AU2017219160A1 - Improved mesh, mesh panels, composite building elements and method of reinforcing and articles reinforced by the method, duct and riser walls and methods for their construction - Google Patents

Abstract

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 also 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. The invention also relates to a mesh panel which is prefabricated and manufactured at a factory for transport to a location for installation and for application of a fire rated material or product, as well a method of making ducts and or building risers and ducts or building risers made by these methods. WO 2014/019015 PCT/AU2013/000789 o 0 t0 r-4 r

Description

WO 2014/019015 PCT/AU2013/000789 1 2017219160 29 Aug 2017

Improved Mesh, Mesh Panels, Composite Building Elements and Method of Reinforcing and Articles Reinforced by the Method, Duct and Riser Walls and Methods for

Their Construction

Field of the invention [001] 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. The invention also relates to a mesh panel which is prefabricated and manufactured at a factory for transport to a location for installation and for application of a fire rated material or product, as well a method of making ducts and or building risers and ducts or building risers made by these methods.

Background of the invention [002] There has been a need to provide better systems and methods of applying fire rated material to building elements and articles which require protection.

[003] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention .

[004] The present invention provides a method of forming a concrete building element, the method including the step of embedding a structural or non structural lath or reinforcing element in both a treatment material and the concrete of the concrete building element.

[005] The method can further include the steps of: (a) preparing a mould or floor or base surface to form the building element; (b) locating the lath or reinforcing element in the mould or on the floor or base surface; (c) applying a layer of treatment material into the mould or the floor or base surface so as to embed a lower portion of the non structural lath or reinforcing material· and leaving an upper portion of the lath or reinforcing material exposed; (d) applying concrete into the mould or on the floor or base surface and embedding the exposed portion of the lath or reinforcing material in the concrete.

[006] There can be included an additional the step of positioning reinforcing material into the mould or above the floor or base surface.

[007] The additional step can be performed either: prior to applying the treatment material; or after the treatment material is applied but before the concrete is applied; or after the concrete has been applied. 2 2017219160 29 Aug 2017 [008] The step of locating the lath or reinforcing element can be performed by suspending the lath or reinforcing element in the mould or above the floor or base surface so that it is at a predetermined height with respect to the base of the mould, floor or base surface.

[009] Bar chairs or similar items can be utilised to suspend the lath or reinforcing element in the mould or above the floor or the base surface.

[010] The method can include the steps of (a) preparing a mould or floor or base surface for the building element which includes allowance for a treatment material; (b) applying concrete to form the building element; (c) embedding a portion of the lath or reinforcing element into the concrete; (d) pouring a treatment material over the concrete slab and to cover the remainder of the lath or reinforcing element.

[011] There can be included an additional the step of positioning reinforcing material into the mould or above the floor or base surface to be embedded into the concrete.

[012] The additional step can be performed either: prior to applying the concrete; or after the concrete has been applied but prior to embedding the lath or reinforcing element.

[013] The step of embedding the lath or reinforcing element in the concrete can be performed either: by suspending the lath or reinforcing element in the mould or above the floor or base surface prior to the concrete being applied and the concrete being applied so as to embed a portion of the lath or reinforcing element; or after the concrete has been applied and pushing the lath or reinforcing element therein to embed the portion.

[014] The upper and lower portions of the lath or reinforcing material embedded respectively in the concrete and the treatment material are approximately 50 % each of the depth of the lath or reinforcing material or to a depth as per design, use or service requirements^ [015] The present invention also provides a method of forming a concrete building element, the method including the step of embedding at least one lath or reinforcing element wholly into the concrete of the concrete building element below a surface of the building element which will be exposed to a fire.

[016] The at least one lath or reinforcing element, can be positioned in the mould or on the floor or the base surface at one or more of the following: prior to application of the concrete; after application of the concrete; prior to structural reinforcing being located in the mould or on the floor or base surface and before the concrete is applied; prior to structural reinforcing being located in the mould or on the floor or base surface and after the concrete is applied; after the structural reinforcing has been located in the mould or above the floor or base surface and prior to the concrete being applied; after the structural reinforcing has been located in the mould or above the floor or base surface and after the concrete has been applied.

[017] The method or methods as described above can be performed by automated means to apply the concrete and or the treatment. 3 2017219160 29 Aug 2017 [018] The method can include the application of at least one structural reinforcing element, which is held in a pre-stressed state in the mould or above the floor or base surface at a predetermined height, prior to a device passes over same to apply the concrete and or the fire rated layer.

[019] The at least one lath or reinforcing element can be a wire mesh array.

[020] The at least one lath or reinforcing element can be formed from two layers of mesh which are spaced apart by one or more connecting rods.

[021] The connecting rods can be one or more of the following: a sinusoidal shaped element; a zigzag shaped element; a rod or rod portion; welded or connected between mesh portions.

[022] 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.

[023] The methods described above can include the step of a second structural or nonstructural lath or reinforcing element being vertically spaced from the first mentioned lath or reinforcing element, such that a lower most layer of a treatment material is first applied, then the layer of concrete up to a predetermined depth of the second lath or reinforcing element, and then finally an upper or second layer of a treatment material is applied to cover the remainder of the second lath or reinforcing element.

[024] 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.

[025] The treatment material can be one of the following: Vermitex TH; a vermiculite based mortar; a fire rated material having a cement base; a fire rated material having a gypsum or plaster base.

[026] The treatment material can be sprayed on the lower layer so that one or more side located vertical extensions of said layer can be formed at the sides of a mould.

[027] The structural reinforcing can be located between two vertical side extensions.

[028] The present invention also provides a building element as manufactured by the method of any one of the preceding paragraphs.

[029] The building element can be one of the following: a slab, a beam, a column, a duct, a wall, a ceiling panel, an exposed or concealed ceiling panel or a floor panel.

[030] The present invention provides a mesh for use as a reinforcing in the coating of metal and or concrete and/or other material building elements or building service elements, the mesh being made from a grid or array of mesh elements characterised in that at least one location, or at two or more spaced locations, the mesh has in the region of intersection of two or more intersections of mesh elements, an indent formation or indentation.

[031] The indent formation can be formed at discrete crossings on the mesh.

[032] The indent formation or indentation can include a point formation. 4 2017219160 29 Aug 2017 [033] The indent formation or indentation can include a square or rectangular formation.

[034] 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.

[035] The indent formation or indentation can be formed by the intersection of two mesh elements in one direction and two mesh elements in a crossing direction.

[036] Multiple indentations can be present on the mesh.

[037] The multiple indentations can be spaced between 100mm to 400mm in an array or spaced formation on the mesh.

[038] The spacing between adjacent indentations located in lines generally parallel to the mesh elements are at approximatelylOO to 200 mm centres.

[039] The present invention also provides a method of forming indentations in a mesh, the method including the formation of point or planar indentations spaced from the general plane of the mesh, at spaced locations on the mesh.

[040] The method can be performed by means of a rolling process.

[041] The method can be performed by a pair of rollers respectively having a concave part and a convex part to form the indentation.

[042] The present invention also provides a method of applying fire rating material to a building, a building element or a building services element, the method comprising the steps of: forming a wire mesh as described above and locating it on or adjacent the building element; and securing the element via the indentation to the building element.

[043] The mesh can be secured as a discrete panel to the building, the building element, or the building services element.

[044] The mesh can be bent to conform to the shape of the building element or the building services element or a portion of the building.

[045] Edges or corners of the building element, the building services element, or a portion of the building can be positioned between lines of indentations in the mesh.

[046] The mesh can be joined to itself, by at least 50mm or two mesh interstices are overlapped.

[047] The indent formations or indentations can be overlapped and secured together to the building element, the building services element, or a building portion.

[048] 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.

[049] 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.

[050] The attachment means can be adapted to be secured so as to be adjacent to the rearward face. 5 2017219160 29 Aug 2017 [051] The attachment means can be adapted to be secured to the article to be protected from fire.

[052] The attachment means can be secured to the tile before the tile is secured to the article.

[053] 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.

[054] 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.

[055] The pin means can receive on a pin portion thereof, a securing means which is adapted to hold or retain an adjacent tile.

[056] The tile can be fabricated by forming a hole in a tile and inserting a pin means there through.

[057] The tile can be moulded in a mould and the hole is formed by one of the following: the mould; by a hole forming tool as the tile is setting in the mould; or by a hole forming tool after the tile has set.

[058] 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.

[059] The tile can be one of the following shapes: rectangular, square, triangular, round, any appropriate shape.

[060] The aperture can be located at the centre of the tile.

[061] The securing means can be a speed clip.

[062] 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.

[063] The present invention further provides a method of applying fire rated tiles to an article to be protected, the method including the following steps: securing a multiple of like size tiles as described above to the article, by means of an adhesive, the tiles being in a side by side relationship, so that each the pin means has a pin portion extending away from the article, securing a second layer of multiple like size second tiles over the first layer the second tiles made of a fire rated material which have no aperture, each the second tile being positioned so that at four locations thereof, a securing means applied to a pin portion of the pin means will overlap a periphery of the second tile.

[064] The second layer can be secured to the first layer by one of the following: solely the securing means; adhesive and the securing means. 6 2017219160 29 Aug 2017 [065] The securing means can be a speed clip which has a flange or engaging portion extending radially or radially in several directions from a central aperture which receives the pin portion.

