AU685414B2 - Fire-rated enclosure - Google Patents

Description

Title: "FIRE-RATED ENCLOSURE"

FIELD OF THE INVENTION

The present invention relates to fire-rated enclosures and more particularly to fire-rated, light-weight concrete enclosures. The invention has been developed primarily for use as a fire-rated enclosure for electrical equipment, hazardous goods, explosives and documents as well as a site for laboratories and remote telephone exchanges. However, it will be appreciated that the invention is not limited to these particular fields of use. BACKGROUND OF THE INVENTION

The storage of electrical equipment and hazardous goods, particularly chemicals and explosives has, until recently, been unregulated and hazardous goods, chemicals, explosives and electrical equipment, have been stored in make shift enclosures without sufficient regard to the potential damage to goods or danger to the site. Those make shift enclosures are often built in brick using existing fixed walls, floors and -ceilings, often in the corner of an existing facade where only one or two walls are required to complete the enclosure. However, with the advent of a regulatory scheme for the housing of hazardous chemicals such aforesaid makeshift enclosures do not meet the required standards and cannot be moved in to a preferred position without dismantling the enclosure and rebuilding.

Regulatory schemes aside, freestanding enclosures for the storage of dangerous goods are known but are often built on fixed concrete slabs or necessarily include separate wall, floor and roof portions fastened together with angled metal fastening means thereby necessitating fire-rated sealing means between the portions. Although gaps between portions are sealed with sealing means often the sealing means and fastening means represent a first line of weakness during burn through should a fire break out within or outside the enclosure. Further, the angled, metal fastening means are often not fire rated and can be responsible for static electricity within the enclosure.

Further, panels used for the portions and fastening means are usually made of reinforced heavy concrete which means that although the buildings are technically portable, in fact can only be moved with the assistance of heavy-duty forklifts or cranes.

In addition and in the past, document storage has presented a problem because the quantity of documents to be protected quite often exceeds the normal storage capacity of units for example metal safes. Accordingly, many documents are exposed to water and fire damage in the event of a fire. Yet further, the quantity of documents to be stored often exceeds conventional storage space and it is therefore often necessary to store documents off site. However, storage of documents off site necessitates packing and boxing of documents and labelling and transporting the documents to a remote storage site. The remoteness of the storage site means that documents cannot be accessed quickly or easily.

Further, it is often desirable to have portable laboratories at an existing premises or to be erected at a a preferred site and to be able to move the laboratory at will when a job is finished or a business premises changes its business address. It is also desirable to build a laboratory that is fire-rated in case of an explosion inside the laboratory or fire external to the laboratory. However, previously it has not been possible to provide a portable building that is fire-rated and capable of containing an explosion or fire within the enclosure. Prior art enclosures that provided a suitable fire-rating were not portable and if technically portable were so heavy that they were not easily dismantlable. In the past, portable laboratory buildings were often make-shift and flimsy and simply offered a location for testing but did not offer containment of a f re in the event of a fire or explosion.

It is therefore an object of invention to at least in its preferred embodiment ameliorate at least some of the deficiencies of the prior art. DISCLOSURE OF THE INVENTION

According to the present invention there is provided a fire-rated, light-weight concrete, freestanding enclosure wherein the enclosure comprises a front section, one or more intermediate sections and an end section, each section having aperture means located substantially adjacent one or more corners of the sections said aperture means capable of receiving a bolt means, said bolt means extending from one or more aperture means in the front section through one or more corresponding aperture means in one or more intermediate sections and terminating in one or more corresponding aperture means in said end section, wherein the bolt means extends the length of the enclosure and acts to orientate and secure the sections with respect to each other to form the enclosure.

In a preferred embodiment, the enclosure includes one or more wall sections located at predetermined positions between the front and end sections to form one or more modules or rooms within the enclosure wherein said wall sections include one or more aperture means located substantially adjacent one or more corners of the wall sections said aperture means capable of receiving said bolt means.

Preferably, each section is sealed with respect to each other by fire-rated sealing means. More preferably, the sections include aperture means adjacent at least two corners of the sections. Preferably, the corners are top corners of the sections. In a preferred embodiment, the intermediate sections are shaped in a square O-ring configuration. In yet a further embodiment the front section includes fire-rated doors.

In a preferred embodiment, the front, intermediate, walled and rear sections are moulded individually and in one piece. Most preferably, the sections are moulded from lightweight, foamed concrete and may be substantially square in cross section. Preferably, the concrete has a density of approximately 900kPa. Most preferably, each section has a base panel, two side panels and a roof panel. Yet further, it is preferred that the roof panel has an exterior pitched face.

