Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/92—Protection against other undesired influences or dangers
  • E04B1/94—Protection against other undesired influences or dangers against fire
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B1/00—Producing shaped prefabricated articles from the material
  • B28B1/008—Producing shaped prefabricated articles from the material made from two or more materials having different characteristics or properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B28—WORKING CEMENT, CLAY, OR STONE
  • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
  • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
  • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/92—Protection against other undesired influences or dangers
  • E04B1/94—Protection against other undesired influences or dangers against fire
  • E04B1/941—Building elements specially adapted therefor
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
  • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
  • E04B1/92—Protection against other undesired influences or dangers
  • E04B1/94—Protection against other undesired influences or dangers against fire
  • E04B1/941—Building elements specially adapted therefor
  • E04B1/943—Building elements specially adapted therefor elongated
  • E04B1/944—Building elements specially adapted therefor elongated covered with fire-proofing material
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
  • E04B5/16—Load-carrying floor structures wholly or partly cast or similarly formed in situ
  • E04B5/32—Floor structures wholly cast in situ with or without form units or reinforcements
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
  • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
  • F16L57/00—Protection of pipes or objects of similar shape against external or internal damage or wear
  • F16L57/04—Protection of pipes or objects of similar shape against external or internal damage or wear against fire or other external sources of extreme heat
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
  • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
  • E04B2/84—Walls made by casting, pouring, or tamping in situ
  • E04B2/842—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf
  • E04B2/845—Walls made by casting, pouring, or tamping in situ by projecting or otherwise applying hardenable masses to the exterior of a form leaf the form leaf comprising a wire netting, lattice or the like
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
  • E04C5/16—Auxiliary parts for reinforcements, e.g. connectors, spacers, stirrups
  • E04C5/162—Connectors or means for connecting parts for reinforcements
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
  • E04C5/16—Auxiliary parts for reinforcements, e.g. connectors, spacers, stirrups
  • E04C5/162—Connectors or means for connecting parts for reinforcements
  • E04C5/163—Connectors or means for connecting parts for reinforcements the reinforcements running in one single direction
• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
  • E04C5/00—Reinforcing elements, e.g. for concrete; Auxiliary elements therefor
  • E04C5/16—Auxiliary parts for reinforcements, e.g. connectors, spacers, stirrups
  • E04C5/162—Connectors or means for connecting parts for reinforcements
  • E04C5/166—Connectors or means for connecting parts for reinforcements the reinforcements running in different directions

Definitions

• the invention relates to building elements which are a composite of concrete and a treatment material such as a fire rating material.
• the invention is applicable to such building elements as concrete or lightweight concrete slabs, beams, columns which can be pre-formed or pre-cast or can be formed in situ.
• the present invention relates to mesh which can be utilised as reinforcing for the application of a fire rating material to building elements such as beams of steel or concrete or slabs of concrete, or other building services elements such as air-conditioning duct work or airflow duct work.
• the invention also relates to a method of manufacturing such mesh and a method of applying a fire rating material to such building elements and or building service elements.
• Bar chairs or similar items can be utilised to suspend one or both of: the at least one lath or reinforcing element in the mould or above the floor or base surface or in the building element and or the structural reinforcing in the mould or on the floor or base surface or the building element.
• the treatment material can be one or more of the following: a fire rated material; a fire resistant material; an acoustic material; a sound absorbing material; an anti-spalling material.
• the indent formation or indentation can be formed in two members of a first direction and two other members which cross the previously mentioned two members.
• the method can be performed by a pair of rollers respectively having a concave part and a convex part to form the indentation.
• the mesh can be joined to itself, by at least 50mm or two mesh interstices are overlapped.
• the present invention also provides a fire rated tile including a fire rated material and being sized and shaped for application to an article to be protected from a fire, the tile including an aperture there though so as to receive a pin means.
• a pin means having an attachment portion can be positioned so that a pin part of the pin means passes through the aperture with the attachment portion being positioned adjacent a rearward face of the tile.
• the attachment means can be secured to the tile before the tile is secured to the article.
• the attachment means can be secured relative to the article or tile by the action of attaching the tile to the article by a single application of an adhesive applied to the article and the tile with captured pin means applied to the adhesive.
• the present invention further provides a fire rated tile including a fire rated material and being sized and shaped for application to an article to be protected from a fire, the tile including protruding from an outer surface thereof, a pin means.
• the tile can be compressed and the hole is formed by one of the following: a compression mould; by a hole forming tool after the tile has set.
• the tile can be one of the following shapes: rectangular, square, triangular, round, any appropriate shape.
• the aperture can be located at the centre of the tile.
• the tile can include one or more of the following or be made with one or more of the following: a mesh panel embedded in said fire rated material; a mould which remains integral with said tile when said fire rated material has set; is moulded in a reusable mould; is moulded in a single use mould; is moulded in a mould that has lock-in formations in the side thereof; is moulded in a mould which is rigid; is moulded in a mould which is flexible.
