set body 12 of settable material. Cladding 14 is provided over at least part of the surface of the body 12, as will be described. This forms a stairway 10 of cladding 14 supported by the set body 12.
In this example, the body 12 is formed of a settable material such as a cementitious material. This may be a cement mix, a plaster mix or a combined mix of plaster and cement. The use of settable material for forming the body 12 allows other material to be incorporated into the stairway 10. For example, thermal insulating material may be incorporated in the body 12, in the form of beads or other small particles. This material may be a polymer material. Polystyrene is an example of an insulating material which may be incorporated in bead form in a cement mix, forming material sometimes called 1 5 "polyconcrete". Thermal insulating materials, such as polystyrene, may also provide enhanced insulation of other parameters, such as sound and/or fire.
The body 12 also incorporates reinforcement 16. The reinforcement 16 is illustrated in this example as a square mesh of elongate reinforcing members, which may be metal. Other forms of metal reinforcement and other mesh forms could be used. Alternatively, the reinforcement 16 could be in the form of fibres, such as synthetic fibres, which may be in the form of a woven or non-woven mat of reinforcing fibres.
The body 12 of set material, in combination with the reinforcement 16, forms a structure which is sufficiently strong to provide the structural strength of the stairway 10.
The upper face of the stairway 10 has a series of steps 20 separated by risers 22. In this example, the cladding 14 dads the steps 20 and risers 22, thus forming the steps and risers as seen by a user. Thus, the cladding 14 covers substantially the whole exposed face of the steps 20 and risers 22.
In other examples, the body 12 may be only partially clad In this example, the cladding 14 is in the form of sheets of material, such as wood. The cladding 14 is provided with features which provide, in use, mechanical engagement between the cladding 14 and the body 12. In this example, the features are recesses 24 formed in the back face of the cladding 14. The recesses 24 may be grooves, each receiving a small ridge 26 of material of the body 12, to provide the mechanical engagement or keying. In this example, recesses 24 are formed in the cladding 14. Other possibilities include projections formed on the cladding 14, received in recesses in the body 12. The security of fixing between the cladding 14 and the body 12 may be further enhanced by providing bonding material at the 1 5 abutting surfaces of the body 12 and cladding 14, as will be described.
An example of a method for manufacturing the stairway 10 will now be described with reference to the remaining drawings.
Fig. 3 shows the cladding 14, formed as the first step of the method. In Fig. 3, the cladding 14 is inverted Accordingly, the surfaces visible in Fig. 3 are the rear faces of the cladding, which include the grooves 24. Chocks 28 may be used to maintain the form of the cladding 14 at this stage of the method Timber cheeks 30 may be used at both sides of the cladding 14, to form finishing trim in the stairway 10.
Accordingly, it can be seen from Fig. 3 that the upturned cladding 14 forms a shallow trough with a stepped floor and side walls provided by the cheeks 30. Thus, the cladding 14 is in the form of a mould which, when inverted as shown in Fig. 3, can receive settable material for forming the set body 12, prior to setting. Fig. 4 illustrates the step of introducing the settable material into the mould provided by the cladding 14. Prior to the introduction of settable material 32, the back surfaces of the cladding 14 may be prepared by coating with a bonding agent, such as a styrene-butadiene co-polymer latex, common known as SBR and available from Degussa Construction Chemicals (UK) of Manchester, United Kingdom, under the name FEBOND SBR. Prior to setting, the material 32 will flow across the back faces of the cladding 14, constrained by the cheeks 30, and into the grooves 24. This flow may be encouraged, for example by placing the cladding mould on a vibrating table. When the cladding mould 14 is partially filled, the reinforcement 16 is introduced, as illustrated in Fig 5. Again, this example illustrates a reinforcement 16 in the form of a square mesh of elongate metal reinforcing members, but other forms of reinforcement could be used. Introduction of settable material 32 then continues, covering the reinforcement 16. The final level of the settable material 32 is a little below the height of the cheeks 30, leaving a short lip of the cheeks 30, proud above the material 32. The purpose of these lips will become apparent below.
While the material 32 is still unset, score marks 34 are provided across its upper face. The settable material 32 is then left in the cladding mould 14 until set. Typically, this may take about twenty four hours, but this time will depend on the composition of the material 32, ambient conditions and other factors.
The purpose of the scores 34 is to prepare the body 12 for plastering.
In this example, manufacturing of the stairway 10 is concluded by forming a plaster layer 36. Alternatively, the stairway 10 could be left unplastered, for subsequent cosmetic finishing.
Once the material 32 is fully set, and the plaster layer 36 is set, if present, the construction can be inverted to the orientation illustrated in Fig. 1.
This results in the cladding layer 14 being above the body 12, with the plaster layer on the downward-facing face 38 (indicated by an arrow in Fig. 1).
Accordingly, when the stairway 10 is installed in a building, a user will have the impression of climbing a staircase made entirely of the cladding material. In this example, the impression would be of climbing a wooden staircase From below, if the lower surface is exposed in the building, a neat finish is provided by the plaster layer 36, which may be decorated as soon as the stairway 10 is installed. However, the structural strength of the stairway is provided by the body 12 and reinforcement 16. In addition, the body 12 provides enhanced thermal, acoustic and fire retardant properties in comparison with a conventional, wholly wooden stairway. These effects are expected to be particularly demonstrated if the body 12 incorporates polystyrene or other insulating material, as described above.
It is envisaged that the stairway is formed at a first site, such as a 1 5 factory, to ensure consistent quality of manufacture. The manufactured stairway 10 can then be transported to a second site for installation in a building.
The stairway 10 may be extended at the top or bottom to form an area of floor or landing formed in the same manner described, that is by extending the cladding mould 14 and providing additional settable material to form a set body behind the cladding of the floor or landing.
Many variations and modifications can be made to the apparatus and method described above, without departing from the scope of the invention.
In particular, a wide range of dimensions and relative dimensions, and alternative materials could be used.
Whilst endeavouring in the foregoing specification to draw attention to those features of the invention believed to be of particular importance it should be understood that the Applicant claims protection in respect of any patentable feature or combination of features hereinbefore referred to and/or shown in the drawings whether or not particular emphasis has been placed thereon.

