AU2015201478A1 - MgO interwall barrier system, method of installation and method of constructing a building wall - Google Patents

Abstract

An MgO Interwall barrier system for generally parallel walls, the system including 5 a plurality of panels for installation between frames of the walls in an edge to edge configuration to form a barrier between the walls and coupling means to couple ends of the panels together, wherein the panels are formed of a material including magnesium oxide. H: \zi\Interwoven\NRPortbl\DCC\MZI\7582690_1docx-20/03/2015 10 12 12 12 12 MMINNNN l\\M \00 MEMommENNNIMEN, gw: Figure 1 Ab m Figure 2

Description

- 1 MGO INTERWALL BARRIER SYSTEM, METHOD OF INSTALLATION AND METHOD OF CONSTRUCTING A BUILDING WALL FIELD OF THE INVENTION 5 The present invention relates to an MgO Interwall barrier system, a method of installing an MgO Interwall barrier system and a method of constructing a party wall. More particularly, but not exclusively, the invention relates to a fire/noise resistant party wall or wall separating two adjoining buildings. 10 BACKGROUND OF THE INVENTION Adjoining buildings having a common wall, which is typically referred to as a party wall, these separating walls require certain standards of noise insulation and fire resistance, these standards typically being stipulated under relevant building codes and standards. Previous party walls have been difficult and time consuming to construct, complicated to install, 15 expensive and/or require a large amount of building space to install. Currently used Gypsum based Party walls are easily damaged either accidentally or deliberately and repairs are very expensive and timely. For example, masonry or brick party walls can be expensive and time consuming to install 20 and due to their weight require considerable support/foundations. Multi layer party walls have also been proposed, though these require a number of different layers to be installed, adding to the cost and time required for installation, particularly where expensive fire resistant panels are used. Furthermore, previous multi layer party walls have used conventional plaster board panels that are vulnerable to the weather during and after the 25 installation process. Gypsum based party walls are prone to degradation by moisture and mould unless adequately protected from moisture intrusion though this is expensive to do. Some building complexes such as townhouse or apartment complexes have many party walls so it is desirable to minimise the cost and time required for installation, simplify 30 design requirements and minimise the amount of space consumed by the party wall so that a maximum of space is available to the occupants. H: \zi\Interwoven\NRPortbl\DCC\MZI\7582690_1docx-20/03/2015 -2 Examples of the invention seek to solve, or at least ameliorate, one or more disadvantages of previous party walls. SUMMARY OF THE INVENTION According to the present invention, there is provided an MgO Interwall barrier system for 5 generally parallel walls, the system including a plurality of panels for installation between frames of the walls in an end to end configuration to form a barrier between the walls and coupling means to couple ends of the panels together, wherein the panels are formed of a material comprising magnesium oxide. 10 According to a preferred embodiment, the material further comprises magnesium chloride, Perlite and glass fibres. Preferably, the material further comprises woodchips. More preferably, the panels are available between 10-20mm in thickness. According to a preferred embodiment, the coupling means includes a plurality of elongate 15 securing members configured to extend substantially around a periphery of each panel to fix the panels relative to the walls, the securing members having a channel in which ends of the panels can be received. Preferably, each securing member disposed at a base of the panels has at least one flange 20 extending transversely to the channel to define a space between the panels and the wall frames. Each securing member disposed at an upper edge the panels can have at least one flange extending transversely to the channel to define a space between the panels and the wall frames. According to a preferred embodiment, the space is approximately 20mm. 25 Preferably, the securing members disposed between adjacent panels have oppositely extending channels in which opposing ends of the adjacent panels can be received. Preferably, the channels are approximately between 20-25mm deep. The securing members can be formed of steel, preferably galvanised steel. 30 Preferably, the system further includes a plurality of fixing brackets for fixing the panels to at least one frame of the walls, the fixing brackets being formed of a material having a lower fire protection rating than the panels or the securing members. H: \zi\Interwoven\NRPortbl\DCC\MZI\7582690_1docx-20/03/2015 -3 The fixing brackets can be formed of aluminium and are preferably formed of 1.6mm thick aluminium. A plurality of the fixing brackets can be disposed on both sides of the panels for fixing the system to each wall. 5 In a preferred embodiment, the system is configured for use as a party wall system. Preferably, the system is configured to be both fire & acoustically resistant. According to another aspect of the present invention, there is provided a method of 10 installing an MgO Interwall barrier system, comprising the steps of: providing at least one elongate channel member, the channel member having a longitudinally extending channel and a base extending laterally from the channel; installing the channel member near a lower portion of a first wall frame so that the base of the channel member spaces the channel from the first wall frame; and installing lower ends of a plurality of panels into the 15 channel to form a barrier. In preferred embodiments, the channel member is fixed to a floor or base of a building. The method can further include the step of installing securing members between adjacent panels, the securing members having oppositely extending