AU2022203833A1

AU2022203833A1 - A firestopping device and associated method

Info

Publication number: AU2022203833A1
Application number: AU2022203833A
Authority: AU
Inventors: John RAKIC
Original assignee: Rakman International Pty Ltd
Current assignee: Rakman International Pty Ltd
Priority date: 2016-02-12
Filing date: 2022-06-02
Publication date: 2022-06-23
Also published as: AU2020226994A1; AU2018204687A1; AU2017101778A4; NZ722508A; AU2017101778B4; AU2016208262A1

Abstract

An embodiment of the firestopping device 1 has a first portion 2, which may be fastened to an external object, such as a concrete slab, for example. The device 1 also has a second portion 4 that is separate from the first portion 2 and which can be mated to the first portion 2 such that together they define the firestopping device 1. At least one service may extend through the firestopping device 1. Intumescent material 15 is housed within the firestopping device 1. An extra piece of intumescent material 31 is externally disposed on the device 1. The device allows for the implementation of an inventive method of constructing a barrier having at least one service routed there through.

Description

A FIRESTOPPING DEVICE AND ASSOCIATED METHOD TECHNICAL FIELD

The present invention relates to the field of passive fire protection. Embodiments of the present invention find application, though not exclusively, in the construction of buildings such as residential apartment buildings and the like.

BACKGROUNDART

Any discussion of documents, acts, materials, devices, articles or the like which has been included in this specification is solely for the purpose of providing a context for the present invention. It is not to be taken as an admission that any or all of these matters form part of the prior art base or were common general knowledge in the field relevant to the present invention as it existed in Australia or elsewhere before the priority date of this application.

In a typical prior art method for constructing a residential apartment building the walls are constructed prior to installation of the services such as electrical cables, water pipes, etc. In this prior art method, a hole is made in the wall for each of the services, which typically must be separated by a standard separation distance, such as 200 mm for example. This separation distance requires significantly larger overall areas for services, which severely limits the design options for construction. Additionally, the typical prior art method often requires ladders and the like to be set up and moved repeatedly. Each of the individual holes through which the services extend must then be separately sealed in a fire rated fashion, which can be time consuming and expensive.

SUMMARY OF THE INVENTION

It is an object of the present invention to overcome, or substantially ameliorate, one or more of the disadvantages of the prior art, or to provide a useful alternative. In one aspect of the present invention there is provided a firestopping device including: a first portion formed from a metallic material or a thermally insulative material having formations for fastening of the first portion to an external object; and a second portion formed from a metallic material or a thermally insulative material being separable from the first portion and being mateable to the first portion such that the first and second portions,

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when mated together, define the firestopping device; wherein the firestopping device has a first opening at a first end, a second opening at a second end and an internal volume intermediate the first and second ends, the internal volume and each of the openings being sized such that at least one service may extend through the firestopping device, and wherein an intumescent material is housed within the internal volume, the intumescent material being responsive to heat so as to swell within the internal volume.

Preferably the first and second portions are mateable to each other without the use of any tools. In one embodiment the first and second portions are click-lockingly mateable to each other. In another embodiment the first and second portions are mateable to each other by means of an interference fit. However, in another embodiment the first and second portions are mateable to each other by at least one mechanical fastener.

In one embodiment the first portion is a planar panel defining a pair of opposite sides each having a side wall extending therefrom and the second portion is U-shaped so as to define a base connected to a pair of opposed side walls. In this embodiment the pair of side walls of the second portion are slidingly receivable within the pair of sidewalls of the first portion. At least one tab is preferably disposed on each of the side walls of the second portion and slidably receiving the pair of side walls of the second portion within the pair of sidewalls of the first portion sandwiches the sidewalls of the first portion between the sidewalls of the second portion and the tabs.

In one embodiment a piece of intumescent material is externally disposed on the planar panel of the first portion.

Preferably wall engaging formations are disposed on an outer surface of the second portion.

Preferably the first portion includes at least one redundant formation for fastening of the first portion to an external object.

According to another embodiment of the invention there is provided a method of constructing a barrier having at least one service routed there through, the method including the steps of: providing a firestopping device as described above; fastening the first portion to an external object at a position that straddles the proposed positioning of the barrier; positioning at least one service such that it is adjacent to, or in alignment with, the first portion; positioning the second portion around the at least one service; mating the first and second portions to each other such that the at least one service extends through the firestopping device; and constructing the barrier around the firestopping device.

