WO2007129028A2

WO2007129028A2 - System and method for paving cladding

Info

Publication number: WO2007129028A2
Application number: PCT/GB2007/001564
Authority: WO
Inventors: David William Trueman
Original assignee: David William Trueman
Priority date: 2006-05-05
Filing date: 2007-04-27
Publication date: 2007-11-15
Also published as: GB0609006D0; WO2007129028A3

Abstract

A system and method for paving cladding is described which can provide a highly efficient and cost effective method for creating areas of stylish pavement and patio areas. An innovative and balanced ratio of concrete components incorporating a fibre material makes possible the creation of lightweight and very strong paving cladding flagstones which are reduced in thickness compared with conventional concrete flagstones. The invention of this unique product concept makes possible the creation of patios and precinct areas at very high speed by providing a paving tile suitable for paving cladding of various shapes to make possible the cladding of pre-existing areas of flagstones with high quality simulated stone tiles. This paving cladding technique avoids the need to remove and dispose of existing flagstones and to prepare the underlying supporting layer. The invention also teaches techniques for tapering and shaping the cladding tile in the vicinity of doorways, steps, wall capping stones and pavement edges.

Description

SYSTEM AND METHOD FOR PAVING CLADDING DESCRIPTION

BACKGROUND OF THE INVENTION

The invention relates to a system and method for paving cladding. More particularly, it relates to a system and method for creating a new and improved pavement or patio or pedestrian-precinct paving-flagstone or paving tile which may clad, or cover, or replace a pre-existing paved area. The invention is particularly addressed towards the creation of a lightweight flagstone tile of reduced thickness which exhibits the properties of highly increased strength and durability. This makes possible the rapid paving-over of a pre-existing area of flagstones or tiles or concrete underlay while avoiding the excessive work involved in removing and disposing of the pre-existing flagstones or tiles or needing to prepare a new hardcore foundation layer.

In particular, the invention teaches a method for creating a new and improved lightweight cladding tile which saves transport costs and which is easy to lift and lay safely which greatly reduces the need for specialised lifting equipment.

The composite components of the concrete tile and its method of manufacture are key to the invention and the invention also addresses the key problems areas of transportation, the storage of flagstones in transit and at point of sale, the staining of flagstones, the breakage of flagstones due to vehicles, the health and safety issues due to the excessive weight of conventional flagstones, and the environmental problems associated with the disposal of packaging materials. Many methods exist for manufacturing concrete paving slabs. Spanish patent ES 2010148 to Mendoza published 16^th October 1989 describes a method of manufacturing stones from concrete using elastomeric moulds with a textured surface derived from natural elements, e.g. slabs of stone. During moulding, the elastic moulds are supported in rigid moulds, which after vibration and setting of the concrete are removed before de-moulding. The visible surface of the concrete slab is coloured, and sealant and hardener are applied, with final drying in an oven. This method does not produce flagstones of increased strength and the use of elastic moulds reduces the definition of the resultant tile and introduces some variation in the position of the corners of the tiles which may make them difficult to align with other tiles.

In French patent FR 2688240, published 10^th September 1993 is described a method for casting flagstones in situ using juxtaposable compartmented moulds which are placed on the floor or other surface which is to receive the flagstones or slabs. While this method may offer a method of paving a path or terrace in the form of flagstones or tiles, the solution is more directed towards shaping a concrete aggregate mix in situ rather than to the manufacture of flagstones.

In Japanese patent JP 11229306 to Yamada, published 24^th August 1999 is described a method to manufacture a precast concrete paving slab using a mould which is suitable for the manufacture of slabs 2 to 2.7 metres wide, 4 to 6 metres long and 0.2 to 0.3 metres thick. The method provides a solution for controlling the thickness within a tolerance of 2mm over the slab surface area. Methods for improving the strength of aggregate mixes using a fibre binding element are also known. In US patent 5897928 to Sanders et al, published April 27^th 1999 is described improving the strength of concrete using fibres. The application area and the efficient and effective way of addressing the problems of repaving tiled areas using fibre reinforced paving cladding tiles according to the current invention is not disclosed.

Generally, there are many problems associated with the manufacture, transportation, storage and laying of flagstones. Also, flagstones are often broken by vehicles driving upon them because they cannot support weights in excess of 30 metric tons. Power washes and foot traffic erode conventional flagstones causing them to discolour as aggregate gets exposed and also these flagstones have poor resistance against surface staining.

In the building industry, flagstones typically comprise concrete tiles which are can be made of different sizes and thicknesses such as having a thickness of between 35mm and 70mm and which may be of dimensions of 900mm long and 600mm wide. Flagstones of even half these dimensions are very heavy and Health and Safety regulations demand the use of specialised lifting equipment such as vacuum lifters or mechanical grabs to reduce the possibility of injury to workmen when loading or moving and or laying these flagstones. These regulations were introduced to protect workers from risks associated with musculoskeletal disorders and work-related upper limb disorders.

In particular, it is the weight of the flagstone which is the cause of many back injuries because often the flagstone needs to be moved to an area where vehicles or lifting equipment have limited or no access. Often patios need to be laid behind houses where there may only be access through the house itself. This poses significant problems to bring the heavy flagstones through the house.

Conventional flagstone thickness is associated with the strength of the flagstone which is why in areas where vehicles may drive onto the flagstones that the flagstones are consequently so heavy and difficult to lay. The typical weight of a conventional flagstone can range between 10 kilograms and 80 kilograms which poses a significant challenge for workers when laying these flagstones safely.

Whenever a householder wishes to build or replace an existing patio using conventional materials and techniques, this involves substantial effort to prepare the designated area which will be tiled with flagstones. Any existing flagstones must be first removed and disposed of in a builder's skip or constructional material waste container and the ground material below the designated tiled area must often be removed and replaced with an appropriate underlay. This underlay for the patio flagstones is often prepared of hardcore which may comprise pieces of broken brick and tile and sand. Consequently, it is the extent of this preparation work and the removal and disposal of any pre-existing flagstones which may comprise excavating several tons of material which generally makes patio replacement or patio creation a much more expensive undertaking than it should be. In particular, the preparation work involved before any flagstone tiles may be laid may typically take more than half the time involved in creating the patio area. The current invention is particularly directed towards this problem area and can provide a highly efficient and rapid and low cost technique for creating patios of stylish prefabricated flagstone tiles. The industry of flagstone manufacture is not experiencing much growth or innovation. Flagstones made of concrete do not look very appealing and low cost natural stone products are being imported into the market such as stone tiles quarried in South East Asia. While these natural tiles do indeed look attractive and are very durable, they are very expensive to transport due to their high density and they require substantial packing material to protect them in transit. In addition, naturally cleaved stone tiles, which are often sourced from different quarries, comprise a variable thickness due to the tile being cleaved down preexisting fault lines in the stone and these tiles will often be of variable colour. This means that any batch of tiles generally will not all be of the same thickness or of the same colour and this poses challenges when creating a tiled area. Adjacent tiles should match in colour and also should form a continuous level surface. The builder laying the tiles must thus compensate for any variation in thickness by adding underlay material so that the patio or paved area is flat and does not comprise any protruding edges which can cause injury from tripping. A significant additional problem is that these stone tiles are very difficult to cut and require heavy duty angle grinders and cutting is best performed by experienced workmen.

