U.S. patent application number 10/954249 was filed with the patent office on 2006-04-06 for fire-resistant panel and method of manufacture.
This patent application is currently assigned to R E P Technologies Ltd.. Invention is credited to B. L. Au.
Application Number | 20060070321 10/954249 |
Document ID | / |
Family ID | 36124170 |
Filed Date | 2006-04-06 |
United States Patent
Application |
20060070321 |
Kind Code |
A1 |
Au; B. L. |
April 6, 2006 |
Fire-resistant panel and method of manufacture
Abstract
A highly fire-resistant and environmentally-friendly panel of 2
mm to 28 mm may be manufactured by a blending of magnesium
compounds, sodium silicate, kaolin, fillers, and additives to form
the core materials, reinforced by 4 layers of fire-resistant glass
fiber meshes and fabrics. Using a proprietary ITC process that
accelerates the chemical reactions of the ingredients to generate
sufficient heat without external supply of energy, the panels may
be completely cured within 24 hours instead of 10 days. The use of
waste materials, energy-saving curing system and no gas emission
manufacturing process combined to make this panel an eco-friendly
product which offers the world's highest-rated fire resistance of 5
hours, high flexural strength, low density, durability and
effective water-resistance.
Inventors: |
Au; B. L.; (Hong Kong,
HK) |
Correspondence
Address: |
KOLISCH HARTWELL, P.C.
200 PACIFIC BUILDING
520 SW YAMHILL STREET
PORTLAND
OR
97204
US
|
Assignee: |
R E P Technologies Ltd.
|
Family ID: |
36124170 |
Appl. No.: |
10/954249 |
Filed: |
September 29, 2004 |
Current U.S.
Class: |
52/232 ;
52/741.1 |
Current CPC
Class: |
C04B 28/26 20130101;
C04B 2111/27 20130101; C04B 2111/28 20130101; H02G 3/0412 20130101;
E04B 9/045 20130101; Y02W 30/91 20150501; E04B 9/0421 20130101;
E04B 9/001 20130101; Y02W 30/97 20150501; H02G 3/0487 20130101;
E04B 2/7411 20130101; E04B 1/942 20130101; C04B 40/02 20130101;
C04B 2111/00612 20130101; C04B 28/26 20130101; C04B 14/106
20130101; C04B 14/18 20130101; C04B 14/303 20130101; C04B 14/304
20130101; C04B 18/24 20130101; C04B 18/26 20130101; C04B 18/30
20130101; C04B 22/124 20130101; C04B 24/32 20130101; C04B 40/02
20130101; C04B 40/0263 20130101; C04B 2103/65 20130101; C04B 28/26
20130101; C04B 14/106 20130101; C04B 14/18 20130101; C04B 14/303
20130101; C04B 14/304 20130101; C04B 18/24 20130101; C04B 18/26
20130101; C04B 18/30 20130101; C04B 22/0013 20130101; C04B 22/124
20130101; C04B 24/32 20130101; C04B 40/02 20130101; C04B 40/0263
20130101; C04B 28/26 20130101; C04B 14/106 20130101; C04B 14/18
20130101; C04B 14/303 20130101; C04B 14/304 20130101; C04B 18/24
20130101; C04B 18/26 20130101; C04B 18/30 20130101; C04B 22/124
20130101; C04B 24/085 20130101; C04B 24/32 20130101; C04B 40/02
20130101; C04B 40/0263 20130101 |
Class at
Publication: |
052/232 ;
052/741.1 |
International
Class: |
E04C 2/00 20060101
E04C002/00; E04B 1/00 20060101 E04B001/00 |
Claims
1. A method of manufacturing a fire-resistant panel, comprising:
(a) preparing a panel composition having an exothermic curing
process; (b) forming the panel composition into a panel; (c)
arranging a plurality of panels so that the heat released by the
panels during the exothermic curing process is sufficient to cure
the plurality of panels with no additional heating.
2. The method of claim 1, wherein the panels are cured within about
24 hours with no additional heating.
3. The method of claim 1, wherein forming the panel composition
into a panel includes incorporating one or more layers selected
from fire-resistant glass fiber and fire-resistant fabric within
the panel.
4. The method of claim 1, wherein the panel composition includes
magnesium oxide, magnesium chloride, and sodium silicate.
5. The method of claim 4, wherein the panel composition further
includes kaolin, one or more fillers, one or more hydrophobic
agents, and one or more additives.