[066] The corners of the article which have tiles applied thereto and which meet at a join line, can have overlying them, a matching angled member, such that multiple matching angled members on the article are secured to each other, thereby providing an exo-skeletal support to the tile arrangement.

[067] 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.

[068] The angled members can be located around the article provide a compressive force to the corners of the article.

[069] The angled members can be secured by securing or tensile elements which extend between adjacent angled members.

[070] The present invention also provides a method of applying fire rated wire mesh based panels to an article to be protected, the method comprising the step of first assembling and forming the panels including application of fire rated material, cutting the panels to match the sides of the article to be protected, placing the panels so as to be adjacent to the sides, so that wire elements of adjacent panels can be secured together, joining adjacent wire elements thereby allowing the wire elements of the panels to be structurally connected and thus holding the panels to the article.

[071] Joining adjacent wire elements can be performed by means of metal fixers.

[072] The metal fixers can include wire or strand bent, or hog rings, around the adjacent wire elements to secure them together.

[073] Once these method steps are completed, comers of the article which have tiles or panels applied thereto and which meet at a join line, have overlying them, a matching angled member, such that multiple matching angled members are secured to each other, thereby providing an exo-skeletal support to the tile arrangement.

[074] The article to be protected can be a building element, such as a column, a beam, a ceiling, a floor; or a building service element such as an air conditioning duct, a return air duct, a conditioned air duct, an air duct.

[075] The present invention also provides a mesh panel comprising a mesh element having a foil backing attached thereto the panel being characterised by the application of a layer of fire rated material or adhesive to the mesh and the foil while the foil is in contact with the mesh.

[076] The adhesive or fire rated material is applied to a thickness of the order of 1 to 10 mm. 2017219160 29 Aug 2017 7 [077] After the fire rated material or adhesive has been sprayed thereon or applied thereto, is stored with the foil in an upward location on the mesh element thereby allowing the fire rating material or adhesive to set under the influence of gravity pulling the fire rated material and the foil in a generally downward direction.

[078] 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.

[079] The present invention also provides method of manufacturing a mesh panel, the method comprising the attachment of foil to the base of a mesh element by means of clips or other appropriate means; positioning the mesh element and foil onto a generally flat base so that the foil maintains contact with, or will be located near to base wire elements on the mesh; spraying or applying a fire rated material or adhesive material to the mesh and foil, through the mesh element so as to adhere to the surface of the foil in contact with the mesh elements, so as to bind the foil to the mesh element.

[080] The generally flat base can include a generally planar surface or it can include a layer of mesh or similar.

[081] After spraying a first mesh element, a second mesh element can be positioned on the first, with an upper mesh layer of the first element providing support for the foil and mesh of the second mesh element, so as to position the foil in contact with or be located near to base wire elements on the second mesh element.

[082] The process of the previous paragraph can be repeated to produce a stack of mesh panels which have been sprayed with or have applied thereto the fire rated material or adhesive.

[083] The panels can be inverted once sprayed or have the layer applied, so that the fire rating material or the adhesive and foil is located at a top location, and is allowed to set whilst inverted.

[084] The present invention further provides a method of forming a fire rated duct in a building riser or a wall of a building riser, said method including the step of providing means to suspend mesh elements or fire rated panels or a duct formation to a wall of said riser or other building element associated with said riser.

[085] The method can include a step of installing channels in said riser or to building elements at said riser location.

[086] The method can include connecting supporting rods to channels mounted to building elements at said riser location, or to walls of said riser.

[087] The method can include use of a beam system to suspend mesh elements or fire rated panels or a duct formation to a wall of said riser or other building element associated with said riser location.

[088] The beam system can include telescoping portions to accommodate variations in width of riser mounting locations. 8 2017219160 29 Aug 2017 [089] The duct formation or riser wall can be made from fire rated panels with reinforced wire corners, all coated with a fire rated material.

[090] The present invention also provides a building duct or riser wall being constructed by the method described in the previous paragraphs.

Brief description of the drawings [091] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [092] Figure 1 illustrates a perspective view of another mesh.

[093] Figure 2 illustrates a perspective view of a mesh of an alternate construction.

[094] Figure 3 illustrates a detail of a portion of the mesh of Figure 2.

[095] Figure 4 illustrates a detailed proportion of the mesh of Figure 1.

[096] Figure 5 illustrates the mesh of Figure 2 applied to the external portions of a straight duct and secured thereto.

[097] Figure 6 illustrates a perspective view of the duct of Figure 5 having both its upper and lower, or left and right portions with mesh applied to it with one of the portions showing a cut away view of the fire rating material applied to it.

[098] Figure 7 illustrates a detail showing the method of securing of said mesh to a duct work.

[099] Figures 8, 9 and 10 illustrate the mesh of Figures 1 or 2 as applied to respectively a concrete slab, a steel beam and a concrete beam.

[0100] Figure 11 illustrates rollers forming the indentations of figures 1 or 2.

[0101] Figure 12 illustrates a perspective view of a fire rated tile having an aperture to receive a pin to extend from its in-use outer surface.

[0102] Figure 13 illustrates an underneath view of a fire rated tile of figure 12 [0103] Figure 14 illustrates an underneath view of the fire rated tile of figure 12 with adhesive applied thereto and prior to insertion of a pin and assembling to a duct or other building element.

[0104] Figure 15 illustrates the tile of figure 14 with the pin and its backing material inserted into the aperture of the tile prior to assembling to a duct or other building element.

[0105] Figure 16 illustrates the preferred dimensions in millimetres and process of pin being pushed through a preformed tile, either before or after it has set.

[0106] Figure 16A illustrates a perspective view of an aluminium foil or steel mould with preformed aperture.

[0107] 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.

[0108] Figure 16C illustrates the mould of figure 16A with a strengthening mesh in the form of Trimesh mesh positioned in the mould before the fire rated material is poured in.

[0109] Figure 16D illustrates a portion of the moulds of figures 16 to 16C, which shows how the apertures in the sides are formed and are of a single piece. · 9 2017219160 29 Aug 2017 [0110] Figure 16E illustrates a view similar to the apertures of figure 16 D, where the push out portion is formed from two discrete bent out pieces.

[0111] Figure 17 illustrates the application of the tile of figure 12 to an article to be protected, in this instance a sheet metal duct.

[0112] Figure 18 illustrates the application of a second layer of tiles, without pins to the first layer of tiles.

[0113] 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.

[0114] Figure 20 illustrates a cross section front elevation of the assembly pattern of figure 18.

[0115] Figure 20A illustrates a detail cross sectional view of a portion of figure 20.

[0116] Figure 21 illustrates a perspective view of an exoskeletal restraint system for use with the system of figure 18, or in a separate method of applying a duct width tile to the duct.

[0117] Figure 22a illustrates a plan view of a speed clip.

[0118] Figure 22B illustrates perspective view of a hog ring which shows it open and after it has been applied. " [0119] Figure 23 illustrates a schematic of a method of joining mesh based panels to a rectangular duct.

[0120] Figure 24 illustrates a schematic detail of the use of hog rings to secure the mesh panels of figures 22 and 23.

[0121] Figure 25 illustrates the step of forming a tile or mesh panel having a mesh base and foil under layer.

[0122] Figure 26 illustrates the final formed mesh panel or tile.

[0123] Figure 27 illustrates a stack of mesh panels of figure 26, to allow same to cure.

[0124] Figure 28 illustrates the panels of figures 26 and 27 being applied to a rectangular duct.

[0125] Figure 29 illustrates the panels of figure 28 being joined by hog rings.

[0126] Figure 30 illustrates a method of applying mesh elements first to the duct then spaying same with a fire rated material.

[0127] Figure 31 illustrates a front view of the system of figure 30 [0128] 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.

[0129] Figure 33 illustrates a method similar to that of figure 32, where a fire rated tile is positioned and or adhered to the under surface of the duct.

[0130] Figure 33A illustrates a method similar to that of figure 32 and 33, except that the mesh of figure has been used.

[0131] Figure 34 illustrates a fire rated tile with the pin captured in the moulded tile. 10 2017219160 29 Aug 2017 [0132] 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.

[0133] Figure 36 illustrates a mesh element of another embodiment of the invention; [0134] Figure 37 illustrates the mesh element of Figure 36 having fire rated material applied thereto; [0135] Figure 38 illustrates the mesh element of Figures 36 and 37 in a storage position to allow said fire rated material to set; [0136] Figure 39 illustrates a schematic representation of the process of manually spraying mesh panels; and [0137] Figure 40 illustrates a schematic representation of the step of rotating sprayed mesh panels to an inverted orientation to allow for the drying or setting of the applied layer of fire rated material or adhesive.

[0138] Figure 40A illustrates a schematic representation of an embodiment of a panel where cement based adhesive is utilised to give an outside strength which satisfies Australian standard AS2185.

[0139] Figure 40B illustrates the embodiment of figure 36 to 40, which shows how gravity works against the formation before setting.

[0140] Figure 40C illustrates the embodiment of figures 36 to 40 similar to figure 40B where gravity assists in the formation of the cement or plaster based adhesive.

