Support structure

Abstract

A support structure comprising a composite material, wherein the composite material comprises at least 50 weight % of hemp derived material; and at least 15 weight % of resin. The material may be melt

Description

FIELD This invention relates to a support structure, in particular support structures comprising a renewable biomass. BACKGROUND The construction and building industries are responsible for the depletion of large amounts of nonrenewable resources and for the emission of high levels of carbon dioxide. Conventionally, the construction industry heavily relies on light gauge steel elongate studs for framing in building structures. These steel studs provide structural support and form the framework for walls in various types of constructions, from residential buildings to commercial structures. Steel is favoured because of its strength, durability, and ease of use. However, steel production is energy-intensive and steel products, such as steel studs, have high levels of embodied carbon. Embodied carbon is the carbon dioxide emitted in producing materials, and is estimated from the energy used to extract and transport raw materials as well as emissions from manufacturing processes. Further, building materials, including steel, are often disposed of at the end of their life thereby producing waste. As governments and industries increasingly focus on sustainability, there is a growing demand for alternatives that can reduce the embodied carbon in construction materials and for achieving a more sustainable construction industry, in which building materials can be reused or recycled efficiently. However, it is challenging to find alternative building materials, and in particular alternatives to steel studs, that are environmentally friendly and possess comparable or superior structural properties such as strength and durability. There is a need for improved support structures for use in the construction industry. SUMMARY The present invention provides a support structure comprising sustainable bio mass mixed with a resin. For example, the support structure may be an elongate structure with a substantially C-shaped cross section for use in the construction industry. Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. The detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended to be given by way of example only. In a first aspect of the invention, there is provided a support structure comprising a composite material, wherein the composite material comprises: at least 50 weight % of hemp derived material; and at least 15 weight % of resin. Plant based natural materials are low cost renewable materials which can be found in abundant supply in many countries. Hemp is a plant in the botanical class of Cannabis sativa cultivars which may be grown specifically for industrial and consumable use. Hemp is a fast-growing resource, which removes carbon from the atmosphere by fixing carbon dioxide in the plant itself. Hemp grows in abundant supply in many countries, which advantageously limits transport costs and supply chain carbon emissions. The use of hemp advantageously contributes to the low embodied carbon and sustainability of the support structure of the present invention. In an embodiment of the invention, the hemp derived material may comprise hemp fibres and / or hemp shives. The hemp derived material may consist of hemp fibres and / or hemp shives. Hemp fibre (or tow) is the fibre which has been collected from the phloem (or bast) surrounding the stem of the hemp plant. Hemp shives (also known as shoves or hurd) are often a by-product of the hemp fibre production, and are the woody inner portion of the hemp plant stem, which may be chopped into pieces. The hemp fibre and hemp shives may be dried before use, for example by using heat and / or a vacuum. In an embodiment, the moisture content of the hemp fibre and hemp shives after drying may be between 1 and 15 weight % water, between 2 and 10 weight % water, or between 4 and 8 weight % water, and following the addition of the resin may be between 2 and 25 weight % water, 5 and 20 weight % water, or 9 and 12 weight %. In an embodiment of the invention, the composite material may comprise at least 50 weight %, optionally at least 70 weight %, optionally at least 80 wt %, optionally at least 85 wt %, and further optionally at least 90 wt%, of the hemp derived material. The hemp fibres have inherent mechanical strength and advantageously provide reinforcement support to the composite material. The hemp shives may be interspersed between the hemp fibres providing additional support and reinforcement to the composite material. Use of hemp shives in the composite material is also advantageous as the hemp shives are not discarded so there is less overall waste. In an embodiment of the invention, the composite material may comprise hemp fibres and hemp shives in substantially equal weight %. For example, the composite material may comprise 42.5 wt % hemp fibres and 42.5 wt % hemp shives, so that the total content of hemp derived material in the composite material is 85 weight %. The hemp derived material, including the hemp fibres and hemp shives, may be dried so that the hemp derived material has between 4 and 8 weight % water. There may be 15 weight % of thermoplastic resin. The use of equal weight % quantities of hemp fibres and shives in the composite material is advantageous because the density of shives interspersed between the hemp fibres provides excellent reinforcement to the composite material. In an embodiment of the invention, the hemp fibres may be arranged in random directions and distributed substantially homogeneously throughout the composite material. In this way, the elongate fibres provide excellent structural integrity, reinforcing support and strength in all directions to