6. A method of manufacturing a fire-resistant panel, comprising:
(a) blending an aqueous composition that includes magnesium
compounds, sodium silicate, and kaolin; (b) incorporating one or
more layers selected from fire-resistant glass fiber and
fire-resistant fabric within the composition and forming the
composition into a panel; (c) arranging a plurality of panels so
that heat released by the panels collectively raises the
temperature of the arranged panels sufficiently to cure the
composition, with no external heating; (d) shaping the sheets into
fire-resistant panels.
7. The method of claim 6, wherein the composition further includes
one or more of additional fillers, hydrophobic agents, and
additives.
8. The method of claim 6, including incorporating one or more
layers of glass fiber mesh and one or more layers of fire-resistant
fabric within the composition on each side of the panel.
9. The method of claim 6, wherein the panels are arranged with
substantially no intervening space between adjacent panels.
10. The method of claim 6, wherein the panels are held at a
temperature sufficient to cure the panel composition, for a time
sufficient to cure the composition.
11. The method of claim 10, wherein the time sufficient to cure the
composition is about 24 hours.
12. The method of claim 6, wherein the temperature of the panels is
raised to about 100.degree. C.
13. The method of claim 6, wherein the composition is prepared from
an aqueous solution of magnesium chloride and magnesium oxide.
14. The method of claim 7, wherein the fillers include perlite.
15. The method of claim 7, wherein the fillers include organic
agricultural waste.
16. The method of claim 15, wherein fillers include at least one of
sawdust, wood fibers, rice hulls, and wheat straw.
17. The method of claim 7, wherein the hydrophobic agents are
selected from oils, fatty acids and boric acid.
18. The method of claim 7, wherein the additives include at least
one of aluminum oxide and polyoxyethylene alkyl ether.
19. A fire-resistant panel, prepared according to the method of any
of claims 1-18.
20. The fire-resistant panel of claim 19, having a composition that
is 45%-60% by weight of magnesium compounds; 8%-15% by weight of
sodium silicate; 10%-15% by weight of kaolin; 15%-20% by weight of
fillers; 0.5%-1% of hydrophobic agents; and 2%-3% of additives.
21. The fire-resistant panel of claim 19, wherein the panel is
capable of withstanding fire at a temperature of at least
1,000.degree. C., and is configured for use in fire-resistant
construction.
22. The fire-resistant panel of claim 20, wherein the fillers
include organic agricultural waste materials.
23. The fire-resistant panel of claim 19, wherein the panel has a
thickness of about 2 mm to about 28 mm, and a width of about 1 foot
to about 4 feet, and a length of about 1 foot to about 16 feet.
24. An environmentally-friendly fire-resistant panel, comprising a
core material that includes magnesium compounds, sodium silicate,
kaolin, fillers, and additives, which is reinforced by 2 or more
layers of fire-resistant glass fiber mesh and 2 or more layers of
fire-resistant fabric; where the panel is cured by an internal
exothermic process in about 24 hours without the application of
external heating; and the panel exhibits high fire-resistance, low
density, high flexural strength and effective water-resistance.
25. A suspended ceiling system comprising a fire-resistant panel of
any of claims 19-24, characterized in that the suspended ceiling
system is capable of achieving a fire rating of 5 hours integrity
at a temperature of approximately 1,200.degree. C. in accordance
with the British Standard 476: Part 22: 1987.
26. A non-loadbearing partition system comprising a fire-resistant
panel of any of claims 19-24, characterized in that the partition
system is capable of achieving a fire-rating of 4 hours integrity
and insulation at a temperature of approximately 1,200.degree. C.
in accordance with the British Standard 476: Part 22: 1987.
27. A steel stud hoarding system comprising a fire-resistant panel
of any of claims 19-24, characterized in that the hoarding system
is capable of achieving a fire-rating of 4 hours integrity at a
temperature of approximately 1,200.degree. C. in accordance with
the British Standard 476: Part 22: 1987.
28. An electrical and mechanical services enclosure system
comprising a fire-resistant panel of any of claims 19-24,
characterized in that the enclosure system is capable of achieving
a fire-rating of 2 hours integrity and insulation at a temperature
of approximately 1,050.degree. C. in accordance with the British
Standard 476: Part 20: 1987.
Description
TECHNICAL FIELD
[0001] The invention relates to the preparation of fire-resistant
building materials. More particularly, the invention relates to
fire-resistant panel materials that exhibit increased
fire-resistance, and are lightweight, strong, and durable.
BACKGROUND
[0002] Government regulations now typically require that
construction projects incorporate fire-resistant materials for
purposes of enhancing fire safety. Building codes may even require
the use of materials having established fire resistance ratings.