In a further embodiment, the sections include reinforcing cornice means which substantially surround the aperture means and any bolt means located therein. Preferably, the cornice means are fire-rated and have a burn through rating of at least 4 hours. Most preferably, the sections are individually reinforced. In a preferred embodiment, the sections are reinforced with mesh moulded into a cage configuration.

Each section has by definition a front and back face. To assist assembly and security of the enclosure it is preferable that at least the intermediate and wall sections are assembled in a tongue and groove configuration. Therefore it is preferable that the front section include at least one tongued protrusion on its back face which corresponds to at least one depression on the front face of the intermediate, wall or end sections. Similarly, it preferred that the intermediate and wall sections include at least one tongued protrusion on their back faces.

Preferably, the protrusions and depressions are stepped in from and extend around a substantial portion of the perimeter of a face.

In accordance with a further aspect of the present invention there is provided a method of storage comprising the steps of a) storing items inside a fire rated, light-weight concrete, freestanding enclosure wherein the enclosure comprises a front section, one or more intermediate sections and an end section, each section having aperture means located substantially adjacent one or more corners of the sections said aperture means capable of receiving bolt means, said bolt means received in one or more aperture means of said front section and extending through one or more aperture means of one or more intermediate sections and terminating in one or more corresponding aperture means in the said end section, wherein the bolt means extends the length of the enclosure and acts to orientate and secure the sections with respect to each other to form the enclosure, b) arranging the goods within the enclosure to minimize contamination, damage and/or reaction of goods.

Preferably, the enclosure includes one or more wall sections located at predetermined positions between the front and end sections to form one or more modules or rooms within the enclosure wherein said wall sections include one or more aperture means located substantially adjacent one or more corners of the wall sections said aperture means capable of receiving said bolt means .

In accordance with a further aspect of the present invention, there is provided a method of erecting a fire-rated, light-weight concrete, freestanding enclosure comprising the steps of: a) erecting a front section of the enclosure and inserting bolt means into one or more aperture means located in one or more corners of said section, b) positioning the bolt means through one or more corresponding aperture means located in one or more corners of one or more intermediate sections of the enclosure and fitting a first intermediate section to said front section and securing the two sections together, c) securing any subsequent intermediate sections to any preceding intermediate sections, d) positioning the bolt means through one or more apertures located in one or more corners of an end section and fitting the end section to a preceding intermediate section and securing the sections together.

Preferably, the method includes the step of including one or more wall sections fitted at predetermined locations between the front and end sections .

Preferably, each section has at least one face having depressions or tongued protrusions which correspond to complimentary depressions or tongued protrusions in the face of a preceding or subsequent sections.

In accordance with a further step, the sections are secured together by positioning the protrusions to fit into complimentary depressions in preceding or subseqent sections. In yet a further step the sections are sealed with respect to each other by fire-rated sealing means.

In accordance with yet a further embodiment there is provided a fire-rated, light-weight concrete section having a substantially square configuration having a density of approximately 900kPa. Preferably, the section includes aperture means located substantially adjacent one or more corners of the section said aperture means capable of receiving a bolt means.

More preferably, the section is reinforced by reinforcing cornices which substantially surround the aperture means and any bolt means located therein.

Yet more preferably, the section is a square O-ring in configuration. The section is preferably comprised of a base panel, two sided panels extending vertically from the base panel terminating in a roof panel. Preferably, the roof panel has an exterior pitched face. More preferably, the roof panel includes one or more ventilation ducts. BRIEF DESCRIPTION OF THE DRAWINGS

A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

Fig 1 is a perspective view of an enclosure in accordance with a first aspect of the present invention.

Fig 2 is a perspective, exploded view of an enclosure substantially in accordance with Fig 1.

Fig 3 is a perspective view of a front section of an enclosure in accordance with a first aspect of the present invention.

Fig 4 is a rear elevational view of a front section in accordance with Fig 3. Fig 5 is a perspective view of an intermediate section in accordance with a first aspect of the present invention.

Fig 6 is a rear view of an intermediate section in accordance with Fig 5.

Fig 7 is a perspective rear view of an intermediate section in accordance with a first aspect of the present invention.

Fig 8 is a front view of an end section in accordance with Fig 7.

Fig 9 is a perspective view of an enclosure in accordance with a second aspect of the present invention.

Fig 10 is a perspective view of an enclosure in accordance with a third aspect of the present invention.

Fig 11 is a cut-away perspective view of the enclosure of the present invention in accordance with a fourth aspect of the present invention.

Fig 12 is a cut-away perspective view of the enclosure of the present invention in accordance with a preferred embodiment of a fourth aspect of the present invention.

Fig 13 is a perspective view of an enclosure in accordance with a preferred embodiment of Fig 1.

Fig 14 is a perspective, exploded view of an enclosure in accordance with a preferred embodiment of Fig 2.