Preferably the step of positioning the at least one service includes supporting the at least one service with at least one fastening device.

The method preferably further includes the step of placing a first piece of graphite impregnated foam around the at least one service and packing the first piece of graphite impregnated foam into the first opening and placing a second piece of graphite impregnated foam around the at least one service and packing the second piece of graphite impregnated foam into the second opening.

Another embodiment of the method includes the step of spraying expanding foam into the first and second openings, wherein the expanding foam has intumescent and/or fire retardant properties.

In one embodiment of the method wall engaging formations are attached to the ceiling and to the exterior of the second portion immediately prior to construction of the barrier. In another embodiment of the method wall engaging formations are pre-installed upon an outer surface of the second portion.

The features and advantages of the present invention will become further apparent from the following detailed description of preferred embodiments, provided by way of example only, together with the accompanying drawings.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

Figure 1 is an upper perspective view of afirst embodiment of a firestopping device;

Figure 2 is a front view of thefirst embodiment (with the rear view being identical);

Figure 3 is a plan view of thefirst embodiment;

Figure 4 is a side view of the first embodiment (with each side being identical);

Figure 5 is an upper perspective view of thefirst portion of thefirst embodiment;

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Figure 6 is alower perspective view of thefirst portion of the first embodiment;

Figure 7 is an upper perspectiveview of the sec ondportion of the first embodiment;

Figure 8 is afront view of the second portion of the first embodiment;

Figure 9is aplan view of the second portion of the first embodiment;

Figure 10 is a side view of the first embodiment showing line A-A;

Figure 11 is a sectional view of the first embodiment taken through line A-A of figure 10;

Figure 12 is a perspective view of the first embodiment showing a pair of graphite impregnated foam inserts prior to their insertion into the first embodiment;

Figure 13 is a lower perspective view of thefirst portion of thefirst embodiment shown as attached to a ceiling;

Figure 14 is a lower perspective view of the first embodiment shown as attached to a ceiling;

Figure 15 is a lower perspective view of a wall as constructed in accordance with an embodiment of the method of the present invention;

Figure 16 is a lower perspective view of a second embodiment of the firestopping device;

Figure 17 is a bottom view of the second embodiment;

Figure 18 is a front view of the second embodiment; and

Figure 19 is a side view of the second embodiment.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

The first embodiment of the firestopping device 1 is best illustrated in figures 1 to 4. It has a first portion 2 illustrated in figures 5 and 6, which is in the form of a planar panel 9

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defining a pair of opposite sides each having a side wall 10 and11 respectively extending therefrom. Each of the side walls 10 and 11 has a pair of dimples 12 positioned adjacent to each of their ends. The first portion 2 has formations in the form of holes 3 for fastening of the first portion 2 to an external object. In typical implementations the object to which the first portion 2 is likely to be fastened is an overhead concrete slab, although other possibilities include wooden frame structures, walls, floors, service shafts, etc. Fasteners, in the form of bolts, screws, or the like, extend through the holes 3 so as to fasten into the concrete slab, thereby securing the first portion 2 in place.

As illustrated for example in figures 7 to 9, the firestopping device 1 also has a second portion 4 that is separate from the first portion 2. The separability of the first and second portions 2 and 4 allows the firestopping device 1 to be used in the method that is described in detail below. The second portion 4 is U-shaped so as to define a base 17 connected to a pair of opposed side walls 7 and 8. A pair of outwardly projecting tabs 13 are disposed on each of the side walls 7 and 8 of the second portion 4. Each of these tabs 13 has a small inwardly facing projection 14.

The second portion 4 can be mated to the first portion 2 such that together they define the firestopping device 1. The first and second portions 2 and 4 are mateable to each other without the use of any tools, allowing the method outlined below to be performed quickly and easily. More specifically, the first and second portions 2 and 4 are click lockingly mateable to each other. In an alternative embodiment (not illustrated), the first and second portions are mateable to each other by means of an interference fit. Yet other embodiments make use of direct mechanical fixing for mating of the first portion 2 to the second portion 4, such as rivets, screws, etc. However, such embodiments are likely to be less desirable due to the increased effort required to mate the first and second portions 2 and 4.