Although a variety of non-combustible panel materials are
commercially available, including gypsum boards, fiber-cement
boards, calcium silicate boards, and the like, many demonstrate
limited fire-resistance, and are environmentally-hazardous in their
manufacture, use and disposal. Additionally, some non-combustible
panel materials exhibit excessive weight, lack of strength and
durability, and are susceptible to water damage.
[0003] In the manufacture of fire-resistant panel materials, it is
therefore desirable to develop a product that is not only
substantially fire-resistant, but is also water-resistant, light in
weight, rigid, strong, and durable. For the protection of public
health, such a product is preferably free of toxic materials such
as formaldehyde and arsenic, and carcinogenic substances, such as
asbestos and crystalline silica.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 is a partial cross-sectional view of a fire-resistant
panel, according to an embodiment of the invention.
[0005] FIG. 2 is a flowchart depicting a fire-resistant panel
manufacturing process, according to an embodiment of the
invention.
[0006] FIG. 3 is a partial perspective view of a suspended ceiling
system, according to an embodiment of the invention.
[0007] FIG. 4 is a perspective sectional view of a partition
system, according to an embodiment of the invention.
[0008] FIG. 5 is a cross-sectional view of the partition system of
FIG. 4.
[0009] FIG. 6 is a perspective sectional view of a hoarding system,
according to an embodiment of the invention.
[0010] FIG. 7 is a cross-sectional view of the hoarding system of
FIG. 6.
[0011] FIG. 8 is a perspective sectional view of an electrical and
mechanical services enclosure system according to an embodiment of
the invention.
[0012] FIG. 9 is a cross-sectional view of the enclosure system of
FIG. 8.
[0013] FIG. 10 is a longitudinal cross-sectional view of the
enclosure system of FIG. 8.
DETAILED DESCRIPTION
[0014] Referring to FIG. 1, the present invention relates to a
fireproof or fire-resistant panel material 10, such as a board,
that offers a combination of a high degree of fire resistance, a
low density, high flexural strength, and effective water
resistance. These advantageous properties may be obtained by the
preparation of a panel core 12 that includes magnesium compounds,
sodium silicate, and kaolin, and may further include one or more
fillers, and hydrophobic agents. The panel may further include one
or more fire-resistant layers 14.
[0015] As used herein, the terms "fireproof" and "fire-resistant"
refer to a substance that is resistant to the effects of fire, that
is, describing a material that is substantially or completely
non-combustible and/or substantially insulating. By panel is meant
a generally planar construction material. In one aspect of the
invention, the panel is a fire-resistant board, dimensioned so as
to be compatible with standard construction methods and
materials.
[0016] The fire-resistant panel of the present invention may
generally be prepared by first blending the above core materials
with the desired fillers, hydrophobic agents and additives in
appropriate proportions, followed by a process of strengthening the
panel through the application of one or more layers of
non-combustible fibrous glass mesh and fabric. The panels may then
be cured by accelerating the exothermic chemical reactions of the
ingredients, thereby generating heat and typically curing the
panels within about 24 hours. As this process requires no applied
energy or external heating, both the curing time and the associated
energy costs may be dramatically reduced, in one example by about
90%. In one aspect of the invention, the panel is manufactured
using recycled and/or waste materials, resulting in a construction
material that is environmentally-friendly, as well as providing a
reduction in overall waste production.
[0017] Referring to FIG. 1, the fire-resistant panel according to
the present invention includes a core material 12, including
fire-resistant materials, fillers, hydrophobic agents and
additives. Preferably, the core materials are non-toxic and
non-carcinogenic. The core material typically includes a matrix
formed by one or more magnesium compounds, a silicate, and kaolin
clay. The magnesium compounds may be selected from magnesium
chloride and magnesium oxide. The addition of silicates, preferably
sodium silicate, and kaolin serve to enhance the fire-resistance
and thermal resistance of the panel. The core material is generally
formulated so that the resulting fire-resistant panel is composed
of about 45% to about 60% by weight of the magnesium compounds,
about 8% to about 15% by weight of sodium silicate, and about 10%
to about 15% by weight of kaolin. The combination of these core
matrix ingredients yield a panel core that contributes to the high
flexural strength of the resulting cured panel.
[0018] The core material 12 may incorporate one or more fillers
that serve to lower the weight of the panel. Appropriate filler
materials may include organic fillers, such as sawdust, wood
fibers, and agricultural waste materials such as rice hulls and
wheat straw. Alternatively, or in addition, the filler material may
be inorganic, such as perlite. The addition of perlite as a filler
material may serve to reduce the weight of the resulting panel.
Typically, the fire-resistant panel includes about 15% to about 20%
by weight of such filler materials.