the composite material. Alternatively, in an embodiment, the hemp fibres may be arranged substantially in one direction and distributed substantially evenly throughout the composite material. In this way, the elongate fibres may provide more reinforcing support and strength in a particular direction. In an embodiment, the average length of a hemp fibre may be between 30 and 100mm, optionally between 50 and 80mm, and further optionally between 60 and 70mm. It is advantageous to use hemp fibres with an average length of between 30 and 100mm in the composite material, as fibres shorter than this minimum length provide lower levels of reinforcement in the composite material. The hemp shives may have an average length of up to 25mm, wherein the length is the longest measurement that can be measured in any direction. In an embodiment, the hemp shives are milled into pieces with an average longest length of up to 5mm, optionally up to 4 mm, and further optionally up to 3mm. In an embodiment, the hemp shives may have an average length of between 2 and 3mm. It is advantageous to use shives with an average longest length of up to 5mm, because shives larger than 5mm mix less readily with the resin. The shives may be distributed substantially homogeneously throughout the composite material. In this way, the shives are embedded in the polymer resin between the fibres providing bulk reinforcement and strength to the composite material. In an embodiment, the composite material may be constructed of two or more layers of composite material, in which a first layer may comprise a different plant based material and / or a different resin when compared to a second or further layer. The two or more layers may be stacked and bonded together using heat and pressure. The plant based material may include a particular part of a plant, such as the fibrous stem, which provides a particular type of support for the composite material. The particular plant based material and resin may be chosen depending upon the desired use of the composite material. In an embodiment, the support structure may comprise two or more layers of composite material, in which each layer substantially comprises either hemp fibres or hemp shives. In an embodiment, a first layer substantially comprises hemp fibres as the plant based material, and a second layer substantially comprises hemp shives as the plant based material. The resin used in each layer may be the same, for example AcForm® Power 2889 X (produced by BASF in 2024). The resulting composite material may be used to form an elongate support structure with a substantially C-shaped cross-section, in which the inside of the C-shape comprises the hemp fibre layer, and the outside of the C-shape comprises the hemp shives layer. In this way, the hemp fibres may provide excellent structural integrity to the innermost layer of the support structure, and the hemp shives provide strength. As herein disclosed, alternative sustainable materials may be used in combination with the hemp derived material or in place of the hemp derived material. For example, other plant fibres that could be used include coir, plantain, banana, bamboo, water hyacinth, flax, ramie, sisal and jute, and / or the bast fibres from wild plants, such as stinging nettles, and from trees such as lime, linden, willow, oak, wisteria, and / or mulberry. Optionally, other natural fibres may be used such as basalt fibres. For example, the composite material may comprise up to 40 weight % of hemp derived material and up to 45 weight % of a different plant derived material. Optionally, the different plant material may be coir. As herein disclosed, the composite material may comprise coir in place of the hemp derived material. In an embodiment, the ratio of hemp derived material to resin in the support structure of the present invention is from 98:2 to 60:40, optionally from 95:5 to 70:30, and further optionally from 90:10 to 80:20. Further optionally, the ratio of hemp derived material to resin in the support structure is about 85:15. The resin may be a thermoplastic resin. A property of thermoplastic resins is that they can be melted down again after curing. In contrast, thermoset resins retain their form and remain solid after curing. The glass-liquid transition, or glass transition, is the gradual and reversible transition in amorphous materials from a hard and relatively brittle "glassy" state into a viscous or rubbery state as the temperature is increased. The glass transition temperature (Tg) of the thermoplastic resin may be between 50°C and 250°C, between 55°C and 210°C, between 60°C and 170°C, between 65°C and 140°C, between 70°C and 110°C, or between 80°C and 100°C. Further optionally, the glass transition temperature of the thermoplastic resin may be between 85°C and 97°C. In an embodiment of the invention, the resin may comprise one or more selected from the acForm® resins (produced by BASF in 2024, including acForm® Power 2888 and acForm® Power 2889 X), ACRODUR® (BASF), MDI (melamine-urea-formaldehyde) resin, and transfurans PFA (perfluoroalkoxy copolymer) resin. In an embodiment, the resin may be any suitable thermoplastic resin, or the resin may be any suitable thermoset resin. In an embodiment of the invention, the resin may comprise a bio resin, and wherein the bio resin is derived from renewable biological sources. For example, the bio resin may be derived from renewable and sustainable agricultural crops and residual agricultural waste. In this way, the emissions are minimised during processing as well as in the final product, helping to promote sustainability, reduce embodied carbon emissions and to achieve a structure support product which is carbon neutral. In an embodiment, the bio resin is not obtained from fossil fuels. In an embodiment of the invention, the resin or bio resin may be