WO2014174232A1

WO2014174232A1 - A method of, and system for, manufacturing a composite sett

Info

Publication number: WO2014174232A1
Application number: PCT/GB2014/000151
Authority: WO
Inventors: Leigh Chapman; Derek Witchell
Original assignee: Quicksetts Limited
Priority date: 2013-04-22
Filing date: 2014-04-22
Publication date: 2014-10-30
Also published as: GB201307232D0; GB2514542A; GB2514542B; EP3233435A1; HK1245724A1

Abstract

This invention relates generally to a type of brick, known as a sett. More particularly this invention relates to a composite sett formulated from a mixture of polymeric matrix and stone aggregate. The invention is a composite sett, an apparatus for making the composite sett and a method for making the composite sett. Each composite sett comprises a matrix which is a combination of resin, catalyst, and flexibility additive and also comprises a dried aggregate so that the aggregate is bound by the matrix.

Description

A Method of. and System for. Manufacturing a Composite Sett

Field of the invention

This invention relates generally to a method of, and system for, manufacturing a composite sett. More particularly this invention relates to a composite sett formulated from a mixture of polymer resin matrix and an aggregate.

Background

Traditional stone setts were often made by splitting them from stone blocks, such as solid granite or similar hard-wearing stone or marble. Traditional stone setts that are split from solid stone are expensive. They are made by splitting them from larger granite or similar hard-wearing stone lumps and sometimes shattered during fabrication.

Splitting solid stone traditional stone setts was therefore a time consuming and laborious process.

The usual manner for holding stone setts in place was to dig a recess in a road or path, sufficiently deep to accept the sett. They were located by way of a grit or sand bedding or fixed by embedding them into cement or concrete.

A problem with stone setts was the need to excavate a road or path in order to form a sufficiently deep hole to receive the stone set. In practical terms this has entailed closing a road, or at best diverting traffic along one lane, so as to allow the setts to be fitted into the recesses. This inconvenienced traffic and resulted in delays and so for these and other factors, it was often considered too disruptive to warrant the use of stone setts.

One way in which this problem was mitigated was to produce thin artificial paving blocks that adhere to surfaces. However, these did not resemble authentic stone setts; rather they were paving slabs or brick-like in appearance.

Another problem was that previous artificial stone setts were prone to splitting or cracking in use because they were so brittle.

Prior Art

Examples of techniques of making paving blocks that adhere to a surface are taught in the following documents.

European patent application EP-A2-467025 (Flato) discloses a process for the production of natural stone paving block.

European patent EP-B1-0 958 257 (Cairn Holdings UK) discloses mixtures of materials settable on exposure to the atmosphere.

European patent application EP-A2-1 706 363 (Mix UK Limited) relates to filling materials for use with paving flags and the like. The flags comprise at least one base material, at least one binder, at least one cross-linking agent, a solvent and at least one cure retarder.

US Patent US-A-5 372 676 (Lowe) relates to a method for producing replicated paving stones.

The aforementioned blocks or paving flags appear to relate to methods for manufacturing blocks or paving flags and for holding them in position. None of the aforementioned systems or methods is concerned with the aesthetic appearance of artificial stone setts, which is often sacrificed by mass produced artificial stone sett manufacturing processes.

Another problem with many of the existing artificial blocks or paving flags was that they were prone to cracking when driven over, especially by heavy goods vehicles.

It is an object of the present invention to overcome the aforementioned problems and to provide an improved artificial stone sett that aesthetically resembles a traditional granite or similar hard-wearing stone sett and does not crack or fracture in use.

Summary of the Invention

According to a first aspect of the invention there is provided a system for manufacturing a composite sett comprises: a mixing vat for receiving resin, aggregate, catalyst and a flexible additive and for mixing these into a slurry mixture; a mixer for mixing the slurry mixture; a plurality of flexible sett moulds each having contoured surfaces for providing contoured surface finishes and defining a sett mould cavity into which the slurry mixture is introduced; and a means for removing bubbles from the poured slurry mixture so as to form suitable cast-out ready composite setts.

