GB2157704A - Building materials; artificial slate - Google Patents

Building materials; artificial slate Download PDF

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Publication number
GB2157704A
GB2157704A GB08503848A GB8503848A GB2157704A GB 2157704 A GB2157704 A GB 2157704A GB 08503848 A GB08503848 A GB 08503848A GB 8503848 A GB8503848 A GB 8503848A GB 2157704 A GB2157704 A GB 2157704A
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GB
United Kingdom
Prior art keywords
building material
resin
material according
aggregate
weight
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Withdrawn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
GB08503848A
Other versions
GB8503848D0 (en
Inventor
Peter A Jones
Dennis Oldfield
Charles A Lister
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.)
E H BRADLEY BUILDING PRODUCTS
Original Assignee
E H BRADLEY BUILDING PRODUCTS
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 E H BRADLEY BUILDING PRODUCTS filed Critical E H BRADLEY BUILDING PRODUCTS
Publication of GB8503848D0 publication Critical patent/GB8503848D0/en
Publication of GB2157704A publication Critical patent/GB2157704A/en
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/18—Polyesters; Polycarbonates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/06—Acrylates

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Macromonomer-Based Addition Polymer (AREA)

Abstract

A building material comprises a settable resin and an aggregate. The material is particularly suitable for the production of artificial slates. In a preferred embodiment the aggregate comprises a plurality of different quartz aggregates. The resin may be of the acrylic or polyester type.