Fig 15 is a perspective view of a front section of an enclosure in accordance with a preferred embodiment of Fig 3.

Fig 16 is a rear elevational view of a front section in accordance with a preferred embodiment of Figs 3 and 4.

Fig 17 is a perspective view of an intermediate section in accordance with a preferred embodiment of Fig 5.

Fig 18 is a rear view of an intermediate section in accordance with a preferred embodiment of Figs 5 and 6.

Fig 19 is a perspective rear view of an intermediate section in accordance with a preferred embodiment of Fig 7.

Fig 20 is a front view of an end section in accordance with a preferred embodiment of Figs 7 and 8.

Fig 21 is a perspective view of an enclosure in accordance with a preferred embodiment of Fig 9.

Fig 22 is a perspective view of an enclosure in accordance with a preferred embodiment of Fig 10.

Fig 23 is a cut-away perspective view of the enclosure in accordance with a preferred embodiment of Fig 11.

Fig 24 is a cut-away perspective view of the enlosure in accordance with a preferred embodiment of Fig 12.

Fig 25 is a perspective view of a wall section in accordance with a further aspect of the present invention.

Fig 26 is a perspective view of an enclosure in accordance with a preferred embodiment of the enclosure of Fig 1.

Fig 27 is a perspective view of an enclosure in accordance with a preferred embodiment of the enclosure of Fig 9.

Fig 28 is a perspective view of a section in accordance with a preferred embodiment of Fig 17.

Fig 29 is a perspective view of an enclosure in accordance with a preferred embodiment of the enclosure in Fig 21.

Fig 30 is a perspective sectional view of a ventilation unit in accordance with a further aspect of the invention. PREFERRED EMBODIMENTS OF THE INVENTION

The enclosure is a fire-rated portable building 10 suitable for housing hazardous goods such as chemicals and explosives, as well as documents and electrical equipment and equally suitable for housing laboratories and electrical switch rooms.

The building 10 comprises a front section 11, one or more intermediate sections 12 and a rear section 14 and an optional wall section 13. Each section 11, 12, 13 and 14 is moulded in one piece from light-weight foamed concrete.

The front section 11 is an end section and houses the fire-rated doors 15 and frame 16. Fig 4 shows a version of section 11 which does not include tongued protrusions or depressions whilst Fig 16 shows, a version that includes two rows of depressions 11a which are stepped in from the perimeter lib and extend around the perimeter of section 11. The doors 15 are outward opening and swing on frame 16. Both the doors 15 and frame 16 are 2 or 3 hour fire rated. Entry to the building 10 is via access ramp 17 and doors 15. The ramp 17 is particularly useful for movement of goods in and out of the building 10 and providing the building 10 is of sufficient dimensions allows access by truck, fork lift or trolley (not shown) . The ramp 17 is graded and capable of bearing wheeled loading of 4 x 200 litre capacity containers. The inclination of ramp 17 is based on a 1:10 gradient. Means (not shown) for attachment of the ramp to building 10 are located under the doors 15.

Primarily the doors 15 are located on the front section 11 but other optional locations are envisaged for example on one or both sides of the building 10 as shown in Figs 26 and 27 as doors 15 and 15a. The doors 15 are fitted with matching fire-rated door jambs (not shown) . Crashbars or panic bolts (not shown) may be fitted internally to the doors 15 for emergency hands free outward operation.

Ventilation start switches (not shown) may be fitted to a leading edge of door jambs to facilitate manual operation of the ventilation system (not shown) . The doors 15 are fabricated from standard timber certified sandwich construction utilizing fire-rated materials, fire-rated jambs and hinges. The door jambs are designed to be located in section 11 at the time of fabrication for inclusion in the casting process of the section 11. The doors 15, panic bolts and automatic door closures are fitted during assembly.

Section 11 is essentially a square ring in shape and cross section and in the embodiment shown in Fig 3 has a stabilizing foot 21. The section 11 is comprised _c of a front face 22, a rear face 23 side panels 24 and 25, a top panel 26, base panel 27 and a central aperture 28. The top panel 26 may, as shown in Fig 15, include a pitched roof comprising of panels 26a and 26b.

Aperture 28 is square or rectangular in configuration having side walls 29 and 30, top wall 31 and bottom wall 32. The shape and dimensions of aperture 28 are dictated by the doors 15 (or 15a appropriate) and the dimensions of building 10.

