Patent ID: 7811495

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; a reinforcing fabric positioned concentrically around the flexible bladder wall, wherein the fabric is one of a flexible braided and flexible woven fabric; 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; applying tension in a longitudinal direction to the fabric and 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 while maintaining the fabric under tension; infusing the elongated annular space and permeating the fabric with a rigidification material; and hardening the rigidification material while maintaining the fabric in tension to form a rigid hollow composite construction member.