[0019] The core material may incorporate one or more hydrophobic
agents. Such hydrophobic agents may be added in order to increase
the overall water-resistance of the fire-resistant panel. Any
suitable hydrophobic agent may be used during panel manufacture,
including for example oils and fatty acids. Alternatively, or in
addition, boric acid may be used as a hydrophobic agent. Typically,
the fire-resistant panel includes about 0.5% to about 1% by weight
of hydrophobic agents.
[0020] Other additives may be selected to alter one or more
performance characteristics of the fire-resistance panel. That is,
characteristics such as flexibility, density, hardness, and the
like may be tailored for a particular application. For example,
aluminum oxide may be added in order to increase the hardness and
compression strength of the resulting panel. Alternatively, or in
addition, polyoxyethylene alkyl ether may be used as a defoaming
agent to reduce the foaming of the ingredients during the
manufacture of the panel. Typically, the fire-resistant panel
includes about 2% to about 3% by weight of such additives.
[0021] The fire-resistant panel may be manufactured according to a
process set out in flowchart 20 of FIG. 2. More specifically, the
raw materials for the manufacturing process may be obtained at 22,
and pre-processed for the manufacturing process at 24. Magnesium
chloride, in aqueous form, is first blended with the appropriate
fillers, hydrophobic agents, and additives in the desired
proportions at 26, and thoroughly mixed in a mixer at 28. Magnesium
oxide and fillers may be combined at 30, and the magnesium chloride
mixture may then be added to the magnesium oxide mixture in a
high-speed blender, and blended at high speed at 32. The mixture of
core ingredients may then be placed in a panel form, or mold, and
pressed into the desired thickness, such as by using a rolling
mill, at 34.
[0022] In a selected aspect of the fire-resistant panel, one or
more fire-resistant layers 14 may be applied to the panel during
manufacture at 36. For example, one or more layer of fire-resistant
glass fiber mesh 16 and/or fire-resistant fabric 18 may be applied
to the panel to strengthen the panel, and to confer enhanced
fire-resistance. An exemplary glass fiber mesh may have a density
of 60 gram per square meter, and exhibit a fishnet mesh structure.
An exemplary non-combustible fabric may have a density of 15 grams
per square meter. Although any combination and arrangement of such
layers may be used, typically, a single layer of glass fiber mesh
and a single layer of fire-resistant fabric are applied to each
side of the panel, so that the finished panel incorporates two
layers each of glass fiber mesh and fabric.
[0023] Typically the fire-resistant glass fiber mesh 16 and fabric
18 are applied by placing them in the panel form before the mixture
of core ingredients is added. After the core ingredient mixture is
added to the form, additional layers may be applied to the upper
surface of the core ingredients. The panel may then be compressed
by a rolling mill to the desired thickness at 34. During this
panel-forming process, the surface layers are typically
encapsulated by the core material to at least some extent, and may
be encapsulated entirely by the core material. Therefore, as shown
in FIG. 1, the four layers of the reinforcing materials are
enclosed within the core material, without additional
adhesives.
[0024] The formed panel may then be cured using an Interactive
Thermal Curing process (ITC process). The ITC process shortens
conventional curing time by up to a factor of 10, thereby providing
a substantial saving of both energy and labor. In addition, the
core material may be selected so that the curing process emits no
greenhouse gases.
[0025] Typically, the curing process of fire-resistant boards such
as gypsum boards, fiber-cement boards, calcium silicate boards, and
the like, requires the use of heat, steam, pressure, or a
combination of all of the above. In contrast, the ITC process
accelerates the exothermic chemical reactions of the core
ingredients in order to generate a sufficient amount of heat to
cure the sheets without requiring any applied energy. In addition,
curing time may be reduced considerably while the moisture content
in the panel reaches an equilibrium value quickly and
automatically.
[0026] The shaped `green` (or uncured) panels are initially stacked
up in racks and stored at room temperature for 24 hours, at 38 of
FIG. 2. A plurality of panels are then released from the racks and
stacked closely together. Preferably, the panels are stacked with
little or no intervening space between panels. The closely stacked
panels are then placed in a curing chamber, where the chemical
reactions occurring among the core ingredients within the panels
collectively generates sufficient heat to rapidly complete the
curing process for the stacked panels, at 40 of FIG. 2. When panel
temperatures reach about 100.degree. C., excessive moisture inside
the panel may be forced out as steam. Therefore the curing chamber
may be so constructed as to permit the condensate to be collected
for subsequent disposal.
[0027] As indicated, by using the ITC process, the chemical
reactions occurring in the core materials are accelerated, and so
the amount of the time required to complete the curing process for
the panels may be drastically reduced. A conventional 10-day curing
process may be reduced to one single day (24 hour period).