Each corner of section 11 comprises a reinforced shoulder 33 which essentially joins panels 24, 25, 26 (and 26a and 26b) and 27. Shoulder 33 is shaped to provide a maximum burn through area to protect each corner because each corner houses a connecting bolt 34 which bolt 34 acts to reinforce and frame building 10 whilst securing the sections 11, 12, 13 and 14 together. Recesses 35 are located adjacent each corner to receive bolts 34, the recesses terminating at end walls 36 on front face 22. As can be seen in Fig 4 the section 11 is recessed and rear face 23, the doors 15 and aperture 28 are set back from contact surface 37. Contact surface 37 abuts the front contact surface 38 of section 12.

Stepped portions 39 are located between internal wall 40 and internal base wall 41 and internal wall 42 and internal base wall 41. Stepped portions 39 receive a suspended floor (not shown) resting on face 43 and 44. The floor is preferably of a thickness to be flush with faces 45 and 46 when in use. The advantage of a suspended floor is that the floor may be elevated (not shown) and comprise independent floor panels. The panels may be fitted to allow separate removal for spillage inspection and under floor cleaning. The space 46 created between the base wall 41 and the suspended floor panels may act as a spillage containment (bunding) area. The floor is fabricated from pre-stressed concrete support lintels (not shown) with fibrous cement floor panels fitted in demountable sections to maintain intrinsic safety and corrosion resistance. The corners 33 at either side of the base of section 11 also act as lateral supports for the building 10 that lateral support extends the length of building 10 and is continued by similar lateral supports in sections 12 and 14.

The bolts 34 are fabricated from 306 machinable stainless steel or galvanised reinforced bars and are dimensioned to the full length of building 10 as well as tension fitted laterally within the corners of sections 11, 12, 13 and 14. The bolts 34 are secured with hexangonal securing nuts 47 and washers (not shown) on the rear section 14.

Intermediate section 12 is fabricated as a square ring in light-weight concrete. Section 11, includes a base floor 51 having walls 49 and 52 extending vertically from the base 51 to a roof 50. Section 12 can be of any length and width but it has been found that the most appropriate or preferred length is 1400mm. Sections 12 when assembled in a line form the main body of the building 10 and are assembled on lateral securing bolts 34, extending the length of the building 10, section 12 has a stepped portion 52 bridging walls 49 and 53 with base surface 55. The suspended floor (not shown) sits flush with shoulder 54 and rear wall 55 thereby defining a space 46 for spillage containment (bunding) . Roof 50 may have as an embodiment a pitched roof, as shown in Fig 17, comprised of panels 50a and 50b.

For internal support of the building 10 and greater fire-rated protection of bolts 34 the section 12 provides corner gussets 56 and an external support rail 57. The external support rail is of particular assistance if section 12 is rolled into place.- Whatever external face of section 12 is facing downwards the external support rail 57 will act as support for the section 12 as does foot 21. Bolts 34 are received through apertures 58 which apertures extend the length of section 12.

Intermediate section 12 may include a ventilation duct 70, as shown in Figs 28 and 29, in roof 50 situated across the apex 71 of the roof 50 and jointing point of panels 50a and 50b. The ventilation duct is in relief from the surface of roof 50 and includes two openings 72 and 73 which may serve as outlets or inlets as the case demands.

A review of Fig 5 reveals a version of section 12 without protrusions or depressions. However, Figs 17 and 18 reveal a version that has two rows of protrusions 12a and depressions 12b the protrusions 12a complimentary with the depressions 11a of section 11.

The rear section 14 is also fabricated from lightweight concrete and serves to cap or terminate the building 10. Section 14 may contain access doors or openings as appropriate for the situation and incorporates identical apertures to front section 11 for receiving lateral bolts 34. The apertures 60 terminate at wall 59 and the bolts 34 are secured by nuts 49. The roof 68 of the end section 14 may have a pitched roof comprising panels 68a and 68b, see Fig 19.

It is envisaged that building 10 can be manufactured in sections for assembly at a site or pre-assembled as shown in Figs 9 and 21 and external features such as fire extinguishers 19, signs 18, a ramp 17 and suspended flooring may be added as required. As an alternative, the building may be moulded either as one piece as shown in Figs 10 and 22 or the body portion 60 moulded as one piece and front panel 61 and end panel 62 secured to portion 60 by lateral bolts 34 extending the length of the building 10. The basis of the design and the portability component is intended to ensure that building 10 may be transported, dismantled and reassembled on or off site with relative ease and in a reasonable time frame, and at an acceptable commercial cost.

It is envisaged that the building 10 will provide a system of fire-rated separate compartments 78 separated by wall section 13 to divide and isolate varying risks within building 10. The segregation is effected by the insertion of fire-rated wall panels 13 at predetermined positions between the front section 11 and end section 14 of the building 10. The positioning of any section 13 depends on how many intermediate sections 12 are required to size the compartments 78.

Any number of panels 12 and 13 can be inserted providing multiples of segregated compartments 78.