[0141] Figure 41 is a schematic representation of a concrete or lightweight building element representing the element and method of manufacture; [0142] Figure 42 illustrates an embodiment similar to Figure 41, however, the concrete slab is formed by concrete or lightweight concrete (formed or otherwise) only; [0143] Figure 43 illustrates a layer of mesh, called TRIMESH®, and foil for use with the invention; [0144] Figure 44 illustrates a schematic perspective view of a mobile spraying apparatus to coat a layer of TRIMESH® onto which can be formed a concrete slab, [0145] 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; [0146] Figure 46 illustrates a series of tri-mesh laid end to end, or an elongated or long length of such tri-mesh prior to a fire rated material being applied thereto; [0147] Figure 47 illustrates a mobile application device to apply fire rated material in an automated process; [0148] Figure 48 illustrates the depth to which fire rated material is laid down after the device of figure 47 has passed; [0149] Figure 49 illustrates a schematic perspective view of a concrete laying device and process of applying concrete after the device of figure 7 has completed its pass; 11 2017219160 29 Aug 2017 [0150] Figure 50 illustrate the depth to which fire rated material has been applied, with the upper tri-mesh exposed and reinforcing in place ready to be covered by concrete; [0151] 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 trimesh layer into the concrete; [0152] Figure 52 illustrates a building element in cross section having both a lower and an upper layer of treatment material, being the element produced by Method 12 described below; and [0153] Figure 53 illustrates a building element in cross section in which the sides of the treatment layer extend generally vertically from the upper level of the treatment layer.

[0154] 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.

[0155] 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.

[0156] Figure 56 illustrates a schematic perspective view of an assembly method to produce a duct for attachment to a building riser or the like.

[0157] Figure 57 illustrates a detail schematic assembly method to produce a fire rated duct of appropriate strength for attachment to a building riser.

[0158] Figure 58 illustrates a detail schematic assembly of a corner and upper section with an expandable upper and lower support.

[0159] Figure 59 illustrates a detail schematic assembly of a support to secure a fire rated duct manufactured by the method of Figures 56 to 58 to a building riser.

Detailed description of the embodiment or embodiments [0160] 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. While the mesh is illustrated as a square mesh, a rectangular mesh could also be used. 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.

[0161] At distances 11.1 and 12.1 which are of the order of 75 to 200mm each in length. A series of indentations 13 are formed in the mesh by means of the plastic deformation of two mesh elements by pressing at the intersection of them, so as to form the indentations, which in this instance is a point. By means of an optical illusion, if Figure 1 is rotated 180° the underneath view is visible. The portions of the elements 11 and 12 at the indentations 13 form the wire frame edges of a generally square pyramidal formation. 12 2017219160 29 Aug 2017 [0162] The mesh of Figure 1 can be manufactured by any appropriate means but the most preferred method is that the mesh has the indentations formed, as illustrated in Figure 11 by means of roll forming whereby opposed rollers have respectively mating projections and recesses to plastically deform the mesh elements 11 and 12 in the required direction.

[0163] By such 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.

[0164] In the illustration of Figure 1 the mesh elements 12 are spaced from each other approximately 25mm whilst the mesh elements 11 are spaced a similar distance. In the illustration of Figure 1 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.

[0165] 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.

[0166] The centre of the indentations 13 in mesh of figure 2 are spaced approximately 200mm apart on the basis that each square measures approximately 25mm. The mesh 10 of Figure 2 can be formed in much the same way as that described above in respect of Figure 1.

[0167] It will be noted that in respect of the mesh of Figures 1 and 2 the plastically deformed members 11.2 and 12.2 (see Figures 3 and 4) 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. However, if desired 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. .

[0168] 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. Because 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. As this planar frame is of a 25mm square arrangement, the insulated head 21 is sized to prevent at any 13 2017219160 29 Aug 2017 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.

[0169] It will be noted in Figure 5 that the mesh is folded around the duct and where one end of the mesh joins the other end there will be provided an overlap of preferably 2 lines of mesh squares that is approximately 50 mm. This is provided by aligning the indentations 13 near the free ends of the mesh, so as to be secured by means of the weld on studs 20, or by squares of mesh being aligned thereby allowing twisted wire or tie wire connections.

[0170] If desired 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.

[0171] As illustrated in Figure 7 if desired instead, of forming or bending the mesh around the duct, 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.

[0172] As illustrated in Figure 6 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. Alternatively, 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.

[0173] Illustrated in Figures 8, 9, 10 the mesh of Figure 2 is seen applied to respectively a concrete slab 50, or a steel beam 51, and a concrete beam 52, but it will be readily understood that the mesh of Figures 1 or 2 an be applied to any appropriate building element or portion of a building to have a fire rating material applied thereto.

[0174] Illustrated in Figures 11 is a cross section through upper and lower rollers respectively having a convex part and a mating concave part, by which the indentation described above can be formed.

[0175] Illustrated in Figures 54 and 55 are two alternative embodiments of the mesh of figures 1 and 2. In figure 54 the mesh 5410 has equispaced channels or rows of indentations 5413 along its width or length, which channels terminate in a line of indentation. Whereas 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 14 2017219160 29 Aug 2017 flat panel on the base. Both the mesh forms 5410 and 5510 can be used instead of the meshes of Figure 1 or 2.

[0176] Due to the strength of the reinforcing, 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.

[0177] Illustrated in figure 12 and 13 is a fire rated tile 100 which is made from a moulded or compressed fire rated material. The fire rating material utilised can be any appropriate fire rating material such as vermiculite or the like or such as that sold under the brand name VERMIDUCT. At the geometrical centre of the tile 100 is an aperture 105 through which can be located a pin or pin means 200. The diameter of the hole or aperture 105 will be dependent upon the diameter of the pin means 200. The height or extension of the pin 200 which will be chosen to extend from the outer face of the tile will need to be of sufficient length so as to receive, adjacent to the pin, another tile 120 (see figures 18, 19 and 20), in a second tile layer, with the pin 200 extending past the outer surface of the second tile layer, with sufficient remaining length so as to receive a securing member, like a speed clip (as illustrated in figure 22A), on the end of the pin, as will be described below.

[0178] Manufacture of the tile 100 can occur in several ways.

[0179] TILE MANUFACTURE METHOD 1: One method of manufacturing the tile 100 is to form the tile by moulding or compressing the fire rated material 101 into a rectangular or square tile form, then after setting or forming, drilling, or punching or otherwise forming a hole of a predetermined diameter therein, which will be sufficient to allow the pin means 200 to pass through the hole and the backing 210 to remain adjacent the inner face of the tile 100.

[0180] TILE MANUFCATURE METHOD 2: As illustrated in figure 16A and 16, a mould 150, which can be made from steel or aluminium and is re-usable, can have the fire rated material poured or sprayed therein to form the tile 100. The mould 150, due to the presence of a preformed hole 151, will allow the pin 200 with a metal backing 210 as illustrated in figure 15, to be pushed through the tile 100.

[0181] 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. In the case of Figure 16D 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. Whereas in is 2017219160 29 Aug 2017 respect of the aperture 150.1 illustrated in Figure 16E, 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. While aluminium is a preferred material other materials such as steel and stainless steel can also be used.

[0182] 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.

[0183] TILE MANUFACTURE METHOD 5: As illustrated in figure 16C, this method is similar to method 4, except that instead of the galvanised wire mesh 10 described above being used, a mesh element 520 which is generally comprised of an upper mesh sheet and a lower mesh sheet held in a spaced apart relationship by intervening supporting wire members is used. Such mesh type elements, called Trimesh, are described below in relation to Figures 25 and 43. In Figure 43 for simplicity of illustration the lateral lower mesh elements are not shown.

[0184] TILE MANUFACTURE METHOD 6: the tile can be made by moulding whereby the hole is formed by a pin core in the mould so that as the fire rated material is sprayed or poured into the mould, the pin core will form a predetermined sized hole when the tile is extracted form the mould.

[0185] TILE MANUFACTURE METHOD 7: The tile can be made by compressing fire rated material, but as this is done, the compressing die has a pin core, so that the tile comes off the compressing machine with a hole formed at the same time as the tile.

[0186] TILE MANUFACTURE METHOD 8: forming large sheets of fire rated material then these are cut into tiles, and the tiles are drilled or punched so as to form a central aperture to receive the pin 200 and its backing 210.

[0187] 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.

[0188] What will result from the above tile manufacture methods is a fire rated tile 100, as illustrated in figures 15 or 34, which has the pin 200 through it, with the pin extending away from the outer face of the tile, and the pin backing member 210 located at the inner face.

[0189] The backing member 210, depending upon the application method, can provide a surface to adhere to an article to be protected against fire by the tile. To adhere the backing member, 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) can be used, or the member 210 can 16 2017219160 29 Aug 2017 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. Alternatively 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. While it is generally impractical, it is possible that the duct can have the pins pre-welded in place on the outer duct surface whereby once installed a tile with an appropriately formed hole or pre-defined weakness can then be spiked on to the pin, in which case the pin structurally holds the tile to the duct. Otherwise the back of the tile can have the previously mentioned adhesive, and then its back will adhere to the duct, thereby providing two methods of attachment i.e. the pin and the adhesive.