Description

SPECIFICATION Building Materials The invention relates to building materials, and in particular, but not exclusively, to building materials for use in manufacturing artificial roofing slates.
Presently used building materials include natural slate, concrete and asbestos. Natural slate has the disadvantage that it is not always uniform in colour, and different batches, even from the same quarry, are sometimes of different shades, resulting in a non-uniform finish. The size of natural slates depends on how the slates are cut in the quarry, so that construction must be planned with the size of slates in mind, rather than vice versa. Also, slate is becoming more scarce due to exhaustion of supplies, with the inevitable increase in price. Concrete and asbestos are used as alternatives to slate, but these do not have the natural appearance of slate, and they are disliked by many. Also, concrete and asbestos building materials are heavier than slate, necessitating sturdier overall construction.Asbestos has the additional disadvantage of being a health hazard.
It is an object of the invention to provide a building material which has the appearance of natural stone, for example slate, but which can be manufactured to any desired specification of size and colour. The problems of size and variations in colour and availability associated with natural stone, e.g. slate, are thus overcome, whilst still producing a material which looks natural, unlike concrete and asbestos.
Accordingly, the invention provides a building material comprising a settable resin and an aggregate.
Preferably the resin is set by means of a catalyst.
Preferably the mixture of the resin and the catalyst produces an exothermic reaction.
The resin may be a polyester resin.
The resin may be an acrylic resin.
The resin may be a methacrylate resin.
The resin may be a methyl methacrylate resin.
Preferably, the catalyst is benzyl peroxide.
The aggregate may comprise a plurality of quartz aggregates.
Preferably the aggregate comprises the following six aggregates: BLR3,TR1, S1, F25, F35, G2.
Preferably, the aggregates are in the following relative proportions: Percentage of total Aggregate weight of aggregate BLR3 110% TR1 1--10% S1 515% F25 1025% F35 1530% G2 3550% Preferably, the aggregates are in the following relative proportions: Percentage of total Aggregate weight of aggregate BLR3 5.78% TR1 3.85% S1 10.01% F25 17.32% F35 19.25% G2 43.79% The weight of the resin may be equal to between 5% and 20% of the weight of the aggregate.
Preferably the weight of resin comprises from 11.935% to 15.399% of the weight of the aggregate.
The building material may comprise the following constituents in the following relative proportions: Percentage of total weight of all the materials in the Material opposite column.
BLR3 5.14% TR1 3.42% S1 8.90% F25 15.41% F35 17.12% G2 38.96% methyl methacrylate resin 10.62% benzyl peroxide 0.425% Alternatively, the building material may comprise the following constituents in the following relative proportions: Percentage of toal weight of all the materials in the Material opposite column.
BLR3 4.99% TR1 3.33% S1 8.66% F25 14.98% F35 16.65% G2 37.87% polyester resin 13.32% benzyl peroxide 0.206% Pigments may be included to produce a building material of the desired colour, and the pigments may be vegetable pigments.
The building material may comprise the following constituents in the relative proportions given: Material Relative proportion methyl methacrylate resin 1550 benzyl peroxide 62 BLR3 750 TR1 500 S1 1300 F25 2250 F35 2500 G2 5687.5 blue vegetable pigment powder 10 black vegetable pigment powder 15 Alternatively, the methyl methacrylate resin may be replaced by polyester resin in a relative proportion of 2000, with the benzyl peroxide in a relative proportion of 31 and all the other materials in the same relative proportions.
The invention includes a method of manufacturing a building material, in which the solid materials are mixed together, then the resin is added to the solid materials and mixed in and the mixture is placed in moulds of the desired shape and size to set or cure.
The invention includes an artificial roofing slate comprising building material according to the invention.
Specific embodiments of the invention will now be described, with reference to the following examples.
In a first embodiment, a building material composition sufficient to manufacture 28 artificial roofing slates of dimensions 50 cm x 20 cm x 0.6 cm is made from the following materials: Material Weight Methylmethacrylate resin 6.2 kg Benzyl peroxide 0.248 kg BLR3 quartz aggregate 3.0 kg TR1 quartz aggregate 2.0 kg S1 quartz aggregate 5.2 kg F25 quartz aggregate 9.0 kg F35 quartz aggregate 10.0 kg G2 quartz aggregate 22.75 kg Blue vegetable pigment powder 0.04 kg Black vegetable pigment powder 0.06 kg In order to manufacture artificial roofing slates according to the invention, the following method is used.
The six aggregates, the benzyl peroxide and the two vegetable pigments, all in powdered or granular form, are thoroughly mixed together so that each component is substantially evenly distributed throughout the mixture. The methylmethacrylate resin is then added to the mixture of aggregates, benzyl peroxide and pigments and the new mixture is thoroughly mixed to ensure the resin is substantially evenly distributed throughout the mixture. The benzyl peroxide acts as a catalyst on the methylmethacrylate resin. As the resin is acted upon by the benzyl peroxide, the temperature of the mixture rises to about 70 Centrigrade, and the resin starts to harden or cure.
As soon as possible after the resin has been added, and before the curing is complete, the mixture is placed in twenty eight artificial tile moulds which are in the forms of shallow polypropylene trays. The mixture is then allowed to harden or cure fully in the moulds, producing solid slabs of artificial slate, which are very similar in appearance to natural slate. This process takes about forty minutes from the time when the resin is added. This hardening time varies according to uncontrollable factors such as air temperature, and the setting time can be considerably longer or shorter than forty minutes.
The artificial slate produced can be treated exactly the same as present building materials. The slates have a flexural strength of 26 MN/m2, a tensile strength of 15.3 MN/m2 and a compression strength of 120 MN/m2.
The slates are frost proof (DIN 53.472 0.2%) and are totally resistant to normal atmospheric conditions. The artificial slate has a specific gravity of 2.3 gm/cm3 and an expansion coefficient of 0.017 mm/m/ C at 20"C.
The material has an abrasion resistance similar to that of concrete and is heat resistant up to 160 C.
In a second embodiment, a building material composition, sufficient to manufacture 28 artificial roofing slates of dimensions 50 cm x 20 cm x 0.6 cm is made from 8.0 kg of polyester resin, 0.124 kg of benzyl peroxide and the same amounts of aggregates and vegetable pigment powders as used in the first embodiment. The method of manufacture is substantially identical to that of the first embodiment, except that methylmethacrylate resin is replaced by polyester resin. The artificial slates produced have properties similar to the artificial slates produced in the first embodiment.
The invention is not restricted to the details of the foregoing embodiments. The above embodiments are for making a building material for use as artificial roof slates which have a colour very similar to that of natural slate, but the colour of the building material can be varied by varying the amounts and colours of pigments added. For example, white, green and/or red pigments may be used instead of or in addition to blue and/or black pigments to obtain a desired colour.
The building material produced need not be used for artificial roofing slate but can be used to manufacture other building components.