According to a second aspect of the invention there is provided a method of manufacturing a composite sett comprising the steps of: mixing resin, catalyst and a flexible additive with granite or similar hard-wearing stone aggregate into a slurry; transferring the slurry into a sett mould cavity; maintaining the slurry in the sett mould cavity for a curing period to form a solid composite sett; casting the solid composite sett from the sett mould cavity; and maintaining the cast-out composite sett on a flat surface for a sufficient time for the composite sett to cure.

The method of making composite setts, the system for making composite setts and the method of operating the system of the present invention solve this problem. The present invention does not form composite setts from solid stone; neither does it require labour intensive splitting or expensive complex machinery to cut traditional setts from solid stone.

Ideally discontinuities are removed by way of a reduced pressurization stage, which may include a pump and/or a slow mixing processor which avoids entrapment of air bubbles. Optionally a vibrating table or jigger may also be used in conjunction with the above or as an alternative to the above, so as to urge bubbles from the poured slurry mixture. Layers of slurry mixture may be added and vibrated so as to encourage air bubbles from the

Additives such as bauxite or high Polished Stone Value aggregate (PSV), or slag or other processed or recycled aggregates or ceramics, may be used as a filler to provide additional hardness, wear and skid resistance. Ideally the composite sett is less than 100 mm thick, more preferably less than 20 mm thick and most preferably less than 7 mm thick. The benefits and advantages of this thickness of sett are explained below.

Optionally the setts may be square setts, corner setts, octagonal, trapezoidal, circular, oval or any other shape. Ideally the setts have regular, shaped, angled or chamfered edges.

Preferably any gas bubbles that are formed during mixing are removed so as to render the composite sett solid and void free. The presence of voids, created by bubbles, weakens the composite sett and is avoided by way of mixing techniques and/or additives and/or pressure variation and/or vibration which tends to draw the air bubbles from the mixture before it is cured. One way in which bubbles are removed is by forming a vacuum over the slurry in the mixing vat.

The mould size and shape, and the contoured surface, together help reproduce the appearance of stone setts.

An advantage with the composite sett is that it is able to flex, for example when driven over. When used in combination with flexible bedding and jointing adhesive superior shock absorbing properties are obtained which help to absorb impact and accommodate movement even when driven over by heavy trucks or buses.

Where appropriate, setts can be marked, by colouring or painting or incorporating an embossed shape, letter, character or figure, such as an indentation or logo or other marker within the underside of the sett, in order to help to differentiate different types of setts.

Ideally the mixture or slurry is chemically cured with a catalyst, such as a methyl ethyl ketone peroxide based substance such as methyl ethyl ketone peroxide. Another advantage is that after the slurry is cured it forms a continuous, solid mass, without occlusions (bubbles) or discontinuities that might otherwise weaken the artificial stone sett.

Preferably the system for manufacturing the composite sett includes a dryer arranged to dry the aggregate before mixing the aggregate. Ideally, but not necessarily, a plurality of sett moulds is supported on a continuous surface, such as an endless belt or conveyor belt, as part of a continuous production line. An advantage is that this continuous surface enables more efficient production of composite setts compared with batch production.

Preferably a slurry transfer mechanism is arranged to transfer slurry from mixing vat into sett mould cavities on the conveyor belt in an efficient manner and prior to curing of adhesive is complete. Advantageously consecutive sett mould cavities are filled and then levelled, further along a production line, consecutive sett mould cavities are emptied, after sufficient curing has taken place, so that the setts are relatively stiff. However, setts do not completely cure for some considerable time after leaving the mould cavity, so they are placed on a flat surface, for example in a curing bay or rack, for a sufficient duration to enable them to reach their final hardness. This may or may not be done at elevated temperatures. In one embodiment the continuous conveyor belt includes a chute arranged to receive, part cured, cast-out composite setts ejected from mould cavities. Optionally there is provided a means for urging the composite setts from their respective cavities, although this step could be performed manually.

After a sufficiently rigid sett is removed from the sett mould cavity, the sett mould is reused as ideally quickly as possible so that it can receive slurry for forming a subsequent composite sett. The moulds may or may not require cleaning prior to re-use.