[0190] For ease of description, the article to be protected in the following description will be referred to as a duct, but it will be understood that the article to be protected can be any appropriate building element such as a beam, or column, or surface such as a ceiling or floor, or pipes or other service conduits etc. The fact that the following description refers to ducts, does not limit the generality of the articles to be protected by the invention.

[0191] 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. As the tiles are all of the same size and shape, most preferably of width 300mm by length 300 mm, and 20 mm thick, 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. 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. to overlie the backing member 210, or it could be applied at the periphery of the tile, so as to not overlie the backing member 210 as in Figure 15, or it can be applied in “walnut” or appropriately sized daubs at three or four locations on the back of the tile, spaced from and around the pin and its backing as represented by the daubs in dotted lines in Figure 15. Of course only one of these method would be used, even though both are represented on the back of the tile of Figure 15. Irrespective of which method is used to distribute the adhesive, it is desired that an adhesive layer to a thickness of 1mm to 2mm results.

[0192] 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. 17 2017219160 29 Aug 2017 [0193] 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.

[0194] FIRST TILE LAYER - ASSEMBLY METHOD 4. this method is similar to that of methods 1 and 2, however a tile 100 having a pre-captured pin is simply adhered to the duct 300, in the array as indicated in figure 17, to provide a first layer of tiles to cover the duct 300.

[0195] FIRST TILE LAYER - ASSEMBLY METHOD 5: as illustrated in figures 14 and 15, this method is similar to that of methods 1 and 2, however a tile 100 first has its rear face coated with adhesive 700, such as a plaster or gypsum based adhesive like that sold under the brand Vermitex AF, as in Figure 14, and then a pin 200 is pushed through the aperture 105, with the adhesive on the backing 210 exposed, so that the sub-assembly of the tile and pin can then be adhered to the duct 300, in the array as indicated in figure 17, to provide a first layer of tiles to cover the duct 300.

[0196] 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. Instead 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. When four such speed clips 220 are in position as illustrated in figure 19, all four corners of the tile 120 are secured and the second layer is positioned. When this second layer is applied in a fire rating factory or on the building site, 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.

[0197] SECOND TILE LAYER - ASSEMBLY METHOD 2: The second layer of tiles 120 can be applied by a method similar to that of Second Tile Layer Assembly Method 1, except that an adhesive can be applied to the rear of the second layer tiles 120, so that such tiles 120 will also adhere to the front surface of the first layer tiles 100. By the use of such adhesives it also removes the preference of assembling on generally horizontally oriented surfaces, as such adhesives can replace gravity to keep the second layer tiles 120 in place, until the speed clips 220 are put into position.

[0198] It will be noted from fgure 19, 20 and 20A, whether the second layer tiles are only mechanically fixed or both glued and mechanically fixed, that there is no line of sight path for 18 2017219160 29 Aug 2017 externally located fire to affect the duct 300. This is even more so if the pin 200 is integrally formed in the tile 100 (as will be described below in relation to figures 34 and 35) such that there is no line of sight through the tile around the pin, or if the tile 100 is spiked onto the pin, the hole or aperture 105 which is formed is sized so as to be an interference type fit with the diameter of the pin 200, so that there is no line of sight around the hole 105.

[0199] By the above described method, whether performed on site or in a fire rating factory, it would be possible to apply most of the pins and tiles to cover a major proportion of the duct 300, before the duct is positioned and secured into it’s designed for location. The remaining portions of the duct can then be completed, once the ducts have been joined and erected. Any areas which cannot receive tiles can be subsequently sprayed on site.

[0200] Once the above methods have been applied, an exoskeletal frame such as is illustrated in figure 21, can then be applied to the duct 300. The exoskeletal frame comprises longitudinally extending angle edges 400, at the four corners of the duct 300, which are held in place by adjustable tension struts or stringers 410. This will mechanically hold adjacent edges of the tiled surfaces together while the application system and the pins and speed clips 220 will mechanically hold the tiles together, whereby they will act as a single tile or panel 125 such as that illustrated in figure 21.

[0201] Illustrated in figure 21, in an alternative method of applying a fire rating material to a duct, whereby a single pre-formed tile, pre-moulded tile or cut to size tile 125 can be provided, so that one tile extends across the duct, and is held in place at its edges by the angle members 400 and struts 410.

[0202] Illustrated in figures 22 to 29 is an alternative method of applying fire rating material to a duct. In this method, as best illustrated in figure 25, firstly a fire rated panel or tile 500 is formed from a mesh base 520 (or mesh 3660 as described below in regards to Figure 36) to provide structural support and an aluminium foil base 530 (or foil 3670 also as described below in regards to Figure 36 and 37). Then vermiculite based material 540, such as Vermiduct gypsum based fire rated material, is then sprayed onto the mesh and foil so as to form panels or tiles 500 as illustrated in figures 26 and 27. By the mesh 520, and thus the panel 500, being of a predetermined size for application to a specific duct configuration, effectively tiles of a duct side’s width are formed which can then be applied to a duct.

[0203] In the next stage of this method, the tiles 500 can be applied to the duct 300 by means of the previously discussed daubs of adhesive 700. Otherwise, or in addition to adhesive 700, as illustrated in figures 22B to 24 and 29, the adjacent tiles can be joined by means of an inner and or an outer hog ring 510. The hog ring 510 as illustrated in figure 22B is effectively like a surgical staple which is work hardened while being mechanically bent around wire elements of the mesh 520 as illustrated in figure 24, so as to join or clamp the wire elements together, thus joining the adjacent tiles or panels 500. By such hog rings 510 being applied at spaced locations along the joint line of adjacent panels 500, as illustrated in figure 29, it is expected that a join between 19 2017219160 29 Aug 2017 adjacent panels will be effected, which will not be adversely affected by fire, at least so as to allow the system to meet pre-specified fire rating standards.

[0204] The fire rating system of figures 22 to 29 while being particularly applicable to rectangular shaped duct work, is also applicable to cylindrical duct work as illustrated in figure 23. In Figure 23, the rectangular or square duct 300 is represented by a broken line, while the cylindrical duct 310 is represented in unbroken line.

[0205] Illustrated in figures 30 and 31, are tile or panel application methods, which are applicable to rectangular and cylindrical ducts respectively, which are methods similar to that of figures 22 to 29, except that in the method of figures 30 and 31, prior to the application of the fire rating material 540, the mesh 520 and foil 530 (or 3670 as described below in respect of Figures 36 and 37) are first secured to duct, and the adjacent edges of the mesh 520 are hog ringed together, in a similar manner to that as illustrated in figure 29. Alternatively the mesh 520, such as TRIMESH can be adhered by means of sticky pins such as pins 210 described above and speed clips 220 also described earlier. Once appropriate securing of the mesh panels has been made, 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. Once 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.

[0206] The panels or tiles 500 discussed above, are of the order of 20mm to 38mm of sprayed vermiculite material, while the tiles 100 and 120, can be any appropriate thickness, but of the order of 10mm to 20mm in thickness are preferred.

[0207] 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.

[0208] The mesh 520 is secured to the bottom of the duct 300 and then mesh 10, such as galvanised steel wire mesh of 1mm wire at 25 mm spacing, square mesh or Trimesh is applied to the other three sides, and secured to each other at their edges by hog rings 510 and to the base Trimesh 520, but need not be secured per se to the duct 300. If desired the mesh 10 can be secured to the duct 300 by means of sticky pins and speed clips. Once the rneshlO is in position, vermiculite 540 can be sprayed onto the assembly.

[0209] Alternatively, the Trimesh 520 is used on one side of the duct (usually the bottom face) and the other three have galvanised steel square mesh of approx 1mm wire with 25mm spacings. The mesh can be pre-sprayed to form a rigid panel which can then be cut into proper 20 2017219160 29 Aug 2017 sizes to fit snugly around the duct. In such an arrangement there need not be any foil used, such as foil 530, as the surface of the duct 300 acts as a containment layer if the vermiculite is sprayed onto the duct 300.

[0210] By these two methods the Trimesh base panel 520 will assist to prevent compression of the sprayed vermiculite by the supports 600, as well as the use of the Trimesh will minimise issues which may arise from vibrations from the supports 600 over time.

[0211] Illustrated in figure 33 is a method similar to that described with respect to figure 32, except that the base Trimesh panel 520 is replaced by a tile or panel 125 which has no mesh therein, but this may be susceptible to compressive forces exerted by the support 600. Illustrated in Figure 33A is another similar method, except that the mesh applied to the duct 300 is the mesh of figure 2, with the duct resting on a Trimesh panel 520 to transfer the weight to the support 600.

[0212] 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 16C) 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. However, once the second layer is formed and chemically and or mechanically adhered by speed clips 220, and with a exoskeletal system formed by members 400 and 410, an appropriate duct fire rating system results. Such a tile is expected to be of less desirable qualities as it will be more difficult to transport and store due to its height dimension as created by the pin.

[0213] The fire rating systems, once the above methods and articles are applied, is expected to work in the following manner. Once a fire were to start, whilst it may be that the first pin and or tile may detach itself from the duct during its initial heating phase deflection, the system is held mechanically together so as to continue performing its fire rating function.