channels in which ends of the 20 panels can be received. According to another aspect of the present invention, there is provided a method of constructing a party wall, comprising the steps of. installing a first wall frame; installing an MgO Interwall barrier system using a method of the above described type; and installing a 25 frame of a second wall. H: \zi\Interwoven\NRPortbl\DCC\MZI\7582690_1docx-20/03/2015 -4 BRIEF DESCRIPTION OF THE DRAWINGS Preferred embodiments of the invention will be further described, by way of non-limiting example only, with reference to the accompanying drawings in which: 5 Figure 1 is a perspective view of an MgO Interwall barrier system of one embodiment of the invention; Figure 2 is a perspective view of the MgO Interwall barrier system installed between two wall frames; Figure 3 is a close perspective view of an MgO Interwall barrier system configured for use 10 in a multi story building; Figure 4 is a sectional view of the MgO Interwall barrier system; Figure 4a is a close perspective view of a party wall including the MgO Interwall barrier system; Figure 5 is a securing member for use with the MgO Interwall barrier system, the securing 15 member being configured for use along the bottom edge of the system; Figure 6 is a securing member for use with the MgO Interwall barrier system, the securing member being configured for use between adjacent panels of the system; Figure 7 is a securing member for use with the MgO Interwall barrier system, the securing member being configured for use as an end cap; and 20 Figure 8 is a bracket for use in fixing the MgO Interwall barrier system to a wall frame. DETAILED DESCRIPTION With reference to Figure 1, there is shown an MgO Interwall barrier system 10, according 25 to a preferred embodiment of the present invention. The system 10 is configured for use with generally parallel walls to form a party wall or separating wall between adjacent buildings/rooms to form a fire resistant and noise resistant barrier. The system 10, includes a plurality of panels 12, for installation between frames 14a & 14b 30 (see Figure 2) of the walls in an end to end configuration to form a barrier between the walls. The system also includes coupling 16b, means to couple ends of the panels 12, together. The panels 12, are formed of a material comprising magnesium oxide. H: \zi\Interwoven\NRPortbl\DCC\MZI\7582690_1docx-20/03/2015 -5 Magnesium oxide panels 12, have a number of properties that make them particularly suitable for use in a party wall system. For example, they have excellent fire resistance and are resistant to moisture damage. In contrast, previous party wall systems have focused on the use of plasterboard panels that have generally poor fire resistance and can 5 be vulnerable to mould and moisture damage. Previous plasterboard panels incorporating materials to improve fire or moisture resistance have generally been expensive and very thick, requiring significant space for their installation. The inventors have found that by departing from conventional practice and providing a panel that does not include plasterboard, a party wall system having numerous technical advantages is obtained. 10 It will be appreciated that numerous panel compositions are possible, though the material used for the panel construction preferably includes magnesium chloride, Perlite and glass fibres. The material can also include a small amount woodchips, for example 5% to 20% by weight. 15 In a preferred form, the panel composition is 4 5 % magnesium oxide, 3 5 % magnesium chloride, 19% Perlite, and 1% fibreglass. Using this preferred form, panels having a thickness of between 10-20mm have been found to provide satisfactory performance. In this regard, a party wall constructed of such panels can meet the requirements of Fire 20 Resistance Level (FRL) 60/60/60 or 90/90/90, or sound insulation performance for separating walls of. Rw + Ctr 50 & Discontinuous Construction. In a preferred form, the panels are 600mm wide and 3000mm long. It will be appreciated that panels can be used in various thicknesses to achieve more 25 tailored project requirements. For example, the panels may have a thickness of 12mm, 15mm, up to 20mm or more. The panels are coupled together in a tight fitting relationship so as to block a path through which heat and/or fire and or sound can travel, thereby forming an effective fire barrier 30 between the walls. The system also provides an effective acoustic barrier to reduce the transmission of noise through the walls. As illustrated in Figure 1, the coupling means includes a plurality of elongate securing H :\m\Interwoven\NRPortbl\DCC\MZI\75826901 dx-20/03/2015 -6 members 16a, 16b, 16c which are configured to extend substantially around a periphery of each panel 12, to fix the panels 12, relative to the frames 14a, 14b. As illustrated in more detail in Figures 5 to 7, the securing members 16a, 16b, 16c each have a channel 17 in which ends of the panels 12, can be received. Securing member 16a is configured to be 5 disposed at the base of the panels 12, securing member 16b is configured for use between adjacent panels and securing member 16c is configured for use as an end cap around the periphery of the system. As illustrated in Figure 6, the securing member 16a has a pair of flanges extending 10 transversely to the channel 17, to form a base 19 which in use defines a space between the panels and the wall frames. It will be appreciated that the securing member 16a may be provided with a single flange on either side of the channel 17. Furthermore, the flange(s) may be discontinuous along the length of the securing member 16a and formed as individual flange members extending from the securing member at predetermined 15 locations, potentially on alternating sides of the securing member 16a. It will also be appreciated that only a single securing member may be used along the base of the system 10, though multiple securing members can be used where convenient to do so. If multiple members are used they will preferably be abutting so as to maintain the continuity of the fire/noise barrier. A fire sealant should be used at the ends of the abutting members. 