Patent ID: 8591788

Claim:
A method of forming a hollow composite construction member of the type suitable for use as building material, the method comprising: providing an elongated inflatable mold assembly having a longitudinal axis, and further having: a flexible, substantially tubular bladder wall defining an elongated inflatable cavity, wherein the cavity is movable between a deflated condition, an inflated condition, and a plurality of partially inflated conditions; reinforcing fabric positioned concentrically around the flexible bladder wall; and a flexible air-impervious outer layer positioned concentrically around the fabric, with the bladder wall and the outer layer defining an elongated annular space, with the fabric being positioned within the space; inserting a flexible, substantially tubular intermediate member within the elongated annular space between the reinforcing fabric and the tubular bladder, wherein the intermediate member is a shear transfer member that includes a body formed as an array of elongated members and spaces between the elongated members; introducing a fluid into the cavity to at least partially inflate the mold and shape the fabric; bending the mold assembly along the longitudinal axis to a curved shape; infusing the elongated annular space and permeating the fabric with a rigidification material; and hardening the rigidification material to form a rigid hollow composite construction member.