Mating of the first and second portions 2 and 4 commences by sliding the pair of side walls 7 and 8 of the second portion 4 within the pair of sidewalls 10 and 11 of the first portion 2. As best shown in figure 2, this sandwiches the sidewalls 10 and 11 of the first portion 2 between the sidewalls 7 and 8 of the second portion 4 and the tabs 13. The sliding continues until the projections 14 disposed on each of the tabs 13 respectively align with the four dimples 12, at which point an inwardly directed force arising from the resilience of the tabs

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13 causes each of the projections 14 to be seated into a corresponding dimple 12. This seating provides the click-locking effect and functions to retain the first and second portions 2 and 4 in the mated configuration. This fixing system advantageously positions the fixings away from the services (which could include live cabling) so that mating of the first and second portions 2 and 4 is unlikely to damage any of the services.

In an alternative embodiment (not illustrated), the outwardly projecting tabs are disposed on the pair of sidewalls of the first portion. Mating for this embodiment entails sliding the side walls of the first portion into those of the second portion so as to sandwich the sidewalls of the second portion between those of the first portion and the tabs.

As shown in the illustrations, once mated the second portion 4 forms the base 17 and the majority of the side walls of the firestopping device 1. However, in other embodiments the second portion mates with the first portion so as to form one of the sides and/or the top of the firestopping device.

The firestopping device 1 has a first opening 5 at a first end and a second opening 6 at a second end that is opposite to the first end. An internal volume extends intermediate the first and second ends 5 and 6. The internal volume and each of the openings 5 and 6 are sized such that at least one service (not illustrated) may extend through the firestopping device 1.

Four pieces of intumescent material 15 are housed within the internal volume of the firestopping device 1. More specifically, with regard to the second portion 4, one piece of intumescent material 15 is disposed against each of the side walls 7 and 8 and against the base 17. With regard to the first portion, a piece of intumescent material 15 is disposed along the inner facing side of the planar panel 9. Each piece of intumescent material 15 is retained in position by a pair of flanges 16, which allows for easy initial installation and subsequent replacement of the intumescent material 15 for long term maintenance purposes. In the event of exposure to the heat of a fire, the intumescent material 15 responds by swelling within the internal volume of the firestopping device 1. This resists the passage of fire and smoke through the firestopping device 1. As is described in more detail below, the use of ceramic fibre insulation can further improve the performance of the preferred embodiment.

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Another embodiment makes use of differing specifications of intumescent materials to provide a two-stage expansion process, which has the potential to improve the performance of the firestopping device 1.

If exposed to the heat of a fire, there is a risk that the planar panel 9 of the first portion may buckle due to heat expansion because the ends of the panel remain bolted to the external object. Such buckling has the potential to create an air gap between the upper surface of the planar panel 9 and the object to which it is bolted. This may allow fire and/or smoke to transfer through the gap. To help guard against this eventuality, an extra piece of intumescent material 31 is externally disposed on the planar panel 9 of the first portion 4. This allows the externally disposed intumescent material 31 to respond to heat by sealing off any air gap that may have formed between the upper surface of the planar panel 9 and the object to which it is fastened. The external piece of intumescent material 31 is disposed along the centre of the planar panel 9 with two additional planar panels 32 and 33 being disposed on either side of the external piece of intumescent material 31. The holes 3 are disposed adjacent to the edges of these two additional planar panels 32 and 33.

In the illustrated embodiment the firestopping device 1 (with the exception of the intumescent material 18) is made from a metallic material such as mild steel, or 1.1 mm Zincanneal steel sheeting, which is folded on brake presses and turret punched to form the first and second portions 2 and 4. Special forming tools are used to create the 'clip in' attachments tabs 13. However, in another embodiment the casing of the firestopping device 1 (i.e. the planar panel 9, the side walls 7, 8, 10 and 11, and the base 17) is made from a thermally insulative material, such as calcium silicate for example, to resist the thermal conduction of heat across the firestopping device.

The second embodiment of the firestopping device 19, as shown in figures 16 to 19, has wall engaging formations in the form of channels 20 disposed upon outer surfaces of the side walls 21 and 22 and upon the base 23 of the second portion 24. These channels 20 each define a pair of surfaces to which a walling material, such as plaster board or the like, may be attached. Alternatively, if the wall is to be formed by means of formwork, the channels 20 each define a pair of surfaces against which formwork panels may rest.

