GB2475852A - Composite paving element - Google Patents
Composite paving element Download PDFInfo
- Publication number
- GB2475852A GB2475852A GB0921077A GB0921077A GB2475852A GB 2475852 A GB2475852 A GB 2475852A GB 0921077 A GB0921077 A GB 0921077A GB 0921077 A GB0921077 A GB 0921077A GB 2475852 A GB2475852 A GB 2475852A
- Authority
- GB
- United Kingdom
- Prior art keywords
- paving element
- support layer
- lower support
- composite
- layer
- 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- Withdrawn
Links
- 239000002131 composite material Substances 0.000 title claims abstract description 44
- 239000010410 layer Substances 0.000 claims abstract description 53
- 239000002344 surface layer Substances 0.000 claims abstract description 27
- 239000000463 material Substances 0.000 claims abstract description 20
- 238000004519 manufacturing process Methods 0.000 claims abstract description 7
- 230000035939 shock Effects 0.000 claims abstract description 5
- 238000000034 method Methods 0.000 claims description 14
- 239000002861 polymer material Substances 0.000 claims description 7
- 238000000465 moulding Methods 0.000 claims description 6
- 229920000642 polymer Polymers 0.000 claims description 4
- 239000007767 bonding agent Substances 0.000 claims description 2
- 239000010791 domestic waste Substances 0.000 claims description 2
- 239000002440 industrial waste Substances 0.000 claims description 2
- 239000000203 mixture Substances 0.000 claims description 2
- 230000008569 process Effects 0.000 description 7
- 239000004575 stone Substances 0.000 description 6
- 239000004743 Polypropylene Substances 0.000 description 4
- -1 polypropylene Polymers 0.000 description 4
- 229920001155 polypropylene Polymers 0.000 description 4
- 229920002635 polyurethane Polymers 0.000 description 4
- 239000004814 polyurethane Substances 0.000 description 4
- 230000008901 benefit Effects 0.000 description 3
- 239000004567 concrete Substances 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 229920005830 Polyurethane Foam Polymers 0.000 description 2
- 208000027418 Wounds and injury Diseases 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000006378 damage Effects 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 230000036541 health Effects 0.000 description 2
- 208000014674 injury Diseases 0.000 description 2
- 239000011496 polyurethane foam Substances 0.000 description 2
- 229920002994 synthetic fiber Polymers 0.000 description 2
- 208000019693 Lung disease Diseases 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 201000010001 Silicosis Diseases 0.000 description 1
- 206010061363 Skeletal injury Diseases 0.000 description 1
- 239000004809 Teflon Substances 0.000 description 1
- 229920006362 Teflon® Polymers 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 230000003466 anti-cipated effect Effects 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910002026 crystalline silica Inorganic materials 0.000 description 1
- 239000006260 foam Substances 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 230000003387 muscular Effects 0.000 description 1
- 239000011178 precast concrete Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000012502 risk assessment Methods 0.000 description 1
- 238000007493 shaping process Methods 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000012815 thermoplastic material Substances 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C5/00—Pavings made of prefabricated single units
- E01C5/22—Pavings made of prefabricated single units made of units composed of a mixture of materials covered by two or more of groups E01C5/008, E01C5/02 - E01C5/20 except embedded reinforcing materials
-
- E—FIXED CONSTRUCTIONS
- E01—CONSTRUCTION OF ROADS, RAILWAYS, OR BRIDGES
- E01C—CONSTRUCTION OF, OR SURFACES FOR, ROADS, SPORTS GROUNDS, OR THE LIKE; MACHINES OR AUXILIARY TOOLS FOR CONSTRUCTION OR REPAIR
- E01C2201/00—Paving elements
- E01C2201/20—Drainage details
- E01C2201/202—Horizontal drainage channels
- E01C2201/207—Horizontal drainage channels channels on the bottom
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Road Paving Structures (AREA)
Abstract
The paving element, in particular slabs or blocks for use in driveways, patios and other hard landscaping, comprise an upper layer 2 and a lower layer 3, the lower layer being formed of a relatively lighter layer as compared to the upper layer. One or more conduits 5 may be provided in the lower layer, which preferably comprises a polymeric material with shock absorbency characteristics. The polymeric material is preferably recycled material. The underside of the upper surface layer is preferably roughened so as to facilitate bonding of the upper and lower layers. At least one alignment layer is preferably provided on the paving element to aid correct positioning relative to other elements. Also claimed is a method of manufacturing a composite paving element.