Furthermore, as no external source of energy is required for the
ITC process, the energy and labor costs for the production of the
fire-resistant panels may be reduced by 90%, relative to a curing
process that requires heating to effect curing.
[0028] After curing, the cured fire-resistant panels may be
released and trimmed, at 42 of FIG. 2. As the panels may be
manufactured in a wide range of sizes and thicknesses, the panels
may then be cut into any desired size and shape, at 44. The
fire-resistant panel is generally shaped to be fully compatible
with standard construction methods and materials. The
fire-resistant panel may be at least about 2 mm thick to about 28
mm thick. Preferably, panel is about 3 mm to about 18 mm thick. The
fire-resistant panel is generally at least 1 foot wide, and
preferably is about 4 feet wide. The fire-resistant panel may be up
to 16 feet or any other suitable length. Typically the panel is at
least 1 foot long, preferably at least 6 feet long, and more
preferably at least 8 feet long.
[0029] After trimming and cutting, the panels may be inspected for
flaws and to guarantee consistency and quality, at 46. The
fire-resistant panels may then be warehoused and/or shipped, as
needed, at 48.
[0030] The disclosed fire-resistant panel is particularly
advantageous in that it is non-combustible, decay-resistant,
water-resistant, weather-resistant, heat-insulating,
sound-insulating, impact-resistant, termite-repellent, and
fungi-repellent. The advantageous characteristics of the
fire-resistant panel have been verified under stringent testing, as
described in the following specific examples.
[0031] The disclosed fire-resistant panel passed the
non-combustibility fire test in accordance with both the British
Standard 476: Part 4 and Chinese GB 8624 (GB 5464-85) test
standards. In one embodiment, the fire-resistant panel may
withstand an intense heat of 1,200.degree. C. for up to about 4-5
hours.
[0032] The disclosed panel is verified to be water-resistant in
that it typically exhibits a water absorption rate of 0.23
g/m.sup.3 or less in accordance with the ASTM (American Society of
Testing and Materials) C1185 test standard for
water-resistance.
[0033] The heat-insulating qualities of the disclosed
fire-resistant panel may be verified in that the disclosed panel
typically exhibits a thermal conductivity between 0.089 W/mK and
0.3096 W/mK and an R Value of between 0.0577 m.sup.2K/W and 0.143
m.sup.2K/W in accordance with the ASTM C518 test standard for
heat-insulation.
[0034] The sound-insulating qualities of the disclosed
fire-resistant panel may be demonstrated using a partition
constructed with 2 layers of 6 mm thick fire-resistant panel on
each side of a common steel stud frame, providing an overall
thickness of 124 mm, where the cavity is filled with 50 kg/m.sup.3
mineral wool. A partition constructed in this manner is capable of
exhibiting a Sound Transmission Class (STC) of at least 51
according to the BS 2750: Part 3 test standard. An STC value
represents a single number rating used to characterize the sound
insulating value of a partition. The higher the STC rating, the
less sound will be transmitted through the partition. An STC rating
of 50 or higher is considered very good or excellent.
[0035] The disclosed fire-resistant panel may demonstrate an impact
strength of greater than or equal to 4.04 m-kg, as determined in
accordance with the ASTM D3029 test standard, and with a modulus of
rupture greater than or equal to 31.42 MPa (Longitudinal); 30.84
MPa (Traverse) in accordance with the ASTM C120 test standard.
[0036] As the disclosed fire-resistant panel incorporates inorganic
materials, as described above, the panel is substantially
termite-repellent, and the ingredients further repel termites,
woodworms and bugs. Additionally, the fungi-resistance of the
disclosed fire-resistant panel may be verified in that the panel
exhibits a rating of 0 (fungi free) in accordance with the ASTM G21
test standard.
[0037] The disclosed fire-resistant panel typically exhibits a
density of about 690 kg/m.sup.3 as determined in accordance with
the ASTM C1185 test standard, making the panel substantially
lightweight in comparison with other non-combustible boards.
[0038] The disclosed fire-resistant panel typically exhibits a
creep modulus that is greater than or equal to about 433 MPa/cm,
and its load deflection is generally less than or equal to
2.59.times.10.sup.-3 of span, both in accordance with the ASTM
D2990 test standard, making the disclosed panel highly
dimensionally-stable. In addition, the disclosed fire-resistant
panel is substantially non-deforming, exhibiting a modulus of
elasticity greater than or equal to 7,820 MPa (Longitudinal); 6,347
MPa (Traverse) in accordance with the ASTM C120 test standard.