• the present invention further provides a method of applying a fire rated tiles or panels to an article to be protected, the tiles or panels being cut or sized to be substantially the full width of respective sides of the article so that at junctions of the sides there are join lines between adjacent panels the join lines have overlying them, a respective matching angled member, such that matching angled members are secured to each other, thereby providing an exo-skeletal support to the tile or panel arrangement.
• the metal fixers can include wire or strand bent, or hog rings, around the adjacent wire elements to secure them together.
• the fire rated material or adhesive can be any one of the following or a combination of one or more of the following: a gypsum based fire rated material; a cement based fire rated material, an adhesive; a silicate adhesive, a non-flammable adhesive.
• the generally flat base can include a generally planar surface or it can include a layer of mesh or similar.
• the method can include a step of installing channels in said riser or to building elements at said riser location.
• the method can include connecting supporting rods to channels mounted to building elements at said riser location, or to walls of said riser.
• Figure 1 illustrates a perspective view of another mesh.
• Figure 3 illustrates a detail of a portion of the mesh of Figure 2.
• Figure 11 illustrates rollers forming the indentations of figures 1 or 2.
• Figure 16B illustrates the mould of figure 16A with a strengthening mesh in the form of galvanized wire mesh having 25mm mesh squares and 1mm wire in the mesh (herein after called Quikmesh), positioned in the mould before the fire rated material is poured in.
• a strengthening mesh in the form of galvanized wire mesh having 25mm mesh squares and 1mm wire in the mesh (herein after called Quikmesh), positioned in the mould before the fire rated material is poured in.
• Figure 17 illustrates the application of the tile of figure 12 to an article to be protected, in this instance a sheet metal duct.
• Figure 19 illustrates a schematic view of the first and second tile layers of figure 18, showing the arrangement of the pins and speed clips attached.
• Figure 27 illustrates a stack of mesh panels of figure 26, to allow same to cure.
• Figure 29 illustrates the panels of figure 28 being joined by hog rings.
• Figure 32 illustrates a method of protecting a building element such as duct, whereby a preformed mesh based fire rated panel is provided as a base under the duct, then mesh elements joined thereto and to each other to surround the duct, then the mesh elements are sprayed with fire rated material.
• Figure 33A illustrates a method similar to that of figure 32 and 33, except that the mesh of figure has been used.
• Figure 34 illustrates a fire rated tile with the pin captured in the moulded tile.
• Figure 35 illustrates the tile of figure 34 prior to being removed from its mould, or having an aluminium foil mould that remains with the tile.
• Figure 38 illustrates the mesh element of Figures 36 and 37 in a storage position to allow said fire rated material to set
• Figure 45 illustrates a representation of a layer of tri-mesh being coated by hand to a required depth with self-levelling material or otherwise;
• Figure 48 illustrates the depth to which fire rated material is laid down after the device of figure 47 has passed
• Figure 51 illustrates the concrete being formed after the machine of figure 49 having applied the concrete, showing embedment of the reinforcing layers and the upper half of the tri- mesh layer into the concrete;
• Figure 54 illustrates a perspective view of a mesh which can be put to similar uses as that of figures 1 and 2, except that it has rows of indentations with the indentations have a line base.
• Figure 55 illustrates a perspective view of a mesh which can be put to similar uses as that of figures 1 and 2, except that it has rows of indentations with a generally flat base.
• Figure 57 illustrates a detail schematic assembly method to produce a fire rated duct of appropriate strength for attachment to a building riser.
• FIG. 1 Illustrated in Figure 1 is a square mesh 10 made up of an array of mesh elements 11 in one direction and an array of mesh elements 12 in another direction in this case being at approximately 90 degrees to each other providing a generally square mesh product.
• the spaces between the elements 11 and 12 being open or interstices.
• the mesh elements 11 and 12 are preferably of a rod diameter of approximately 0.8mm to 3mm and are most preferably of a diameter of approximately 1.5 to 1.6 mm. Mesh constructed from rods of such diameters are readily bendable to conform to shapes of articles to be coated with a fire rated material.
• rollers being rotatably connected by a chain or gear mechanisms the recesses which effectively form a die and the projections which form a push rod will form the indentations 13 in an efficient manner into the die.
• a tolerance can be provided, which will allow for the appropriate elongation and retention of the shape, between the rollers used.
• the mesh elements 12 are spaced from each other approximately 25mm whilst the mesh elements 11 are spaced a similar distance.
• the spacing between adjacent indentations 13 is thus approximately 125mm. If desired, the spacing can be made to measure by utilising larger diameter or different diameter rollers to achieve the required spacing.