Any method of manufacture which can address the problem of colour variation and can create highly desirable flagstone tiles of any desired shape and thickness will be able to make possible an easier and more efficient technique for laying tiles.

Transportation and storage of flagstones and natural stone tiles remains a challenge for this industry segment. Builders' merchants and garden centres have limited space available for storing inventories of tiles. Any tile design which is of a greatly reduced weight and thickness will greatly save on transportation costs per unit tile and make more efficient use of storage space in merchants' yards.

In addition, flagstones and stone tiles are transported using substantial amounts of protective packaging material comprising wooden crates and palettes as well as plastic wrapping. Any flagstone tile solution which reduces the volume of tile material transported per unit area of patio or pavement created will substantially reduce the amount of packaging material used when transporting the tiles which not only reduces packaging cost but is also highly desirable for environmental reasons.

Packaging material is rarely reused and represents waste in the tile delivery process and all measures should be taken to reduce this wastage of materials. When preparing a pedestrian precinct, which may arise when conventional flagstones have been broken by vehicles driving over them, there are additional challenges due to the significant amount of time required to lay the flagstones. This causes some disruption to the pedestrian area because areas must be fenced off from the public to reduce injury from walking upon uneven surfaces. Not only is this unsightly for quite a long duration, but it also reduces access to shopping centres and restaurants which may affect their business. Clearly any method which provides a rapid and elegant solution for cladding the surface of a preexisting flagstone precinct with a highly reduced thickness and very strong paving cladding tile will avoid many of the problems associated with conventional techniques. Also, paving cladding may make use of environmentally approved industrial glues to stick the cladding onto existing paved structures. In this case it is possible to walk directly upon the new paving cladding as soon as it is laid down. Additional challenges are presented by metal drain inspection covers and water meter covers as well as pre-existing draining gratings which serve to drain rainwater into drainage channels. These metal covers and gratings can be of varying sizes and shapes such as 600mm by 600mm square covers or 450mm round covers for example. Conventional techniques for laying patios and pedestrian precincts generally involve laying flagstone tiles adjacent to these metal covers. Often this technique can render the patio unsightly where an inspection cover remains visible and breaks the beauty of the patio design. Any method of tile manufacture and laying technique which can enhance the appearance of a patio by hiding any drain covers effectively will result in a more pleasing patio design.

Generally, tile manufacturers have been unable to approach this innovative area of paving cladding because the technique of cladding existing tiles requires the invention of a very strong and lightweight tile which can be shaped easily to taper as required when laid near to doorways and pavement edges. For the tile itself, a highly innovative concrete composite mix is required as well as new tile moulding techniques which are suitable to high volume production.

In other application areas, there are challenges when laying flagstone steps such as from a patio down to a grass area. Conventional flagstones are heavy to move and like the patio, this construction project is difficult for homeowners to do themselves due to the problem of levelling the underlying surface and the weight of the tiles.

During flagstone manufacture, care must be taken to avoid key problem areas. Flagstones are typically manufactured from concrete using rubber or fibreglass moulds. Rubber moulds create tiles of lower definition but are easier to work with.

Desired tile shapes such as those of hard stone tiles are created by making a mould from a stone tile and then by casting concrete into the mould shape. Before the mould is used, the inner surface of the mould is coated with a mould release agent. Next a concrete mix is prepared which may comprise two parts sand to one part cement which may have some colouring added. This is finely mixed together and some water added. The concrete mix is then poured into the mould. The mould is then moved to a drying room for 24 hours after which the tile is removed.

There are many problems associated with concrete tile manufacture. Steps must be taken to control the optimum ratio between the sand and the cement because this affects the hardness and durability of the concrete. In addition, the amount of water used must be minimised because water content reduces strength which is why the mix should comprise a water reducing agent in the correct proportion.

Generally flagstones need to repel water and be frost resistant because temperature extremes can cause them to develop cracks due to ice forming in surface cavities. The lack of a sealant also means that the colour of the tile does not remain vibrant.

During the tile-hardening process itself, steps must be taken to ensure that the flagstone tiles are dried at the correct rate and with optimum air circulation around them. Problems can arise if the tile-moulds are too closely stacked which can lead to retention of moisture and consequent efflorescence. Efflorescence is an unsightly white crystalline or powdery deposit on the surface of masonry materials like concrete tiles. It is directly caused by water within the concrete material dissolving salts inside the concrete while moving through it, which then evaporates leaving the salt on the surface. These salts are water soluble and can be removed using substances like hydrochloric acid but these are hazardous to handle. Insufficient airflow around drying concrete flagstones can cause crystalline efflorescence which leaves salt crystals tightly bonded to the surface of the tile. Particular production techniques which can avoid the problem of crystalline efflorescence are of great interest to the flagstone production market.

The surface finish and texture and colour of fabricated flagstones as well as their durability are significant factors for securing high market volume for flagstone products. As has been indicated, there are particular challenges to overcome when manufacturing. In addition, the success of any prefabricated flagstone will be greatly improved if a high definition tile is created of high durability and uniform structure so that the flagstone does not discolour as it ages or with excessive use.

Production techniques for flagstone tiles have changed little over the past 30 years which is probably why many of the conventional problem areas have not been adequately addressed. Concrete flagstones are generally associated with outside paving applications due to their lacklustre appearance and the difficulty of transporting and laying the flagstones. If it were possible to create a very strong and durable flagstone of reduced thickness and weight while comprising a strength per unit area which is greater than that of heavy conventional flagstones, and one which is of high definition and of good surface finish of attractive shades of colour, this product would secure great market potential.

This product would also lend itself to interior applications such as in hotels and conference centres where there is much foot traffic. In addition, the tile would be highly suited to driveways and to the manufacture of a strong and lightweight roofing tile of a high quality simulated stone appearance. In residential areas, new housing developments comprise houses with standard patios of concrete flagstones.

Unless, there is an opportunity for a house buyer to intervene during the construction process, the upgrading of the patio into something more attractive using flagstone tiles of a simulated stone effect is a highly expensive building project as has been outlined above. The provision of a new product concept of a lightweight, yet very strong and durable, paving cladding which comprises a high definition simulated stone effect of a variety of types, makes possible the cladding of concrete flagstones directly while avoiding all the waste materials and unnecessary effort of removing the existing patio. In addition, being able to clad an existing pre-prepared solid foundation layer with paving cladding tiles provides significant opportunities to optimise the pattern of the tiles to be laid.