It is envisaged that the separate compartments 78 be vapour tight and fire-rated, each compartment 78 can then be utilized and fitted out in accordance with its particular application.

For example, flammable liquids can be contained in one compartment with a suspended floor, spillage bund and specialized ventilation, such as that shown in Fig 30, while an adjoining compartment can contain flammable solids protected with the specific requirements of this class of storage. Hazardous work areas can be isolated from hazardous storage areas and if required internal fire-rated access doors can be fitted through the section 13 between compartments 78.

Separate hazardous storage compartments 78 can be adjoined to laboratories and in the case of document storage, documents can be separated from disc or tape storage with individual environments created and maintained separately if required.

Practically any combination of risks and compartments 78 can be combined within the building 10 either indoor or outdoors.

Compartments with side entry access door 15a either single or double are provided, front panels with access doors 15 can be fitted at either end of the building 10 in lieu of standard rear panels.

Internally, it is envisaged that there will be an ordered system of storage to ensure that the risk of contamination or reaction of dangerous goods with each other is minimized. The goods may be stored in drums 63 or packages 63a and stacked on platforms 64. The platforms 64 and support frame 65 will be fabricated from treated steel materials and it is envisaged that the materials used internally in the building 10 will be such as to reduce the incidence of static electricity and frictional energy. The suspended floor panels may periodically be supported by supports 66. As drum 63 and package 63a weights can over a period of time place a strain on the support frame 65, cross bars 67 are incorporated within the frame 65 to minimize movement of the frame 65 and reduce the incidence of frame fatigue. The building 10 is capable of storage and handling of flammable liquid, solid or vapourized materials and dangerous goods in general up to a recommended maximum of 38,000 litres and 38,000 kg and the materials used in the fabrication of the building 10 result in a 4 hour fire resistance rated building 10 with air handling and ventilation systems and a spillage containment area. Alternatively, the building 10 is capable for use as an electrical switchroom providing protection for commercial and industrial electrical control equipment having a controlled and specific atmospheric environment to minimize sparking. Building 10 may also be suitable for use in document, disc and tape storage and as well as laboratory sites. The atmospheric environment includes positive and negative pressurization, heating, cooling and humidification controls for the protection of low or high voltage electrical equipment, electronic and computerised equipment.

Building 10 is designed for both indoor and outdoor application. Used indoors, building 10 does not require any existing walls and only a solid base for support. A suitable ceiling height is preferred and building 10 may be used for ground or upper floor storage. Used outdoors, building 10 is waterproof but requires adequate ground support such as a slab.

The ventilation system 74 is designed to comply with appropriate environment legislation and maybe fitted as standard equipment to building 10 when sold commercially. The system 74 provides, separate inlet and exhaust fans (not shown) , a modular 3 hour FRR inlet 75 and outlet ducts 76 to a standard maximum length of 5 metres, as well as an air intake cowl and an air exhaust cowl (not shown) . The system may also provide for internal air ducting to floor level for both intake and exhaust and may include the fitting of air grills (not shown) on opposing internal walls. The system is envisaged to incorporate continuous negative and positive internal atmospheric pressure between intake and exhaust equipment with an air handling capacity to suit the area. It is envisaged that the access doors 15 and 15a will incorporate automatic ventilation start circuits through an operation switch maintained by the internal lighting circuit. The switch may have an additional time sequence/delay mechanism.

The ventilation systems breakdown into two basic types natural and mechanical.

The natural ventilation is a system of weatherproof air grills (not shown) fitted to the external walls of the units in complying sizes are provided where required. In the case of dangerous goods this system is predominantly utilized in outdoor locations. In other applications such as electrical and communication equipment and document storage, natural ventilation is utilized when pressurization is not required.

The mechanical ventilation is normally used when either negative or positive pressurization is required in the case of some types of dangerous goods, electrical and communication equipment, laboratories and document storage. These systems can be utilized to provide smoke control in emergencies when required.

Equipment provided in the ventilation system generally includes EXE rated exhaust fan, modular 3hr FRR concrete inlet and outlet air ducts within building 10 with a standard maximum length of 3.0 metres above building 10 height, additional fire-rated air ducts and an air supply fan when the duct heights exceeds 3.0 metres, weatherproof air intake cowl and exhaust cowl. Air ducting within building 10 from roof 50 level down to floor level of building 10 for both intake and exhaust systems, complete with air grills on opposing walls.

A manually adjustable damper is fitted to the air supply grill within building 10 for balancing purposes

The ventilator system may include continuous negative or positive internal pressure between intake and exhaust (whichever is required) with a complying air handling capacity to suit the requirements of the storage or work area involved and manual ventilation start circuits maintained through an external light switch as well as a micro-processor based pre-purge, automatic purge and time sequence option available for fitting to the mechanical ventilation system on request.