[0214] Illustrated in Figures 36 to 38 is a wire mesh element 3660 which has a layer of aluminium foil 3670 attached thereto. The aluminium foil 3670 can be of the sort sold under the brand SISALATION, or such as described in Australian patent application 16633/67(196716633) or AU570338, which are generally made with foil on the outer sides, which sandwiches a reinforcing layer of fibreglass mesh and or kraft paper. The foil on the outer sides assists by acting a vapour barrier.

[0215] The foil 3670 is attached by means of speed clips or any appropriate means to the wire mesh. Such mesh elements 3660 are generally comprised of an upper mesh sheet and a lower mesh sheet held in a spaced apart relationship at a distance of the order of 20mm to 75mm, by intervening supporting wire members. The wire diameter can be of the order of 1.5mm to 3mm. 21 2017219160 29 Aug 2017

One such mesh element 3660 is known by the name TRIMESH and is available from LAF Group and described in more detail below.

[0216] As illustrated in Figure 37, 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.

[0217] Once in this condition, then an operator or machine can spray a relatively thin layer of fire rated or fire retardant material generally indicated by the layer 3680 in Figure 37. 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. By spraying a 1 to 10 mm layer of fire rated material 3680 (or an average depth of 5mm), and with the foil 3670 on a flat surface and contacting the base wires of the mesh element 3660, also on the foil 3670 and on the flat surface with the foil 3670 intervening, the spraying of a layer of 1 to 10 mm of fire rated material as in Figure 8 allows the foil once the fire rated material is set, to adhere to the mesh 3660 at multiple locations and to all wire elements in the base of the mesh panel 3660.

[0218] As illustrated in Figure 40A, by the mesh and foil first being sprayed to a depth of 5mm to 10mm with a cement based fire protective layer 3680, which is sprayed in the direction of arrows 3665 which is generally in a downward direction in figures 36 and 37, the outer surface of the foil ' 3670, that is on the side opposite to the layer 3680, when the layer 3680 sets, will provide sufficient hardness to satisfy the criteria required by Australian standard AS2185 for Fibrous plaster products.

[0219] The primary function of cement based fire protective coating or layer 3680 is so that the foil 3670 can be set in place to be in close proximity of the mesh avoiding the foil 3670 bulging out as in Fig 40B and requiring more wasteful quantities of sprayed fire rated material. Without this layer 3680 the foil 3670 can be pushed out by as much as 25 mm as in Fig 40B. This is an excessive amount which would require spraying an additional 30% of fire rated material to what would otherwise be required.

[0220] Additionally, 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.

[0221] Alternatively, 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. In the case of an adhesive being sprayed, a layer 3680 would probably be of the order of 1 to 2 mm in 22 2017219160 29 Aug 2017 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.

[0222] 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.

[0223] After such a panel has been sprayed the fire rated material 3680 can be allowed to set by inverting the mesh element 3660 as illustrated in Figure 38, whereby the weight of the material 3680, is assisted by gravity, to pull down or in a downward direction, the foil 3670 which is now located at an upper surface of the assembly, as is also visible in Fig 40C.

[0224] 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.

[0225] As the under surface or uncoated surface of the foil 3670 is now on an upper location, a multiplicity of panels 3660 with a layer of fire rated material 3680, or adhesive applied, can be stacked on top of each other in the orientation of Figure 38. In figure 38, a rack 3690 can be seen and this is optionally provided, that is, it is not necessary to stack them onto a rack, rather as illustrated in Figure 40, the sprayed mesh panels can be simply stacked on the ground or other location, in a generally horizontal orientation.

[0226] The description in relation to Figures 36 to 38 describes how the foil 3670 and the mesh 3660 are placed on a flat surface, whether horizontal or vertical. As can be seen from Figure 39, a flat surface is not essential, because a first mesh element 3660 and its foil 3670 can be sprayed on a ground or flat location, but then a second one can be placed on top of the first, with the second one being sprayed too, and so on, creating a .stack of sprayed mesh panels.

[0227] This is achieved by ensuring that the spray gun which ejects the fire rated material or adhesive to form the layer 3680, does so with a relatively light pressure setting, so as the air/material sprayed does not have enough force to tear or bulge out the foil material 3670, even though that material is supported by the upper mesh layer on the mesh panel beneath.

[0228] Once the stack has been completed, as is illustrated in Figure 40, one or more work persons can lift and or rotate the panels so as to invert them and re-stack them into a stack for drying and or setting purposes in the manner of Fig 40 or 40C. It will be noted in the stacked condition for drying or setting, the upper panels press downwardly on the foil backing 3670. 23 2017219160 29 Aug 2017 [0229] This method of manufacturing and the product produced thereby, whilst being slightly heavier than the original mesh product without a pre-sprayed layer 3680 and whilst possibly increasing transport costs, does result in a product that allows the mesh panel 3660 to utilise a minimum or an optimum amount of fire rated material, relative to the thickness of the panel 3660 when on site.

[0230] 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.

[0231] Prior to this invention installers would use masking tape or aluminium tape to stick flapping foil to the mesh element, and this is a labour intensive process [0232] By providing a pre-sprayed layer 3680 which secures the foil 3670 to the adjacent wire of the mesh elements 3660, at all locations on the base of the panel 3660 when cutting through to form openings in the mesh panel by means of an angle grinder or the like, results in, immediately adjacent the cut, that the foil is still secured to the mesh by means of the previously set fire rated material in that region.

[0233] 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.

[0234] As illustrated in Figure 40B, if the foil layer 3670 is not supported, such as may happen if directly sprayed on site, gravity or force of the spray, will cause the cement based bond coat layer 3680 to bow the foil relative to the base of the mesh 3660. Then when the final layer 3685 is sprayed this will then result in extra material being sprayed due to the undulations or bowing which would otherwise be present. However, after spraying the layer 3680, as in figure 40B and then inverting the panel as in figure 40C, this will remove the undulations and allow the cement or gypsum based bond coat layer 3680 will, when set, will be close to the base of the mesh structure, and will remain in this condition due to the setting of the layer 3680. With the layer 3680 being of an average depth of approx 5mm,this will ensure that the final sprayed layer will be of relatively even thickness, thus saving on material by comparison with prior art methods or spraying on site.

[0235] 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 24 2017219160 29 Aug 2017 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.

[0236] 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. The following is a description of the methods used to manufacture the building element.

[0237] While a pre-cast forming of the element is preferred it will be understood that several methods below will be suitable for in-situ casting as well.

[0238] 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. In this method, 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. At this point in time the fire rating layer 4120 can be applied to the base of the mould by pouring or spraying through the mesh 4130 to develop the lowermost layer 4120 of fire rating material. The fire rating material is sprayed until such time as approximately 50 percent of the height of the mesh 4130 has been immersed or has been covered with the fire rating material or to a depth as per design requirements. This will leave the upper half of the mesh 4130 exposed and able to be immersed or embedded into the concrete 4150 of the slab. Once the fire rating material has been applied it is allowed to set adequately before pouring of the concrete 4150.

[0239] Once the fire rating material layer 4120 has set sufficiently, bar chairs can be placed upon the top surface of the TRIMESH® 4130 to space the reinforcing mesh 4140 therefrom and then concrete can be poured to envelop the reinforcing 4140 as well as the upper proportion of the TRIMESH® 4130. Once the concrete slab has set it can be removed from its mould and shipped to a site for construction.

[0240] 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 25 2017219160 29 Aug 2017 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.

[0241] In this method, the TRIMESH® 4130 is positioned above the floor or base surface at a predetermined height where it is held at that height by means of bar chairs or other appropriate means. Once this is done, the fire rating layer 4120 can be applied to the floor or base surface through the tri-mesh by spraying, either by hand or manual means as in Figure 45, or by machine as in Figure 44 of Figure 47. The fire rating material passes through the mesh 4130 to develop the lowermost layer 4120 of fire rating material. The fire rating material is applied until such time as approximately 50 percent of the height of the mesh 4130 immersed or has been covered with the fire rating material, as is illustrated in Figure 48 or Figure 50. This will leave the upper half of the mesh 4130 exposed and able to be immersed or embedded into the concrete of the slab. Once the fire rating material has been applied it is allowed to set for adequately before applying the concrete.

[0242] Once the fire rating material layer 4120 has set sufficiently, bar chairs or other appropriate spacers can be placed upon the top surface of the TRIMESH® 4130 to space a reinforcing mesh 4140 therefrom as is illustrated in Figure 50. Alternatively over the fire rating material layer 4120 and TRIMESH® 4130 a pre-stressed reinforcing element can be positioned. Once the appropriate structural reinforcing has been positioned, then concrete can be poured or applied as illustrated in Figure 49 by the machine 4180 so as to envelop the reinforcing 4140 or prestressed element, as well as the upper proportion of the TRIMESH® 4130, as is illustrated in Figure 51. The machine 4180 moving from left to right in Figure 49, so as to form the building element in a second pass. Once the concrete building element has set it can be removed from its floor or base location and either further cured or shipped to a site for construction.

[0243] 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

I 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.

[0244] . When layer 4120 is set sufficiently, 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.

[0245] In respect of Methods 1 to 3, the mesh or TRIMESH® 4130 is preferably 20mm, 30mm or 50mm in height or depth so that approximately 50% of the depth of the TRIMESH® protrudes into respectively the concrete slab and the fire rate layer. The fire rated layer 4120 is preferably 26 2017219160 29 Aug 2017 approximately 30mm in depth with the concrete slab or other building element being poured to any appropriate depth required.