Curing composite setts until they are completely hardened can take several hours or even days, but once the composite setts have cured to their cast-out- ready condition, they can support their own weight and retain their shape without the support of the sett mould. Therefore the cast-out-ready composite sett is not required to be in the sett mould for complete curing.

Preferably the method of operating a system for making a composite sett includes the step of: mixing the catalyzed liquid combination with the aggregate. Likewise forced heating of part cured setts may be used to accelerate the curing process and so reducing the dwell time that part cured setts spend on a curing rack or in the curing bay.

Ideally at least a partial vacuum is formed during the mixing and/or casting process to reduce the likelihood of air bubbles or discontinuities being left in the slurry. This can be assisted by way of additional additives to the resin and the use of a vibrating table or jigger tray within the curing process.

According to another aspect of the invention there is provided a composite sett comprising a matrix which typically but not limited to is a combination of resin, catalyst, a flexible additive and a dried aggregate so that the aggregate is bound by the matrix and the composite sett is capable of flexing when loaded.

Ideally flexure over a composite sett according to the present invention is 2 to 5 mm. The amount of flexure may be increased by adding more flexible polyester. Preferably the grade of the aggregate in the composite sett is in the size range between 0 mm to 6 mm.

More preferably the grade of the aggregate comprised in the composite sett is in the range of 0 mm to 3 mm. However, in some larger setts, larger granular sizes may be preferred. Ideally therefore aggregate size ranges from grains of dust to pieces of grit or pebbles around 6 mm across.

Composite setts made from a range of particulate sizes, from dust to pebbles of granite or similar hard-wearing stone; appear as traditional granite or similar hard-wearing stone setts. Thus use of the method comprising the contoured mould cavity and a range of particulate sizes creates an artificial composite sett with a realistic appearance of a granite or similar hard-wearing stone sett.

Although reference has been made to artificial setts that appear as if formed from natural stone, it is also envisaged that setts may be brightly coloured with dyes/pigments so that they are visible. Such setts may be white or yellow or red or mixed with a material that reflects light or even fluoresces, for example when shone on by a vehicle's headlights.

Preferably but not necessarily, the resin in the composite sett is polyester or similar synthetic resin.

According to another aspect of the invention there is provided a method of applying composite setts to a surface comprising steps of: preparing the surface, applying a layer of bedding and jointing compound to the surface, pressing a first composite sett into the layer; laying a second composite sett adjacent the first sett with a gap therebetween; and pressing the second composite sett into the layer until the surfaces of the first and second composite setts are flush with one another.

Pressure is applied to the setts once placed on the layer of bedding and jointing compound in order to squeeze the bedding and jointing compound in between edges of setts so as that it becomes the pointing medium.

In some instances additional pointing medium may be required to be used in a secondary application. Setts are ideally slightly trapezoidal in cross section so that cured bedding and jointing compound physically locks setts together. It is understood that the bedding compound is also capable of absorbing shock loading and so when the sett is bound to the bedding compound a hardwearing surface is produced that is capable of repeated heavy loading; which is frost resistant and is relatively cheap, easy and quick to install.

Traditional stone setts are prone to cracking especially when subject to heavy loads, such as from large vehicles, as well as fluctuations in ambient temperature due to seasonal variations. This brittleness is exacerbated as the thickness of setts is reduced. Traditionally the brittle stone setts rarely cracked as they were so thick and so could support very large weights without cracking. However, as mentioned above, use of such traditional setts entailed excavating roadways and pathways and laying a foundation.

The composite setts of the present invention solve this problem by binding stone aggregate in a flexible matrix, so permitting the artificial setts to be made thinner and applied to a roadway or walkway with an adhesive. Furthermore, the composite stone setts do not absorb water as they are not porous because the matrix which binds and covers the aggregate is not porous.

Therefore the stone sett according to the present invention provides a flexible solution once fixed in place, with a suitable bedding and jointing compound or similar adhesive, so that the setts and the jointing compound moves and neither cracks or crumbles.

The bedding and jointing compound adheres very well to aggregate and especially well to the matrix which binds the artificial stone to aggregate. The bedding and jointing compound adheres physically to a surface of a roadway or pathway and physically to the matrix which binds and covers the aggregate in the artificial sett. Advantageously the bedding and jointing compound cures in a few hours and preferably in less than two hours.