20 The securing member 16a may also be disposed at an upper edge of the panels to also define a space between the panels and an upper portion of the wall frames. In a preferred form, the flange is approximately 20mm so that the space between the system and the wall frame is also approximately 20mm. This spacing allows the system to maintain a good fire 25 resistance rating as the panels are offset from the walls. By providing flange(s) extending from the securing member 16a, construction of the wall is simplified because the securing member can be used as a guide in installing either or both walls in a straight and aligned manner. When installing the securing member 16a, a 30 bead of fire sealant is applied to the underside of the securing member 16a and the base 19 brought into contact with the existing wall frame 14a. The securing members 16b which are disposed between adjacent panels 12 have oppositely H :\m\Interwoven\NRPortbl\DCC\MZI\75826901 dx-20/03/2015 -7 extending channels 17 in which opposing ends of the adjacent panels 12 can be received to couple the adjacent panels together. The securing member 16c is used between rows of panels 12, to increase the height of the system so that it can be used in multi level buildings or when a height greater than 3000mm, 6000mm or 9000mm is required, up to 12000mm. 5 When installing securing members 16c at ends and/or along an upper edge of the system, a bead of fire sealant may also be applied in between the joined 16c members to form a continuous fire/noise barrier. So that a continuous barrier is provided, additional sealant, mineral wool and/or other fire resistant materials may be applied to any gaps. At least one 10 of the panels may be trimmed so as to be of a reduced width so that the system provides a fire barrier that is a tight fit within the space provided. In a preferred form, each of the securing members 16a, 16b, 16c have channels 17 that are approximately 25mm deep. It has been found that this depth provides good retention of 15 the panels so as to maintain structural rigidity of the system as well as a suitable fire barrier. So as to provide good fire resistance, the securing members 16a, 16b, 16c are formed of galvanised steel. As illustrated in Figure 2, the system 10 further includes a plurality of fixing brackets 18 20 for fixing the panels 12 to at least one frame 14a, 14b of the walls. The fixing brackets 18 are formed of a material having a lower fire protection rating than the panels 12 or the securing members 16a, 16b, 16c. In a preferred form, the fixing brackets 18 are disposed on both sides of the panels at the top and bottom of the adjoining frame so as to fix the system to each wall and are formed of aluminium which is 1.6mm thick. 25 By providing brackets 18 of a lower fire protection rating than the panels 12, the integrity of the system 10 is maintained in a fire. In this regard, if a fire occurs on one side of the wall, the frame can burn and fall away once damage to the bracket is sufficient that it loses its strength. This allows the wall frame to collapse without pulling the entire system and the adjacent wall with it, thereby acting to confine the fire to one side of the wall without it 30 spreading through the building. Figure 4a illustrates a party wall constructed using the described system 10. Owing to the base 19/flange(s), a spacing of 20mm is maintained between the panels 12 and the walls H: \zi\Interwoven\NRPortbl\DCC\MZI\7582690_1docx-20/03/2015 -8 frames 14a, 14b. Insulation 22 can be provided between the wall studs if desired. The party wall is finished with a conventional sheet of plasterboard 20. Previous party wall systems have required the installation of multiple layers to meet fire/noise requirements. In contrast, the described system 10 can be simply installed and finished using 5 conventional wall coverings such as plasterboard, thereby simplifying installation while meeting fire resistance and noise protection requirements. The described embodiments provide an MgO Interwall barrier system which can be installed using a method comprising the steps of: providing at least one elongate securing 10 member 16a, the securing member 16a having a longitudinally extending channel 17 and a base 19 extending laterally from the channel 17; installing the securing member 16a near a lower portion of a first wall frame 14a so that the base 19 of the securing member 16a spaces the channel 17 from the first wall frame 14a; and installing lower ends of a plurality of panels 12 into the channel 17 to form a barrier. 15 The channel member 16a is fixed to a floor or base of a building so as to secure the system between the respective buildings. Fire sealant is to be used on the underside of channel member 16a to the floor, it is then fixed using conventional fasteners such as screws or nails. Additional securing members 16b are installed between adjacent panels 12 to secure 20 the adjacent panels 12 together. The securing members 16b have oppositely extending channels 17 in which ends of the panels 12 can be received. Additional securing members 16c in the form of end caps can be installed around the periphery of the joined panels. The described embodiments also provide a method of constructing a party wall, comprising the steps of: installing a first wall frame 14a; installing an MgO Interwall 25 barrier system using a method as described above; and installing a frame of a second wall 14b. The embodiments have been described by way of example only and modifications are possible within the scope of the invention disclosed. For example, although the system has 30 been described with reference to a party wall system, it will have others applications, particularly applications with walls that need not be parallel. Other applications will also include non-load bearing fire walls/barriers/fences and non-structural fire wall s/barriers/fences. H: \zi\Interwoven\NRPortbl\DCC\MZI\7582690_1docx-20/03/2015