substantially free from formaldehyde, which advantageously enables a safer working environment. The bio resin may be a low-emission, water-based alternative to traditional formaldehyde-based urea, melamine or phenolic resins. In particular, the bio resin may be formed from an aqueous solution of a modified polyacrylate, such as for example, acForm® Power 2888 or acForm® Power 2889 X (produced by BASF in 2024). In an embodiment, all registered materials disclosed herein conform to the product as manufactured on 1 January 2024. In an embodiment of the invention, the thermoplastic resin may be recyclable, and the composite material may be advantageously melted down and reformed into a new product, such as a new support structure. Ensuring that the support structure has a long life and can be efficiently recycled or repurposed at the end of its useful life helps to align with circular economy principles. In an embodiment, the composite material may additionally comprise one or more additives selected from biocides, pigments, surfactants, water repellents, antifoaming agents, intumescents, hardeners, and / or flame retardants to provide long-term structural integrity. The one or more additives may be simply mixed into the liquid resin before curing. Alternatively, the additive may be absorbed into the hemp derived material, or coated onto the hemp derived material in advance and before mixing with the resin. Advantageously, the additives may be mixed throughout the whole of the support structure. There is no need to separately coat the finished support structure with the additive (although this can also be done). In contrast, steel studs must have any additives sprayed on to the outside of a formed steel stud because steel is formed at very high temperatures and additives can harm the properties of steel. Advantageously, biocides may be used as an additive to help prevent rot, mildew or fungus, and resistance to pests or decay. Advantageously, water repellents may be used as an additive to increase weather resistance. Advantageously, the use of surfactants and antifoaming agents as additives may be used to improve the mixing of the resin with the hemp derived material. Advantageously, the use of pigments as additives may be used to provide a colour indicator of the weight % of hemp derived material in the composite material, or to indicate which other additives have been added to the resin. Further, pigments may be added for aesthetic reasons. The structure support may match or surpass the mechanical properties of traditional steel studs, such as strength and durability, and the acoustic and thermal properties of traditional steel studs. In an embodiment of the invention, the composite material has a physical property which is equal to or better than the same physical property in light-gauge steel, and wherein the physical property is selected from Young’s modulus, tensile strength, compressive strength, acoustic measurement (Rw), and / or thermal transmittance (U-value). For example, the composite material may have the following physical properties: Young’s modulus from 1.9 x 1011 N / m2 to 2.0 x 1011 N / m2 Tensile strength of 8.0 x 108 N / m2 Compressive strength of 250 MPa Acoustic measurement Rw (the weighted sound reduction index) is at least 45 dB Thermal transmittance (U-value) of less than 0.15 W / m2K The composite material is a lighter weight material than steel. Advantageously, the light weight support structure of the present invention may be easier to install in building applications, thereby minimising time and overall labour costs. For example, a 3.7m long steel stud with a substantially C-shaped cross section weighed 1.6kg, compared to the same length of a composite material stud with a similar C-shaped cross section, which weighed 1,2kg. The composite material is advantageously an electrical insulator, in contrast to steel. Therefore, the support structure of the present invention is beneficial as a steel stud alternative in situations in which an electrical conductor is undesirable. Advantageously, the composite material does not expand with heat, unlike steel, which will expand in length, surface area and volume with temperature. The composite material is inert to a broad range of chemicals, and so may be compatible with other building materials. Advantageously, the composite material will not corrode or rust, and so is a favourable alternative to steel in harsh environments, such as structures adjacent to marine environments. The composite material can be pressed into sheets of a desired thickness and molded and / or cut into many different shapes. Sheets of the composite material may be molded into the same shape as traditional steel studs. In this way, the support structure of the present invention is compatible with and will seamlessly integrate with existing construction systems. Advantageously, established construction practices can be maintained to allow for successful implementation in diverse construction projects. In particular, in an embodiment of the invention, the support structure may be used as a stud in the construction of buildings. Studs are elongate structures with a substantially C-shaped, a U-shaped, or optionally an H-shaped cross-section. The sheets of the composite material may be molded into the same profile as a traditional steel stud. For example, in an embodiment of the invention, the support structure may be an elongate structure with a substantially C-shaped, optionally a substantially U-shaped, and / or optionally a substantially H-shaped cross-section (see for example, Figure 1). The desired profile for the support structure may be achieved by bending the edges of the composite material sheet around a mold using heat and pressure. In an embodiment of the invention, the support structure may be a stud with a substantially