The invention is further explained, by way of examples, by the following description, to be read in conjunction with the appended drawings, in which: Brief Description of the Figures

Figure 1 is an overall, diagrammatic view of a traditional stone sett;

Figure 2a shows a view of a composite sett according to the invention;

Figure 2b shows a view of an alternative embodiment of a composite sett;

Figure 3a shows a cross section through the composite sett of Figure 2a; Figure 3b shows a cross section through the composite sett of Figure 2a;

Figure 4a shows one example of a flow chart of the process steps for making a composite sett;

Figure 4b shows another example of a flow chart of the process steps for making a composite sett and includes a vibrating stage; Figure 5 shows a sett mould containing a plurality of sett mould cavities; and

Figure 6 shows an example of a composite sett production apparatus with a sett mould that is supported on or formed as part of, a conveyor belt.

Detailed Description of Preferred Embodiments of the Invention

Referring to the Figures, there is shown in Figure 1 (PRIOR ART) a view of a traditional sett 10 which is generally cube or box-shaped and requires a relatively deep excavation so as to receive the stone or granite sett. The traditional sett 10 is typically cut from a single piece of rock or boulder.

An example of the invention is shown in Figures 2a and 3a, which depict a composite sett 20 which is in the general form of a thin slab or tile with generally square edges. The composite sett shown in Figures 2b and 3b have angled sides so that their bases are slightly larger than their exposed surfaces. An advantage with embodiment is that when the composite setts are fixed to a roadway or surface there is a larger space defined in between them for receiving a jointing compound.

In both the embodiments shown in Figures 2a, 3a and 2b, 3b, the thickness of the composite sett 20 is less than its length and width. The top surface 22 and side edges 24 of the composite sett 20 have an irregular form and the top surface 22 is roughened. In a yet further alternative embodiment (not shown), composite setts the exterior surface may be smooth. In a yet further embodiment one surface may be deliberately roughened and the other surface deliberately fabricated smooth. Because the composite sett is formed in a mould 50, (an example of which is shown in Figure 5), that has been made from a cast of a genuine granite or similar hard-wearing stone sett having random occlusions, raised ridges and indentations, these imperfections are replicated in the outer surface of the composite sett 20. The moulds 50 can be made from fresh new rough setts but also from old worn smooth recycled setts. The composite sett 20 therefore appears very similar to a traditional stone or granite sett 10 when viewed from above.

A person looking down on a traditional sett on a roadway beside a composite sett 20 is therefore hardly able to see a difference between a traditional stone sett and the composite sett according to the invention. Also because of the flexible nature of the composite stone sett they appear to behave as a traditional stone sett in that they are able to withstand heavy and repeated loading, for example by traffic. This is not because they are rigid as the traditional stone or granite stets, but as they are thinner and flexible they are able to flex under loading without cracking or fracturing.

Bottom face 26 of the composite sett is formed flat so that it is able to adhere to a walkway, path or road surface when applied with a suitable adhesive. The bottom face 26 of the composite 20 in use is pressed into bedding and jointing compound against walkway, path or road surface. The advantage of the composite sett having a flat surface is apparent when considering that it is intended to adhere to a flat road or walkway so that it maximizes contact area with the surface. Figure 3a shows a cross section surface 27 through the composite sett 20 of Figure 2a. The cross section shows diagrammatically a matrix 28 which binds together aggregate stones or chippings 30. The aggregate stones or chippings are tiny and appear as specs in the matrix. Figure 3b shows a cross section surface 27 through the composite sett 20 of Figure 2b; a difference between the two embodiments being that the edges of the sett shown in Figures 2b and 3b are chamfered so as to accommodate relatively close packing of the setts on generally rectangular bases whilst presenting sufficient gaps on their upper faces to receive grouting or fixing compound or waterproof sealant. The material forming the matrix can be transparent or translucent. Also some setts will have pigment in the resin mix to aid the visual appearance. In this case the resin is neither translucent nor transparent and the aggregate stones or chipping may include particles so that they are densely packed.

The net effect is that a person looking at the moulded set may be able to see through the matrix to the opaque aggregate particles. Therefore, granite or similar hard-wearing stone composite setts appear nearly identical to a traditional sett.