[0039] In addition to the above properties, the disclosed
fire-resistant panel typically retains fasteners well,
demonstrating a fastener pull resistance between about 937.5 N and
1,160 N, as determined in accordance with the ASTM D473 test
standard.
[0040] Due to the environmentally-friendly manufacturing process
used to prepare the panels, the panels typically do not contain any
environmentally-hazardous toxic glues, such as formaldehyde,
arsenic, or carcinogenic substances such as asbestos or crystalline
silica. More particularly, none of the ingredients typically used
in preparing the disclosed fire-resistant panel are classified as
hazardous by the Superfund Amendments and Reauthorization Act, the
Toxic Substances Control Act, the Recommended Conservation and
Recovery Act and Workplace Hazardous Materials Information System
(Canada). Similarly, none of the ingredients used in preparing the
disclosed panel are classified as carcinogenic by the International
Agency for Research on Cancer, the Occupational Safety and Health
Administration, or the National Toxicological Program. As a result,
the disclosed fire-resistant panel may be considered substantially
non-toxic and non-carcinogenic.
[0041] The disclosed fire-resistant panel is therefore lightweight,
water resistant, durable, strong, and nail-holding, as well as
exhibiting significant fire-resistance. However, in addition to the
above desirable properties, the fire-resistant panel is versatile
and may be readily handled like wood. The panel may be cut, sawn,
drilled, nailed, screwed, stapled, wallpapered, painted and
fabricated with veneer, laminate, or metal covering. The panel is
highly dimensionally-stable, having a negligible expansion and
contraction rate. Further, the panel will not delaminate or
deteriorate even after prolonged exposure to moisture.
[0042] Due to these many advantageous properties, the
fire-resistant panel of the disclosure may be particularly suited
for use in partitions, ceilings, drywalls, hoarding, smoke
barriers, fire doors, air-conditioning or cable ducts, electrical
and mechanical services enclosures, raised floor cores, and the
like. Where the panel is relatively thin, for example having a
thickness of 6 mm or less, the panel may be bent to fit around, for
example, round columns or other intricate architectural designs.
The panel may serve as base for ceramic tiling even in wet
environments. Additionally, the panel manufacture is
environmentally-friendly, as it turns such waste materials as wood
fibers, sawdust, rice hulls into a useful product that saves
energy, emitting no greenhouse gases in the process.
[0043] A comparison between an embodiment of the fire-resistant
panel according to the disclosure and other non-combustible panel
materials is shown in Table 1. TABLE-US-00001 TABLE 1 Fiber-
Calcium Gypsum Cement Silicate Disclosed Feature Panel Panel Panel
Panel Non-Combustible May be Yes Yes Yes Moisture-Resistant No Yes
Yes Yes Weather-Resistant No No No Yes Impact-Resistant No Yes No
Yes Sound-Insulating No No Yes Yes Heat-Insulating No No Yes Yes
Decay-Resistant No Yes Yes Yes Termite-Resistant No Yes Yes Yes
Fungi-Repellent No Yes Yes Yes Non-Deforming No No Yes Yes Safe to
Use Fragile Carcino- Carcino- Non-toxic genic* genic* Easy to Use:
Sawing Yes Yes Yes Yes Drilling Yes Yes Yes Yes Stapling No No No
Yes Gluing Yes No No Yes Nail-holding No No No Yes Screw-holding
Insecure Insecure Insecure Yes Fabricating No No No Yes Foiling No
No No Yes Veneering No No No Yes Varnishing No No No Yes Painting
Yes Yes Yes Yes Wallpapering Yes Yes Yes Yes Tiling No Yes Yes Yes
Bendable No No No Yes (6 mm thick) Fire Resistance 15 min 30 min 60
min 300 min (6 mm Integrity 700.degree. C. 822.degree. C.
925.degree. C. 1200.degree. C. as per BS 476: Part 22) Density
(kg/m.sup.3) 700-950 1200-1450 900-950 690 Life Span (Indoors) ? ?
? Up to 50 Years *Carcinogenic due to the presence of respirable
crystalline silica (CS). The International Agency for Research on
Cancer (IARC) classifies CS as a carcinogenic substance.