• Illustrated in Figure 2 is an embodiment similar to that of Figure 1 except that in forming the indentations 13 two adjacent mesh elements 11 and two adjacent mesh elements 12 are indented to form the indentation 13. This provides a "planar" contact frame on the base of the indentation, so that it can abut a surface to which the mesh 10 of Figure 2 is applied.
• the plastically deformed members 11.2 and 12.2 which form the sloping or curved sides of the indentation are in the case of Figure 1 of a generally convex shape relative to the indentation and in respect of Figure 2 of a relatively straight formation.
• the mesh of Figure 2 could include a convex or concave formation of the elements to produce the indentation or in the case of Figure 1 the convexly deformed mesh elements could be concavely deformed if required, or alternatively straight as in Figure 2, to form a straight sided pyramidal shape.
• the shape of these elements which form the indentation will be dictated by the shape of the recess on the roller which is utilised to manufacture the mesh. It may also be dependent upon the shape of the projection utilised.
• FIG. 5 Illustrated in Figure 5 is a portion of a duct 1 which has the mesh 10 of Figure 2 applied to the outer periphery thereof.
• the mesh 10 is secured to the duct 1 as is illustrated in Figure 7 where a weld on stud 20 having an insulated head 21 and a stem 22 of approximately 4-5mm is welded to the outer surface of the duct 1 so as to sandwich the mesh between the duct and the head of the weld on steel.
• the insulated head 21 is sized to be of approximately 30mm in diameter it will capture portions of 11.4 and 12.4 (see Figure 3) of the elements 11 and 12, which form the generally planar frame which will rest against the surface of the duct 1.
• the insulated head 21 is sized to prevent at any one time either 2, 3 or 4 sides of the planar frame made up of portions 11.4 and 12.4 from escaping the steel head, once the stud 22 is welded to the duct 1.
• Each indentation 13 will include at least one such stud when the mesh is assembled to a building, a building element or building services element.
• the weld on studs 20 can have, as illustrated in Figure 7 a square head which has been utilised in the embodiment or illustrations of Figures 5 and 6. If a square head or rectangular head is utilised the square will be preferably of the order of 30mm square, or if rectangular of the order of 25mmx30mm is preferred based on the interstice width of the mesh being of the order of 25 mm. It will be understood that these dimensions will vary according to the interstice size or spacing between the mesh elements, on the mesh.
• a single panel of mesh 10 can be secured to respective duct surfaces. However, they would extend closer to the edges of the planar surface of the duct than is illustrated in Figure 7 and more will be discussed about this later.
• both ends of the duct 1 are provided with mesh 10.
• the process of the formation of a fire rated duct 1 includes that a fire rating material 15 is sprayed onto the duct 1 and onto the mesh 10 once the duct 1 has been assembled into position in the respective building.
• the fire rating material 15, such as vermiculite or other material can be applied at a factory location and the fire rated duct delivered to the site for assembly.
• the fire rating material utilised can be any appropriate fire rating material such as vermiculite or the like.
• FIGs 54 and 55 Illustrated in Figures 54 and 55 are two alternative embodiments of the mesh of figures 1 and 2.
• the mesh 5410 has equispaced channels or rows of indentations 54 3 along its width or length, which channels terminate in a line of indentation.
• Figure 55 has a mesh 5510 which has flat indentations 5513 spaced along its width or length.
• the flat indentations 5513 have angled sides like those of the indentation 5413, but have an additional flat panel on the base.
• Both the mesh forms 5410 and 5510 can be used instead of the meshes of Figure 1 or 2.
• the building element or building services elements like ducts can have the reinforcing applied to the duct and then transported to the site for assembly and coating with a fire rating material. Further, depending on the OHS issues due to weight, such ducts can be coated with fire rating material at a remote site and then transported to the building site for assembly.
• TILE MANUFACTURE METHOD 3 is substantially the same as method 2, but the mould 150 used is of a single use type, eg of aluminium sheeting of 0.3mm in thickness, where the aluminium mould 150 remains with the tile, and is of a sufficiently pliable material as is the case of aluminium foil, which will allow the pin 200 to be pushed through the foil, or puncture it.
• the mould 150 preferably has punched out square or rectangular apertures 150.1 at spaced locations along the sides so that when the tile material 101 is poured into the mould the tile material will interlock with the mould 150.
• the aperture 150.1 is formed from a pushed in portion 150.2, which remains connected to the side wall of the mould at each end 150.3, thereby allowing interlocking with the tile material 101 when it is poured.
• the wall of the mould is pushed to form two discrete tabs 150.4, each of which remains in contact with the mould 150 at their respective ends 150.3.
• This arrangement too allows the tabs 150.4 to be embedded into the tile material 101 when it is poured in and then sets.
• aluminium is a preferred material other materials such as steel and stainless steel can also be used.