Claims (53)

1 A method of providing a stairway, comprising: providing a set body of settable material; providing cladding over at least part of the surface of the set body to form a stairway of cladding supported by the set body.
2. A method according to claim 1, wherein the cladding is provided in the form of a mould for receiving the settable material, the settable material being introduced to the mould, prior to setting.
3. A method according to claim 2, wherein the cladding is inverted after the settable material is set, to provide a clad surface generally above the set body.
4. A method according to claim 2 or 3, wherein at least part of the mould surface is coated with bonding agent prior to the introduction of the settable material.
5. A method according to any preceding claim, wherein the settable material is a cementitious material.
6 A method according to claim 5, wherein the settable material is a cement mix or a plaster mix or a mixture of these materials.
7. A method according to any preceding claim, wherein the settable material contains thermal insulating material.
8. A method according to claim 7, wherein the thermal insulating material is in bead form.
9. A method according to claim 7 or 8, wherein the thermal insulating material is a polymer material.
10 A method according to claim 7, 8 or 9, wherein the insulating material is polystyrene
11. A method according to any preceding claim, wherein the cladding comprises wood.
12. A method according to any preceding claim, wherein the stairway is formed at a first site and transported to a second site for installation in a building.
13. A method according to any preceding claim, wherein the cladding is provided to form steps of the stairway.
14. A method according to any preceding claim, wherein the cladding is provided to form risers of the stairway.
15. A method according to any preceding claim, wherein the cladding is provided to cover substantially the whole exposed face of the steps and risers of the stairway.
16 A method according to any preceding claim, wherein the cladding is provided with features providing, in use, mechanical engagement between the cladding and the set body.
17. A method according to claim 16, wherein the features comprise recesses formed in the cladding and/or the body.
18 A method according to claim 17, wherein the recesses are grooves.
19. A method according to any preceding claim, wherein bonding material is provided between the surfaces of the cladding and the set body.
20. A method according to any preceding claim, further comprising providing reinforcement for the set body.
21. A method according to claim 20, wherein the reinforcement is provided within the set body.
22. A method according to claim 20 or 21, wherein the reinforcement is provided in the form of reinforcing members.
23. A method according to claim 22, wherein the reinforcing members are intheformofa mesh.
24. A method according to claim 22 or 23, wherein the reinforcing members are of metal and/or synthetic fibre.
25. A method according to any preceding claim, wherein at least a second part of the surface of the set body is prepared for plastering.
26. A method according to claim 25, wherein at least the or a second part of the surface of the set body is plastered.
27. A method according to claim 25 or 26, wherein the second part of the surface is generally downwardly directed when the stairway is in use.
28. A method of providing a stairway, substantially as described above, with reference to the accompanying drawings.
29. A stairway comprising: a set body of settable material; and cladding over t least part of the surface of the set body to form a stairway of cladding supported by the set body.
30. A stairway according to claim 29, wherein the settable material is a cementitious material.
31. A stairway according to claim 30, wherein the settable material is a cement mix or a plaster mix or a mixture of these materials.
32. A stairway according to any of claims 29 to 31, wherein the settable material contains thermal insulating material.
33. A stairway according to claim 32, wherein the insulating material is in bead form
34. A stairway according to claim 32 or 33, wherein the insulating material is a polymer material.
35. A stairway according to any of claims 32 to 34, wherein the insulating material is polystyrene.
36. A stairway according to any of claims 29 to 35, wherein the cladding comprises wood.
37. A stairway according to any of claims 29 to 36, wherein the cladding forms the steps of the stairway.
38. A stairway according to any of claims 29 to 37, wherein the cladding forms the risers of the stairway.
39. A stairway according to any of claims 29 to 38, wherein the cladding covers substantially the whole exposed face of the steps and risers.
40. A stairway according to any of claims 29 to 39, wherein the cladding is provided with features providing, in use, mechanical engagement between the cladding and the set body.
41. A stairway according to claim 40, wherein the features comprise recesses formed in the cladding and/or the body.
42. A stairway according to claim 41, wherein the recesses are grooves.
43. A stairway according to any of claims 29 to 42, wherein bonding material is provided between the surfaces of the cladding and the set body.
44. A stairway according to any of claims 29 to 43, further comprising reinforcement for the set body.
45. A stairway according to claim 44, wherein the reinforcement is within the set body.
46. A stairway according to claim 44 or 45, wherein the reinforcement is provided in the form of reinforcing members.
47. A stairway according to claim 46, wherein the reinforcing members form a mesh.
48. A stairway according to claim 46 or 47, wherein the reinforcing members are metal and/or synthetic fibre.
49. A stairway according to any of claims 29 to 48, wherein at least a second part of the surface of the set body is prepared for plastering.
50. A stairway according to any of claims 29 to 49, wherein at least a second part of the surface of the set body is plastered.
51. A stairway according to claim 49 or 50, wherein the second part of the surface is generally downwardly directed, when the stairway is in use.
52. A stairway, substantially as described above, with reference to the accompanying drawings.
53. Any novel subject matter or combination including novel subject matter 1 5 disclosed herein, whether or not within the scope of or relating to the same invention as any of the preceding claims.
GB0619964A 2006-10-10 2006-10-10 Stairway formed by cladding a body of settable material Withdrawn GB2442729A (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB0619964A GB2442729A (en) 2006-10-10 2006-10-10 Stairway formed by cladding a body of settable material
EP07253918A EP1914053A3 (en) 2006-10-10 2007-10-03 Method of manufacturing a stairway and stairway obtained by this method