C-shaped cross section, wherein the weight ratio of hemp derived material to resin is from 90:10 to 80:20, and wherein the hemp fibres and hemp shives are in substantially equal weight %. One support structure may be connected with another support structure, for example by splicing, to extend the length of the support structure. The support structure comprising the composite material may meet the relevant industry standards (as of 1 January 2024), such as EN13501-1 (which relates to a reaction to fire classification procedure for all construction products &building elements), BS6001 (which is an environmental and sustainability standard) and BS EN ISO 14001 (which relates to a standard used to assess the status of an organisation's environmental management system against defined requirements). The support structure of the present invention has the advantage that it may be adapted to not only meet current industry standards but also may be adaptable to future regulatory changes in the construction industry. The support structure of the present invention may be used for a support for walls in buildings, and also outside of the construction industry for packaging material, decorative panels, and / or fencing and fencing posts. The structural support may be used as a sustainable packaging material, through reuse and recycling. The structural support may be used in interior design. The ability to add colour and its sustainability makes the composite material suitable for interior or exterior design applications. The structural support may be used as an alternative to traditional materials in the manufacture of sustainable furniture, due to its eco-friendly and durable nature. The structural support may be used in the development of other sustainable structures, such as fencing and fencing posts. Further, as herein disclosed, the composite material may be formed into other structural shapes, such as panels, moldings, or other architectural features which are low in maintenance and have a high aesthetic appeal. In a second aspect of the invention, there is provided a process for making the support structure comprising the composite material according to the first aspect of the invention, comprising, mixing the hemp derived material and the resin to form a hemp-resin mix; applying heat and pressure to form a sheet of composite material; and allowing the composite material to cure; and optionally allowing the composite material to cool to room temperature. The required heat and pressure to form a sheet of composite material will vary depending on the resin used and the quantity of hemp derived material used. For example, the heat applied may be between 140 and 250 °C and the pressure applied may be between 500 and 1000 kPa to the hemp-resin mix, and may be for a time period of between 1 and 4 minutes. The hemp derived material may be dried before use so that there is substantially between 4 and 8 weight % water content. The hemp derived material may be thoroughly mixed with the resin so that the hemp derived material is dispersed substantially evenly throughout the resin, to achieve a consistent quality and material strength. The hemp derived material may be sprayed with the resin, for example by using a rotary sprayer. This may help the resin to thoroughly penetrate into the hemp fibres and hemp shives. The hemp derived material may be sprayed with the resin before the hemp derived material is mixed with the resin. Compression manufacturing methods may be used to form the sheets of composite material. For example, the hemp-resin mix may be compressed from around 100mm down to around 3mm. These compression manufacturing methods allow for mass production, offering advantages in terms of speed and scalability compared to traditional manufacturing processes of construction materials. The sheet of the composite material may have any thickness according to the desired use. For example, in an embodiment of the invention, the sheet may have a thickness of between 1 and 15mm, optionally between 1 and 10mm, optionally between 2 and 6mm, and further optionally between 3 and 5mm. Further optionally, the sheet may have a thickness of 3mm or less. In an embodiment of the invention, the sheet of composite material may have a length of up to 1.5m, optionally up to 2.5m, and further optionally up to 4.5m. The compression manufacturing methods may be adjusted so that a sheet of composite material may be made into any appropriate size according to the desired use. For example, compression manufacturing methods and compression moulding techniques may be used to produce the structure support stud in particular dimensions to be used in the construction industry such as 94mm x 47mm x 3000mm, with minimum thickness of between 3 and 5mm. It is advantageous that the composite material may be easily compressed into sheets and / or moulded into different shapes, and then can be melted down again, all without requiring high temperatures required for moulding steel. As herein disclosed, the composite material may also be moulded into different shapes without necessarily first being made into a sheet. The process for making the support structure according to the first aspect of the invention may further comprise: applying heat of between 140 and 250 °C to soften the sheet of the composite material; applying pressure to bend the sheet of the composite material around a mould; and allowing the composite material to cool to room temperature to form the support structure. In an embodiment, a stud may be manufactured according to the process of the second aspect of the invention. FIGURES Embodiments in accordance with the invention will now be described with reference to the accompanying drawings, in which: Figure 1 shows an image of the view along the inside surface of a substantially C-shaped stud of an