• TILE MANUFACTURE METHOD 4 As is illustrated in figure 16B this method is similar to method 2 or 3, except that before spraying or pouring the fire rated material into the mould, a layer of mesh 10, being a galvanised steel wire mesh having 1 mm wire at 25 mm spacing forming a square mesh, or the mesh described previously, is positioned in the mould 150, and then the fired rated material 101 sprayed or poured therein.
• a layer of mesh 10 being a galvanised steel wire mesh having 1 mm wire at 25 mm spacing forming a square mesh, or the mesh described previously
• TILE MANUFACTURE METHOD 9 forming the tile by any method above, without a hole being first formed. Then by the pin, being of relatively small cross sectional area, or having a sharpened point thereon, can be pushed through the tile until the backing member 210 is against the inner face of the tile. This method is particularly useful in the case where the tile material is relatively soft, such as is the case with VERMIDUCT material.
• the backing member 210 can provide a surface to adhere to an article to be protected against fire by the tile.
• a special purpose glue or adhesive such as a plaster type adhesive being gypsum based, water with acrylic binders to increase adhesion or bond strength
• the member 210 can have a pre-applied adhesive, with a non sticky covering layer, which can be peeled off as the tile is being adhered to the article, these pins with a sticky backing are sometimes called a sticky pin.
• the pin backing can be of a weldable type, which would allow the backing and pin to be first welded to the duct, and then the tile can be positioned thereon.
• FIRST TILE LAYER - ASSEMBLY METHOD 1 In a factory environment or on site, as illustrated in figure 17, a series or array of pins 200, by means of the backing member 210, are first applied to the sheet metal duct 300 to be protected. The pins 200 are applied by being welded direct to the duct surface, by means of a stud welding gun or the like, at appropriately spaced locations. Then the tile 100, which has a pre-formed or post-formed hole therein, or is of sufficiently soft material, is spiked onto respective pins.
• the first layer of tiles will form a covering layer over the surfaces of the duct 300, as in Figure 17, with any overhanging tiles being cut once glued into position.
• the back surface of the tile Prior to the tile 100 being spiked onto the pin 100, the back surface of the tile will have a plaster type adhesive being gypsum based, such as that sold under the brand VERMIDUCT, water with acrylic binders to increase adhesion or bond strength, applied to the rear surface so that it adheres to the duct 300.
• This adhesive can be applied to the whole of the back of the tile as in Figure 14, i.e.
• FIRST TILE LAYER - ASSEMBLY METHOD 2 this method is similar to that of Tile Layer One Assembly Method 1 , except that the welded pin 200 and backing member 210, is replaced by means of a self adhesive pin and backing member 210 also known as a sticky pin.
• FIRST TILE LAYER - ASSEMBLY METHOD 3 this method is similar to that of method 1 , except that the duct manufacturer provides the pins 200 and backing members 210 pre-welded to the duct before delivery to the fire rating factory or the site.
• SECOND TILE LAYER - ASSEMBLY METHOD 1 once the first layer of tiles has been assembled by one of the First Tile layer methods described above, a second layer of tiles 120, which do not include a pin, but which may have a central hole or aperture for a pin, or such a hole can be absent, can then be applied to the first layer. It will be noted that after the first layer of tiles has been applied, the distances between four pins 200, due to them being centrally located through the respective tiles, will mean that a second layer tile 120 can be located between the pins as illustrated in figures 18, 19 and 20. This second tile layer assembly method is performed without using adhesive at the back of the second layer tiles 120.
• the second layer tile 120 can be held in position by the assembler attaching a speed clip 220 (as illustrated in figure 22A, onto the end of the pin and pushing it into position so as to apply a compressive force to the tile 120 so that the back surface of the tile 120 will push against the front surface of the tile 100.
• a speed clip 220 as illustrated in figure 22A
• the duct surface being worked is preferably flat, so that gravity will hold the second layer tiles 120 in position until such time as the speed clips 220 are applied.
• the fire rated material 540 can then applied to the assembly.
• This method is particularly suited to factory fire rating articles having flat surfaces such as rectangular ducts and beams, because once the mesh, and particularly a mesh such as Trimesh, is fixed to the duct or article and then sprayed with the fire rated material (preferably vermiculite based material or its branded product Vermiduct), due to the adhesive nature of this material, it will bond or stick to the duct or article.
• the sprayed assembly is allowed to dry it can then be delivered to site. This provides good transportation characteristics so that the product can be delivered to a site without the fire rating material being compromised by road transportation issues.
• FIG 32 Illustrated in figure 32 is another method of applying fire rating material to a duct 300. This method is performed on site.
• a mesh panel 520, with or without foil 530, is positioned under the duct 300, between a duct support 600, which is suspended at opposite sides by means of stringers 610.
• FIG. 34 and 35 Illustrated in figures 34 and 35 is a tile 100, similar to that described above, except that in this tile 100, the pin 200 is captured within the tile 100, by the backing plate 210 being embedded in the fire rated material.