The first portion 25 of the firestopping device 19 illustrated in figures 16 to 19 includes a couple of redundant formations for fastening of the first portion 25 to an external object. More specifically, rather than providing three holes 3 per side for bolting of the first portion 2 to the external object (as shown for example in figure 1), the second embodiment provides seven holes 26 on each side of the first portion 25; despite only requiring three bolts per side. This allows the installer some freedom to re-position a bolt in the event that a first attempt to fasten the bolt to the object fails, for example due to the bolt hitting steel reinforcing that may be embedded within a concrete object. If this occurs, the installer can simply remove the bolt from the failed position and attempt to fasten the bolt through one of the other available holes. This provides other positions in which to insert the bolt whilst the first portion 25 remains in a fixed position the relative to the object.

Either of the above-described embodiments of the firestopping device 1 or 19 may be used in a method of construction of a barrier having at least one service routed there through. For the sake of providing an example, we shall assume that the barrier is a wall. The method commences with the marking of a line 27 on the concrete ceiling 28, which depicts the proposed centre line of the wall. The installer then fastens the first portion 2 to the ceiling 28 at a position that straddles the proposed positioning of the wall. More specifically, the first portion 2 is bolted onto the ceiling such that its intumescent material 15 is centred over, and extends parallel to, the centre line of the proposed wall, as shown in figure 13. Hence the positioning of the first portion 2 on the ceiling 28 provides a visual guide as to where the services are to penetrate through the proposed wall.

Next the installer positions the services (not illustrated) such that they are adjacent to, or in alignment with, the first portion 2. More specifically, the services are typically suspended by fastening devices such as clips, clamps, etc., approximately 50 mm below the ceiling so as to extend below the first portion 2 and generally perpendicular to the intumescent material 15 of the first portion 2. Typically, the installer will be supported by a lifting mechanism, such as a scissor lift or the like, whilst running the services. This process doesn't require the threading of the services through a prior art style of firestopping device, which helps ease of running the services and minimises the potential for the services to be damaged by the firestopping device. It is also time efficient and therefore has the potential to yield cost savings for the construction of the building. It also has the potential to assist project managers to coordinate the activities of various tradesmen and sub-contractors.

The reduction in required space for the firestopping of these services allows for significantly more flexibility in design, and the application of a multi-service firestopping device provides an "all-in-one" solution, allowing easier certification and compliance procedures.

Once the services have been run, the second portion 4 is positioned around the services. That is, the side walls 7 and 8 of the second portion 4 are positioned on either side of the services, with the base 17 of the second portion 4 below the services. The second portion 4 is then slid upwards so as to mate the first and second portions 2 and 4 to each other as shown in figure 14. Hence, the services now extend through the firestopping device 1.

It is now possible to construct the wall 30, as illustrated in figure 15, around the firestopping device 1 using standard barrier building techniques. For example, the wall installer may now attach wall engaging formations, in the form of a head track, to the ceiling 28 and to the exterior of the second portion 4, to which a barrier material, such as plaster board for example, may be attached. Additionally, or alternatively, wooden frame work may be constructed, to which a barrier material, such as plaster board for example, may be attached. Alternatively, formwork may be positioned to allow the pouring of a concrete wall. These processes may be assisted with the use of the second embodiment of the firestopping device 19, as illustrated in figures 16 to 19, to which the wall engaging formations in the form of channels 20 are pre-installed.

The resulting wall 30 has the firestopping device 1, and the services (not illustrated), extending there through. A number of services may extend together through the firestopping device without requiring the approx. 200 mm separation between each of them that is applicable to some prior art techniques.

The next step is to apply sealant around the inner perimeters of the first and second openings 5 and 6. As best depicted in figure 12, the installer then places a first piece of graphite impregnated foam 29 around the services and packs the first piece of graphite impregnated foam 29 into the first opening 5 of the firestopping device 1. Optionally, additional lengths of thermally insulative wrap, such as ceramic fibre wrap, can be fitted around the services externally to the firestopping device 1. The thermally insulative wrap may be held in place by a variety of methods such as the use of metal fixings and/or adhesive tape. Then a second piece of graphite impregnated foam 29 is placed around the services on

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the other side of the wall and packed into the second opening 6. This packing of the graphite impregnated foam 29 preferably occurs after the wall 30 has been constructed, which helps avoid the graphite impregnated foam 29 being lost and allows for specialist contractor involvement in the requisite certification.

