GB2491649A - Concrete core with glass fibre reinforced plastic skin - Google Patents

Concrete core with glass fibre reinforced plastic skin Download PDF

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Publication number
GB2491649A
GB2491649A GB1109795.3A GB201109795A GB2491649A GB 2491649 A GB2491649 A GB 2491649A GB 201109795 A GB201109795 A GB 201109795A GB 2491649 A GB2491649 A GB 2491649A
Authority
GB
United Kingdom
Prior art keywords
structural component
concrete
fibreglass
outer skin
resin
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Withdrawn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
GB1109795.3A
Other versions
GB201109795D0 (en
Inventor
Winston Stuart Tate
Original Assignee
Winston Stuart Tate
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 Winston Stuart Tate filed Critical Winston Stuart Tate
Priority to GB1109795.3A priority Critical patent/GB2491649A/en
Publication of GB201109795D0 publication Critical patent/GB201109795D0/en
Publication of GB2491649A publication Critical patent/GB2491649A/en
Withdrawn legal-status Critical Current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
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/34Moulds, cores, or mandrels of special material, e.g. destructible materials
    • B28B7/346Manufacture of moulds
    • 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
    • B28B19/0046Machines or methods for applying the material to surfaces to form a permanent layer thereon to plastics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06Fibrous reinforcements only
    • B29C70/08Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/30Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04HBUILDINGS OR LIKE STRUCTURES FOR PARTICULAR PURPOSES; SWIMMING OR SPLASH BATHS OR POOLS; MASTS; FENCING; TENTS OR CANOPIES, IN GENERAL
    • E04H13/00Monuments; Tombs; Burial vaults; Columbaria
    • E04H13/003Funeral monuments, grave sites curbing or markers not making part of vaults
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
    • B29K2309/06Concrete

Abstract

A structural component consists of a concrete core 601 and an outer skin of fibreglass. The concrete may comprise cement, sand, gravel, expanded clay, micro silica, fly ash and/or non-metal reinforcement elements 602. A layer of aggregate may be provided between the concrete core and the outer skin of fibreglass. Ideally the concrete is poured into the skin after the resin of the fibreglass has cured and hardened. The structural component could be provided with holes 802-805, to be used as a memorial stone.