Description
A COMPOSITE PAVING ELEMENT
Field of the Invention
The present invention relates paving elements, such as slabs or blocks, for use in the surfacing of domestic driveways and patios and also in the commercial, civil and public hard landscaping sectors.
Background of the Invention
Paving is a commonly used form of landscaping in the domestic, commercial, public and civil sectors. Recently there has been a great deal of legislative change within these sectors, focusing on the manual handling of precast concrete and natural stone products. The general trend is towards the use of mechanical or vacuum lifting equipment on-site to manoeuvre and lay heavy precast or natural stone paving elements such as slabs, flags, setts, kerbs, blocks and other forms of paviour.
The use of mechanical handling aids reduce the risk of operators suffering muscular skeletal injuries but does not eliminate the health and safety risk at source, as is required by legislation such as CDM (Construction Design Management) 2007.
Furthermore mechanical handling does not address the injury risks involved in maneuvering paving elements to gain alignment, or the risks involved in the on-site cutting and shaping of paving elements. The use of mechanical handling means also places further on-site risk assessment and additional traffic management around these cumbersome pieces of kit.
Statement of the Invention
The present invention provides a composite paving element comprising an upper surface layer that is visible in use and a lower support layer, wherein said upper surface layer consists of a suitable paving material, whilst said lower support layer consists of a relatively lighter material, and whereby the
I
weight of the composite paving element is less than a non-composite paving element of similar dimensions.
When precast or natural stone paving elements are machine cut the operator can be exposed to respirable crystalline silica (RCS) dust, which is known to induce silicosis and other pulmonary diseases. Therefore, because only the upper surface layer is made from typical paving materials, the amount of time required to machine cut through the composite paving element of the present invention is reduced. The reduced cutting time means that operators are less exposed to the potentially harmful RCS dust.
Preferably the lower support layer may have one or more conduits running through the layer from one edge of the composite paving element to another edge of the composite paving element. These conduits allow minor services to travel below the upper surface layer of the composite paving element thus allowing quick access to utilities during maintenance and servicing operations and works.
Preferably the lower support layer may comprise a polymer material with shock absorbency characteristics. Suitable materials include polyurethane or expanded polypropylene. This would allow the composite paving element to fall within Manual Handling Guidance 1992 (MAC) of the Health and Safety Executive and allow paving to be installed as it was in previous generations, but in a quicker and safer fashion.
The composite paving element of the present invention would also benefit from better shock resistance and loading capabilities and would adhere to relevant United Kingdom and European specifications such as, but not limited to; BS/7533, BS/EN1 338, BS/EN1 339, BSJENI 340, BS/EN 13198, BS/EN7997 and BS/EN7932.
Preferably the polymer material may comprise a blend of recycled polymers from post-industrial and/or domestic waste streams. This is possible due that fact that the visual appearance of the lower support layer is not crucial because in normal use the layer will be hidden from view.
Preferably the underside of the upper surface layer may be roughened, pitted or otherwise cut into so as to facilitate the bonding of the upper surface layer to the lower support layer.
Preferably 20-30% of the total thickness of the composite paving element is provided by the upper surface layer and 70-80% is provided by the lower support layer.
Preferably the paving element further comprises at least one alignment means to ensure the paving element is correctly positioned relative to neighbouring paving elements. Examples of alignment means include, but are not limited to, various male and female socket arrangements such as tongue and groove
Brief Description of the Drawings
The present invention will be described with reference to the preferred embodiments, wherein: Figure 1 shows a perspective view of a preferred embodiment of the composite paving element of the present invention; Figure 2 shows a perspective view of a preferred embodiment of the composite paving element of the present invention with the addition of conduits; Figure 3a shows a perspective view of a preferred embodiment of the composite paving element of the present invention with an alternative form of conduits; Figure Sb shows an underside view of the composite paving element shown in Figure 3a; Figure 4a shows a perspective view of a preferred embodiment of the composite paving element of the present invention with a second alternative form of conduits; Figure 4b shows an underside view of the composite paving element shown in Figure 4a.
Detailed Description of the Preferred Embodiments
The present invention relates to paving elements, such as paving blocks and paving slabs or flags for example, but other paving elements such as kerbs are also considered to fall within the present invention. However rather than making the paving elements from a single material, such as concrete or natural stone, the paving elements are a composite of an upper surface layer of a standard paving material and a lower support layer of a second, lighter material.
One of the main advantages of the composite paving element of the present invention is the fact that the paving element retains a standard size. and shape, yet weighs less than an equivalent paving element made entirely from standard paving materials, such as concrete or natural stone. The reduced weight of the composite paving elements reduces the risk of an operative suffering injury white handling and lift the paving elements of the present invention.