In particular, there exist problems with making random tile pattern designs which both look appealing as well as truly random while incorporating pre-existing drains and inspection cover locations. If an end-to-end paving cladding solution could be developed, which not only addressed all of the problem areas as outlined above, but also could make use of computer software to generate elegant and truly random pattern tile layouts, new patios could be built much faster, at reduced cost and with very little waste from packaging and building materials. At the same time, such a computer planning tool would provide accurate estimates of materials required including the amounts of tile fixing compounds such as cement or glues. The invention is also directed towards this patio planning need also. In other areas such as the capping of walls, capstones are generally flat and without any profile on their underside. Generally, capstones are not securely fixed to the upper edge of the wall and are prone to being knocked off. If a new and improved stylish and lightweight tile in the shape of a hollow wall-capping stone which would partly enclose the top of the wall in a stylish and elegant way and provide a more secure capping stone, then this would also be of great benefit in this problem area.

In particular, the current applicant believes that this whole industrial area of paving cladding is unique and that no other product concept has yet been described which provides a lightweight and durable paving cladding tile and means of manufacture of the same, which addresses each and every challenge faced by builders and tile and flagstone manufacturers when choosing among all product choices currently available to repave or retile an area.

Further to the limitations of existing methods used for concrete flagstone and tile manufacture and the method for preparing and laying new paved areas for patios, precincts, driveways, roofs and pavements, and so far as is known, no optimum system and method for paving cladding is presently available which is directed towards the specific needs of this problem area as outlined.

OBJECTS OF THE INVENTION

Accordingly, it is an object of the present invention to provide a system and method for paving cladding in which highly desirable paved areas can be formed by introducing a paving cladding flagstone to cover or replace pre-existing paved areas.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which involves a specialised manufacturing method for a new and improved pavement or patio or pedestrian- precinct paving-flagstone or paving tile which may clad or cover or replace a preexisting paved area.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which comprises a new and innovative flagstone composite concrete which enables the manufacture of a lightweight flagstone tile of reduced thickness which exhibits the properties of high strength and durability.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which makes possible the rapid paving- over of a pre-existing area of flagstones or tiles or concrete underlay while avoiding the excessive work involved in removing and disposing of the preexisting flagstones or tiles or needing to prepare a new hardcore foundation layer.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which greatly reduces the transportation and packaging costs of strong prefabricated paving cladding flagstones through the manufacture of a lightweight and highly durable flagstone tile which is easy to lift and to lay and thereby greatly reduces the back problem injuries often associated with the movement, stacking, loading, unloading and laying of concrete flagstones. The creation of such a lightweight tile of highly suitable properties advantageously reduces the need for specialised lifting equipment. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which involves the manufacture of lightweight, strong and durable flagstone tiles of greatly reduced thickness while exhibiting strengths exceeding conventional flagstones such that a greater number of paving cladding flagstone tiles can be transported per unit weight and thereby achieve a correspondingly high saving in packaging materials such as wooden crates and plastic wrapping. In addition, the reduced tile thickness and weight also makes possible the more efficient use of storage yards and warehousing by being able to achieve a much higher number of tiles per unit volume which is particularly advantageous at points of sale. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which comprises the manufacture of a composite concrete paving cladding flagstone tile which comprises a new and improved concrete mix which can demonstrate strengths close to and or exceeding that of natural stone. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which comprises the manufacture of a composite concrete paving cladding flagstone tile which comprises a new and improved concrete mix to which fibre strands are added such as one or combination of more than one of the following fibres: fibreglass fibres, polyethylene fibres, polypropylene fibres, thermotropic liquid crystal polymer fibres, cellulose fibres, coconut cellulose fibres, kenaf cellulose fibres, rubber-wood cellulose fibres, paper pulp cellulose fibres, metal fibres, metal shavings, and the like.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which comprises the manufacture of a composite concrete paving cladding flagstone tile which comprises a new and improved concrete mix which comprises a sealant to reduce water absorption and to make the concrete frost resistant and to make the concrete non-porous as well as providing resistance against tyre marks, oil marks and other stains. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which comprises the manufacture of a composite concrete paving cladding flagstone tile wherein the surface of the tile can be created with a high sheen by applying one or more coats of sealant to the upper surface of the finished tile. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which comprises manufacturing a new concrete composite comprising cement, such as ordinary Portland cement or rapid hardening cement, and or with added lime to act as a plasticiser, and sand and a dye and water and a sealant and a water reducing agent, to improve the strength of the paving cladding tile, and an amount of fibre strands. It is a further object of one embodiment of the present invention to provide a system and method for manufacturing a strong paving cladding tile suitable for a tile of reduced thickness such as 20mm thick in which the ratio of the composite concrete mix is approximately 66% sand to 33% cement, after which is added a volume of concrete dye equivalent to between 3% and 7% of the weight of the 'cement volume' (henceforth the 'equivalent volume'), after this is added 18% to 33% equivalent volume of water depending upon the water content of the sand used, and 0.5% to 1.5% equivalent volume of sealant, and 0.5% to 2% equivalent volume of water reducing agent, and 2.5% to 7% equivalent volume of fibre strands.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding in which the composite concrete mix comprises fibre strands of thickness between 0.5mm and 2mm and of length 5mm to 20mm. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding in which the composite concrete mix comprises water which is approximately 5% to 15% of the total mix and preferably around 10% of the total mix wherein the water content of the sand added is taken into account. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding in which the composite concrete mix comprises sand which has its water content determined by humidity sensors or from determining the weight of a specified volume of the same sand compared to the weight of the same volume of dry sand and taking the necessary steps to adjust the water added so that the optimum strength of composite mix is obtained.

It is a further object of one embodiment of the present invention to provide a system and method for manufacturing a stronger paving cladding tile suitable for a tile of reduced thickness such as 15mm thick in which the ratio of the composite concrete mix is approximately 60% sand to 40% cement, after which is added a volume of concrete dye equivalent to between 4% and 6% of the weight of the 'cement volume' (henceforth the equivalent volume), after this is added 18% to 33% equivalent volume of water depending upon the water content of the sand used, and 0.5% to 1.5% equivalent volume of sealant, and 0.5% to 2% equivalent volume of water reducing agent, and 2.5% to 7% equivalent volume of fibre strands.

