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DJP Patent Mobile Organic Composite Climbing Wall

  • Friday, 27th May 2005
  • Reading time: about 3 minutes

DJP Espace Composites from France have patented the design of a mobile climbing wall made from organic composite materials.

DJP exhibited the composite climbing wall at the JEC composites show in Paris, but have been awaiting the patent before promoting its novel composite structure.

The high performance composite materials manufacturer designed a climbing wall made entirely from organic composite materials consisting of modular panels and featuring natural grips weighing only 50kg.

The wall, “vertige”, is rigid and light and can be fitted on a trailer and transported to any location, with their typical 8 metre high, 6 metre wide wall demonstrated at JEC weighing only 450 kg. The standard dimensions for each 50kg panel are 2 metre by 2 metre.

The manufacturing process of the panels, also patented, is according to the company, based on original technology which consists of polyurethane foam which is injected in situ inside two skins made in GFRP made using wet lay up process.

Each panel can be rotated 90 degrees, in its plane, giving a new appearance to the wall with the infinite tracks to be discovered. As an additional option, there are ropes attached to the back of the wall for additional climbing exercises.

Various studies area in progress prior to the product being commercialised at the end of the months. This involved a series of technical tests which started at the beginning of the year with approval being granted only recently.

DJP’s Organic Composite Wall

The company have developed three walls. The standard model which is the mobile version of the wall. This wall is composed of 8 modular composite panels and two composite half corner panels. The panels are fitted on an aluminium structure, with the stiffness of each panel contributing to the rigidity of the overall structure.

The standard model presents a front track and two side tracks which are automatically bent back the front one for moving equipment. The folded wall is installed on a trailer which can be moved by any vehicle of 3500 kg trailing capacity. The operation of the standard model is fully automated and takes les than an hour to assemble. All the elements of the wall are controlled by twin hydraulic pistons which are supplied by hydraulic pump and an electrical generator set installed on the trailer.

The combined model version combines a standard model and rope exercises. These exercises are installed on the back of the erected wall. During transportation, the different rope equipments are set in a large trunk case fitted on the trailer. The different exercises are monkey bridges, Rope ladders, etc…

The fixed model. The modularity of the panels offers the capability to be set on any structure, in any place, in infinite quantities, in order to create any height of wall required. The set up of a large quantity of panels provides an attractive sight and a duplication of Nature including sloping, overhanging and vertical faces.

The company forecast small production of walls with around 5 climbing walls being produced in 2006, and 10 to 20 climbing walls for year 2007, but accept that as the sport and leisure market is growing fast these may be underestimated.

The wall was also nominated for the JEC Sport and Equipment Award.

Founded in 1996, DJP is a fast growing French SME with 18 staff and an annual turnover of 1,5 million Euros. The company have offices in Vitry-sur-Seine, in the South of Paris. Since 1979 DJP has been involved in the development of manufacturing processes and in the production of monolithic hollow structures in composite materials.

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