The length variation is incremented in compartments 70 of 1400mm, this results in a range of up to six (6) unit sizes graduating from the smallest unit of 1.8 metres in length to the larger unit of 9.0 metres in length.

When building 10 is assembled and in use as shown in Figs 1 and 13, it may be appropriate to display signs 18 externally to warn of the contents of building 10 and that hazardous goods are stored. Legislation or ordinances may also demand the display of signs warning of the specific type of chemicals stored, to ensure that in the event of an explosion or fire, the fire brigade and relevant authorities are able to assess the worst case scenario and take appropriate precautionary measures. Examples of standard signage are 'Flammable Liquids Store' , 'Dangerous Goods Store' , 'Authorised Persons Only' , 'No Smoking or Ignition Sources Allowed' , 'Hazchem Code' signs, 'Fire Extinguisher' signs, 'Fire Blanket Inside' sign, 'Communications Equipment' sign, 'Document Storage' sign, 'Electrical Switchroom' signs and/or 'Laboratory' signs. The front section 11 is also adapted to carry external fire extinguishers 19 for spot or small fires and a warning alarm and/or a warning or occupancy light 20 which alarm may be heat and vibration sensitive. The extinguishers 19 are fitted as standard to the front section and may include a nine litre AFFF foam extinguisher and a 9kg. monmex dry chemical extinguisher.

The internal dimensions of one version of building 10 are 3.2 metre in height, by 4.5 metres in width with a length variation of 4.6 metres for the smallest model, up to a maximum recommended length of 22.0 metres for units where two (2) access doors are utilized.

Internal explosion proof lighting is fitted throughout building 10 with an externally located light switch: Building 10 may have one internal light per two intermediate sections 12. The light switch is not door operated because the doors 15 are self closing obviating continued operation of the internal light. External surface-mounted armour cable circuits are fitted to the lighting with an external plug-in connection fitted with barrier protection.

An external coloured occupancy signal light indicating building 10 occupancy is also envisioned. The external signal light commences operation by operation of the doors 15 and is maintained by the operation of a ventilation system.

It is envisaged that building 10 will be supplied with a 1200mm x 1200mm fire blanket stored internally.

The front section 11, intermediate 12, walled section 13 and rear sections 14 are fabricated from reinforced foam concrete of approximately 900 kPa in density, cast in steel moulds for assembly following a curing period to be determined.

Tests suggest that the concrete used in the present invention does not suffer substantial shrinkage and provides a 4 hr fire resistance. Building 10 is not weatherproof and requires the application of a suitable epoxy sealant for external weatherproofing. Although not required, building 10 is fully workable enabling drilling, sawing, building up, sealing and painting.

Utilising a 150mm (6") wall thickness of sections 11, 12, 13 and 14, the lightweight foam concrete is designed to be approximately 1/3 the weight of standard concrete mixes. It is envisaged that the foam concrete will be reinforced with a standard steel mesh moulded into a cage configuration to be located in the centre of sections 11, 12, 13 and 14.

Due to the modular design, the reinforcing is not continuous and is confined and self contained within each section 11, 12, 13 and 14.

The mating surfaces of the sections 11, 12, 13 and 14 are formed in a demountable tongue and groove configuration and are jointed with a fire-rated and weatherproof sealant.

The various apertures of sections 11, 12, 13 and 14 are filled, after building 10 assembly, with a fire-rated sealant.

The actual capacity of each building 10 over the whole range of building 10 varies in accordance with the application and use.

In general, the limiting factors can be viewed as: "G" Series Lower Range - 2000 litres of less

2000 kg or less Upper Range - 12000 litres - max

12000 kg - max "P" Series Lower Range - 3200 litres or less

3200 kg or less Upper Range - 38000 litres - max 38000 kg - max Internal volumes available are from 16.0 cu/metres to 88.0 cu/metres in the "G" Series, 78.0 cu/metres to 318.0 cu/metres in the "P" Series.

The floor areas range from 5.4 square metres to 27.0 square metres in the "G" Series and 27.0 square metres to 106.0 square metres in the "P" Series.

The bolts 34 are fabricated from high tensile galvanized structural steel bar and are dimensioned to the full length of each building 10 and are tension-fitted laterally through the thickened corners of sections 11, 12, 13 and 14 secured with hexagonal securing nuts 49, locknuts and washers from the front section 11 or rear section 14 of building 10.

Standard lockable, weatherproof one (1) handled latch sets are fitted to the doors 15 and 15a.

When the optional pre-purge mode of ventilation is selected, safety ventilation-start switches are fitted to a leading edge of the doors 15 and 15a incuding a manual external light/ventilation start switch.