[0044] Additional comparisons between an embodiment of the
fire-resistant panel according to the disclosure and calcium
silicate boards with respect to fire resistance, density, modulus
of elasticity, modulus of rupture, water absorption rate, and
toxicity are provided in Table 2. TABLE-US-00002 TABLE 2 Test Test
Standard Disclosed Panel Calcium Silicate Board Percentage
Difference.sup.1 Density ASTM C1185 690 kg/m.sup.3 900 kg/m.sup.3
-23% Modulus of Elasticity ASTM C120 Longitudinal 7,820 N/mm.sup.2
3,200 N/mm.sup.2 +144% Transverse 6,347 N/mm.sup.2 2,500 N/mm.sup.2
+154% Modulus of Rupture ASTM C120 Longitudinal 31.4 N/mm.sup.2
10.0 N/mm.sup.2 +214% Transverse 30.8 N/mm.sup.2 5.5 N/mm.sup.2
+460% Water Absorption Rate.sup.1 ASTM C1185 approx. 0.23 approx.
0.55 -60% g/cm.sup.3 g/cm.sup.3 Fastener Pull Resistance ASTM D473
937.5N-1160N 550-620N +70%-87% Fire resistance.sup.2 BS 476: Part
22 6 mm 9 mm N/A Toxicity No Yes.sup.3 N/A 1 .times. % .times.
.times. Difference = [ Data .times. .times. of .times. .times.
Disclosed .times. .times. Panel ] - [ Data .times. .times. of
.times. .times. Calcium .times. .times. Silicate .times. .times.
Panel ] [ Data of Calcium Silicate Panel ] .times. 100 .times. %
.times. ##EQU1## .sup.2Weight of water absorbed per unit volume of
board .sup.3Panel thickness required to achieve 4 hour integrity
according to BS 476: Part 22 .sup.4Contains carcinogenic
crystalline silica (CS). IARC classified crystalline silica as
carcinogenic. Airborne dust of CS can cause silicosis, an incurable
lung disease, and increase the risk of bronchitis, pulmonary
fibrosis, tuberculosis, lung cancer, renal disease and
scleroderma.
[0045] As detailed above, the fire-resistant panel disclosed herein
exhibits superior performance, particularly in terms of
fire-resistance and heat-insulation. While the use of the disclosed
panel confers these advantageous properties onto any type of
construction that incorporates the panel, particular selected
systems may demonstrate outstanding results, as set out below:
[0046] A section of a suspended ceiling system 50 that incorporates
disclosed fire-resistant panels 51 is depicted in FIG. 3. The
suspended ceiling system section may include a structural framework
formed by U-channels 52, with steel angles 53 present along two
edges. The fire-resistant panels may be attached to the U-channels
for example with self-tapping screws 54 or other fasteners, while
the angle braces may be attached to the concrete wall using, for
example, 6 mm head diameter concrete nails 55. The suspended
ceiling system is typically suspended via hangers 56. Although
using fire-resistant panels having a thickness of only 6 mm, the
resulting suspended ceiling system has achieved a fire-rating of 5
hours integrity at .about.1,200.degree. C. in accordance with the
BS 476: Part 22: 1987.
[0047] A non-loadbearing partition system 60 incorporating the
disclosed fire-resistant panel 61 is depicted in FIGS. 4 and 5. The
partition system provides a nominal partition thickness of 111 mm,
which may include two fire-resistant panels 61 on each side, each
approximately 9 mm thick, enclosing mineral wool 62 having a
density of approximately 100 kg/m.sup.3. The partition system may
include an internal structural framework of upper and lower steel
U-channels 63 and vertical steel U-channels 64, attached to the
panels with suitable fasteners, such as self-tapping screws 65. The
partition may be attached to the ceiling and floor using, for
example, suitable anchor bolts 66. The resulting partition system
is capable of achieving a fire-rating of 4 hours integrity and
insulation at .about.1,200.degree. C. in accordance with BS 476:
Part 22: 1987.
[0048] A steel stud hoarding (temporary fencing) system 70 that
incorporates the disclosed fire-resistant panels is depicted in
FIGS. 6 and 7. The hoarding system provides a nominal partition
thickness of 74 mm, which may include fire-resistant panels 71,
each approximately 6 mm thick, and fire-resistant panel fillets 72,
also approximately 6 mm thick. The hoarding system may include an
internal structural framework having upper and lower steel
U-channels 73, vertical steel U-channels 74, horizontal steel
U-channels 75, and wall-mounted U-channels 76. The framework may be
attached to the panels and fillets with suitable fasteners, such as
self-tapping screws 77, while the hoarding system may be attached
to the ceiling and floor using, for example, suitable anchor bolts
78. Typically joints' between panels 71 would be sealed with a
fire-rated sealant 79. The resulting hoarding system is capable of
achieving a fire-rating of 4 hours integrity at
.about.1,200.degree. C. in accordance with BS 476: Part 22:
1987.