Claims (25)

1. A building material comprising a settable resin and an aggregate.
2. A building material according to claim 1 wherein the resin is set by means of a catalyst.
3. A building material according to claim 2 wherein the catalyst is selected so as to react exothermically with the resin.
4. A building material according to claims 2 or 3, wherein the catalyst is benzyl peroxide.
5. A building material according to any preceding claim wherein the resin is a polyester resin.
6. A building material according to any of claims 1 to 4 wherein the resin is an acrylic resin.
7. A building material according to any of claims 1 to 4 wherein the resin is a methacrylate resin.
8. A building material according to any of claims 1 to 4, wherein the resin is a methyl methacrylate resin.
9. A building material according to any preceding claim, wherein the aggregate comprises a plurality of quartz aggregates.
10. A building material according to any preceding claim wherein the aggregate comprises the aggregates: BLR3; TR1; S1; F25; F35;, and G2.
11. A building material according to claim 10, wherein the proportion of each of the aggregates as a percentage of the total weight of aggregate is as follows: BLR3from 1 to 10%;TR1 from 1 to 10%; S1 from 5 to 15%; F25 from 10 to 25%; F35 from 15 to 30%, and G2 from 35 to 50%.
12. A building material according to claim 11, wherein the relative proportions of the aggregates as a percentage of the total aggregate is as follows: BLR3 5.78%; TR1 3.85%; S1 10.01%; F25 17.32%; F35 19.25%, and G2 43.79%.
13. A building material according to any preceding claim, wherein the weight of the resin is from 5% to 20% of the weight of the aggregate.
14. A building material according to claim 13 wherein the weight of the resin is from 11.935% to 15.399% of the weight of the aggregate.
15. A building material according to any of claims 1 to 4, wherein the constituents are present in the following relative proportions by weight: BLR3 5.14%; TR1 3.42%; S1 8.90%; F25 15.41%; F35 17.12%; G2 38.96%; methyl methacrylate resin 10.62%, and benzyl peroxide 0.425%.
16. A building material according to any of claims 1 to 4, wherein the constituents are present in the following relative proportions by weight: BLR3 4.99%; TR1 3.33%; S1 8.66%; F25 14.98%; F35 16.65%; G2 37.87%; polyester resin 13.32% and benzyl peroxide 0.206%.
17. A building material according to any preceding claim, further including a pigment.
18. A building material according to claim 17 wherein the pigment is a vegetable pigment.
19. A building material according to any of claims 1 to 4, wherein the constituents are present in the following relative proportions: methyl methacrylate resin 1550; benzyl peroxide 62; BLR3 750; TR1 500; S1 1300; F25 2250; F35 2500; G2 5687.5; blue vegetable pigment powder 10, and black vegetable pigment powder 15.
20. A building material according to any of claims 1 to 4, wherein the constituents are present in the following relative proportions: polyester resin 2000; benzyl perioxide 31; BLR3 750; TR1 500; S1 1300; F25 2250; F35 2500; G2 5687.5; blue vegetable pigment powder 10, and black vegetable pigment powder 15.
21. A building material substantially as herein described with reference to either of the Examples.
22. An artificial roofing slate comprising the building material according to any preceding claim.
23. A method of manufacturing a building material comprising a settable resin and an aggregate, in which the solid materials are mixed together, the resin is then added to the solid materials and mixed in, and the mixture is placed in moulds of desired shape and size to set or cure.
24. A method of manufacturing a building material substantially as herein described with reference to either of the Examples.
25. A method of manufacturing artificial slates according to claim 23 or 24.
GB08503848A 1984-02-14 1985-02-14 Building materials; artificial slate Withdrawn GB2157704A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB848403776A GB8403776D0 (en) 1984-02-14 1984-02-14 Building material

Publications (2)

Publication Number Publication Date
GB8503848D0 GB8503848D0 (en) 1985-03-20
GB2157704A true GB2157704A (en) 1985-10-30

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GB848403776A Pending GB8403776D0 (en) 1984-02-14 1984-02-14 Building material
GB08503848A Withdrawn GB2157704A (en) 1984-02-14 1985-02-14 Building materials; artificial slate

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GB848403776A Pending GB8403776D0 (en) 1984-02-14 1984-02-14 Building material