It is a further object of one embodiment of the present invention to provide a system and method for manufacturing a much stronger paving cladding tile suitable for a tile of reduced thickness such as 10mm thick in which the ratio of the composite concrete mix is approximately 50% sand to 50% cement, after which is added a volume of concrete dye equivalent to between 4% and 6% of the weight of the 'cement volume' (henceforth the equivalent volume), after this is added 18% to 33% equivalent volume of water depending upon the water content of the sand used, and 0.5% to 1.5% equivalent volume of sealant, and 0.5% to 2% equivalent volume of water reducing agent, and 2.5% to 7% equivalent volume of fibre strands. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which are of greatly reduced thickness but of significant strength due to their fibre component and which can support the weight of a vehicle without breaking and which do not discolour and which have a great resistance against surface staining.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which are lightweight and do not require the use of specialised lifting equipment.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which are lightweight due to their increased strength per unit area at a reduced thickness compared to conventional flagstone tiles wherein the thickness of the tiles ranges from 25mm to 8mm, and may be uniform thickness or tapering.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which are easy to lift and to move into position such that a householder can transport and move the tiles without the need of lifting equipment or specialist tools.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which are laid over the top of an existing patio or concrete layer wherein a greatly reduced amount of packaging material is used and a greatly reduced amount of waste material is generated from the laying process wherein often no additional preparation of the under layer is required.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which avoids the need to prepare a totally new hardcore under layer from broken brick and tile and sand thereby saving a substantial amount of time.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which can be made of a particular composition so that the tile looks identical to paving tiles of natural stones of a variety of types while having a similar or improved strength at a greatly reduced thickness and a correspondingly reduced weight per tile. In particular this makes it possible to create paving cladding tiles of a similar colour and to avoid the problems of tiles of natural stone which may have very different colours.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which are highly suitable for creating stone-effect floors and which are thin enough to work efficiently with under-floor heating.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which can be made of a controlled thickness both to create a uniform thickness tile as well as a tile with a controlled taper such as that needed when a tile is used adjacent to a doorway or when a patio is laid adjacent to grass. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which look very similar to natural stone but which are easy to cut using easy to use non-heavy-duty tile-cutting tools and which do not required skilled workmen to cut them.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which have no protruding edges and thereby have a very low risk of causing tripping. It is a further object of one embodiment of the present Invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which will greatly save on transportation costs per unit tile and make more efficient use of storage space in merchants' yards.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which will use a reduced amount of protective packaging material comprising wooden crates and palettes as well as plastic wrapping and thereby have a very positive impact upon the environment.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which can be used to clad a pedestrian precinct rapidly in a highly efficient and effective way such that very little disruption is caused to the pedestrian areas and thereby provide little disruption to the access to the shops and businesses from the paved area during the cladding work. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which make use of environmentally approved industrial glues to stick the cladding onto existing paved structures wherein it is possible to walk directly upon the new paving cladding as soon as each is laid down. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which can be cut to match the shape of existing drain inspection covers with holes cut to match the positions of the key-slots in the said metal covers and thereby enhance the final appearance of the clad paved area. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which is highly suited to high volume production techniques.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which is manufactured by making a mould from a stone tile and then casting a specific paving cladding concrete mix into the said mould.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles using prepared tile moulds wherein a tile release agent such as form oil is used to coat the inner surface of the mould and then excess is removed to avoid the formation of pit-holes in the tile surface. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which are manufactured in the ratio of two parts sand to one part cement or in the ratio of one part sand to one part cement after which a colouring dye is added which is finely mixed and water is added after which a water reducing agent is added to reduce water absorption and a sealant is added to increase the resistance of the tile against stain marks and to make the tile frost resistant and to keep the colour more vibrant, and finally fibres are added. This is then thoroughly mixed and after the tile moulds are lubricated with a release agent, the mix is poured into the mould.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles which comprise a colouring dye as well as a surface shade through the application of a surface enhancing mix which can improve the finish of the tile by adding some variation.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles from a composite concrete which are manufactured from moulds wherein before the composite is poured into the mould, a surface enhancing mix is applied to the inner surface of the mould including the comers and edges wherein this surface enhancing mix comprises 75% cement, 25% sand and suitable amounts of dye, water reducing agent, sealant, and water.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates paving cladding flagstone tiles from a composite concrete which are manufactured from moulds wherein before the composite is poured into the mould, a surface enhancing mix is applied to the inner surface of the mould comprising 75% cement, 25% sand, and the following equivalent volumes of the cement volume EVC: 10% EVC Dye, 0.5% to 1.5% sealant, 0.5% to 2% water reducing agent. To this mix is added water equivalent to around 10% of the total volume depending upon the water content of the sand.

It is a further object of one embodiment of the present invention to provide a system and method for manufacturing paving cladding flagstone tiles which are formed using moulds which are filled with a specific concrete and fibre mix wherein the moulds are moved to a drying room and stacked horizontally and separated by spacer elements wherein the room is heated to a temperature of 30 degrees Celsius to 50 degrees Celsius and wherein fans maintain good air circulation to avoid retention of moisture and consequent efflorescence.

It is a further object of one embodiment of the present invention to provide a system and method for manufacturing paving cladding flagstone tiles which are formed using moulds and stored in a heated drying room for a first period of time, until the tiles are hard enough to be extracted from the moulds after which the tiles are stacked vertically with a spacer element separating them to enable the tiles to harden at a controlled rate. It is a further object of one embodiment of the present invention to provide a system and method for manufacturing paving cladding flagstone tiles using a drying room which first involves hardening the tiles, after which the tiles are removed from their moulds and stood vertically back to back with a spacer element separating facing front surfaces of the tiles.

It is a further object of one embodiment of the present invention to provide a system and method for manufacturing moulds for paving cladding flagstone tiles in which the surface form of a natural stone tile is moulded by first painting the stone with release agent and using a sheet of moulding material such as fibreglass matting and resin to create a negative of the stone surface, after which this forms the bottom of a first mould which is then built up from batons of precise height to form a primary tile mould design into which a composite mix can be formed. This composite mix then forms a mould-making tile which comprises accurately defined dimensions and a surface of high definition. Stone chiselling techniques are used to simulate weathering in the sides of the mould-making tile, and along the sides to form an angle to assist with de-moulding, while maintaining the integrity of the corners and thereby guaranteeing that adjacent tiles will be perfectly aligned. After which, the chiselled mould-making tile is used to manufacture a plurality of fibreglass tile-making moulds for high volume production of stone-simulated tiles using the composite mix of the current invention.

It is a further object of one embodiment of the present invention to provide a system and method for manufacturing paving cladding flagstone tiles which are highly suited for the interior of hotels and conference centres where there is much foot-traffic and which are also suited for new housing developments by providing a system of patio improvement without needing to replace the existing patio.