• One method of capturing is that the backing plate 210 can attached or welded to the mesh 10 or 520 (see figures 16B and 6C) before the pouring or spraying of the fire rated material. This will ensure that the pin extends away from the outer surface of the tile 100. If such a tile is used the backing plate 210 will not be adhered to the duct, but rather the rear surface of the tile will be adhered.
• the mesh element 3660 and its aluminium or metal foil 3670 are placed on a base surface so that the foil remains in contact with the base or metal wire elements of the mesh 3660.
• the base surface can be a vertical or angled surface, or it can be a horizontal surface, but it must have a generally planar surface for a mesh element which has a generally planar base. The idea being that the foil is sandwiched between the base of the mesh element and the surface.
• the fire rated material or fire retardant material 3680 can be such as that manufactured under the brand names of Vermitex TH, or other brands and tends to be relatively sticky when first sprayed due to the cement or gypsum based compounds and their carriers.
• the cement based coating or layer 3680 when it is set and installed over a duct or other building feature, with the foil exposed or on the outside and not in contact with the duct or building feature, provides a hard layer or coating which will comply with the Building Code of Australia requirement for hardness in compliance with AS 2185.
• an adhesive can be sprayed to the same effect as a fire rated or fire retardant material, but if an adhesive is sprayed it is preferably a smokeless and or non inflammable type, such as a silicate adhesive or other non-flammable adhesive or the like.
• a layer 3680 would probably be of the order of 1 to 2 mm in thickness.
• the adhesive can have a contraction factor as it sets, so that the foil can be drawn to the mesh rather than away from it during setting.
• Appropriate adhesives will include those like sodium silicate, sodium metasilicate.
• Such an 'adhering' or 'spraying' process can form a bond between the foil and the underneath most portion of the wire element, but it will also, or alternatively, form a saddle type joint by the fire rated material 3680 as it passes over the upper surface of the wire elements and makes contact with the foil immediately below the sides and into any interstices between the wire mesh element and the foil 3670.
• This new product and method assists in ensuring that the foil 3670 does not form concave formations with respect to or relative to the base wires of the mesh which in Figure 38 are now at the top of the unit whilst the fire rated material is setting. This helps to ensure that once the panels 3660 have been installed ready for application of fire rated at a building site that the amount of fire rated material needed is dictated by the relatively solid base 3670 and 3680 in combination and the distance to the upper or outer levels of the wire mesh of the panels 3660.
• Another advantage of the pre-coating of the panels 3660 by the previously mentioned method is that at an on-site location, invariably cut-outs through a panel are required. With respect to the prior art where no layer 3680 had been pre-applied to the wire mesh and foil assembly, such cut-outs would result in foil flapping relative to the base wires of the wire mesh and this would lead to large amounts of fire rated material being utilised. Further, because the edges of the cut-out will generally not be where speed clips are located to hold the foil in place to the panel 3660, the ability of the foil to move away when fire rated material is sprayed can result in an application of fire rated material which has not been appropriately applied at that location.
• a preformed fire rated panel as illustrated in Figure 40A, can be finalised in a factory by spraying the remaining volume of the mesh 3670 with a final layer 3685 of Vermiduct or Vermitex AF or similar which are gypsum based fire rated compounds or Vermitex TH brand fire rated material or similar which is a cement based fire rated compound.
• FIG. 41 Illustrated in Figure 41 is a composite building element 4110, in this case a cast concrete or lightweight concrete slab. Whilst the following description will be directed to cast concrete slabs, other building elements such as walls, columns, beams, ceiling or floor panels and the like can be made by the process of the invention.
• the element 4110 is manufactured so as to integrally capture a lath or reinforcement element 4130 such as TRIMESH® or other into the cast concrete slab as well as in a layer 4120 of fire rating material such as Vermitex TH which has been sprayed onto the floor of the mould so as to immerse approximately half the depth of mesh 4130.
• the concrete slab 4110 can also include layers of reinforcing 4140, as is common in the trade.
• the side walls of the slab or element 4110 can be finished or lined with an intumescent strip such as that sold under the EXPEGNI brand (not illustrated in Figure 41 but shown in Figure 53) so that if elements 4110 are placed adjacent each other the intumescent material will expand in a fire situation to prevent fire from passing between the adjacent elements.
• EXPEGNI brand not illustrated in Figure 41 but shown in Figure 53
• Method 1 As the building element 4110 can be a pre-cast fire rated concrete or precast slab type product, a mould,. floor or base surface is firstly prepared to respectively conform to the shape of the final product.
• the mould will include appropriate depth to include a layer 4120 of fire rating material such as Vermitex TH brand cement based fire rated material, which can be sprayed or cast.
• the TRIMESH® 4130 is positioned in the mould at a predetermined height above the floor of the mould where it is held in at predetermined height by means of bar chairs or other appropriate means, and the base of the mould can include a plastic sheet 4125 or other appropriate material if it is desired or advantageous.