In Figure 4a there is shown a flow chart of one example of the process for making the composite sett 20. Figure 4a shows first step 101 is to select the type and grade of aggregate. For durable setts that stand up to repeated wear, for example by heavy vehicles, the preferred aggregate type is granite or similar hard-wearing stone.

A typical size of aggregate particles is in the range from 0mm to 6mm and these are preferred because these size particles make for a rough, non-skid surface which is very long lasting in a composite sett subjected to heavy traffic. As shown in Figure 4 the next step 102 is to dry the aggregate. Depending on the process used to crush or grind the aggregate into tiny particles, or where the aggregate has been stored prior to delivery the aggregate may be damp or wet and so may need to be dried in order to enable a binder to bind the particles. If aggregate is supplied in a dry state this step is omitted.

If wet, aggregate is typically dried in a kiln or by warm dry air or by other means. The drying and grading of the aggregate may be done as a separate process, for example by a subcontractor. Some resins may not require the aggregate to be dry in which case this step may be omitted.

Steps 201 , 202 and 105 are all done around the same time with the materials being added in pretty much any order. Step 205 applies the vacuum which may be done while mixing, pouring or curing in the mould.

Once mixing is completed slurry is poured out of the vat 70, as shown at step 106, and into moulds 50. Optionally a further stage of degassing may take place on each mould. However, this adds to cost. Alternatively the slurry can pass into a separate degassing vat as shown in step 107. The slurry is now ready to be urged into individual sett mould cavities 55 defined in sett moulds 50.

Referring briefly to Figure 4b which is similar in many respect to the flow diagram of Figure 4a, there are additional process steps 110.5 to 110.8. These additional steps illustrate how a vibrating stage or jigger bed (not shown) is used to remove any excess air bubbles from the sett, thereby improving its mechanical strength.

Figure 5 shows a sett mould 50 comprising a plurality of sett mould cavities, each cavity having their own unique surface finishes and profiled edges. However, each sett mould cavity 55 has the same width, length, and depth so providing a standard overall size of a single sett. It is understood however that the dimensions may vary very slightly from cavity to cavity. Some sett mould cavities may represent smooth setts; some others have a roughened or contoured surface; and some others have completely regular surfaces.

Ideally a single sett mould comprises a plurality of sett mould cavities so that a plurality of composite setts 20 can be made at the same time from a single mould.

High Polished Stone Value aggregate (in excess of 65 according to BSEN 1097-8:2000 on a 10/6mm grading) may be incorporated into the finished product in order to increase skid and slip resistance as either part substitution with the other aggregate or by application to the mould cavity 55 prior to filling with the slurry mix. The slurry is urged into the sett mould cavity by pouring or spooning. Alternatively slurry may be pumped into the set mould cavity, injected into the set mould cavity or squirted into the set mould cavity. A simple gentle gravity feed of the slurry into the sett mould cavity is preferred because this method does not reintroduce bubbles into the slurry mixture and because it is simple and reliable.

The slurry is shown being urged into the sett mould cavity in step 109 shown in Figure 4. What is important is that the slurry mixture is introduced into the mould cavity in any manner so as to minimize the creation of bubbles, for example by way of a batch delivery system, low pressure pump, helical pump or by pouring.

As a further means of reducing the presence of bubbles, vibration may be utilized as step 110, in which case, vibration is applied during urging of the slurry into the mould cavity and/or during the curing process. In some instances the slurry may be required to be urged into the mould cavity a number of times to completely fill the mould cavity.

Once the slurry has been poured into a mould, it hardens over a period of time which may be accelerated by increasing the temperature. It is then cast out of the mould and placed on a flat surface to enable the resin and mixture to cure completely. Alternatively the sett may be left to fully cure in the mould.

In a continual production process, the sett moulds are formed integrally with a continuous conveyor belt production apparatus for example as shown in Figure 6. The method of manufacture can be tailored to suit the desired end dimensions of the solidified combination, so producing composite setts 20 in which the width and length are variable, in the ranges from 30mm to 500mm and whose thicknesses are between 4mm to 100mm.