It is a further object of one embodiment of the present invention to provide a system and method for paving cladding tiles which makes use of a creative software tool to create a truly random paving design using tiles of several predetermined sizes which starts with the dimensions of the area to be clad with paving cladding tiles and the location and sizes of any drain section covers after which the software program creates a complete random pattern of tiles across the whole area to be clad. At the same time, such a computer planning tool would provide accurate estimates of materials required including the amounts of tile fixing compounds such as cement or glues. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding which creates lightweight and desirable stone-effect paving cladding flagstone tiles which can be easily laid by a householder and which are provided with a patio design software such that the product is highly suitable for internet sales. It is a further object of one embodiment of the present invention to provide a system and method for paving cladding tiles which are shaped to provide stone- simulated wall topping cap stones with a profile which greatly reduces the chances that the cap stone is knocked off with an impact.

Further to the limitations of existing methods used for concrete flagstone and tile manufacture and the method for preparing and laying new paved areas for patios, precincts and pavements, and so far as is known, no optimum system and method for paving cladding is presently available which is directed towards the specific needs of this problem area as outlined. Other objects and advantages of this invention will become apparent from the description to follow when read in conjunction with the accompanying drawings.

BRIEF SUMMARY OF THE INVENTION Certain of the foregoing and related objects are readily-attained according to the present invention by the provision of a novel system and method for manufacturing and laying paving cladding flagstone tiles to provide a highly efficient and cost effective solution for stylish pavement and patio areas.

The invention teaches the manufacture of high definition stone-simulated effect lightweight tiles of greatly increased strength using an innovative and balanced ratio of concrete components incorporating a fibre material. This approach makes possible the creation of lightweight and very strong paving cladding flagstones which are reduced in thickness compared with conventional concrete flagstones.

The invention of this unique lightweight product concept makes possible the creation of patios and precinct areas, driveways, and interior areas such as hotels, conference centres and conservatories, as well as an improved stone-simulated roof tile. The innovative manufacturing process makes use of a novel mould- making process which enables the creation of paving cladding tiles and thin yet strong patio tiles which have very attractive surface definition. This paving cladding technique avoids the need to remove and dispose of existing flagstones and to prepare the underlying supporting layer and consequently it offers significant advantages in ^Λnew-build' housing developments by providing the possibility for householders to lay stone-simulated tiles over pre-existing standard concrete patios without the need for heavy lifting equipment or heavy-duty cutting tools. The invention also teaches techniques for tapering and shaping the cladding tile in the vicinity of doorways, steps, wall capping stones and pavement edges.

As a further dimension to this system and method, the invention provides details of a paving planning tool concept which can help plan areas to be paved or tiled. This software solution not only serves to plan the arrangement of the tiles to be laid in conjunction with any obstacles such as drain inspection covers by considering the tile sizes available, but also it provides the means to determine volumes of material and tile fixing agent that are needed as well as guidelines to the duration of the project.

Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings, which disclose a key embodiment of the invention. It is to be understood, however, that the drawings are designed for the purpose of illustration only and that the particular descriptions are given by way of example only and do not limit the scope of the invention. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. Ia illustrates a schematic of a paving cladding tile according to one embodiment of the invention.

FIG. Ib illustrates a schematic of a tapering paving cladding tile according to one embodiment of the invention.

FIG. Ic illustrates a schematic of a wall topping tile according to one embodiment of the invention.

FIG. 2a illustrates the sequence of manufacturing steps involved in the production of the paving cladding tile. FIG. 2b illustrates a spacer element used when drying the tiles.

FIG. 3 illustrates the sequence of steps involved in the production of the paving cladding tile moulds.

FIG. 4a shows a mould design capable of producing a tile with a controlled thickness and an extended front edge which would be suitable to clad over a step. FIG. 4b shows a mould design suitable for producing a wall topping tile and a wall topping end tile.

FIG. 5 illustrates the elements of the software planning tool to be used to plan and implement tile projects.

DESCRIPTION OF A PREFERRED EMBODIMENT

Reference will now be made in detail to some specific embodiments of the invention including the best modes contemplated by the inventor for carrying out the invention. Examples of these specific embodiments are illustrated in the accompanying drawings. While the invention is described in conjunction with these specific embodiments, it will be understood that it is not intended to limit the invention to the described embodiments. On the contrary, it is intended to cover alternatives, modifications, and equivalents as defined by the appended claims.

The following description makes full reference to the detailed features which may form parts of different embodiments as outlined in the objects of the invention.

Referring now in detail to the drawings and in particular FIG. Ia thereof, therein illustrated is a paving cladding tile (101) manufactured according to the invention. The surface of the tile bears the surface of the tile mould and the four base vertices of the tile (A,B,C,D) are at precise locations such as at a separation of 600mm between A and C, and a separation of 600mm between C and B.

The tile (101) comprises a constant thickness H which only varies in height due to the surface irregularities captured by the moulding process when a mould was made from the natural stone. The advantages of the process are that the base of the stone-simulated tile is flat and correspondingly easy to lay and to fix in place upon a flat surface.

To enhance the appearance of the tile, the moulding process involves creating a master tile and then modifying the sides between the vertices to create a weathered and natural effect. The dotted lines AD and CB indicate how the chiselling has moved the edges of the tile inwards while not affecting the precise positions of the vertices (A,B,C,D).

This method ensures that adjacent tiles will align perfectly.

The front corners of the tile (101), namely vertices D and B indicate how the tile is chiselled at an angle to create a bevelled edge. This bevel extends around the whole tile and provides a means to help de-mould the tile when it is manufactured.

Many different types of dye may be used to manufacture this paving cladding tile and thereby all types of stone-simulated affects can be achieved.

Referring now to FIG. Ib therein is shown an alternative form of paving cladding tile (102) which comprises a taper. The tile papers from a height H along the edge AD, down to a vertical height h along the edge CB. In the same way as described with reference to FIG. Ia, the four vertices (A,B,C,D) of the tile (102) are at precise separations and chiselling has been used along the sides during the manufacture of the mould-making tile to create a tile master with weathering effects and a bevelled edge to aid de-moulding.

This tile (102) is formed from a mould which has its bottom surface (or the stone pattern surface imprint) set at an angle within the mould frame so that the underside of the tile (102) forms a flat surface. The angle of the bottom of the tile controls the rate of taper and this angle can be adjusted accordingly to accommodate all types of variations and rates of taper.

With reference now to FIG. Ic, therein is shown a wall topping tile (103) which can serve to protect a brick wall and provide a stylish and elegant stone simulated topping which appears to comprise a significant block of stone. The tile (103) is designed to enclose the top of the wall (104) and it has edges which extend down thereby creating this effect.

In a similar way as was described with reference to FIG. Ia and FIG. Ib, the topping tile is formed from a mould which is created from a chiselled master tile. The differences are that the vertical sides of the topping tile (EF) may be formed from a chiselled effect or from a stone mould imprint. Some chiselling is required to bevel the top edges to assist with the de-moulding.