[0246] Whilst methods 1 to 3 refer to the structural reinforcing being positioned by means of bar chairs on the TRIMESH®, this can be replaced by other techniques such as the installation of the reinforcing after the concrete has been poured and before it sets, to the appropriate depths within the concrete building element, or the suspension of structural elements which are maintained in a prestressed condition until the concrete has set.

[0247] 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°. In manufacturing according to this method 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. When the poured concrete is of appropriate viscosity 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.

[0248] Method 5: this method is similar to Method 4 except that the reinforcing 4140 is positioned after the concrete has been poured to the appropriate depth inside the concrete building element and then the lath or reinforcing element or TRIMESH® 4130 is installed to its appropriate depth whilst the poured concrete is of sufficient viscosity. It is then allowed to set to a sufficient degree whereupon the final layer of fire rating material 4120 can be poured or sprayed onto the concrete to the appropriate depth of approximately 30mm.

[0249] Method 6: As illustrated in Figure 42 is another building element 4111 which has better fire rating properties in terms of resistance to spalling 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 20miji, 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 spalling which would otherwise occur if fire were applied to an underside or top side of the element 4111.

[0250] Method 7: To manufacture the building element of Figure 42 a layer of 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 27 2017219160 29 Aug 2017 reduced spalling 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 spalling of the concrete surface. .

[0251] 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 49 which applies concrete to the whole mesh arrays and embeds all of them in a single pass. 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 spalling 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 spalling of the concrete surface.

[0252] 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.

[0253] 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.

[0254] 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.

[0255] 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 28 2017219160 29 Aug 2017 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. Alternatively if the building element is being formed by a machine 4180 as in later methods, 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.

[0256] Method 13: This method is illustrated in Figure 53. This method 13 can be used with both the in-situ methods described above in methods of forming the building element or with those factory and machined formed methods also described above.

[0257] 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. Thus 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. If desired, 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.

[0258] Between the side skirting or within the space provided between the side wails 4120.2 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.

[0259] 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. ' [0260] 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.

[0261] Preferably, the lath or reinforcing TRIMESH® element 4130 is of a mesh construction such as those having upper and lower layers of square or rectangular mesh of rod size 1.5 to 3mm and preferably 25mm or 50mm squares or spacing which are held in spaced apart configuration be means of zigzag or sinusoidal spacer elements welded or otherwise attached to keep the upper and lower generally planar mesh layers separated, to form a rectangular prism like structure as illustrated in figures 25 and 43. Adjacent lines of zig zag or sinusoidal spacer 29 2017219160 29 Aug 2017 elements can have their peaks and troughs laterally aligned as illustrated in the figures or they can be phase shifted so that a peak of one line has a trough laterally aligned on an adjacent line. 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. Throughout the drawings the TRIMESH is Illustrated in a simplistic manner so as to aid in Illustration. In particular, 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.

[0262] While the above description describes the 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.

[0263] While the above described methods utilise 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.

[0264] By means of the above methods it is expected that a fire rated precast concrete building element which is a slab, wall, column, beam, sealing panel, floor slab, can be formed.

[0265] While 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.

[0266] It will be readily understood that the “pushing’’ of tri-mesh being a non structural reinforcing mesh and or structural reinforcing mesh into concrete and or fire rating material, can only be done if appropriate viscosities of these materials are present. Such steps cannot be performed where there is machine application of concrete, as such machines generally apply only sufficient water to properly set the concrete mix, and an appropriate viscosity of the applied concrete would not necessarily be present to enable such “pushing" of the meshes or reinforcement. Appropriate machine settings may need to be adjusted to achieve an appropriate viscosity. 30 2017219160 29 Aug 2017 [0267] 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.

[0268] As illustrated in Figure 56, 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. At the corners, 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. Once joined, the comers 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.

[0269] For attaching the duct formed by the method described with respect to Figure 56, before the angles 5610 are sprayed, attachment brackets 5910, as illustrated in Figure 59, 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.

[0270] As the duct is of 1200mm in height and of 800mm square construction, this ensures that factory formed ducts can be transported readily to a building site, and relatively easily handled by workpersons for assembly. To create a duct which is the height of a floor of a building, which is approximately 2800mm from floor to ceiling, will require that 2 or more of the ducts of figure 56 be assembled one on top of the other. An intumescent material such as that sold under the brand name EXPEGNI, can be placed between the upper and lower duct elements, so that in the event of a fire the intumescent material will expand, thereby creating a more positive seal between adjacent duct elements.

[0271] As illustrated in figure 59, it can be seen that the 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. Such 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. 31 2017219160 29 Aug 2017 [0272] Building risers are generally constructed, whereby not only are they not made with perfectly vertical walls which contain bumps and other surface irregularities but features have to be formed in them, like lateral passages which need to gain access to the riser, and apertures where floor slabs intersect and the like. The use of the brackets 5910, 5920 and then rails 5930 allow the fixing of the duct element to accommodate such dimensional irregularities as well as other features like apertures which can be bridged by the rails 5930 while providing appropriate support for the duct.

[0273] While the above description in respect to figure 56 and 59 is concerned with manufacturing a duct, it will be understood that the same method can be applied to manufacturing nested ducts or compound ducts where there is a plurality of duct passages formed in the duct or in the building riser.

[0274] 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.

[0275] The illustration of figure 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. These two connection methods, that is, right hand side block wall connection or connection by channel 5720, are alternatives depending upon the site requirements.

[0276] The following description will be made as if the elements are assembled on site, but it will be understood that the walls can be pre-assembled in a factory. Thus, on the left side of the figure, where, in a building riser, there is an aperture between floor slabs 5710 and 5711, a vertical channel section 5720 bridges the gap between the upper and lower slabs 5710 and 5711. The channel 5720 is secured by means of fire rated silicon adhesive on their back (in the manner of line 5763) and bolted by means of slotted holes 5721 to the slabs 5710 and 5711.

[0277] 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.

[0278] On the other side of the riser there may be a fire rated block wall 5750, in which case more rods 5723 which are secured into the block wall 5750 by means drilled holes 5755 and non shrink grout which secures the rods 5723 into the block wall 5750. 32 2017219160 29 Aug 2017 [0279] Then the second or right hand side wire mesh units 4130 are positioned on the rods 5723 which connect to the block wall 5750, and then intermediate rods 5756 are positioned through the wire mesh elements so that they will be adjacent the secured rods 5723, whereupon they can then be connected together to the rods 5723 by means of hog rings 510 or tie wire. The intermediate rods 5756 bridge the gap between the rods 5723 connected to the channel 5720 on the left side and the rods 5723 connected to the block wall 5750 on the right side. In Figure 57 the rods 5756 are illustrated as broken or with a discontinuity so as to represent that an appropriate length of a single rod 5756 will bridge the ends of the supported rods 5723.

[0280] If 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.

[0281] 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.

[0282] Once constructed, if the Trimesh 4130 has one side lined with a barrier material such as foil 530 or 3670 as described above, then mesh can be sprayed with cement based fire rated material, such as Vermitex TH, from the opposite side. However, as described above, for better more consistent spray results and use of an optimum amount of fire rated material, if those mesh panels and foils are first sprayed with Vermitex TH to form an AS2185 compliant outer panel in the factory, as described above in respect of Figure 36 to 40C, as less bulging of the foil 530 will occur, there will be a more consistent thickness of fire rated material on the duct wall produced.

[0283] 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. For ease of illustration the upper left hand corner of the panel 500 and the upper part of the channel 5720 are not illustrated. In this joining system, 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.

[0284] The panel 500 is hung from a horizontal beam system comprising hollow beam 5810 which is preferably square hollow section of 89x89x6mm, by means of an M12 nut 5830 which is welded to a lower channel member 5825 which is itself welded to the underside of the beam 5810, so that a M12 threaded bar or rod 5820 can be secured into a captured nut 5830. The lower end of the rod 5820 will have a nut and washer (not illustrated) attached so as to support the weight of the panel 500 from below. The beam 5810 extends across a large proportion of 33 2017219160 29 Aug 2017 the distance in the riser space, but not the whole distance as will be described below, because telescoping members 5815 take up the remaining space.

[0285] The rest of the distance not occupied by beam 5810 between the opposed channels is taken up by two beam section 5815 (one at either end of the beam 5810, but only the one on the left hand side is illustrated) which terminate in a vertically arranged mounting bracket 5811 which can sit in the channel or groove of the channel member 5720, for mounting the bracket 5811 to the riser or wall, or by simply securing direct to the channel 5720.

[0286] As the beam sections 5815 are square hollow sections of a size of 75x75x6mm, and are of lengths of around 200mm to 400mm, the beams sections 5815 are telescopingly located within the beam 5810. This is particularly helpful where the distances between the opposed channels 5720 on the opposite walls or risers are not constant, that is, different lengths of assembled beams 5810 and 5815 can be readily produced on site. Once beam sections 5815 are positioned on site with beams 5810 to take up the distance between the Channels, 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.