Description

Structural Component and a Method of Forming a Structural Component
CROSS REFERENCE TO RELATED APPLICATIONS
This application represents the first application for a patent directed towards the invention and the subject mailer.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a structural component fabricated substantially from concrete and a method of forming a structural component using concrete.
2. Description of the Related Art
Concrete has been used for many years as a basis for forming structural components. In some known applications, concrete is used to provide a base or a foundation for a substantially ornamental structure, such 4u** eS * : 15 as a memorial. While known techniques provide an adequate structural * a4 solution, the appearance of the concrete can often distract from the ornamental structure that it is supporting. Techniques are known for improving the appearance of concrete but these are expensive and would therefore add significantly to the overall cost of the memorial or other structure. 4. *, ** .
* 20 BRIEF SUMMARY OF THE INVENTION
According to an aspect of the present invention, there is provided a structural component, comprising: a concrete core; and an outer skin of fibreglass.
In an embodiment, the structural component further comprises re-enforcement elements within said concrete to increase tensile strength.
According to a second aspect of the present invention, there is provided a method of forming a structural component, comprising the steps of; moulding a fibreglass outer skin; and pouring wet concrete into said cuter skin.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 shows an initial model; Figure 2 shows a production mould; Figure 3 shows a roll of fibreg lass fabric being cut; Figure 4 shows the operation of a consolidating roller; Figure 5 shows the adhesion of pebbles prior to concrete being added; Figure 6 shows the deployment of wet concrete; Figure 7 shows the removal of rough edges; and Figure 8 shows a finished embodiment.
DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
Figure 1 An embodiment of the present invention is directed towards providing a structural component fabricated substantially from concrete but with an enhanced appearance. The enhanced appearance is achieved by the 5sss* . . . * deployment of an outer skin of fibreglass. An initial model 101 is made from : s glass or plastic in order to provide a smooth surface that does not require **s.
polishing. Edges, such as edge 102 are filled with an appropriate filler. This in turn is prepared for making a negative by being waxed. Gel-coat is then applied, followed by a fibreglass deployment such that, once hardened, the two are separated to produce a negative, defining the profile of the mould. The negative is again waxed, gel-coated ready for a further application of fibreg lass with resin. After drying, the two are separated and positive imperfections are removed by a sanding process. Thus, this creates a positive tool from which many actual moulds may be generated.
Figure 2 A mould 201 for the production process is shown in Figure 2.
Imperfections will have been removed, possibly by a sanding process, so that the internal surface of the mould is smooth. The process of using the mould is initiated by the application of gel-coat; this being a sticky black substance available from Llewellyn Ryland and other suppliers. An amount is weighed out and combined with a catalyser such as a ketone peroxide which will in turn cause the gel-coat to cure and harden. Thus, in the example shown in Figure 2, a layer of gel-coat 202 has been applied to the internal surface of the mould and this is then left to cure.
Figure 3 A roll 301 of fibreglass fabric is shown in Figure 3. In an embodiment, the weight of this fibreglass is such that one metre square of the material weighs six hundred grams. To form an outer skin of fibreglass, pieces 302 of the fibreglass are cut from the roll 301 and in the mould, the cut fibreglass is combined with fibreglass resin. Again, the catalyser will have been applied to the resin to ensure that, when in position, the fibreglass cures and sets.
* : In an embodiment, the resin is applied to the internal surface of the * ** SS * 20 mould 201 and then the cut fibreglass fabric is applied in a process known as a hand lay up. However, it should be appreciated that for higher volumes, a more mechanised approach may be deployed. Thus, in this embodiment, the internal surface of the mould 201 is made wet with the fibreglass resin and *o* then the sheets of fibreglass are deployed therein.
* *s 25 Figure 4 As shown in Figure 4, a consolidating roller 401 may be used to ensure that the fibreglass is pushed down firmly against the internal surface of the mould, thereby forcing the resin outwards; through the fibreglass and towards the surface.
After being fully consolidated but while remaining wet, the entire internal void is preferably filled with pebbles and then left to dry for two to three hours.
Figure 5 After drying, unattached pebbles are removed for re-use, thereby leaving a layer 501 of pebbles stuck to the fibreglass 502. For some applications, it may be necessary to include holes within the structural component and if required, these are masked such that concrete is not deployed in these regions. In the example shown in Figures 2, 5 and 6, the structural component is a kerbside type support. In the example shown in Figure 8, the structural component is a base for a lawn memorial and as such provision has been made for flower containers that will protrude through the granite memorial being supported, for example. In addition, some memorials require a fixing pin and again it is necessary to define a hole before the concrete is deployed.
Figure 6 Wet concrete 6D1 is deployed into the void defined by the coating of pebbles 501. In an embodiment, 110.5 kilograms of concrete may be *...: 20 produced from 28 kilograms of cement, 32 kilograms of sand and gravel, 17.5 kilograms of expanded clay, 3 kilograms of micro silica, 7 kilograms of pulverised fly ash, 16 kilograms of water and 1 kilogram of super plasticiser ::::. that is water reducing. The plasticiser allows for a wet flowing mix to be produced without requiring an excessive quantity of water.
In an embodiment, reinforcement elements 602 are included within the ::::; concrete to increase tensile strength. In an embodiment, these reinforcement * elements are preferably non-metallic, given that memorials and similar constructions will often be required to maintain their integrity for a substantial period of time. The reinforcement members 602 are deployed while the concrete is wet and are pushed downwards, as seen in Figure 6, by an appropriate amount so as to reside within the concrete at an optimum height when deployed. The concrete is then left to harden, typically overnight.
Figure 7 After the concrete has hardened, rough hedges 701 of the fibreglass may be removed by an angle grinder 702 or similar device. The structural component, comprising its concrete core and outer skin of fibreglass is then ready to be deployed in the field. Thus, the process described with respect to Figures 2 to 7 shows a method of forming a structural component, primarily comprising the steps of moulding a fibreglass outer skin and then pouring wet concrete into this outer skin. In an embodiment, an intermediate layer of pebbles may be added, as shown in Figure 5.
Figure 8 In an embodiment, the structural component provides a base for a memorial stone. The base 801 provides a structural base for a granite memorial stone. In this embodiment, the fibreglass outer shell is black and shiny so as to be sympathetic to the appearance of a granite memorial stone; while being substantially less expensive than the granite stone.
*...: 20 In this embodiment, the granite memorial will include holes for flower pots and vases etc therefore the support 801 includes holes 802, 803 and 804 for receiving these receptacles. In addition, in the support 801, a further hole 805 is provided for a restraining pin. * * ** 0 ** * * * S S S.

