GB1604052A - Methods of fire insulation - Google Patents

Methods of fire insulation Download PDF

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Publication number
GB1604052A
GB1604052A GB48473/77A GB4847377A GB1604052A GB 1604052 A GB1604052 A GB 1604052A GB 48473/77 A GB48473/77 A GB 48473/77A GB 4847377 A GB4847377 A GB 4847377A GB 1604052 A GB1604052 A GB 1604052A
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United Kingdom
Prior art keywords
layer
fibres
outer layer
bulk density
cementitious
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
GB48473/77A
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Individual
Original Assignee
Individual
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Filing date
Publication date
Application filed by Individual filed Critical Individual
Priority to GB48473/77A priority Critical patent/GB1604052A/en
Publication of GB1604052A publication Critical patent/GB1604052A/en
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/02—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material with fibres or particles being present as additives in the layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/044—Water-setting substance, e.g. concrete, plaster
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2315/00—Other materials containing non-metallic inorganic compounds not provided for in groups B32B2311/00 - B32B2313/04
    • B32B2315/06—Concrete
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Description

(54) IMPROVEMENTS IN OR RELATING TO METHODS OF FIRE INSULATION (71) We, MICHAEL CLEARY and THOMAS HENRY WAKEFIELD, both British subjects, of 1, Lamberhurst Road, Maidstone, Kent and Wannock, Weavering Street, Maidstone, Kent, respectively, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- This invention relates to a method of insulating a substrate against fire. The substrate may be of metal, wood, plastics materials, for example.
We have previously developed (see Patent Specification No. 1,412,993) a cementitious composite for application to road surfaces and consisting of a mixture of Portland cement and alkali-resistant glass fibre.
According to the present invention there is provided a method of insulating a substrate against fire, which comprises coating the substrate on one or both sides first with a layer of foamed cementitious mass comprising a calcium silicate hydrate matrix having variously sized air-filled cavities therein, said cavities having diameters from 20 to 100 microns, said mass having a bulk density of 180 to 1800 kg/m3, and the distance between said cavities being not less than 5 microns and then with a further layer of said cementitious foam and finally applying an outer layer of said foam containing alkali-resistant glass fibres, said glass fibres having a length of 25 to 38 mm, a diameter of 9 to 15 microns, and constituting 3.5 to 7% by weight of said outer layer.
The calcium silicate hydrate matrix used to produce the foamed mass may be in the form of ordinary Portland cement as specified in British Standard No. 12 or high alumina cement as specified in British Standard No. 915.
The mass may contain up to 50% by weight of non-siliceous material as filler.
Said material should all pass a 600 micron mesh sieve but be retained on a 60 micron mesh sieve and be uniformly graded. Examples of suitable non-siliceous fillers are pulverised fuel ash to British Standard No. 3892, slate fines, cenospheres, carbon, exfoliated vermiculite, bentonite and perlite.
The foamed mass is produced by intimately mixing the cementitious material, water, air, a thixotropic or hydrophilic colloid and a surface active agent. A particularly suitable colloid is a high molecular weight polysaccharide and a particularly useful surface active agent is magnesium lauryl sulphonate. The surface active agent is preferably used in a proportion of 1 part by weight to 15 parts of water and the thixotropic or hydrophilic colloid in the proportion of I part by weight to 100 parts of water.
The foamed mass may be produced in a single stage operation in which the cementitious material is mixed with the colloid, then water and surface active agent are added, and the whole intimately mixed in a high shear mixer.
Alternatively, a preformed foam can be intimately mixed with the cementitious material using a rotary mixer. According to this method, air is introduced into water containing the colloid and the surface active agent.
The air is preferably introduced via a nozzle and a satisfactory foam may be produced, for example, by introducing air at 3 bar pressure via a nozzle having a diameter of 0.88 mm.
The mixing of the foam ingredients is controlled to produce a foam having the desired cavities. The size of the cavities and their spacing can be measured in known manner by taking a slice of the foam and examining it under a microscope.
It has been found that such a foamed cementitious mass is extremely resistant to expansion and contraction since it is believed that the expansion stresses are controlled and directed about the array of variously sized cavities within the mass.
Said glass fibres preferably constitute 5% by weight of the outer layer. Suitable glass fibres are sold under the Registered Trade Mark Cem--FIL.
According to a further feature of the invention, said outer layer may include an aromatic polyamide in the form of fibres.
The use of such fibres being particularly advantageous when the insulated material is to be used under severe environmental conditions. The aromatic polyamide fibres are used in a proportion up to 0.8% wt. preferably 0.45% wt.
Said outer layer may have a thickness of 3 to 6 mm depending upon the physical properties required and should have a bulk density substantially in excess of the base layer of cementitious foam, preferably of the order of 1400 to 2200 kg/m3.
Substrates treated according to the present invention are capable of withstanding temperatures up to 1200 C above ambient and have an efficiency in accordance with I.S.O.
Hydrocarbon fire standards.
An example of the method of the invention will now be described in more detail.
A substrate to be insulated such as a steel plate or an expanded metal mesh, is coated on one or both sides with three layers of material as follows: (a) A primary layer of cementitious foam which is allowed to dry to provide bond and suction to support the main insulation. This layer is applied at a pressure of 1.8 to 2.5 bar so as to penetrate all crevices in th,slIbstrate.
In the case of smooth substrates, a light gauge galvanised wire mesh may be secured to the substrate before application of the primary layer, any suitable method being used to secure the mesh, such as the use of soft mild steel tabs adhered with epoxy resin, or welded studs.
(b) A main insulating layer consisting of cementitious foam with or without a nonsiliceous filler. This layer may have a thickness of 22 to 40 mm depending upon the degree of protection required. The bulk density may be in the range 280 to 1200 kg/m3.
(c) A tensile and impact-resistant outer layer of cementitious foam containing alkaliresistant glass fibres. Said layer may have a thickness of 3 to 6 mm., a bulk density of 1400 to 2200 kg/m3, and a fibre content of at least 5% by weight.
The glass fibres may be of alkali-resistant zirconia glass.
Where the insulated material is to be used under severe environmental conditions, layer (c) advantageously incorporates aromatic polyamide fibres as hereinbefore described.
The method according to the invention is capable of a wide variety of applications, such as on ships' bulkheads and on oil drilling platforms and installations. It may be used in road construction where, for example, a roadway has to pass across a steel bridge, so as to form a fire insulation and a flexible base layer reducing the need for expansion and contraction joints.
WHAT WE CLAIM IS: 1. A method of insulating a substrate against fire, which comprises coating the substrate on one or both sides first with a layer of foamed cementitious mass comprising a calcium silicate hydrate matrix having variously sized air-filled cavities therein, said cavities having diameters from 20 to 100 microns, said mass having a bulk density of 180 to 1800 kg/m3, and the distance between said cavities being not less than 5 microns, and then with a further layer of said cementitious foam, and finally applying an outer layer of said foam containing alkali-resistant glass fibres, said glass fibres having a length of 25 to 38 mm, a diameter of 9 to 15 microns, and constituting 3.5 to 7% by weight of said outer layer.
2. A method according to claim 1, wherein said outer layer includes up to 0.8% by weight of fibres of an aromatic polyamide.
3. A method according to clam 1 or 2, wherein said outer layer has a thickness of 3 to 6 mm and a bulk density substantially in excess of the base layer of cementitious foam.
4. A method according to claim 3, wherein said bulk density is in the range of 1400 to 2200 kg/m3.
5. A method of insulating a substrate against fire, substantially as hereinbefore described.
**WARNING** end of DESC field may overlap start of CLMS **.