• Method 2 This method is similar to method 1 , except that it is an automated method and where, instead of a mould per se being used, a floor or base surface is prepared for example by the laying down of a plastic sheet.
• the floor or base surface may include side dams or skirts 4160 as illustrated in figure 47, which are not the whole height of the building element, so as to contain the fire rating material when it has been applied.
• Method 3 this method is similar to Method 1 or 2 described above except that before any mesh or reinforcement is positioned in the mould or on a floor or base surface, a layer of fire rating material 4120 is applied to the mould or on the floor or base surface (which will have side dams to contain the fire rating material) by spraying or pouring or extruding or other appropriate technique. Once the viscosity of the sprayed fire rating material layer 4120 is at a desired amount and it is appropriate to do so, a mesh layer 4130 can be inserted into the layer 4120 to up to approximately 50% of its depth or other appropriate depth as per design or use or service requirements of the finished building element.
• reinforcing 4140 can be positioned thereon or prestressed elements positioned above and the concrete building element is cast applied or formed so as to envelop, immerse or embed the upper proportion of the mesh 4130 which is protruding from the lower fire rated layer 4120.
• Method 4 In this method the building element 4110 can be formed in reverse order that is at the bottom of the mould, the concrete slab or building element contacts the floor of the mould, whereas the upper surface is the fire rating layer 4120. This is effectively Figure 41 rotated through 180°.
• the reinforcing 4140 is positioned on bar chairs at appropriate locations in the mould with concrete beams cast to the appropriate depth of the concrete building element.
• a lath or reinforcing element 4130 such as the TRIMESH® is inserted into the upper layer of the poured concrete to a depth of approximately half the depth of the TRIMESH® 4130, in this case approximately 15mm.
• the concrete is then given time to set and then a layer 4120 of fire rating material is either poured or sprayed to a depth of approximately 30mm above the level of the previously poured concrete so as to fully embed the upper layer of the TRIMESH® 4130.
• Method 6 As illustrated in Figure 42 is another building element 4111 which has better fire rating properties in terms of resistance to spailing than standard concrete but does not include a fire rating material.
• the building element 4111 is manufactured exclusively from concrete and is characterised by once the concrete has been poured, or prior thereto, the layer of lath or reinforcement 4130, material such as a 20mm, 30mm or 50mm TRIMESH®, is inserted below the upper surface of the slab or positioned above the lower surface as illustrated in the Figure 42.
• Such Trimesh will assist the element 4111 to resist or stop spailing which would otherwise occur if fire were applied to an underside or top side of the element 4111.
• TRIMESH® 4130 (as illustrated in Figure 43) can be positioned on appropriate bar chairs off the base of the floor of the mould with the reinforcing 4140 also being positioned thereabove.
• the concrete is poured into the mould.
• a building element formed by this method is expected to operate better in a fire environment because the provision of the lath element 4130 or TRIMESH® 4130 results in reduced spading occurring when heat is applied to the underside of the concrete slab. Without such TRIMESH® the heat would normally cause the under surface of the concrete to spall. This enables TRIMESH® 4130 to hold the exposed concrete surface together for a longer period of time in a fire environment, because it will result in a reduced level of spading of the concrete surface.
• Method 8 To manufacture the building element of Figure 42 the TRIMESH® 4130 can be positioned on appropriate bar chairs off a machine base or of a floor. A chemical coating or a layer of plastic can be applied to the floor or base first to prevent the concrete/vermiculite sticking to the floor or base.
• the structural reinforcing 4140 can be positioned thereabove, whether that be prestressed elements or reinforcing mesh. The concrete is applied into the TRIMESH® and reinforcing by a device such as that illustrated in Figure 4 ⁇ which applies concrete to the whole mesh arrays and embeds all of them in a single pass.
• Method 9 this method is similar to Method 7 except that the non-structural lath or reinforcement mesh 4130 is located at a spaced position relative to the floor of the mould, then concrete is poured and once poured and of sufficient viscosity reinforcing 4140 is installed in the concrete.
• Method 10 If desired the concrete building element of methods 7 to 9 can be moulded in reverse order whereby the reinforcing 4140 or prestressed elements are placed at the lower end adjacent the floor of the mould, the floor of a factory or a base of a machine and concrete is then poured or applied by hand or automated devices. Then TRIMESH®4130 could either be in place ready for the application of the concrete or if sufficiently viscous concrete is poured the mesh can be pushed to the desired depth into the upper surface of the concrete whilst it is of sufficient viscosity.
• Method 11 In this method it is similar to that of Method 6 wherein structural reinforcing is placed at the lower end of the mould, or adjacent the floor or base of a moulding machine, on suitable bar chairs or appropriate spacers with the TRIMESH®4130 being spaced by bar chairs or other spacers, above the upper layer of reinforcing 4140. Then concrete can be poured into the mould or applied by a concrete application device to the floor or machine base so as to embed the reinforcing and the TRIMESH® to required depths.