Where the sett mould is a conveyor belt, set mould cavities are formed in the conveyor belt all the way around a loop. The slurry is urged into a sett mould cavity and conveyor belt moves along, bringing the next sett mould cavity into position for receiving the slurry. This process of filling the next consecutive sett mould cavity is repeated resulting in an efficient production of slurry filled sett mould cavities which harden to a sufficient state to enable them to be removed at the end of a run.

Setts are manufactured in a warm environment where the catalyzed liquid combination and the slurry are easily kept at the resin manufacturers recommended temperature of use. This temperature is ideally suitable for an efficient production rate at optimum quality levels because the slurry cures to a near solid in the optimum time.

The cast-out-ready-solid sett is not fully cured but it is solid enough to be removed from the sett mould cavity and maintain the mould shape under its own weight. Casting the sett out of the mould as soon as the sett has cured to the cast-out-ready-solid condition is advantageous for fast and efficient sett production and mould rotation.

The cast-out-ready-solid setts are placed on a flat surface. The bottom surface of these composite setts is placed flat against the flat surface. To prevent the edges of the composite sett from curling up, the composite sett 20 may be cast out of the sett mould while it is still soft. The weight of the composite sett itself and the softness of the composite sett in this cast-out-ready condition keep the composite sett flat against the table and prevent the edges from curling up. Once curing commences the setts can get hot if an exothermic reaction occurs and this tends to speed up the curing process. Curing the slurry in the sett mould cavity into a cast-out-ready-solid sett is shown in Figure 4 as step 111.

The conveyor belt sett mould is arranged with the mould cavities facing upwards when the slurry is put into the cavities and as the setts cure in the cavities. As the conveyor belt sett mould moves along eventually each sett mould cavity turns upside down as the mould passes over the end pulley. This is illustrated in Figure 6. Each cast-out-ready-solid sett drops out of the upside down sett mould cavity.

Optionally a vibrating element may be used to shake the conveyor belt sett mould where the sett mould cavities are upside down to urge each cast-out- ready-solid sett to drop out of the mould.

Alternatively the conveyor belt may be articulated and in which case never turns upside down. Each section of the articulated belt comprises at least one sett mould cavity. A bending roller may be used to bend an articulate conveyor belt sett mould as each section passes over it. The sharp bend in the mould acts to remove the cast-out-ready-solid sett from the sett mould cavity. The cast out composite setts are guided to a full cure apparatus.

Casting the cast-out-ready-solid composite sett out of the sett mould cavity in the cast-out-ready-solid condition is shown in Figure 4 as step 1 13.

To fully cure a solid sett from the cast-out-ready-solid condition takes about a week at an ambient temperature of between 20°C to 45°C. The setts are applied to a surface typically in the following fashion:

Step 1 applying a layer of bedding and jointing compound to the surface;

Step 2 pressing a first composite sett into the into the layer;

Step 3 laying a second composite sett adjacent to the first sett with a gap therebetween them; and Step 4 filling the gap with a jointing compound.

The composite setts 20 are therefore tough and sufficiently resistant to cracking to withstand heavy traffic and seasonal fluctuations in temperature and water from runoff and rain.

The invention has been described by way of explanation and examples. Variations and procedures readily apparent to those skilled in the art may be made without departing from the scope of the invention. Such embodiments and modifications fall within the scope of the present invention. For example other ingredients may include: catalysts, flexible additives, degassing agents or pigments, and the aggregates may be substituted with synthetic, recycled, processed or other suitable particles including and without limitation other hard wearing stone aggregate such as slag or ceramic or processed aggregates or recycled materials. List of Numbered Items in Figures Traditional Sett

Sett Thickness

Sett Length

Sett Width

Composite Sett

Top of Sett

Side of Sett

Bottom of Sett

Cross Section Face of Composite Sett

Matrix of Composite Sett

Aggregate of Composite Sett

Mould for Composite Sett

Mould Cavity for Composite Sett

Slurry

Cast-Out-Ready-Composite-Sett

Heater

Vat

Bending Roller

Claims

Claims:

1. A system for manufacturing a composite sett comprises: a mixing vat for receiving resin, aggregate, catalyst and a flexible additive and for mixing these into a slurry mixture; a mixer for mixing the slurry mixture; a plurality of flexible sett moulds each having contoured surfaces for providing contoured surface finishes and defining a sett mould cavity into which the slurry mixture is introduced; and a means for removing bubbles from the poured slurry mixture so as to form suitable cast-out ready composite setts.