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Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2164340A (en) * 1984-09-18 1986-03-19 Marshalls Mono Ltd Resin-based building materials
GB2202544A (en) * 1987-03-11 1988-09-28 John Murdoch Thornton Masson Surface treatment material particularly useful for tiled roofs
GB2231881A (en) * 1989-04-08 1990-11-28 Glasdon Manufacturing Limited Moulded articles of resin-bonded stone particles
GB2197673B (en) * 1986-11-12 1991-04-03 Harris Frederick Brian Oatway Fabricated building products
GB2360039A (en) * 2000-03-07 2001-09-12 Magicmatch Ltd Filler compound
CN104446145A (en) * 2014-11-21 2015-03-25 广东中旗新材料科技有限公司 Double-color double-pattern artificial quartz stone plate and production process thereof

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB997841A (en) * 1963-02-18 1965-07-07 Ici Ltd Facing materials
GB1167188A (en) * 1965-11-06 1969-10-15 Dyna Plastik Werke Building Unit particularly for Floors.
GB1244857A (en) * 1967-12-06 1971-09-02 Repla Sa Method for making panels of the artificial stone-type and products so produced
GB1277005A (en) * 1968-05-15 1972-06-07 Taylor Woodrow Const Ltd Improvements in or relating to concretes
GB1292034A (en) * 1969-05-08 1972-10-11 Bp Chem Int Ltd Unsaturated polyester resin/aggregate concrete compositions
GB2041959A (en) * 1979-02-02 1980-09-17 Dutton E P Slate-filled resin products
GB2052471A (en) * 1979-06-22 1981-01-28 Fijon Ltd Artificial granite
GB1588132A (en) * 1977-09-06 1981-04-15 Univ Cardiff Resinous moulding compositions containing reinforcing material
GB1593043A (en) * 1977-07-06 1981-07-15 Burns & Russell Co Cast article containing ceramic coated quartz particles
GB2124201A (en) * 1982-07-20 1984-02-15 Fidalgo Lopez B Process for the reconstitution of slates
GB2129002A (en) * 1982-09-13 1984-05-10 Brian Bennett Filled thermosetting resin compositions
GB2135324A (en) * 1983-02-25 1984-08-30 Diasol Sarl Process for manufacture of slates from waste slate

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB997841A (en) * 1963-02-18 1965-07-07 Ici Ltd Facing materials
GB1167188A (en) * 1965-11-06 1969-10-15 Dyna Plastik Werke Building Unit particularly for Floors.
GB1244857A (en) * 1967-12-06 1971-09-02 Repla Sa Method for making panels of the artificial stone-type and products so produced
GB1277005A (en) * 1968-05-15 1972-06-07 Taylor Woodrow Const Ltd Improvements in or relating to concretes
GB1292034A (en) * 1969-05-08 1972-10-11 Bp Chem Int Ltd Unsaturated polyester resin/aggregate concrete compositions
GB1593043A (en) * 1977-07-06 1981-07-15 Burns & Russell Co Cast article containing ceramic coated quartz particles
GB1588132A (en) * 1977-09-06 1981-04-15 Univ Cardiff Resinous moulding compositions containing reinforcing material
GB2041959A (en) * 1979-02-02 1980-09-17 Dutton E P Slate-filled resin products
GB2052471A (en) * 1979-06-22 1981-01-28 Fijon Ltd Artificial granite
GB2124201A (en) * 1982-07-20 1984-02-15 Fidalgo Lopez B Process for the reconstitution of slates
GB2129002A (en) * 1982-09-13 1984-05-10 Brian Bennett Filled thermosetting resin compositions
GB2135324A (en) * 1983-02-25 1984-08-30 Diasol Sarl Process for manufacture of slates from waste slate

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2164340A (en) * 1984-09-18 1986-03-19 Marshalls Mono Ltd Resin-based building materials
GB2197673B (en) * 1986-11-12 1991-04-03 Harris Frederick Brian Oatway Fabricated building products
GB2202544A (en) * 1987-03-11 1988-09-28 John Murdoch Thornton Masson Surface treatment material particularly useful for tiled roofs
GB2231881A (en) * 1989-04-08 1990-11-28 Glasdon Manufacturing Limited Moulded articles of resin-bonded stone particles
GB2360039A (en) * 2000-03-07 2001-09-12 Magicmatch Ltd Filler compound
CN104446145A (en) * 2014-11-21 2015-03-25 广东中旗新材料科技有限公司 Double-color double-pattern artificial quartz stone plate and production process thereof

Also Published As

Publication number Publication date
GB8503848D0 (en) 1985-03-20
GB8403776D0 (en) 1984-03-21

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