• Method 12 This method utilises the methods 1 to 11 described above, except that a building element as illustrated in Figure 52 is produced, which has an upper and a lower layer of treatment or fire rated material applied to it.
• the additional steps of this method include that in addition to the lower layer of TRIMESH® element 4130 there is located with respect to the mould or base surface an upper layer of TRIMESH® element 4130 in the element.
• the upper layer of TRIMESH® element 4130 is embedded in the concrete before curing if the method utilises poured concrete, or is spaced by spacers from either the reinforcing 4140 or the lower TRIMESH® element 4130, and ten layer 4120 poured and after it concrete poured.
• the upper layer of TRIMESH® element 4130 is spaced by spacers from either the reinforcing 4140 or the lower TRIMESH® element 4130, with the lower layer 4120 first being formed then the concrete layer and finally the upper layer 4120.
• Method 13 provides that in the mould, the left and right sides 4120.1 of the fire rated layer 4120 of the building element are prevented or have a reduced chance of spalling around the left and right side reinforcements 4140.
• the side 4120.2 can have a strip of intumescent material 4120.1, such as EXPEGNI brand material supplied by LAF Group in Sydney, located at the sides or skirting 4160 of the mould, or on the ends and or sides of the Trimesh 4130.
• the intumescent material 4120.1 can be provided also at the locations 4120.11 which are at the sides of the slab, and or to lower locations 4120.12 adjacent the lower portions of the fire rated layer 4120.
• the structural reinforcing 4140 can be located, so that the outermost left and outermost right side elements 4140 can be protected by the fire rated material.
• the Trimesh 4130 can be spaced from the factory floor or floor of the mould by means of spacers 4125, and similar spacers, such as bar chairs or the like, can be used to hold or keep the structural reinforcing 4140 at the required height in the mould.
• the sides 4120.1 can be of a height appropriate to the thickness of the fire rated layer 4120, and the location of the structural reinforcing 4140. A height of a minimum of 50mm, 75mm or 100mm above the level of the base of the mould or factory floor, would be appropriate. "
• the fire rating material 4120 applied to a depth of from 25mm to 50mm can be any appropriate fire rating material such as Vermitex TH which is a cement based fire rating bond material or other vermiculite based mortars or other fire rated or resistant materials.
• Alternative spacing mechanisms instead of zig zag elements can include individual rods which are welded in place between the upper and lower generally planar mesh elements.
• the TRIMESH is illustrated in a simplistic manner so as to aid in illustration.
• the square mesh on the upper and lower layers of mesh have wire or rod elements missing in most drawings.
• Illustrated in figure 25 and 36 some elements of the upper layer of wire or rod elements are illustrated in solid line, while those illustrated at 90 degrees are shown in a line of dashes on the upper layer, while on the lower mesh layer the 90 degree elements are shown as a line of dashes interspersed with two dots.
• the TRIMESH used in the embodiments related to Figures 41 to 53 are preferably construct of wire of 3mm in diameter, whereas, the TRIMESH used in respect of embodiments of other figures are preferably of 2mm wire diameter.
• TRIMESH® 4130 being enveloped to 50% of its depth by the fire rated or resistant material or treatment material, and the rest by the concrete
• other depths and thus ratio of depth of fire rated material to concrete can be used, as per design requirements or the use or service of the finished building element.
• a layer 4120 which is a fire rated material
• other building element treatment materials can be used such as a fire resistant materials; an acoustic materials; sound absorbing materials; anti-spalling materials and any appropriate treatment material.
• the fire resistant or fire rated materials can also have acoustic properties, or the acoustic materials can have fire rated properties, and thus combinations of treatments are also envisaged.
• precasting is the preferred method of manufacture, if necessary some of the methods described above, particularly those where the fire rating material is formed at the bottom of the casting mould, can be cast in situ on a building site. While the use of machines to extrude or form concrete as they move tend to be used in a factory setting, such machines could also be used at building sites.
• Illustrated in Figures 56 to 59, and 57 and 58 are methods of manufacturing a fire rated duct or a series of fire rated ducts for assembly in buildings or for attachment to building risers, which methods can also be used to manufacture a wall of a riser with fire rated panels instead of riser walls being made of cast concrete.
• the method comprises the making of 1200mm segments of 800mm square duct, or rectangular duct as required.
• the method comprises the steps of locating four Trimesh panels 4130 as illustrated in Figure 43, or panels or tiles 500, such as those illustrated in Figure 26, to provide the four sides of a duct being constructed.
• four 90 degree bent mesh angles 5610 are positioned adjacent to and overlapping ends of the panels 4130 or 500.