It is envisaged that the external treatment of the building will provide a weatherproof sealer, as well as a protective and distinctive appearance and a zone of safety awareness.

The internal treatment is designed to recommend workplace safety provisions including anti-glare considerations and reflectivity limits.

The floor panels are fitted to allow for separate removal and inspection of the underfloor space. The clear space available under the suspended flooring is designed for spillage containment where required and for cabling space where electrical applications apply.

Two models of graded access ramps are available for personal use and the wheeled conveyance of goods and equipment in and out of building 10 for suspended and solid floors. An optional hydraulically operated loading pad is available fitted with a remote pump and a manually operated switch (not shown) located at the door 15, this unit provides assisted access for loaded pallet trucks and push trollies.

As with the standard single door provision, double door frames are fitted to the pre-cast sections at production stage.

The "G" Series building 10 was originally developed as a working/storage environment for dangerous goods and includes a provision for single level palletized storage utilizing small pallet trucks in lieu of any specialized fork lift equipment.

The "P" Series was added to the range to provide for double stack palletization using flameproof fork-lift equipment.

The classes of dangerous goods suitable for containment in this system are flammable gases, non-flammable gases, poisonous gases, flammable liquids, flammable solids, spontaneous combustible substances, dangerous when wet substances, oxidising agents, organic peroxides, poisonous (toxic) substances and corrosives.

Automatic gas injection fire protection systems such as C0₂ can be provided for internal equipment protection, modularized if required to suit relocation or later expansion.

Both "G" and "P" Series units can be utilized depending on the volume, the type of racking system selected and whether palletized or manual shelf storage is required.

Work spaces, fixed equipment, lighting, power supply and environmental consideration such as air conditioning and humidification are available as required. Natural light utilizing fire-rated construction can be incorporated where required.

A multiple series of laboratories can be configured, each fully separated from each other with separate access. Isolated storage can also be included in this system.

The front 11, intermediate 12, wall 13 and rear 14 sections constituting the basic sections of building 10 are fabricated from reinforced foam concrete of approx. 900 kPa in density, cast in steel moulds steam cured to achieve high early strength.

Complying lifting devices (not shown) are fixed to the reinforcing steel cage prior to manufacture of the pre-cast components. These devices are permanent and are located in accordance with the requirements of handling of the components at manufacture, loading for cartage, assembly on site and relocation purposes

The devices are installed flush with the external surfaces of sections 11, 12, 13 and 14.

The door jambs (not shown) are metal and fitted to the front modular panel moulds at the time of pre-casting to ensure fire-rated installation.

The suspended floor system is fabricated from full width prestressed concrete support lintels with individual and removeable fibrous cement floor panels providing intrinsic safety, corrosion resistance and removability.

It is envisaged that the system is fabricated in a modular form from sheet metal ducting within the unit and 3hr FRR lightweight concrete ducting externally when the system is located within the host building.

Fans, grill terminations, inlet and outlet cowls are fabricated from steel and alloy materials.

The electrically driven air handling fan is explosion proof (EXE) and is fitted with two (2) flexible vibration couplings (not shown) .

All internal electrical systems are constructed in a modular configuration from explosion proof (EXE) materials utilizing steel armour wired cable, (EXE) switches and light fittings. Vertical wiring is carried in PVC conduct fitted within the pre-cast components at production.

The ramp 17 is fabricated from mild steel, hot dipped galvanized and finished with a non-slip, anti-spark surface and line marked for safety purposes In the alternative the ramp may be an hydraulic pad fabricated and finished as per the ramp 17 fitted with a remotely located hydraulic pump, steel hydraulic tubing and flameproof controls.

Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms. For example, building 10 may be used for the storage, containment and operations of goods other than those mentioned above.

Claims (28)

1. A fire-rated, light-weight concrete, freestanding enclosure wherein the enclosure comprises a front section, one or more intermediate sections and an end section, each section having aperture means located substantially adjacent one or more corners of the sections said apertures capable of receiving bolt means, said bolt means extending from one or more apertures in the front section through one or more corresponding apertures in one or more intermediate sections and terminating in one or more corresponding apertures in said end section, wherein the bolt means extends the length of the enclosure and acts to orientate and secure the sections with respect to each other to form the enclosure.

2. A fire-rated, light-weight concrete, freestanding enclosure in accordance with Claim 1 wherein the enclosure includes one or more wall sections located at the predetermined positions between the front and end sections to form one or more modules or rooms within the enclosure wherein said wall sections include one or more aperture means located substantially adjacent one or more corners of the wall sections said aperture means capable of receiving said bolt means.

3. A fire-rated, light-weight concrete, freestanding enclosure in accordance with Claims 1 or 2 wherein each section is sealed with respect to each other by fire-rated sealing means.