[0287] On the top and bottom of the beam 5810 are a cold formed channels 5825, which can be welded thereto and are coextensive with the beam 5810. The upper channel 5825 has an upwardly facing groove to receive the lower edge of an upper panel 500, and which will be assembled once the lower panel 500 has been secured into place. Whereas a lower panel 500 is received in the downwardly facing channel of the lower channel member 5825 [0288] By the system described above with respect to figure 58 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. As one panel 500 has been secured into place, 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.

[0289] Such ducts built according to the above methods provide fire rated construction which also provide acoustic and thermal insulation. Further as building riser wall formations are generally provided so as to carry the weight of ducts to be supported thereon, and those ducts 2017219160 29 Aug 2017 34 are also normally held in relatively heavy steel frames, such riser walls can be dispensed with, as the ducts produced by the methods of figures 56 to 59, can be suspended from floor slabs such as slabs 5710 and 5711, without there needing to be an intervening riser wall. This can lead to considerable savings in high rise building construction.

[0290] In respect of the description above the compounds mentioned above, have the following compositions: VERMITEXTH-Cement based fire rated material:

Vermiculite 30.00-60.00%

Portland cement 30.00-60.00%

Hydrated lime 10.00-30.00%

Binder unregulated 1.00-10.00%

Waterproofing agent unregulated 1.00-10.00%

Thickener, plasticising agent unregulated 1.00-10.00%

Dispersing agent unregulated 0-5.00%

Acrylic textile fibre unregulated 0-1.00%

Lightweight Polymer microspheres 0-1.00% VERMITEX AF - Gypsum or plaster based fire rated material:

Vermiculite (exfoliated, asbestos & silica free) 30.00-80.00%

Plaster as Calcium sulfate hemihydrate 10.00-60.00%

Foaming agent 0-10.00% VERMIDUCT :

Vermiculite (exfoliated, asbestos & silica free) 1318-00-9 25.00-80.00%

Calcium sulfate 7778-18-9 10.00-60.00%

Foaming agent 0-10.00%

Pigment 147-14-8 0-5.00% [0291] Where ever it is used, the word "comprising’’ is to be understood in its “open" sense, that is, in the sense of “including”, and thus not limited to its “closed" sense, that is the sense of “consisting only of'. A corresponding meaning is to be attributed to the corresponding words “comprise”, “comprised” and “comprises” where they appear.

[0292] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention.

[0293] While particular embodiments of this invention have been described, it will be evident to . those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.

Claims (82)