Figures 1-4b show the present invention embodied in the form of paving slabs. However it is appreciated that the present invention is equally applicable to other paving elements such as paving blocks and even kerbing elements as such would all benefit from the weight reduction provided.
Figure 1 shows an example of the composite pavin.g element of the present invention in its broadest form. The example shown is in the shape of a typical square paving slab 1. The paving slab i is made up of two layers.
The first layer 2 is the upper surface layer, which will be made from any standard paving material. Examples of standard paving materials include concrete and natural stone, but other materials, such as suitable synthetic materials or a composite slip could also be used.
The second layer 3 is the lower support layer, which will be made from a polymer or synthetic material, such as polyurethane or expanded polypropylene. The skilled person will appreciate what polymer materials have a suitable modulus to meet the required installed performance levels for a paving element. By using a polymer material to make up the rest of the paving stab I the overall weight of the slab 1 is reduced. It is also appreciated that by using materials such as polyurethane or expanded polypropylene the lower support layer can provide a shock resistance characteristic to the paving element.
Although not shown in the figures, it is appreciated that the underside of the lower support layer could be provided with recesses or another form of keying element that would assist with the laying of the paving element, It is anticipated that the bedding material into which the paving element is laid would form around the recesses or keying elements to make the positioning of the paving element stable.
It is important to ens.ure that a balance is struck between a reduction in the overall weight of the composite paving elements of the present invention a level of structural strength is maintained.
The paving elements shown in the figures comprise about one third upper surface layer and about two thirds lower support layer. Thus, for example, a typical paving slab with a thickness of 50mm is made up of an upper surface layer 2 that is 12mm thick and a lower support layer 3 that is 38mm thick.
These values are provided as an indication only and would obviously depend on the dimensions of the paving element itself.
It is appreciated that the upper surface layer and the lower support layer could be manufactured separately and the stuck together using a suitable bonding agent This is particularly suitable when the lower support layer is made. from polyurethane.
S
When the lower support layer is made from a thermoplastic material, such as High Density Polyethylene or Polypropylene, corona discharge can be used to make the material wetable, which allows most materials to bond to the lower support layer.
Alternatively the upper surface layer and the lower support layer could be moulded together. The manufacturing process could be, but is not limited to, an in-mould process, for example, compUession moulding, high or low pressure injection moulding or casting.
An example of a manufacture process which is considered particularly useful in the production of the said two layers of the paving element together is automated foam injection with a carousel moulding process. This process allows numerous moulds manufactured from, for example, stainless steel with aluminum and Teflon coated parts to be used.
In this process the upper surface layer of a paving element is placed within a carousel moulding operation. A mould is then closed over the upper surface layer of the composite paving element so that high density polyurethane foam can be injected on to the upper surface layer.
Upon completion of the polyurethane foam injection phase the mould moves away from the injection station, thus allowing the next mould to move into position and process to be repeated again. The previous mould then begins its cooling process/cycle before de-moulding of the finished product allows operatives to then package the finished composite paving element The functionality of the composite paving element of the present invention can be further improved by the addition of conduits in the lower support layer 3.
Figure 2 shows a composite paving slab 4, similar to that shown in Figure 1, but with the addition of conduits 5. Such conduits 5 provide a means of passing utilities, such as phone cables or cabling for low voltage lighting for example, under a paved area without having to disrupt a large portion of the paved area.
The conduits 5 shown in the embodiment of Figure 2 take the form of two bore holes that pass through the lower support layer 3 from one edge of the paving slab 4 to the opposite edge of the paving slab 4. It is appreciated that the two bore holes may intersect one another at the mid-point of the paving slab. Of course it is appreciated that more or less than two conduits could be used as appropriate.
Alternative conduit arrangements will be appreciated from Figures 3a, 3b, 4a and 4b. In Figures 3a and 3b the paving slab 6 is provided with two conduits 7 in the form of channels in the lower support layer.
In Figures 4a and 4b the paving slab 8 is provided with four conduits 9 in the form of channels in the lower support layer. In both arrangements the conduits 7, 9 provide a network of routes for utility cables and the like to be passed underneath the upper surface layer 2.
The conduits could be either cut out of the lower support layer 3 during the manufacturing process or alternatively formed during the moulding of the polymer that makes up the lower support layer 3.