4. A fire-rated, light-weight concrete, freestanding enclosure in accordance with any one of the foregoing claims in which the sections include aperture means adjacent at least two corners of the sections.

5. A fire-rated, light-weight concrete, freestanding enclosure in accordance with Claim 4 wherein the corners are top corners of the sections.

6. A fire-rated, light-weight concrete, freestanding enclosure in accordance with any one of the foreging claims wherein the intermediate sections are shaped in a square O-ring configuration.

7. A fire-rated, light-weight concrete, freestanding enclosure in accordance with any one of the foregoing claims wherein the front section includes fire-rated doors.

8. A fire-rated, light-weight concrete, freestanding enclosure in accordance with any one of the foreging claims wherein the front, intermediate, wall and rear sections are moulded individually and in one piece.

9. A fire-rated, light-weight concrete, freestanding enclosure in accordance with any one of the foregoing claims wherein the sections are moulded from lightweight, foamed concrete.

10. A fire-rated, light-weight concrete, freestanding enclosure in accordance with any one of the foregoing claims wherein the sections are substantially square in cross-section.

11. A fire-rated, light-weight concrete, freestanding enclosure in accordance with anyone of the foregoing claims wherein, the concrete has a density of approximately 900kPa.

12. A fire-rated, light-weight concrete, freestanding enclosure in accordance with anyone of the foregoing claims wherein the sections include reinforcing cornices which surround the bolt means.

13. A fire-rated, light-weight concrete, freestanding enclosure in accordance with Claim 12 wherein the cornices are fire-rated and have a burn through rating of at least 4 hours.

14. A fire-rated, light-weight concrete, freestanding enclosure in accordance with anyone of the foregoing claims wherein sections are individually reinforced.

15. A fire-rated, light-weight concrete, freestanding enclosure in accordance with Claim 14 wherein the sections are reinforced with mesh moulded into a cage configuration.

16. A fire-rated, light-weight concrete, freestanding enclosure in accordance with anyone of the foregoing claims wherein each section has at least one face having depressions or tongued protrusions which correspond to complimentary depressions or tongued protrusions in the face of a preceding section.

17. A method of storage comprising the steps of a) storing items inside a fire-rated, light-weight concrete, freestanding enclosure wherein the enclosure comprises a front section, one or more intermediate sections and an end section, each section having aperture means located substantially adjacent one or more corners of the sections said apertures capable of receiving bolt means, said bolt means received in one or more apertures of said front section and extending through one or more apertures of one or more intermediate sections and terminating in one or more corresponding apertures in the said end section, wherein the bolt means extends the length of the enclosure; b) arranging the goods within the enclosure to minimize contamination and/or reaction of goods.

18. A method of storage in accordance with Claim 17 wherein the enclosure includes one or more wall sections located at predetermined positions between the front and end sections to form one or more modules or rooms within the enclosure wherein said wall sections include one or more aperture means located substantially adjacent one or more corners of the wall sections said aperture means capable of receiving said bolt means.

19. A method of erecting a fire-rated, light-weight concrete, freestanding enclosure comprising the steps of a) erecting a front section of the enclosure and inserting bolt means into one or more apertures located in one or more corners of said section, b) positioning the bolt means through one or more corresponding aperture means located in one or more corners of one or more intermediate sections of the enclosure and fitting a first intermediate section to said front section and securing the two sections together, c) securing any subsequent intermediate sections to any preceding intermediate sections, d) positioning the bolt means through one or more apertures located in one or more corners of an end section and fitting the end section to a preceding intermediate section and securing the sections together.

20. A method in accordance with Claim 19 which includes the step of including one or more wall sections fitted at predetermined locations between the front and end sections.

21. A fire-rated, light-weight concrete enclosure section having a substantially square configuration said concrete having a density of approximately 900kPa.

22. A section in accordance with Claim 21 wherein the section includes aperture means located substantially adjacent one or more corners of the section said aperture means capable of receiving a bolt means.

23. A section in accordance with any one of Claims 21 or 22 wherein the section is reinforced by reinforcing cornices which substantially surround the aperture means and any bolt means located therein.

24. A section in accordance with any one of Claims 21, 22 or 23 wherein the section formed of foamed concrete.

25. A section in accordance with any one of Claims 21 to 24 wherein the section include ventilation ducts.

26. A fire-rated, light-weight section as hereinbefore described with reference to the examples.

27. A method of erecting a fire-rated, light-weight concrete, freestanding enclosure as hereinbefore described with reference to the examples.

28. A method of storage of a fire-rated, light-weight concrete, freestanding enclosure as hereinbefore described with reference to the examples.

28. A fire-rated, light-weight concrete, freestanding enclosure as hereinbefore described with reference to the examples.