1. Claims

   1. A method of forming a concrete building element, said method including the step of embedding a structural or non structural lath or reinforcing element in both a treatment material and the concrete of said concrete building element.
2. 2. A method as claimed in claim 1, further including the steps of: , (a) preparing a mould or floor or base surface to form said building element; (b) locating said lath or reinforcing element in said mould or on said floor or base surface; (c) applying a layer of treatment material into said mould or said floor or base surface so as to embed a lower portion of said non structural lath or reinforcing element and leaving an upper portion of said lath or reinforcing element exposed; (d) applying concrete into said mould or on said floor or base surface and embedding the exposed portion of said lath or reinforcing element in said concrete.
3. 3. A method as claimed in claim 2, wherein there is included an additional the step of positioning reinforcing elements into said mould or above said floor or base surface.
4. 4. A method as claimed in claim 3, wherein said additional step is performed either: prior. to applying said treatment material; or after said treatment material is applied but before said concrete is applied; or after said concrete has been applied.
5. 5. A method as claimed any one of the preceding claims wherein the step of locating said lath or reinforcing element is performed by suspending said lath or reinforcing element in said mould or above said floor or base surface so that it is at a predetermined height with respect to the base of said mould, floor or base surface.
6. 6. A method as claimed in claim 5, wherein bar chairs or similar items are utilised to suspend said lath or reinforcing element in said mould or above said floor or said base surface.
7. 7. A method as claimed in claim 1, wherein said method including the steps of (a) preparing a mould or floor or base surface for said building element which includes allowance for a treatment material; (b) applying concrete to form said building element; (c) embedding a portion of said lath or reinforcing element into said concrete; (d) pouring a treatment material over said concrete slab and to cover the remainder of said lath or reinforcing element.
8. 8. A method as claimed in claim 7, wherein there is included an additional the step of positioning a reinforcing element into said mould or above said floor or base surface to be embedded into said concrete.
9. 9. A method as claimed in claim 8, wherein said additional step is performed either: prior to applying said concrete; or after said concrete has been applied but prior to embedding said lath or reinforcing element.
10. 10. A method as claimed any one of claims 7 to 9, wherein the step of embedding said lath or reinforcing element in said concrete is performed either: by suspending said lath or reinforcing element in said mould or above said floor or base surface prior to said concrete being applied and said concrete being applied so as to embed a portion of said lath or reinforcing element; or after said concrete has been applied and pushing said lath or reinforcing element therein to embed said portion.
11. 11. A method as claimed in any one of claims 2 to 10, wherein said upper and lower portions of said lath or reinforcing material embedded respectively in said concrete and said treatment material are approximately 50 % each of the depth of said lath or reinforcing material or to a depth as per design, use or service requirements.
12. 12. A method of forming a concrete building element, said method including the step of embedding at least one lath or reinforcing element wholly into the concrete of said concrete building element below a surface of said building element which will be exposed to a fire.
13. 13. A method as claimed in claim 12, wherein said at least one lath or reinforcing element, is positioned in said mould or on said floor or said base surface at one or more of the following: prior to application of said concrete; after application of said concrete; prior to structural reinforcing being located in said mould or on said floor or base surface and before said concrete is applied; prior to structural reinforcing being located in said mould or on said floor or base surface and after said concrete is applied; after said structural reinforcing has been located in said mould or above said floor or base surface and prior to said concrete being applied; after said structural reinforcing has been located in said mould or above said floor or base surface and after said concrete has been applied.
14. 14. A method as claimed in any one of the preceding claims wherein the method is performed by automated means to apply said concrete and or said treatment.
15. 15. A method as claimed in any one of the preceding claims wherein the method includes the application of at least one structural reinforcing element, which is held in a pre-stressed state in said mould or above said floor or base surface at a predetermined height, prior to a device passes over same to apply said concrete and or said fire rated layer.
16. 16. A method as claimed in any one of the preceding claims wherein said at least one lath or reinforcing element is a wire mesh array.
17. 17. A method as claimed in any one of the preceding claims wherein said at least one lath or reinforcing element is formed from two layers of mesh which are spaced apart by one or more connecting rods. • 18. A method as claimed in claim 15, wherein the connecting rods are one or more of the following: a sinusoidal shaped element; a zigzag shaped element; a rod or rod portion; welded or connected between mesh portions. . · _
18. 19. A method as claimed in any one of the preceding claims, wherein bar chairs or similar items are utilised to suspend one or both of: said at least one lath or reinforcing element in said mould or above said floor or base surface or in said building element and or said structural reinforcing in said mould or on said floor or base surface or said building element.
19. 20. A method as claimed in ay one of the preceding claims wherein the method includes the step of treatment material being sprayed on the lower layer so that one or more side located vertical extensions of said layer are formed at one or more sides of the mould.
20. 21. A method as claimed in claim 20, wherein structural reinforcing is then located between two vertical side extensions of said treatment layer.
21. 22. A method as claimed in any one of the preceding claims wherein a second structural or non-structural lath or reinforcing element is vertically spaced from the first mentioned lath or reinforcing element, such that a lower most layer of a treatment material is first applied, then the layer of concrete up to a predetermined depth of the second lath or reinforcing element, and then finally an upper or second layer of a treatment material is applied to cover the remainder of said second lath or reinforcing element.
22. 23. A method as claimed in any one of the preceding claims, wherein said treatment material is 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.
23. 24. A method as claimed in any one of the preceding claims wherein said treatment material is one of the following: Vermitex TH; a cement based fired rated material; a vermiculite based mortar.
24. 25. A building element as manufactured by the method of any one of the preceding claims.
25. 26. A building element as claimed in claim 25, wherein said building element is one of the following; a slab, a beam, a column, a duct, a wall, a ceiling panel, an exposed or concealed ceiling panel or a floor panel.
26. 27. A mesh for use as a reinforcing in the coating of metal and or other material building elements or building service elements, said mesh being made from a grid of mesh elements characterised in that at least one location, or at two or more spaced locations, said mesh has in the region of intersection of two or more intersections of mesh elements, an indent formation.
27. 28. A mesh as claimed in claim 27 wherein said indent formation is formed at discrete crossings of mesh elements on said mesh.
28. 29. A mesh as claimed in claims 27 or 28 wherein the indentation includes a point formation.
29. 30. A mesh as claimed in claim 27 wherein the indentation includes a square or rectangular formation.
30. 31. A mesh as claimed in claim 30 wherein said indentation is formed in two members of a first direction and two other members which cross the previously mentioned two members.
31. 32. A mesh as claimed in claim 27, where a series of indent formations form a channel like formation or line of indents in said mesh.
32. 33. A mesh as claimed in claims 27 to 32, wherein said indentation is formed by the intersection of two mesh elements in one direction and two mesh elements in a crossing direction.
33. 34. A mesh as claimed in any one of claims 27 to 33, wherein multiple indentations are present on said mesh.
34. 35. A mesh as claimed in any one of claims 27 to 34, wherein the multiple indentations are spaced between 100mm to 300mm in an array or spaced formation on said mesh.
35. 36. A mesh as claimed in any one of claims 27 to 35, wherein said spacing between adjacent indentations located in lines generally parallel to said mesh elements are at approximately 100 to 200 mm centres.
36. 37. A method of forming indentations in a mesh, said method including the formation of point, planar or line indentations spaced from the general plane of the mesh, at spaced locations on said mesh.
37. 38. A method of applying fire rating material to a building, a building element or a building services element, said method comprising the steps of: 1) forming a wire mesh of claim 27 to 36; 2) securing said wire mesh via said indentation to said building element.
38. 39. A method as claimed in claim 38 wherein said mesh is secured as a discrete panel to said building, said building element, said building services element is bent to conform to the shape of said building element or said building services element or a portion of said building.
39. 40. A method as claimed in claim 39, wherein edges or corners of said building element, said building services element, or a portion of said building are positioned between lines of indentations in said mesh.
40. 41. A method as claimed in claim 40, wherein where said mesh is to be joined to itself, at least 50mm or two mesh interstices are overlapped.
41. 42. A method as claimed in claim 41, wherein indentations are overlapped and secured together to said building element, said building services element, or a building portion.
42. 43. 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, said tile including an aperture there though so as to receive a pin means.
43. 44. A fire rated tile as claimed in claim 43, wherein a pin means having an attachment portion is positioned so that a pin part of said pin means passes through said aperture with said attachment portion being positioned adjacent a rearward face of said tile.
44. 45. A fire rated tile as claimed in claim 44, wherein said attachment means is adapted to be secured so as to be adjacent to said rearward face.
45. 46. A fire rated tile as claimed in claim 44, wherein said attachment means is adapted to be secured to said article to be protected from fire.
46. 47. A fire rated tile as claimed in claim 45, wherein said attachment means is secured to said tile before said tile is secured to said article.
47. 48. A fire rated tile as claimed in claim 44, wherein said attachment means is secured relative to said article or tile by the action of attaching said tile to said article by a single application of an adhesive applied to said article and said tile with captured pin means being applied to said adhesive.
48. 49. 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, said tile including protruding from an outer surface thereof, a pin means.
49. 50. A fire rated tile as claimed in any one of claims 43 to 49, wherein said pin means receives on a pin portion thereof, a securing means which is adapted to hold or retain an adjacent tile.
50. 51. A fire rated tile as claimed in any one of claims 43 to 50, wherein said tile is one or more of the following: fabricated by forming a hole in a tile and inserting a pin means there through; moulded in a mould and said hole is formed by one of the following: said mould; by a hole forming tool as said tile is setting in said mould; or by a hole forming tool after said tile has set; formed by compressed material and said hole is formed by one of the following: a compression mould; by a hole forming tool after said tile has set; is one of the following shapes: rectangular, square, triangular, round, any appropriate shape.
51. 52. A fire rated tile as claimed in any one of claims 43 to 51 wherein said aperture is located at the centre of the tile.
52. 53. A fire rated tile as claimed in claim 50, wherein said securing means is a speed clip.
53. 54. A fire rated tile as claimed in any one of claims 43 to 53, wherein said tile includes one or more of the following or is 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.
54. 55. A method of applying fire rated tiles to an article to be protected, said method including the following steps: securing a multiple of like size tiles as claimed in any one of claims 43 to 54 to said article, by means of an adhesive, said tiles being in a side by side relationship, so that each said pin means has a pin portion extending away from said article, securing a second layer of multiple like size second tiles over said first layer said second tiles made of a fire rated material which have no aperture, each said second tile being positioned so that at four locations thereof, a securing means applied to a pin portion of said pin means will overlap a periphery of said second tile.
55. 56. A method as claimed in claim 55, wherein said second layer is secured to said first layer by one of the following: solely said securing means; adhesive and said securing means.
56. 57. A method as claimed in claim 55 or 56, wherein said securing means is a speed clip which has a flange or engaging portion extending radially or radially in several directions from a central aperture which receives said pin portion.
57. 58. A method as claimed in any one of claims 55 to 57, wherein corners of said article which have tiles applied thereto and which meet at a join line, have overlying them, matching angled member, such that multiple matching angled members on the article are secured to each other, thereby providing an exo-skeletal support to said tile arrangement.
58. 59. A method of applying a fire rated tiles or panels to an article to be protected, said tiles or panels being cut or sized to be substantially the full width of respective sides of the article so that at junctions of said sides there are join lines between adjacent panels said 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 said tile or panel arrangement.
59. 60. A method as claimed in claim 59, wherein said angled members located around said article provide a compressive force to the corners of said article.
60. 61. A method as claimed in any one of claims 59 or 60, wherein said angled members are secured by securing elements or tensile elements which extend between adjacent angled members.
61. 62. A method of applying fire rated wire mesh based panels to an article to be protected, said method comprising the step of first assembling and forming the panels including application of fire rated material, cutting said panels to match the sides of said article to be protected, placing said panels so as to be adjacent to said sides, so that wire elements of adjacent panels can be secured together, joining adjacent wire elements thereby allowing the wire elements of the panels to be structurally connected and thus holding said panels to said article.
62. 63. A method as claimed in claim 62, wherein joining adjacent wire elements is performed by means of metal fixers.
63. 64. A method as claimed in claim 63 wherein said metal fixers include wire or strand bent, or hog rings, around said adjacent wire elements to secure them together.
64. 65. A method as claimed in any one of claims 62 to 64, wherein once said method steps are completed, corners of said article which have tiles or panels applied thereto and which meet at a join line, have overlying them, a matching angled member, such that multiple matching angled members are secured to each other, thereby providing an exo-skeletal support to said tile arrangement.
65. 66. A tile or method as claimed in any one of claims 43 to 65 wherein said article to be protected is a building element, such as a column, a beam, a ceiling, a floor; or a building service element such as an air conditioning duct, a return air duct, a conditioned air duct, an air duct.
66. 67. A mesh panel comprising a mesh element having a foil backing attached thereto, said panel being characterised by the application of a layer of fire rated material or adhesive to said mesh element and said foil while said foil is in contact with said mesh.
67. 68. A mesh element as claimed In claim 67 wherein said adhesive or fire rated material is applied to a thickness of the order of 1 to 10 mm.
68. 69. A mesh element as claimed in claim 67 or 68, wherein after said fire rated material or adhesive has been sprayed thereon or applied thereto, said panel is stored with the foil in an upward location on said mesh element, thereby allowing said fire rating material or adhesive to set under the influence of gravity pulling said fire rated material and said foil in a generally downward direction.
69. 70. A mesh panel as claimed in any one of claims 67 to 69 wherein said fire rated material or adhesive is any one of the following or a combination of one or more of the following: a gypsum based fire rated material; a fire rated adhesive material; an adhesive, a silicate adhesive; a nonflammable adhesive; a cement based fire rated material.
70. 71. A method of manufacturing a mesh panel, said method comprising the attachment of foil to the base of a mesh element by means of clips or other appropriate means; positioning the mesh element and foil onto a generally flat base so that said foil maintains contact with, or will be located near to base wire elements on said mesh; spraying or applying a fire rated material or adhesive material to said mesh and foil, through said mesh element so as to adhere to the surface of said foil in contact with said mesh elements, so as to bind said foil to said mesh element.
71. 72. A method as claimed in claim 71, wherein said generally flat base includes a generally planar surface.
72. 73. A method as claimed in claim 71, wherein said generally flat base includes a layer of mesh or similar so as to position said foil in contact with or be located near to base wire elements.
73. 74. A method as claimed in any one of claims 71 to 73, wherein after spraying a first mesh element, a second mesh element can be positioned on the first, with an upper mesh layer of said first element providing support for the foil and mesh of the second mesh element, so as to position said foil in contact with or be located near to base wire elements on said second mesh element.
74. 75. A method as claimed in claim 74, wherein said process is repeated to produce a stack of mesh panels which have been sprayed with or have applied thereto the fire rated material or adhesive.
75. 76. A method as claimed in any one of claims 71 to 75, wherein said panels are inverted once sprayed or have the layer applied, so that said fire rating material or said adhesive and foil is located at a top location, and is allowed to set whilst inverted, so that gravity will urge said foil in contact with said mesh.
76. 77. A method of forming a fire rated duct in a building riser or a wall of a building riser, said method including the step of providing means to suspend mesh elements or fire rated panels or a duct formation to a wall of said riser or other building element associated with said riser.
77. 78. A method as claimed in claim 77 wherein said method includes a step of installing channels in said riser or to building elements at said riser location.
78. 79. A method as claimed in claim 77 or 78, wherein said method includes connecting supporting rods to channels mounted to building elements at said riser location, or to walls of said riser.
79. 80. A method as claimed in any one of claims 77 to 79, wherein a beam system is provided to suspend mesh elements or fire rated panels or a duct formation to a wall of said riser or other building element associated with said riser location.
80. 81. A method as claimed in claim 80 wherein said beam system includes telescoping portions to accommodate variations in width of riser mounting locations.
81. 82. A method as claimed in any one of claims 77 to 81, wherein said duct formation or riser wall is made from fire rated panels with reinforced wire corners, all coated with a fire rated material.
82. 83. A building duct or riser wall being constructed by the method as claimed in any one of claims 77 to 82.