A cross section of the tile is shown (106) where the tile encloses the top of the wall (104) and is fixed in place using mortar (105).

With reference to FIG. 2a, therein is described a sequence of steps to manufacture the paving cladding tile according to the current invention. Depending upon the strength of the tile required, a different composite mix should be used. The advantage of this composite mix is that it enables the production of very thin and therefore very light but very strong paving cladding tiles.

The steps listed in FIG. 2a comprise the following:

2.01. Combine the sand and cement according to a specific ratio. For a 20mm thick tile, tests have established that a ratio of 66% sand to 33% cement provides sufficient strength to resist a 30 tonne vehicle driving over and damaging the tile. For a tile which is used to taper around a doorway, the strength of the base mix should be increased and a ratio of 50% sand to 50% cement should be used for a tile which tapers from 20mm to 10mm in thickness. For any thicknesses in-between, a ratio of 60% sand to 40% cement may be used.

2.02. An amount of concrete dye is added to provide the correct colour of the resultant tile and simulate the stone. Ideally the ratio of dye added should be 3% to 7% of the weight of the cement used. For example, if 100kg cement are used then between 3kg and 7kg of dye should be used.

2.03. Water is added to the mix equivalent to 18% to 33% of the weight of the cement. The moisture content of the sand can vary. In most cases this is negligible but as a guide water will represent around 10% of the total mix. 2.04. Sealant such as Rheomix 790 or Sika F Stop is added equivalent to 0.5% to 1.5% of the weight of the cement. Sealant provides a strong resistance to water absorption and it creates sheen over the tile surface.

2.05. Water reducing agent such as Glenium 51 or Sika 10 Visco or Viscocrete CR141 is added equivalent to 0.5% to 2% of the weight of cement used. This is a very important ingredient to increase the strength of the resultant tile.

2.06. Fibre strands are added equivalent to 2.5% to 7% of the weight of the cement. Many different types of fibre strands may be used. In a preferred embodiment, fibreglass fibre strands such as Vetrotex are used of an approximate length of 12mm and a thickness of 0.5mm to 1.5mm. This is now mixed together until the mix is uniform.

2.07. A production tile-mould is prepared for the mix by first wiping the tile-mould with a tile release agent such as form oil. Any excess is then removed.

2.08. As a means to enhance the appearance of the tile and to create a surface of strong colour and sheen, before the mix is poured into the mould, the internal surface surfaces of the mould are lightly coated with a surface enhancing mix which does not comprise fibres. The amount used is very small but sufficient is used to coat the complete tile face surface and the corners and edges. This composite mix comprises: 75% cement, 25% sand, 10% of the weight of the cement used in the total mix (or equivalent cement volume, ECV) of cement dye, 0.5%-1.5% ECV sealant, 0.5% to 2% water reducing agent, and water which is added in an amount equivalent to 10% of the total mix taking into account the moisture content of the sand.

2.09. The tile mix is poured into the mould which is vibrated to bed down the mix. Care is taken not to vibrate the mould excessively so that the surface enhancing mix remains on the surface of the tile mould and not mixed into the tile mix.

The moulds are then moved to a drying room and stacked horizontally with spacer separations to allow air circulation. The drying room temperature is optimally between 40 degrees Celsius and 65 degrees Celsius with fans to give good air circulation and an even temperature distribution. For tiles of 10mm and 20mm thickness, the first period of drying may take around 4 to 8 hours at 50 degrees Celsius.

2.10. The tiles are removed from the moulds and stacked vertically, back to back with every tile front facing another tile front but separated from it using a special spacer element. This spacer element may comprise a simple plastic rod comprising plastic spacers as shown in FIG. 2b. FIG. 2b shows a number of tiles (220) which are now de-moulded and stacked vertically. The flat back surfaces of the tiles are positioned back to back and the stone simulated surfaces are facing each other. A spacer means (221) comprising a plastic inverted U shaped rod is used to keep the tile surfaces apart and to assist with their drying by improving the air circulation to the tile surfaces.

The spacer means (221) comprises plastic spacer elements, here shown as plastic spheres (222) although any shape of spacer element may be used. The width W of the spacer means (221) is chosen to match the thickness of two tiles and half the diameter of the spacer element (222). Different widths W are selected for the spacer means (221) to accommodate tiles of different thicknesses.

The tile spacer means (221) and the spheres (222) may be manufactured of polypropylene. For tiles of changing thickness, such as a tapering tile (225), the spheres (224) may comprise movable spheres which can slide up and down the rod element, wherein the rod is circular in cross section, and spheres of different diameters may be used.

In this way, the use of spacer elements such as movable spheres of different diameter makes possible the creation of a spacer means which can serve to space out tiles while drying which comprise different or variable thickness. With reference now to FIG. 3, therein is shown a sequence of steps to create a tile mould for a stone-simulated paving cladding tile according to the current invention.

3.01. First identify a natural stone surface of the desirable stone texture and coat it with a release agent. 3.02. Make a mould of the surface of the stone using a mould making technique such as with fibreglass matting and resin. By building up many layers of resin and matting a fine impression is created of the stone surface.

3.03. The resin matting stone imprint, which is essentially flat is laid out upon a suitable mould-making surface and a frame of precise dimensions (height and internal length and breadth) is formed upon the matting surface mould. In this way a tile master mould is created which comprises vertical sides and a surface comprising the stone-simulated effect from the imprint mould at the base of the tile master mould.

3.04. The inner surfaces of the tile-master mould are painted with release agent and then the mould is filled with a strong concrete mix to form a mould-making tile.

3.05. The master tile is then dried in a drying room and extracted from the mould and fully hardened by further drying.

3.06. When dry, the tile master is then chiselled along its edges to create a weathered look while care is taken not to damage the four vertices of the tile which define its base dimensions. The surface edges of the tile are also bevelled to assist with de-moulding.

3.07. When the mould-making tile is finished it comprises the surface of a stone tile and a weathered set of edges and bevelled surface edges with its base vertices at precise separations to assist with adjacent tile alignment. 3.08. The tile master is then fully coated with release agent and then layers of fibreglass matting and resin are used to create many tile moulds from this master tile. Each of the tile moulds produced in this way forms a mould for the paving cladding tile production process. In FIG. 4a is shown one type of paving cladding mould which can be used to create a paving cladding tile with an extended front edge.

The mould (401) comprises a movable section (402) which moves around an axis (403) to create a space for the tile concrete composite mix. The movable section (402) has a baton (405) which comprises a specific height such that the thickness of the movable section (402) and the height of the baton (405) define the amount by which the tile will extend on its lower edge.

The stone-simulated effect of the tile is created from a surface mould (407) which covers the bottom and extends up the front face of the tile mould (401).

The movable section (402) may be further secured in place by the provision of extended arms (404) which may comprise locking means to prevent the movement of the movable arm while concrete is poured into the mould.

AH manner of locking means may be employed such as a baton (409) which lies over the extended arms and which may itself be hinged to the side of the frame. The extended arms may be semi-permanently locked down to the frame edge using screws or the like or a clamp like fastener may be used. To assist with understanding the image, the baton (409) is not shown in the lower figure.

The baton (405) may comprise a separate movable spacer element which can be slotted into the space between the moveable section (402) and the extended arms (404). In this way batons of different heights may be used with the same mould structure. The extended arms (404) may correspondingly comprise a baton securing means (408) such as screws which can be firmly locked to the moveable section and which pass through corresponding holes within the baton. In this way, the securing means (408) can be removed, the baton can be replaced, and the securing means refastened. Appropriate adjustments are then made to the front edges of the extended arms so that they rest upon the side edge of the mould (401) in relation to corresponding adjustments in height made to the baton locking means (409).

Concrete (406) is poured into the mould and the mould is moved to the drying room. Due to the presence of the moveable section (402) additional care is needed to ensure that the tile composite is sufficiently hard to maintain its form, before the section is opened.

With reference to FIG. 4b is shown an alternative tile mould suitable for a wall topping tile. The inner surface of the mould comprises a stone-effect moulding on its lower surface and on its two vertical sides.

The mould (401) comprises a moveable element (402) which moves around an axis (403) and a front extended edge (410) which closes against the left had side of the mould a shown. The mould comprises two baton structures (411) which provide the vertical edges to the mould so that a tile similar to that shown in FIG. Ic may be manufactured. Concrete (406) is poured into the mould along its open sides to create the wall topping tile. In the lower part of FIG. 4b is shown a variant of the tile mould which uses the extended arm means of FIG. 4a. This mould provides the means to form stone- effect wall tiles which will be placed at the end of a wall section, thereby enclosing three sides of the brick wall with a cladding wall-topping tile. This mould comprises an additional front baton (413) and three extended arms (412) which are locked to the left hand side of the mould as shown.

With reference now to figure 5, is shown the elements of a tile cladding project management software tool which can be used to plan and implement paving cladding projects according to the current invention. The software program works with reference to a database containing all of the tile types and sizes and thicknesses and their suitability in different applications. In using the program, the user is asked to define the project type, whether it is an interior or exterior project. In the instance that the project is exterior, the user is then asked to specify whether the project is paving cladding, or paving replacement, or new paving, whether it is a patio, or a\ driveway, or a larger project such as a pedestrian precinct or a roof of a building.

In the instance that the project is interior, the user is asked to specify whether it is for a restaurant, or a conservatory, or a conference centre, or for a corridor.

The user is then presented with an onscreen map and is asked to define, using a mouse, the vertices of the area to be covered and to input the measurements of the area. The user is also requested to input the boundaries of the area, including boundary type, such as wall or grass etc., and also to indicate the locations and dimensions of metal inspection covers. It may be possible to cover the metal inspection covers with existing standard size tiles. The user then specifies the paving design such as whether it is to be fully random or symmetrical.

Finally, the program asks for data about the surface, what it is made of and whether it is uneven. If the surface to be tiled is even, such as when cladding a newly laid surface of concrete flagstones, an adhesive may be used such as Pink Grip. Alternatively, if the surface is very uneven, it is better to use a mortar such as four parts sand to one part cement.

By working from the boundary conditions this program is very effective in determining the best tile design to fit the available space.

The program then calculates the best tile design using the tile types available and specifies the following data: number of tiles required of a particular size, shape, colour and thickness, the amount of fixing adhesive (such as Pink Grip) required, the amount of pointing compound required, and the sizes of any special tiles which need to be cut or shaped to fit over inspection covers.

The user is presented with a map showing where specific tiles are to be laid and an estimate of the time to implement the project and the cost of all the materials needed.

The system and method for a paving cladding solution has been described with reference to the examples given and the objectives of different embodiments of the invention. The substantial advantages of this technology are particularly in the significant savings that this paving cladding method brings to the construction industry. Labour costs of production are significantly less. Due to the higher strength and reduced thickness of the tiles, significant workshop overheads are saved due to a much higher number of tiles that can be stored in the drying room. IN addition, the speed of drying is increased. There are significant savings on transportation due to the increased number of tiles per unit weight that can be moved. The packaging and pallet costs are significantly reduced.

The method is easy to use and does not require heavy lifting equipment or heavy duty cutting tools. As described above, the present invention can be created in diverse forms. It should be understood however, that the present disclosure is for the purpose of illustration only and does not include all modifications or improvements obvious to the man skilled in the art which may fall within the scope of the appended claims.

Claims

Claims:

1. A paving cladding tile (101, 102, 103) characterised by: precise base measurements, wherein said base of said paving cladding tile (101, 102, 103) being flat for facilitating the placement of said paving cladding tile (101, 102, 103) or the covering or replacement of existing paved area or the covering of indoor or outdoor walls or of ceilings or roofs, or for forming a wall topping tile (103) being fixed by mortar (105), and/or a natural stone-simulated surface achieved by a moulding process either of a stone imprint, or by creating a master tile further comprising modified sides in order to create a weathered effect, and a constant reduced thickness (H) wherein H has one of a plurality of values ranging from 25mm to 8mm and wherein said constant thickness (H) slightly varying in height due to the surface irregularities captured by said moulding process, or wherein the thickness of said paving cladding tile (102) further forming a taper where on a side (AD) said height being H and on the other side (BC) said height being h wherein H>h, wherein said reduced height for reducing the storage space and the lifting and transportation means of said paving cladding tile (101, 102, 103), and/or bevelled edges wherein said edges being slightly moved inward for facilitating the demoulding of said light paving cladding tile (101, 102) , and for ensuring a perfect alignment of a plurality of adjacent tiles of said light composite mix paving cladding tiles (101, 102), and an optimised composite mix rendering said paving cladding tile (101, 102, 103) thin (2 cm), light and strong and further making said paving cladding tile (101, 102, 103) safer to lay and durable and easy to precisely cut, and/or suitable for under-floor heating.

2. A paving cladding tile (101, 102, 103) according to claim 1 wherein said paving cladding tile (101) having a H= 20mm thickness being made of a composite mix with a ratio of 66% sand to 33% cement, and said composite mix paving cladding tile (102) forming a taper [from H=20mm to h=10mm] around a doorway being made with a ratio of 50% sand to 50% cement, for allowing both of said composite mix paving cladding tile (101), and said composite mix paving cladding tile (102) forming a taper, to resist up to a 30 tonnes weight vehicle driving over said composite mix paving cladding tile (101) or said composite mix paving cladding tile (102) forming a taper.

3. A method of manufacturing paving cladding tiles (101, 102, 103) being characterised by the step of making a composite mix wherein said step of making a composite mix further comprising: i. combining the sand and cement according to a specific ratio adapted to a desired strength, wherein said ratio being 66% sand to 33% cement for a paving cladding tile (101) having a thickness of 20mm and 50% sand to 50% cement for a tapering paving cladding tile (102) from 20mm to 10mm in thickness for resisting a 30 tonne vehicle driving over said paving cladding

stacking said paving cladding tile (101, 102) vertically, back to back, separating said paving cladding tile (101, 102) by means of spacer means (221, 223).

6. A method of manufacturing paving cladding tiles (101, 102, 103) according to claim 5 wherein said tile surface enhancing mix being composed of 75% cement, 25% sand, 10% of the weight of the cement used in the total mix (or equivalent cement volume, ECV) of cement dye, 0.5%-1.5% ECV sealant, 0.5% to 2% water reducing agent, and water which is added in an amount equivalent to 10% of the total mix taking into account the moisture content of the sand, and wherein said step of drying horizontally said paving cladding tiles (101, 102) lasting for 4 to 8 hours at 50 degrees Celsius for tiles of 10mm to 20mm thickness, and wherein said spacer means (221, 223) comprising a plastic inverted U shaped rod for keeping the surfaces of said paving cladding tiles (220, 223) apart and for improving the air circulation, wherein said spacer means (221) further comprising plastic spacer elements (222, 224), said plastic spacer elements (222, 224) being in the form of plastic spheres, and wherein the width W of the spacer means (221) is chosen to match the thickness of two tiles and half the diameter of the spacer element (222) and wherein said paving cladding tile spacer means being made of polypropylene.

7. A method of manufacturing a paving cladding tiles mould for stone-simulated paving cladding tiles (101, 102,103) characterised by the steps of making a tile- master further comprising the steps of; i. coating a natural stone surface of the desired stone texture with a release agent, ii. making a mould of the surface of the stone by using a fibreglass matting and resin, and creating a fine impression of the stone surface by building up a plurality of layers of resin,

Hi. laying out upon a suitable mould-making surface a flat resin matting stone imprint, and forming a frame of precise dimensions (height and internal length and breadth) upon the matting surface mould, and creating a tile- master mould wherein said tile master mould comprising vertical sides and a surface comprising said stone-simulated effect from the imprint mould, iv. coating the inner surfaces of said tile-master mould with a release agent, and filling said mould with a strong concrete mix in order to form said tile-master or mould-making tile.

8. A method of manufacturing a paving cladding tiles mould for stone-simulated paving cladding tiles (101, 102, 103) according to claim 7 further comprising the step of making a tile mould from a tile master for a production process wherein said step of making a tile mould for production process further comprising the steps of: v. drying said tile master in a drying room in said tile-master mould, and further extracting said tile master from said tile-master mould, and further drying said tile master for fully hardening said tile master until completely dry, and/or vi. chiselling said tile master along its edges for creating a weathered look and leaving the 4 vertices defining the base dimensions of said tile master intact for further allowing a precise adjacent tile alignment of further tiles made upon said master tile, and lightly bevelling the surface edges of said tile master for facilitating the de- moulding of further tiles made upon said master tile, and vii. coating said master tile with a release agent, fabricating a plurality of said tile moulds from said master tile for the paving cladding production process using layers of fibreglass matting and resin.

9. A paving cladding tile mould (401) for stone-simulated paving cladding tiles (101) with an extended front edge characterised by: a movable section (402) moving around an axis (403) in order to create a space for the tile concrete composite mix (406), said movable section (402) further comprising a baton (405) wherein the thickness of said movable section (402) and the height of said baton (405) defining the amount by which said paving cladding tile will extend on the lower edge of said paving cladding tile, a surface mould (407) covering the bottom and extending up the front face of said tile mould (401) for creating said stone-simulated effect, extended arms (404) in order to secure in place said movable section (402) and locking means (409) for preventing the movement of said extended arms (404) while concrete is poured into said paving cladding tiles mould (401).

10. A paving cladding tile mould (401) for stone-simulated paving cladding tiles (101) with an extended front edge according to claim 9 wherein said baton (405) further comprising a separate movable spacer element slotted into the space between the moveable section (402) and the extended arms (404) for allowing batons of different heights to be used with the same mould structure, and/or said extended arms (404) further comprising a baton securing means (408) such as screws for firmly locking said moveable section (402), allowing said securing means (408) to be removed, said baton (405) to be replaced, and said securing means (408) to be refastened.

11. A wall topping tile mould (401) for a stone-simulated paving cladding tiles (103) characterised by: a moveable section (402) moving around an axis (403) and a front extended edge (410) closing against the left hand side of said mould (401) two baton structures (411) providing the vertical edges to said mould (401), a surface mould covering the lower surface and said two vertical edges for creating a stone-simulated effect, an additional front baton (413) and three extended arms (412) in order to secure in place said movable section (402), wherein concrete (406) is poured into the mould along its open sides.

12. A paving cladding tile project management software tool characterised by: a software design application, a database comprising concrete mixes, fibre strands types, experimented mix ratios with their strength and elasticity and other characteristics, sealants, concrete dyes, tile types, and sizes and thickness and their suitability in different applications, said software tool defining, according to said project, the best tile design using the tile types available in said database and further specifying;

- the number of tiles including papers and special shaped tiles required of said particular concrete and/or fibre mix ratio, size, shape, colour and thickness

- the amount of fixing adhesive (Pink Grip) required,

- the amount of pointing compound required,

- the sizes of any special tiles which need to be cut or shaped in order to fit over inspection covers,

- the time to implement said project,

- the cost of all material needed.

13. A paving cladding tile project management software characterised by the steps of: i. defining a project type, ii. if said project type is interior, defining if it is: a paving cladding or a paving replacement or a patio or a driveway or a pedestrian precinct or a roof, iii. if said project type is exterior defining if it is: a restaurant or a conservatory or a conference room or corridor, iv, defining the layout of the area to be paved:

1. drawing the total area as a set of vertices upon a map

2. indicating the boundaries and obstacles and location of metal covers and/or all other irregularities of said area v. specifying a paving design vi. specifying if or where said area surface is uneven vii. calculating the best tile available and specifying the following data:

- number of tiles required of each size,

- amount of fixing adhesive and pointing compound required,

- the sizes of any special tiles for drain covers or other special tiles needed viii. generating a tile map indicating:

- where the different tiles are to be laid

- the cost of the materials

- the estimated time to implement the work wherein said paving cladding tile project management software is interactive comprising multiple choices from a database and is highly suitable for internet sales.