2. A system according to claim 1 in which the means for removing bubbles from the poured slurry mixture includes a pump.

3. A system according to claim 1 or 2 includes a dryer arranged to dry the aggregate prior to mixing.

4. A system according to any preceding claim includes a means for covering the walls of the sett mould cavity with a layer of powder prior to introducing the slurry mixture into the sett mould cavity.

5. A system according to any preceding claim wherein the sett moulds are supported on a continuous surface, such as a conveyor belt.

6. A system according to claim 5 wherein a chute is located at an end of the continuous surface and is arranged to receive cast-out composite setts ejected from sett mould cavities in a continuous production process.

7. A system according to any preceding claim wherein the means for removing bubbles from the poured slurry mixture includes a vacuum chamber means and/or a pump and/or a vibrating table.

8. A system according to claim 6 or 7 comprises a means for urging composite setts from sett mould cavities.

9. A method of operating a system for manufacturing a composite sett comprising the steps of: mixing resin, catalyst and a flexible additive in a mixing vat into a catalyzed liquid combination; mixing the catalyzed liquid combination and an aggregate into a slurry mixture; transferring the slurry mixture into a sett mould cavity; to form a cast-out-ready-solid composite sett; supporting the cast- out-ready-solid composite sett on a flat surface for at least one hour to complete the cure of the composite sett.

10. A method according to claim 9 includes the step of: operating an aggregate dryer so as to dry an aggregate prior to mixing the catalyzed liquid combination with the aggregate.

11. A method according to claim 9 or 10 comprises the step of: removing air bubbles from the slurry mixture.

12. A method according to any of claims 9 to 11 includes the step of mixing a catalyst so as to remove air bubbles from the slurry mixture.

13. A method of operating a system according to any of claims 9 to 12 in which a vacuum apparatus is used to apply a vacuum to the slurry whilst in the sett mould cavity.

14. A method of operating a system according to any of claims 9 to 13 includes vibrating the slurry in the sett mould cavity so as to remove air bubbles from the slurry mixture.

15. A method of operating a system according to any of claims 9 to 14 includes heating the slurry in the sett mould cavity so as to remove air bubbles from the slurry mixture.

16. A composite sett comprising a shaped and cured mixture of resin, a catalyst, a flexibility additive and dried aggregate so that the aggregate is bound into a matrix.

17. A composite set according to claim 16 in which the aggregate grade is in the range between 0 mm to 6 mm preferably the range is between 0 mm to 3 mm.

18. A composite sett according to either claim 16 or 17 wherein the resin is a polyester.

19. A composite sett according to any of claims 16 to 18 whose width and length are in the ranges from 30 mm to 500 mm and whose thickness is between 4 mm to 100 mm.

20. A composite sett according to any of claims 16

includes a methyl ethyl ketone.

21. A composite sett according to claim 20 wherein the catalyst is methyl ethyl ketone peroxide.

22. A composite sett according to any of claims 16 to 21 includes a colouring or dye.

23. A composite sett according to claim 22 wherein the colouring or dye is yellow.

24. A composite sett according to any of claims 16 to 23 includes a reflective and/or fluorescent material.

25. A composite sett according to any of claims 16 to 24 wherein the sett has an embossed shape such as an indentation or logo or other marker on its underside.

26. A composite sett according to any of claims 16 to 25 is adapted to flex when loaded.

27. A method of applying composite setts according to any of claims 16 to 25 to a surface comprising steps of: applying a layer of bedding and jointing compound to the surface; pressing a first composite sett into the into the layer; laying a second composite sett adjacent to the first sett with a gap therebetween them; and filling the gap with a jointing compound.

28. A system for manufacturing a composite sett substantially as herein described with reference to the Figures.

29. A method of operating a system substantially as herein described with reference to the Figures.

30. A composite sett substantially as herein described with reference to the Figures.