• the mesh angles 5610 are made from mesh elements or rods of 5mm in diameter, which will allow for connection to the panels 4130 or 500, by means of hog rings 510 of figure 22B, or by any other appropriate means such as tie wire or by welding joining brackets to the angles 5610, so as to form a structurally sound duct unit.
• the corners 5610 can then be sprayed with a cement based vermiculite fire rated material, such as Vermitex TH, as can the wire panels 4130, to form a fire rated duct.
• attachment brackets 5910 can be attached to the vertical 5mm rods of the mesh angles 5610, so that the brackets 5910 can be secured directly onto the vertical walls of a building riser or other building formation so that a fire rated duct can be put into service.
• bracket 5910 will also allow engagement and support of the duct by an adjacent bracket 5920.
• the bracket 5920 has horizontal axis holes 5925 for this purpose to engage the horizontal axis holes of bracket 5910.
• the bracket 5920 also includes vertical axis holes 5926, which will allow for engagement as an intermediate bracket to connect to a rail 5930 which would be bolted to a building riser or wall element, allowing the duct to be secured thereto.
• a rail 5930 will in particular allow the mounting system to readily accommodate walls and building risers which do not have a perfectly straight line or vertical construction or to bridge gaps in a riser wall, and thus allows upper and lower duct elements to be properly aligned.
• Illustrated in Figures 57 and 58 is another method of forming a duct element 5700. which can be assembled into a building riser or attached to a building wall, and assembled with a like duct element.
• the method of Figure 57 allows a duct 5700 to be formed on site, or the duct wall portions can be formed in a factory environment and transported to the site for assembly to a building riser or wall.
• FIG. 57 shows on the left hand side a means of attachment to a building riser by a channel 5720, whereas on the right can be seen a fire rated block wall, should one exist in situ, or to the far right a second channel 5720 which can interact with a supporting block 5762 as will be explained below.
• connection methods that is, right hand side block wall connection or connection by channel 5720, are alternatives depending upon the site requirements.
• the channels 5720 have a series of welded nuts or fixings 5722, which are able to receive horizontal reinforcing rods 5723 which are screwed therein.
• Trimesh elements 4130 either a single element which spans the distance between the channels 5720 and the opposite fire rated black wall element, or as illustrated in Figure 57 two separate elements, are secured in place by means of slotting into the channel 5720, and having the reinforcing rods 5723 pass through their middle regions, and the mesh can be secured to the rods 5723 by tie wire or hog rings 510 or the like.
• the right hand side of the riser is not a block wall 5750, but is rather another opening which is bounded by upper and lower slabs, then a similar arrangement to the left side of figure 57 would be used, as illustrated by presence of the channel 5720 on the right side of the figure 57. However if there is an aperture, that aperture can be bridged by a beam 5762 to which a channel 5720 can be attached.
• the use of the channel 5720 also assists in taking up dimensional differences in the riser wall due to irregularities or dimensional variance.
• the depth of channel portion in the channel 5720 can be selected according the requirements on site to achieve this dimensional variance take-up.
• Illustrated in Figure 58 is an other jointing system to produce a fire rated duct in a building riser, or to construct a riser wall per se whereby a fire rated panel 500, such as described above, can be hung into a building riser space to directly form a duct therein.
• a fire rated panel 500 such as described above
• the upper left hand corner of the panel 500 and the upper part of the channel 5720 are not illustrated.
• the channel 5720 is used and secured to the riser at one end and another similar channel 5720, not illustrated, on an opposing riser surface, or bridging a riser aperture as described above.
• the beam sections 5815 are welded to the beam 5810 by fillet welds 5817 at the ends of the beam 5810, but can also be welded by mean of large diameter holes 5816, which are located at a predetermined distance from the end of the beam.
• the holes 5816 which can be provided to also ensure that sufficient length of the beam section 5815 is in fact located inside the beam 5810. This distance may be say 200mm, but the distance would be worked out according to the dimensions and thickness of the beams, and the load they need to bear.
• the panels 500 are hung in place in a riser to form ducts in a riser, or multiple ducts therein or a riser wall, whereby the riser or slabs adjacent a riser space carries the weight of respective panels 500, by the beam system described, to directly form a fire rated duct or riser wall therein with relatively little spraying compared to prior art systems.
• further channel 5720 can be situated above a lower secured in place channel 5720, and the panels 500 either assembled on site or pre attached to the beams 5810, are positioned to sit in the groove of the channel 5720 (which groove helps to take up dimensional differences), and the lower edge of the panel 500, being received in the lower located channel member 5825 on top of the beam 5810.
• Intumescent material can be used between the member 5825 and the lower edge of an upper panel 500, so that it will expand in the case of a fire.
• Vermiculite (exfoliated, asbestos & silica free) 30.00-80.00%
• Vermiculite (exfoliated, asbestos & silica free) 1318-00-9 25.00-80.00%

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