In addition to, or as an alternative to, the use of graphite impregnated foam 29, another embodiment of the method makes use of sprayable expanding foam that has intumescent and/or fire-retardant properties. This expanding foam-in-place material is sprayed into the first and second openings 5 and 6 after all the services have been run and the first and second portions 2 and 4 mated.

If, at some point in the future, it is necessary to retro-fit one or more further services through the wall, it is possible to do so provided that the sizing of the firestopping device allows for additional services to be accommodated. This is done by removing the pieces of graphite impregnated foam 29, threading the new services through, and re-installing the graphite impregnated foam 29. This avoids the need to create any additional penetrations through the wall.

While a number of preferred embodiments have been described, it will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. A firestopping device including: a first portion formed from a metallic material or a thermally insulative material having formations for fastening of the first portion to an extemal object; and a second portion formed from a metallic material or a thermally insulative material being separable from the first portion and being mateable to the first portion such that the first and second portions, when mated together, define the firestopping device; wherein the firestopping device has a first opening at a first end, a second opening at a second end and an internal volume intermediate the first and second ends, the internal volume and each of the openings being sized such that at least one service may extend through the firestopping device, and wherein an intumescent material is housed within the internal volume, the intumescent material being responsive to heat so as to swell within the internal volume.

2. A firestopping device according to claim 1 wherein the first and second portions are mateable to each other without the use of any tools.

3. A firestopping device according to claim 2 wherein the first and second portions are click-lockingly mateable to each other.

4. A firestopping device according to claim 2 wherein the first and second portions are mateable to each other by means of an interference fit.

5. A firestopping device according to claim 2 wherein the first and second portions are mateable to each other by at least one mechanical fastener.

6. A firestopping device according to any one of the preceding claims wherein the first portion is a planar panel defining a pair of opposite sides each having a side wall extending therefrom.

7. A firestopping device according to claim 6 wherein a piece of intumescent material is externally disposed on the planar panel of the first portion.

8. A firestopping device according to claim 6 or 7 wherein the second portion is U-shaped so as to define a base connected to a pair of opposed side walls.

9. A firestopping device according to claim 8 wherein the pair of side walls of the second portion are slidingly receivable within the pair of sidewalls of the first portion.

10. A firestopping device according to claim 9 wherein at least one tab is disposed on

each of the side walls of the second portion.

11. A firestopping device according to claim 10 wherein slidably receiving the pair of side walls of the second portion within the pair of sidewalls of thefirst portion sandwiches the sidewalls of the first portion between the sidewalls of the second portion and the tabs.

12. A firestopping device according to any one of the preceding claims wherein wall

engaging formations are disposed on an outer surface of the second portion.

13. A firestopping device according to any one of the preceding claims wherein the first portion includes at least one redundant formation for fastening of the first portion to an

external object.

14. A method of constructing a barrier having at least one service routed there through, the method including the steps of: providing a firestopping device as defined in any one of claims I to 13;

fastening the first portion to an external object at a position that straddles the proposed positioning of the barrier;

positioning at least one service such that it is adjacent to, or in alignment with, the first portion; positioning the second portion around the at least one service; mating the first and second portions to each other such that the at least one service extends through the firestopping device; and constructing the barrier around the firestopping device.

15. A method according to claim 14 wherein the step of positioning the at least one service includes supporting the at least one service with at least one fastening device.

16. A method according to claim 14 or 15 further including the step of placing a first piece of graphite impregnated foam around the at least one service and packing the first piece of graphite impregnated foam into the first opening and placing a second piece of graphite

impregnated foam around the at least one service and packing the second piece of graphite impregnated foam into the second opening.

17. A method according to claim 14 or 15 further including the step of spraying expanding foam into the first and second openings, wherein the expanding foam has intumescent and/or fire-retardant properties.

18. A method according to any one of claims 14 to 17 wherein wall engaging formations are attached to the ceiling and to the exterior of the second portion immediately prior to construction of the barrier.

19. A method according to any one of claims 14 to 17 wherein wall engaging formations are pre-installed onto an outer surface of the second portion.