Claims (5)
- Claims 1. A composite paving element comprising an upper surface layer that is visible in use and a lower support layer, wherein said upper surface layer consists of a suitable paving material, whilst said lower support Layer consists of a relatively lighter matenal, and whereby the weight of the composite paving element is less than a non-composite paving element of similar dimensions.
- 2. The composite paving element of claim 1, wherein the lower support layer comprises one or more conduits running through the layer from one edge of the composite paving element to another edge of the composite paving element.
- 3. The composite paving element of claim I or 2, wherein the lower o support layer comprises a polymer material with shock absorbency r characteristics.r
- 4. The composite paving element of claim 3, wherein the polymer material comprises a blend of recycled polymers from post-industrial and/or domestic waste streams.
- 5. The composite paving element of any of the preceding claims, wherein the underside of the upper surface layer is roughened, pitted or otherwise cut into so as to facilitate the bonding of the upper surface layer to the lower support layer.6 The composite paving element of any of the preceding claims, wherein 20-30% of the total thickness of the composite paving element is provided by the upper surface layer and 70-80% is provided by the lower support layer.7. The composite paving element of any of the preceding claims, fUrther comprising at least one alignment means to ensure the paving element is correctly positioned relative to neighbouring paving elements.8. A composite paving element substantially as described herein with reference to the drawings.9. A method of manufacturing a composite paving element comprising combining a upper surface layer made from: a standard paving material with a lower support layer made from second, hghter matenal than the upper surface layer.10. The method of claim 9, wherein the lpwar support layer is made from a polymer material.11. The method of claim 9 or 10, wherein the upper surface layer and the lower support layer are manufactured separately and stuck together using a suitable bonding agent.12 The method of claim 9 or 10, whereon the upper surface layer and the lower support layer are moulded together O 13. The method of claim 9, 10, It or 12, further comprising the step of providing the lower support layer with recesses or another form of keying element that assists the laying of the paving element.14. The method of any of claims 9 to 13, further comprising the step of providing one or more conduits in the lOwer support layer.15. The method of claim 14, wherein the one or more conduits are: cut out of the lower support layer.16. The method of claim 14, wherbin the one or mote conduits are formed during the moulding of the lower support layer.17. A method of manufacturing a composite paving element substantially as described herein with reference to the drawings.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0921077A GB2475852A (en) | 2009-12-02 | 2009-12-02 | Composite paving element |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0921077A GB2475852A (en) | 2009-12-02 | 2009-12-02 | Composite paving element |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB0921077D0 GB0921077D0 (en) | 2010-01-13 |
| GB2475852A true GB2475852A (en) | 2011-06-08 |
Family
ID=41573015
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB0921077A Withdrawn GB2475852A (en) | 2009-12-02 | 2009-12-02 | Composite paving element |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2475852A (en) |
Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CH614480A5 (en) * | 1975-05-21 | 1979-11-30 | Bernhard Kessel | Modular-construction elements for erecting a water gulley |
| JPH11193503A (en) * | 1997-12-26 | 1999-07-21 | Kawasaki Refract Co Ltd | Elastic composite pavement material, and execution of work therewith |
| EP1489242A1 (en) * | 2003-06-17 | 2004-12-22 | Step 2706 SA Holding | Brick |
| US20060251862A1 (en) * | 2002-12-31 | 2006-11-09 | Thomas Sievers | Composite shaped block |
| WO2008156355A1 (en) * | 2007-06-18 | 2008-12-24 | Van Nieuwamerongen Johannes Co | Natural stone element having a stress absorbing layer |
-
2009
- 2009-12-02 GB GB0921077A patent/GB2475852A/en not_active Withdrawn
Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CH614480A5 (en) * | 1975-05-21 | 1979-11-30 | Bernhard Kessel | Modular-construction elements for erecting a water gulley |
| JPH11193503A (en) * | 1997-12-26 | 1999-07-21 | Kawasaki Refract Co Ltd | Elastic composite pavement material, and execution of work therewith |
| US20060251862A1 (en) * | 2002-12-31 | 2006-11-09 | Thomas Sievers | Composite shaped block |
| EP1489242A1 (en) * | 2003-06-17 | 2004-12-22 | Step 2706 SA Holding | Brick |
| WO2008156355A1 (en) * | 2007-06-18 | 2008-12-24 | Van Nieuwamerongen Johannes Co | Natural stone element having a stress absorbing layer |
Also Published As
| Publication number | Publication date |
|---|---|
| GB0921077D0 (en) | 2010-01-13 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| COOA | Change in applicant's name or ownership of the application |
Owner name: ECONPRO LIMITED Free format text: FORMER OWNER: PHILIP SUTTON |
|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |