Con with Iron or Steel, and Apparatus or Means Employed in Moulding such Materials or Compositions.
Year: 1886

page_text: Date of Application, 2nd Feb., 1886.
Complete Left, 2nd Nov., 1886.
Complete Accepted, 5th Jan., 1887.
either Alone or in Conjunction with Iron or Steel, and Apparatus
or Means Employed in Moulding such Materials or Compositions.
I JAMES WILLIAM BUTLER of Blyth House Humber Road, Blackheath in the
County of Kent, Civil Engineer, do hereby declare the nature of this invention to be
as follows:-
My invention relates to materials or compositions adapted for use for making roads
or footways either in the form of paving blocks, or laid down in mass in a similar
manner to any other of the mastic materials used for this purpose, also as railway
sleepers, for water, sewer or other pipes, for receptacles for electric wires or cables
when laid underground, and for other purposes, the said materials or compositions
being either used alone, or, where great strength is required, in conjunction with iron
or steel.
In carrying out my Invention I use the following ingredients in say about the
undermentioned proportions, which however may be varied according to circum-
stances viz. —
Trinidad Bitumen
Crude parafine
D
Compound silicate of Lime and Alumina
(commonly called Portland Cement)
Aylesford
or similar Sand or finely
powdered Limestone
Roughly pulped wood
Taranaki Sand
916
*
lbs. ozs.
15 0
12
6
0
0
8
88
The bitumen and parafine are first mixed together and boiled for say about an
hour, and the pulped wood is then gradually added; after which the mixture previously
prepared of the, compound silicate of Lime and Alumina (Portland Cement) the
Price 8d.1

page_text: Aylesford or other sand or finely powdered Limestone, and the Taranaki sand, 18
gradually worked in.
In some cases the Taranaki sand may be dispensed with.
In place of pulped wood, tan yard waste may be used where it can be readily
obtained; and for certain purposes, as for example for water, sewer or other pipes, I 5
may substitute for the pulped wood, finely sifted sawdust, in which case I prefer to
use say double the quantity above indicated of portland cement for the proportions
above given of the other ingredients.
When the material or composition is employed in the form of paving blocks, it may
be made into the size of the ordinary blocks used for roadways by any one of the
machines ordinarily used in the manufacture of artificial fuel. Paving blocks made
of this material or composition possess great advantages over wooden blocks, being
better adapted for withstanding heavy traffic, more uniform, not liable to split, and
not slippery, whilst when taken up they may be utilized in making fresh blocks.
When the material or composition is used for roadways or footways laid down in 1
mass,
it will be more durable than the other mastic materials ordinarily used, it not
wearing away from attrition to so great an extent as the latter.
'
In hot climates where wooden sleepers are much subjected to the attacks of the
white ant, the material or composition is admirably adapted in conjunction with iron
or steel in making an imperishable sleeper. The iron or steel may be used as a core
consisting of a bar bent round at right angles at its two ends and entirely imbedded in
or surrounded by the material or composition, so as to form a vertical web extending
throughout the greater part of the length of the sleeper, but horizontal at the parts
: beneath the rails. The iron or steel being thus imbedded in the materials or com-
position is protected from the injurions action of the atmosphere in hot climates, and
the material or composition is by the stiffening of the iron or steel enabled to stand
the great shocks of heavily laden trains without injury.
In the case of water, sewer or other pipes, I adopt any of the well known modes of
making pipes. The pipes produced from this material or composition possess con-
siderable strength and are well adapted for bearing great strains either externally or
internally.
When the material or composition is used for receptacles for enclosing electric wires
or cables when laid underground, it is moulded in the form of blocks perforated with
any required number of holes, in which the electric wires or cables are laid, and the
blocks are made horizontally of a considerable length so as to reduce the number of
joints. For this purpose, I use a peculiarly constructed mould or case of the diameter
required for the outside of the block, and hinged at say the centre and if required
higher up so as to admit of the case being built up as the ramming in of the material
or composition proceeds, until the top is nearly reached, a slit being then left for
ramming in the last portion. The ends of the mould are formed by plates having
holes through which the cores or mandrels for forming the perforations in the blocks
are passed, the ends of the cores or mandrels being thus supported by these end
plates. Each mandrel may be enclosed in a cylinder of prepared bituminous cloth or
bituminous paper which enables the mandrel to be withdrawn easily as soon as the
block is formed.
In some cases, longitudinal iron or steel rods or T irons may be inserted in the
mould so as to be imbedded in the material or composition, this arrangement being
particularly suitable where great lengths and extra strength are required. The blocks
may be connected together with spigot and faucet joints as in the ordinary drain pipe,
or by butt joints, slight depressions and corresponding projections being made in the
opposite ends of the block so as to ensure the proper alignment of the holes through
which the cables are to pass. These depressions and projections may be conveniently
made by means of corresponding projections and depressions provided on the end
plates of the mould. In the case moreover of butt blocks, that is to say blocks
connected together with butt joints, I may provide short sockets of the same material
or composition slightly larger in their internal diameter than the external diameter of
the blocks; by placing one of these sockets over the ends of each two contiguous

page_text: blocks and then sealing the junctions with a molten preparation of the same material
or composition, a perfectly continuous block will be obtained.
Where blocks are to be formed on the curve, I employ for the mandrels jointed
cables or cores (of the diameter required for the inside of the holes) each enveloped
in a sleeve of prepared bituminous cloth or bituminous paper, the articulations in the
jointed cable or core admitting of its readily following the sharpest curve required.
Or I may use suitably prepared ropes or tempered wires working in sleeves as before
mentioned in substitution for the jointed cables or cores.
In providing perforated blocks or receptacles for belt electric cables, the mandrels
may be made of a square or other rectangular section, the cables being placed in the
holes in the blocks either vertically or horizontally; and the blocks themselves may be
made of a flat shape in lieu of cylindrical. The material or composition may also be
used for insulating bell cables.
If desired the blocks may be manufactured in situ thus saving carriage.
The perforated blocks may be vulcanized, or treated by the ordinary processes for
converting caoutchouc into vulcanite; and a similar treatment may be adopted when
the material or composition is to be used as an insulating medium for electrical
purposes, as also for door handles, finger plates, and other articles usually made of
bone, metal or wood.
THOS. J. HANDFORD,
50, Bedford Row,
London, W.C., Agent.

page_text: sand is gradually worked in whilst continuing to stir and maintain the whole at or
near the boiling point. The order or sequence in which the several ingredients are
introduced may be somewhat varied without detriment. For example, the pulped
wood may be introduced after the heated Aylesford Fontainebleau or other similar
sand or finely powdered Limestone is added to the boiling mixture of bitumen and
parafine, in lieu of before; but in all cases I have found it desirable to introduce the
mixture of compound silicate of Lime and Alumina (Portland Cement) and Taranaki
sand after the whole of the other ingredients have been intimately mixed together so
as to become thoroughly incorporated.
In some cases the Taranaki sand may be dispensed with. In place of pulped wood
I may use tan yard waste where it can be readily obtained, or finely sifted sawdust, in
which latter case I prefer to use say double the quantity above indicated of portland
Cement for the proportions above given of the other ingredients.
In moulding the material or composition for general purposes, it is introduced when
in a heated condition into moulds of the required shape and tamped down with hot
irons, and when sufficiently set the articles so made are removed from the moulds, and
will be ready for use.
When the material or composition is employed in the form of paving blocks, it may
be made into the size of the ordinary blocks used for roadways by any one of the
machines ordinarily used in the manufacture of artificial fuel. Paving blocks made
of this material or composition possess great advantages over wooden blocks, being
better adapted for withstanding heavy traffic, more uniform, not liable to split, are not
slippery, whilst when taken up they may be utilized in making fresh blocks.
When the material or composition is used for roadways or footways laid down in
mass, the operation is carried out in a manner similar to that adopted with the other
mastic materials ordinarily used for the purpose. This material or composition will
however be more durable, it not wearing away from attrition to so great an extent as
the ordinary mastic materials used for roadways or footways.
In hot climates where wooden sleepers are much subjected to the attacks of the
white ant, the material or composition is admirably adapted in conjunction with iron
or steel in making an imperishable sleeper. The iron or steel may be used as a core
(inserted in the mould in the operation of moulding the sleeper) such core consisting
of a bar bent round at right angles at its two ends and entirely imbedded in or surrounded
by the material or composition, so as to form a web which is vertical throughout the
greater part of the length of the sleeper, but horizontal at the parts beneath the rails.
The iron or steel being thus imbedded in the material or composition is protected from
the injurious action of the atmosphere in hot climates, and the material or com-
position is by the stiffening of the iron or steel enabled to stand the great shocks of
heavily laden trains without injury.
In the case of water, sewer or other pipes, I adopt any of the well known modes of
making pipes. The pipes produced from this material or composition possess con-
siderable strength and are well adapted for bearing great strains either externally or
internally.
When the material or composition is used for receptacles for enclosing electric wires
or cables, it is moulded in the form of blocks perforated with any required number of
holes, in which the electric wires or cables are laid; and the blocks are made horizon-
tally of a considerable length so as to reduce the number of joints. For this purpose,
I use a peculiarly constructed horizontal mould or case formed of jointed sections and
end plates carrying cores or mandrels covered with sleeves of prepared bituminous
cloth or bituminous or other paper.
Both the blocks and their internal holes may be of a circular, square or other
suitable section according to circumstances and the exigencies of the purpose to which
they are to be applied the shape of the mould and of the cores or mandrels being
modified accordingly.

page_text: .
I have shown in the accompanying drawings two examples of perforated blocks or
receptacles and of moulds or cases for manufacturing the same but obviously other
modifications may be employed.
Figures 1 and 2 of the accompanying drawings illustrate a block of a circular
section having five holes also of a circular section, Figure 1 being a central longitudinal
section and Figure 2 an end elevation of the same; Figures 3 and 4 illustrate a block
of a square section having four holes of a circular section, Figure 3 being a longitudinal
section taken along the line 1-2 (Figure 4) and Figure 4 an end elevation of the same.
Figures 5, 6 and 7 represent the mould or case for manufacturing the block Figures
1 and 2, Figure 5 being a longitudinal sectional elevation and Figures 6 and 7 trans-
verse vertical sections taken respectively along the lines 3-4 and 5-6 (Figure 5).
Figures 8, 9 and 10 represent the mould or case for manufacturing the block
Figures 3 and 4, Figure 8 being a longitudinal sectional elevation and Figures 9 and
10 transverse vertical sections taken respectively along the lines 7-8 and 9-10
(Figure 8).
Referring to Figures 5, 6 and 7 the mould or case consists of the body (carried on
the base B) and the end plates CC. The body of the mould or case is composed of
any required number of sections or divisions k, l, m, n, o, p the consecutive sections
being hinged or jointed together at 5, 6, 7, 8 and 9 respectively and the upper ones
m, n, o, p built up as the operation of ramming in and tamping proceeds.
narrow space q is left between the free ends of the sections o, p, for the ramming in
of the last portion, the sections o, being held together by clips arranged at inter-
vals along the length of the mould.
The
To the base B is secured vertical pins d d with which engage sockets e e¹ carried by
the end plates C C (or the sockets may be carried by the base and the pins carried by
the end plates if preferred) for maintaing the vertical position of the ends of the
mould. D, D are the cores or mandrels covered with sleeves of prepared bituminous
cloth or bituminous or other paper and supported in holes in the end plates C, C¹.
shews a depression in the end plate C and a projection on the end plate C¹ for
forming engaging projections and depressions on and in the blocks so as to ensure the
proper alignment of the holes through which the wires or cables pass.
In the operation of moulding the perforated blocks with the aid of this apparatus,
the lower part of the mould is closed, the upper jointed sections being open during the
first part of the operation, and the end plates are placed in position. A portion of
the bituminous composition is then introduced in a heated condition and tamped down
with hot irons until the place for the lowermost mandrel is reached, when it is intro-
duced through the hole designed for it in one of the end plates and passed along until
its further extremity rests in the corresponding hole of the other end plate, the mandrel
being thus supported at its opposite ends by the said end plates. A further quantity
of the composition is then introduced and tamped down as before, and another row of
mandrels is inserted, and more of the composition is introduced and tamped down, and
so on in succession, the jointed sections of the mould being built up as required, as
before explained, until the top of the mould is reached, when the upper surface is
smoothed off with any convenient instrument. Or the mandrels may be placed in
position first, and the composition then introduced and rammed down with hot irons
beneath, between and above the mandrels until the mould is full, when the upper surface
is smoothed off as before. When the composition is sufficiently set the mould con-
taining the moulded block is removed bodily from the base and may be immersed in
cold water, after which the mandrels are withdrawn (the sleeves of bituminous cloth
or bituminous or other paper with which they are surrounded facilitating their with-
drawal) the end plates are removed and the upper hinged sections turned down and
the perforated block is liberated from the mould.
The perforated block formed by the mould Figures 5, 6 and 7 is represented in
Figures 1 and 2, F being the body of the block, g the holes for the wires or cables, i a
praigation on one and and 1 dan
L

page_text: Referring to Figures 8, 9 and 10 the mould or case consists of the bottom A
(carried on the base B) the sides a a¹ hinged or jointed at 1, 2 to the bottom A, and
the end plates C, C', the top being by preference left uncovered. The hinges bb¹ of
the sides a al are provided with pins 3, 4, respectively, with which engage holes in the
tie bars c.
The small core E is provided to form a longitudinal space for the reception of any
water which may accumulate beneath the blocks when laid in the ground and which is
thus prevented from rising into the holes for the wires or cables. The arrangement is
otherwise similar to that of Figures 5, 6 and 7 and requires no further description.
In the operation of moulding the perforated blocks with the aid of the apparatus
Figures 8, 9 and 10, the hinged sides of the mould are closed and rigidly secured by
the tie bars, and the end plates are placed in position. The cores or inandrels are
inserted and the composition introduced and tamped down in the manner before
explained with reference to the arrangement Figures 5, 6 and 7.
Figures 3 and 4 represent the perforated block formed by the mould Figures 8, 9
and 10. being the safety water space.
It is obvious that the block shewn in Figures 1 and 2 may also be formed with a
safety water space by adding a small core E to the mould or case Figures 5, 6 and
7, space being provided therein for its reception. The blocks may be connected
together in various ways; in the examples illustrated butt joints are employed, a
slight depression and corresponding projection being made in the opposite ends of the
block as before explained so as to ensure the proper alignment of the holes through
which the cables are to pass. The projection of one block is caused to engage with
the depression in the contiguous block, and an efficient junction is obtained by sealing
the engaging projections and depressions of the blocks with a molten preparation of
the same composition, but, if necessary, I may employ in addition short sockets of the
same composition slightly larger in their internal diameter or dimensions than the
external diameter or dimensions of the blocks; one of which sockets is placed over the
ends of each two contiguous blocks and the junction sealed with a molten preparation
of the same composition, whereby a perfectly continuous block will be obtained.
In some cases, longitudinal iron or steel rods or bars or Tirons may be inserted in
the mould so as to be imbedded in the material or composition this arrangement being
particularly suitable where great lengths and extra strength are required.
If desired the perforated blocks may be manufactured in situ thus saving carriage.
When the perforated blocks made of this material or composition and other similar
articles are required to be formed on the curve, they may be moulded in a rectilinear
form and bent when in a warm condition so as to follow the sinuosities of the curva-
ture desired.
Having now particularly described and ascertained the nature of my said Invention,
and in what manner the same is to performed, I declare that what I claim is :-
1. The new or improved materials or compositions which consist of
(a) Trinidad or other Bitumen.
Crude or other Parafine.
Compound silicate of Lime and Alumina (commonly called Portland
Cement).
(d) Aylesford sand, Fontainebleau sand, or similar sand, or
finely powdered Limestone, and
(e) roughly pulped wood, or
sawdust, or tan yard waste,
in conjunction or not with
(Taranaki sand,

page_text: 2. In moulding or forming horizontally, perforated blocks or receptacles of a
bituminous inaterial or composition such as herein described, for containing electric
wires or cables, the horizontal moulds or cases formed of jointed sections, and end
plates carrying cores or mandrels covered with sleeves of prepared bituminous cloth
or bituminous or other paper, substantially as hereinbefore described.
3. A Railway sleeper constructed of a bituminous material or composition, such as
herein described, with an internal core of iron or steel forming a web which extends
vertically throughout the greater part of the length of the sleeper but is horizontal
at the parts beneath the rails, substantially as hereinbefore described.
THOS. J. HANDFORD,
50, Bedford Row,
London, W.C., Agent.