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB0619964A GB2442729A (en) 2006-10-10 2006-10-10 Stairway formed by cladding a body of settable material

Publications (2)

Publication Number Publication Date
GB0619964D0 GB0619964D0 (en) 2006-11-15
GB2442729A true GB2442729A (en) 2008-04-16

Family

ID=37454258

Family Applications (1)

Application Number Title Priority Date Filing Date
GB0619964A Withdrawn GB2442729A (en) 2006-10-10 2006-10-10 Stairway formed by cladding a body of settable material

Country Status (2)

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EP (1) EP1914053A3 (en)
GB (1) GB2442729A (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110017021A (en) * 2019-04-18 2019-07-16 中国一冶集团有限公司 A kind of stair, which are poured, whole tears fixative composition formula template open with whole spell

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB769434A (en) * 1952-12-30 1957-03-06 Karl Ivan Forssell Improved method for casting single-flight stairs and stairs produced thereby
GB865141A (en) * 1956-11-16 1961-04-12 Costain Ltd Richard Improvements in or relating to staircases of concrete and like materials
DE2522239A1 (en) * 1974-05-22 1975-12-11 Hug Interlizenz Ag Suspended staircase of elements united by core - has string boards, treads and riser walls with infill
GB2115852A (en) * 1981-12-24 1983-09-14 Ferodo Ltd Cladding staircase tread and riser surfaces; floor cladding
DE3433455A1 (en) * 1984-09-12 1986-03-27 Otto J. 2000 Hamburg Jahncke Prefabricated flight of stairs
EP0987381A1 (en) * 1998-09-18 2000-03-22 Stefan Schmid Staircase

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR758051A (en) * 1933-07-05 1934-01-10 monolithic element for making or covering stair treads, and method of making
AT378222B (en) * 1983-12-22 1985-07-10 Leidinger Kurt METHOD FOR PRODUCING A STAIRCASE
US5713166A (en) * 1994-05-23 1998-02-03 Structures Monocoques Inc. Monocoque staircase and method for joining wooden pieces
DE19652901A1 (en) * 1996-12-19 1998-06-25 Neucon Masch Bausystem Factory production process for staircases

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB769434A (en) * 1952-12-30 1957-03-06 Karl Ivan Forssell Improved method for casting single-flight stairs and stairs produced thereby
GB865141A (en) * 1956-11-16 1961-04-12 Costain Ltd Richard Improvements in or relating to staircases of concrete and like materials
DE2522239A1 (en) * 1974-05-22 1975-12-11 Hug Interlizenz Ag Suspended staircase of elements united by core - has string boards, treads and riser walls with infill
GB2115852A (en) * 1981-12-24 1983-09-14 Ferodo Ltd Cladding staircase tread and riser surfaces; floor cladding
DE3433455A1 (en) * 1984-09-12 1986-03-27 Otto J. 2000 Hamburg Jahncke Prefabricated flight of stairs
EP0987381A1 (en) * 1998-09-18 2000-03-22 Stefan Schmid Staircase

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110017021A (en) * 2019-04-18 2019-07-16 中国一冶集团有限公司 A kind of stair, which are poured, whole tears fixative composition formula template open with whole spell

Also Published As

Publication number Publication date
GB0619964D0 (en) 2006-11-15
EP1914053A2 (en) 2008-04-23
EP1914053A3 (en) 2010-08-11

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