embodiment of the present invention. DESCRIPTION The description of illustrative embodiments according to principles of the present invention is intended to be read in connection with the accompanying drawings, which are to be considered part of the entire written description. In the description of embodiments of the invention disclosed herein, any reference to direction or orientation is merely intended for convenience of description and is not intended in any way to limit the scope of the present invention. Relative terms such as “lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,” “down,” “top” and “bottom” as well as derivatives thereof (e.g., “horizontally,” “downwardly,” “upwardly,” etc.) should be construed to refer to the orientation as then described or as shown in the drawing under discussion. These relative terms are for convenience of description only and do not require that the apparatus be constructed or operated in a particular orientation unless explicitly indicated as such. Terms such as “attached,” “affixed,” “connected,” “coupled,” “interconnected,” and similar refer to a relationship wherein structures are secured or attached to one another either directly or indirectly through intervening structures, as well as both movable or rigid attachments or relationships, unless expressly described otherwise. Moreover, the features and benefits of the invention are illustrated by reference to the exemplified embodiments. Accordingly, the invention expressly should not be limited to such exemplary embodiments illustrating some possible non-limiting combination of features that may exist alone or in other combinations of features; the scope of the invention being defined by the claims appended hereto. Figure 1 shows an image of the view along the inside surface of a substantially C-shaped stud of an embodiment of the present invention. In this embodiment, the composite material is comprised of two layers which have been bonded together by heat and compression, in which the layer on the inside of the C-shape comprises hemp shives and the layer on the ouside of the C-shape comprises hemp fibres. The resin used is acForm® Power 2888 (produced by BASF in 2024). EXAMPLES Example 1 Hemp shiv and hemp hurd are dried with heat and in a vacuum, to obtain dried hemp shiv and dried hemp hurd with a maximum of between 4 and 8 weight % water. The thermoplastic resin AcForm® Power 2889 X (produced by BASF in 2024) is heated to between 150 and 175°C to obtain a flowing liquid and to ensure best mechanical performance. 42.5 weight % of dried hemp shiv and 42.5 weight % of dried hemp fibres are mixed with the heated liquid thermoplastic resin in a mixer and mixed until the hemp fibres and hemp shives are substantially evenly dispersed within the thermoplastic resin, to obtain the hemp-resin mix. The hemp-resin mixture is compressed using a heated hydraulic press (or alternatively a double belt press) from around 100mm to obtain the composite material as sheets with around 3mm thickness. The composite material sheets are softened by heating to around 140°C and the sheets compressed around a mould to form C-profile shaped studs. Example 2 Hemp shiv and hemp fibres are dried with heat and in a vacuum, to obtain dried hemp shiv and dried hemp fibres with a maximum of between 4 and 8 weight % water. The thermoplastic resin AcForm® Power 2888 (produced by BASF in 2024) is heated to between 150 and 175°C to obtain a flowing liquid and to ensure best mechanical performance. 245.5g of dried hemp fibres are evenly distributed over a flat surface and sprayed with 43g of the AcForm® Power 2888 resin to obtain a hemp fibre-resin mix. 245.5g of dried hemp shives are thoroughly mixed with 43g of the AcForm® Power 2888 resin to obtain a hemp shiv-resin mix and evenly distributed over the layer of hemp fibres. The hemp-resin mixture is compressed using a heated hydraulic press (or alternatively a double belt press) from around 100mm to obtain the composite material as sheets with around 3mm thickness. The composite material sheets are softened by heating to around 140°C and the sheets compressed around a mould to form C-profile shaped studs, such as that shown in Figure 1. It should be appreciated that in the above description of exemplary embodiments, various features are sometimes grouped together in a single embodiment, figure, or description thereof for the purpose of streamlining the disclosure and aiding in the understanding of or more of the various inventive aspects. This method of disclosure, however, is not to be interpreted as reflecting an intention that the claimed invention requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. While some embodiments described herein include some, but not other features included in other embodiments, combinations of features of different embodiments are meant to be within the scope of the disclosure, and form different embodiments, as would be understood by the skilled person. For example, in the following claims, any of the claimed embodiments can be used in any combination. Thus, while certain embodiments have been described, it will be appreciated that other and further modifications may be made thereto without departing from the spirit of the disclosure, and it is intended to cover all such modifications, enhancements, and other implementations, which fall within the true spirit and scope of this disclosure. To the maximum extent permitted by law, the scope of this disclosure is to be determined by the broadest permissible interpretation of the following claims and shall not be restricted or limited by the foregoing detailed description. While various implementations of the disclosure have been described, it will be readily 5 apparent to the skilled person that many more implementations are possible within the scope of the disclosure.