Claims (21)

1. An MgO Interwall barrier system for generally parallel walls, the system including a plurality of panels for installation between frames of the walls in an edge to edge 5 configuration to form a barrier between the walls and coupling means to couple ends of the panels together, wherein the panels are formed of a material including magnesium oxide.

2. A wall system as claimed in claim 1, wherein the material further includes magnesium chloride, Perlite and glass fibres. 10

3. A wall system as claimed in claim 2, wherein the material further includes woodchips.

4. A system as claimed in any one of the preceding claims, wherein the panels are approximately 10mm thick but may be up to 20mm in thickness depending on the installations technical requirements. 15

5. A system as claimed in any one of the preceding claims, wherein the coupling means comprises a plurality of elongate securing members configured to extend substantially around a periphery of each panel to fix the panels relative to the walls, the securing members having a channel in which ends of the panels can be received.

6. A system as claimed in claim 5, wherein the or each securing member disposed at a 20 base of the panels have at least one flange extending transversely to the channel to define a 20mm space between the panels and the wall frames.

7. A system as claimed in claim 5 or claim 6, wherein the or each securing member disposed at an upper edge the panels have at least one flange extending transversely to the channel to define a space between the panels and the wall frames. 25

8. A system as claimed in claim 5 or claim 6, wherein the space is approximately 20mm.

9. A system as claimed in any one of claims 5 to 8, wherein the securing members disposed between adjacent panels have oppositely extending channels in which opposing ends of the adjacent panels can be received. 30

10. A system as claimed in any one of claims 5 to 9, wherein the channels are between 20 - 25mm deep.

11. A system as claimed in any one of claims 5 to 10, wherein the securing members are formed of steel. H: \zi\Interwoven\NRPortbl\DCC\MZI\7582690_1docx-20/03/2015 - 10

12. A system as claimed in claim 11, wherein the securing members are galvanised.

13. A system as claimed in any one of the preceding claims, further including a plurality of fixing brackets for fixing the panels to at least one frame of the walls, the fixing brackets being formed of a material having a lower fire protection rating than the 5 panels or the securing members.

14. A system as claimed in claim 13, wherein the fixing brackets are formed of aluminium.

15. A system as claimed in claim 13 or claim 14, wherein a plurality of the fixing brackets are disposed on both sides of the panels for fixing the system to each wall. 10

16. A system as claimed in any one of the preceding claims, configured for use as a party wall system.

17. A system as claimed in claim 16, configured to be fire & acoustically resistant.

18. A method of installing an MgO Interwall barrier system, comprising the steps of. providing at least one elongate channel member, the channel member having a 15 longitudinally extending channel and a base extending laterally from the channel; installing the channel member near a lower portion of a first wall frame so that the base of the channel member spaces the channel the required distance from the first wall frame; and installing lower ends of a plurality of panels into the channel to form a barrier, 20 whereby the MgO Interwall barrier is between the wall frames.

19. A method as claimed in claim 18, wherein the channel member is fixed to a floor or base of a building.

20. A method as claimed in claim 18 or claim 19, further including the step of installing securing members between adjacent panels, the securing members having 25 oppositely extending channels in which ends of the panels can be received.

21. A method of constructing a building wall, comprising the steps of: installing a first wall frame; installing an MgO Interwall barrier system using a method according to any one of claims 18 to 20; and 30 installing a frame of a second wall. H: \zi\Interwoven\NRPortbl\DCC\MZI\7582690_1docx-20/03/2015