Claims (1)

  1. Claims What we claim is: 1. A structural component, comprising: a concrete core; and an outer skin of fibre glass.
    2. The structural component of claim 1, wherein said concrete has set from a wet mix of cement, sand and gravel, and expanded clay.
    3. The structural component of claim 2, wherein said concrete also includes micro silica.
    4. The structural component of claim 2 or claim 3, wherein said concrete also includes pulverised fly ash.
    5. The structural component of any of claims 1 to 4, wherein said outer skin comprises fibre-glass fabric surrounded by cured resin.
    * * S. 55 * 20 * s5ss* 6: The structural component of any of claims 1 to 5, further comprising reinforcement elements within said concrete to increase tensile strength. *50 * S
    *J 25 7. The structural component of claim 6, wherein said reinforcement elements are non-metallic.
    8. The structural component of any of claims 1 to 7, further comprising a layer of aggregate between said concrete core and said outer skin of fibre glass.
    9. The structural component of any of claims I to 8, configured to provide a base for a memorial stone.
    10. The structural component of claim 9, including holes to accommodate attributes of said memorial stone.
    11. A method of forming a structural component, comprising the steps of: moulding a fibre-glass outer skin; and pouring wet concrete into said outer skin.
    12. The method of claim 11, wherein said wet concrete includes cement, sand and gravel, and expanded clay.
    13. The method of claim 12, wherein said wet concrete also includes micro silica. * *S.....
    * 20 14. The method of claim 12 or claim 13, wherein said concrete also : .. includes pulverised fly ash.
    15. The method of any of claims 11 to 14, wherein said step of moulding a fibreglass outer skin comprises the application of fibreglass fabric * 25 and resin, such that a hard surface is produced after said resin has cured.
    16. The method of any of claims 11 to 15, further comprising the step of introducing re-enforcement elements within the concrete to increase tensile strength.
    17. The method of claim 16, wherein said re-enforcement elements are non-metallic.
    18. The method of any of claims 11 to 17, further comprising the step of introducing a layer of aggregate to the fibreglass before the fibreglass resin has cured and then pouring the wet concrete after said resin has cured.
    19. The method of any of claims 11 to 18, further comprising the steps of locating the structural component as a base or a foundation for a memorial stone; and deploying a memorial stone on said base or foundation.
    20. The method of claim 19, further including the step of introducing holes into the structural component to accommodate attributes of a memorial stone.
    21. A structural component substantially as herein described with reference to the accompanying Figures.* : 20 S.....* S 22. The method of forming a structural component substantially as : .°. herein described with reference to the accompanying Figures. I... * . S. * S S* S *S
GB1109795.3A 2011-06-10 2011-06-10 Concrete core with glass fibre reinforced plastic skin Withdrawn GB2491649A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB1109795.3A GB2491649A (en) 2011-06-10 2011-06-10 Concrete core with glass fibre reinforced plastic skin

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1109795.3A GB2491649A (en) 2011-06-10 2011-06-10 Concrete core with glass fibre reinforced plastic skin

Publications (2)

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GB201109795D0 GB201109795D0 (en) 2011-07-27
GB2491649A true GB2491649A (en) 2012-12-12

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140245691A1 (en) * 2013-03-04 2014-09-04 St Bungalow Llc Method of making housing components
IT202000004651A1 (en) * 2020-03-05 2021-09-05 Rosso & Nero S R L PROCEDURE FOR THE CONSTRUCTION OF STONE AND STONE OBTAINED WITH THIS PROCEDURE

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1130891A (en) * 1964-06-18 1968-10-16 Reginald Warnford Evans Permanent shuttering for reinforced concrete structures
NL8502812A (en) * 1985-10-15 1987-05-04 Poly Products B V Insulating floor unit prodn. - using glass fibre reinforced polyester mould contg. half-encapsulated broken gravel
US5981050A (en) * 1997-03-05 1999-11-09 Kaempen; Charles E. Composite shape forming structure for sealing and reinforcing concrete and method for making same
JP2000045432A (en) * 1998-07-27 2000-02-15 Shimizu Corp Buried form

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1130891A (en) * 1964-06-18 1968-10-16 Reginald Warnford Evans Permanent shuttering for reinforced concrete structures
NL8502812A (en) * 1985-10-15 1987-05-04 Poly Products B V Insulating floor unit prodn. - using glass fibre reinforced polyester mould contg. half-encapsulated broken gravel
US5981050A (en) * 1997-03-05 1999-11-09 Kaempen; Charles E. Composite shape forming structure for sealing and reinforcing concrete and method for making same
JP2000045432A (en) * 1998-07-27 2000-02-15 Shimizu Corp Buried form

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140245691A1 (en) * 2013-03-04 2014-09-04 St Bungalow Llc Method of making housing components
US8991137B2 (en) * 2013-03-04 2015-03-31 St Bungalow Llc Method of making housing components
IT202000004651A1 (en) * 2020-03-05 2021-09-05 Rosso & Nero S R L PROCEDURE FOR THE CONSTRUCTION OF STONE AND STONE OBTAINED WITH THIS PROCEDURE
EP3875713A1 (en) * 2020-03-05 2021-09-08 Rosso & Nero S.r.l. A process for realising tombstones, and tombstones obtained with the process

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