[0049] An Electrical and Maintenance (E&M) services enclosure
system 80 is depicted in FIGS. 8, 9, and 10. The enclosure system
is particularly useful as a fire-resistant enclosure for electrical
and mechanical services 81, for example including one or more of
electrical cables, communication cables, plumbing for water or
other fluids, etc. The E&M services enclosure system may
include fire-resistant panels 82, each approximately 6 mm thick,
with fire-resistant panel fillets 83, also approximately 6 mm
thick, enclosing joints between fire-resistant panels 82. The
joints are internally supported by steel angles 84 secured to the
panels with self-tapping screws 85. The fire-resistant panels
define an interior space that includes a channel for the electrical
and mechanical services 81 defined by a steel channel collar 86,
with the intervening space between the channel collar and the
fire-resistant panel filled with mineral wool insulation, having a
density of approximately 100 kg/m.sup.3 87. The E&M services
enclosure system may be supported by threaded rod hangers 88, with
the hanger penetration openings typically sealed with an
appropriate intumescent joint sealant. Fire-resistant panels and
fillets may be secured to intervening walls using appropriate
concrete nails 89 or other fasteners. FIG. 10 shows a longitudinal
section of an E&M services enclosure system, showing details of
an intersection of the services enclosure duct with a wall. The
depicted E&M services enclosure system is capable of achieving
a fire-rating of 2 hours integrity and insulation in accordance
with BS 476: Part 20: 1987, with respect to an external or internal
fire.
Applications of the Fire-Resistant Panel
[0050] The disclosed fire-resistant panel may provide effective
fire prevention and up to 5 hours of fire protection, and is
particularly valuable when permitting the safe evacuation of human
lives and assets, particularly in disasters like residential,
commercial, or forest fires. The fire-resistant panel may therefore
be used in numerous applications in the following industries:
a. Construction and Renovation
[0051] The panel offers advantageous properties wherever fire
protection is required--including but not limited to offices,
banks, shopping malls, department stores, supermarkets,
restaurants, hotels, cinemas, theaters, opera houses, karaoke,
night clubs, jewelry shops, convention centers, exhibition halls,
schools, churches, hospitals, clinics, dormitories, gymnasiums,
recreation and sports centers, car parks, hi-rise residential
buildings, and the like. Non-combustible, strong and durable, the
disclosed panel may be particularly suitable for partitions,
ceilings, interior walls, drywalls, fire walls, hoarding, fire
doors, soffits, air-conditioning duct liners, E&M services
enclosures, electric conduit liners, plenum ceilings, cores for
raised floors, lining panels for elevators; wall coverings for
elevator shafts, stairwells, garages; roof-decks, generator-covers,
sound-insulating walls, thermal barriers and the like. The
fire-resistant panel can also be used as ceramic tile underlayment
in wet environments.
b. Air Transport
[0052] The disclosed panel with the highest fire-rating is most
effective in fire protection for plane cabins and cargo holds;
ceilings, partitions, wall coverings, fire doors, fire exits, fire
separation barriers, air-conditioning duct coverings, E&M
services enclosures for airports, air cargo terminals, air
caterers, hangars, fuel storage, passengers waiting rooms,
corridors, boarding gates, and the like.
c. Land Transport
[0053] The disclosed panel may be used in fire protective walls,
flooring and body for all types of vehicles, including but not
limited to cars, buses, trams, trucks, trailers, tourist coaches,
mobile homes, school buses, ambulances, trains, cargo trains,
MTR/light railcars, MTR/railway stations, terminals, multi-story
car parks, gas stations, garages, cargo handling areas, and the
like. The fire-resistant panel may offer particular utility in the
transport of materials that exhibit a combustion hazard, such as
oil trucks, flammable goods trucks, and the like.
d. Shipping
[0054] The disclosed panel is well-suited for lightweight and
sound-insulating panels, partitions of cabins for all kinds of
vessels, especially cruise ships, yachts, hydrofoils, ferries, oil
tankers, LPG carriers and naval ships, among others.
e. Industry
[0055] The disclosed panel is well-suited for industrial wall
coverings, partitions, ceilings, electric conduit liners, air
conditioning duct covering; oil, flammable goods storage, fire
doors, fire exits, fire separation barriers for factories,
warehouses, electric sub-stations, noise silencers and the like. In
particular, the disclosed fire-resistant panel offers advantages in
the construction of fire protective walls, lift shafts, and
stairwell liners for industrial buildings.
[0056] Although the present invention has been shown and described
with reference to the foregoing operational principles and
preferred embodiments, it will be apparent to those skilled in the
art that various changes in form and detail may be made without
departing from the spirit and scope of the invention. The present
invention is intended to embrace all such alternatives,
modifications and variances that fall within the scope of the
appended claims.
* * * * *