Claims

1. A support structure comprising a composite material, wherein the composite material comprises:at least 50 weight % of hemp derived material; andat least 15 weight % of resin.

2. A support structure according to claim 1, wherein the hemp derived material comprises hemp fibres and / or hemp shives.

3. A support structure according to claim 1, wherein the hemp derived material consists of hemp fibres and / or hemp shives.

4. A support structure according to any preceding claim, wherein the composite material comprises at least 70 weight %, optionally at least 85 weight %, and further optionally at least 90 weight % of the hemp derived material.

5. A support structure according to claims 1 to 3, wherein the weight ratio of hemp derived material to resin is from 98:2 to 60:40, optionally from 95:5 to 70:30, and further optionally from 90:10 to 80:20.

6. A support structure according to any preceding claim, wherein the composite material comprises hemp fibres and hemp shives in substantially equal weight %.

7. A support structure according to any preceding claim, wherein the hemp fibres are arranged in random directions and distributed substantially homogeneously throughout the composite material.

8. A support structure according to any one of claims 1 to 6, wherein the hemp fibres are arranged substantially in one direction and distributed substantially homogeneously throughout the composite material.

9. A support structure according to any preceding claim, wherein the average length of a hemp fibre is between 30 and 100mm, and optionally between 50 and 80mm.

10. A support structure according to any preceding claim, wherein the resin comprises a bio resin, and wherein the bio resin is substantially derived from renewable biological sources.

11. A support structure according to claim 10, wherein the bio resin is substantially free from formaldehyde.

12. A support structure according to any preceding claim, wherein the resin comprises one or more selected from acForm® Power 2888, acForm® Power 2889 X, ACRODUR®, MDI (melamine-urea-formaldehyde) resin, and transfurans PFA (perfluoroalkoxy copolymer) resin.

13. A support structure according to any preceding claim, wherein the resin is a thermoplastic resin, and optionally wherein the thermoplastic resin is recyclable.

14. A support structure according to any preceding claim, wherein the composite material may be melted down and reformed into a new support structure.

15. A support structure according to any preceding claim, wherein the composite material additionally comprises one or more additives selected from biocides, pigments, surfactants, water repellents, antifoaming agents, intumescents, hardeners, and / or flame retardants.

16. A support structure according to any preceding claim, wherein the composite material has a physical property which is equal to or better than the same physical property in light-gauge steel, and wherein the physical property is selected from Young’s modulus, tensile strength, compressive strength, acoustic measurement (Rw), and / or thermal transmittance (U-value).

17. A support structure according to any preceding claim, wherein the support structure is an elongate structure with a substantially C-shaped, a substantially U-shaped, and / or a substantially H-shaped cross-section.

18. A support structure according to any preceding claim, for use as a stud in the construction of buildings.

19. A support structure according to claim 18, wherein the support structure is a stud with a substantially C-shaped cross-section, wherein the weight ratio of hemp derived materialto resin is from 90:10 to 80:20, and wherein the hemp fibres and hemp shives in substantially equal weight %.

20. A support structure according to any preceding claim, wherein the support structure is used as a support for walls in buildings, packaging material, decorative panels, and / or fencing and fencing posts.

21. A support structure comprising two or more layers of composite material, in which each layer substantially comprises either hemp fibres or hemp shives.

22. A process for making the support structure comprising the composite material according to any one of claims 1 to 21, comprising:mixing the hemp derived material and the resin to form a hemp-resin mix;applying heat and pressure to the hemp-resin mix to form a sheet of composite material;allowing the composite material to cure; andoptionally allowing the composite material to cool to room temperature.

23. A process according to claim 22, wherein the sheet has a thickness of between 1 and 10mm, optionally between 2 and 6mm, and further optionally between 3 and 5mm, and optionally wherein the sheet has a length of up to 1.5m, optionally up to 2.5m, and further optionally up to 4.5m.

24. The process for making the support structure according to claim 22 or 23, further comprising:applying heat to soften the sheet of the composite material;applying pressure to bend the sheet of the composite material around a mould; andallowing the composite material to cool to room temperature to form the support structure.

25. A stud manufactured according to the process according to any one of claims 22 to 24.

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