Claims (5)

  1. **WARNING** start of CLMS field may overlap end of DESC **.
    cavities within the mass.
    Said glass fibres preferably constitute 5% by weight of the outer layer. Suitable glass fibres are sold under the Registered Trade Mark Cem--FIL.
    According to a further feature of the invention, said outer layer may include an aromatic polyamide in the form of fibres.
    The use of such fibres being particularly advantageous when the insulated material is to be used under severe environmental conditions. The aromatic polyamide fibres are used in a proportion up to 0.8% wt. preferably 0.45% wt.
    Said outer layer may have a thickness of 3 to 6 mm depending upon the physical properties required and should have a bulk density substantially in excess of the base layer of cementitious foam, preferably of the order of 1400 to 2200 kg/m3.
    Substrates treated according to the present invention are capable of withstanding temperatures up to 1200 C above ambient and have an efficiency in accordance with I.S.O.
    Hydrocarbon fire standards.
    An example of the method of the invention will now be described in more detail.
    A substrate to be insulated such as a steel plate or an expanded metal mesh, is coated on one or both sides with three layers of material as follows: (a) A primary layer of cementitious foam which is allowed to dry to provide bond and suction to support the main insulation. This layer is applied at a pressure of 1.8 to 2.5 bar so as to penetrate all crevices in th,slIbstrate.
    In the case of smooth substrates, a light gauge galvanised wire mesh may be secured to the substrate before application of the primary layer, any suitable method being used to secure the mesh, such as the use of soft mild steel tabs adhered with epoxy resin, or welded studs.
    (b) A main insulating layer consisting of cementitious foam with or without a nonsiliceous filler. This layer may have a thickness of 22 to 40 mm depending upon the degree of protection required. The bulk density may be in the range 280 to 1200 kg/m3.
    (c) A tensile and impact-resistant outer layer of cementitious foam containing alkaliresistant glass fibres. Said layer may have a thickness of 3 to 6 mm., a bulk density of
    1400 to 2200 kg/m3, and a fibre content of at least 5% by weight.
    The glass fibres may be of alkali-resistant zirconia glass.
    Where the insulated material is to be used under severe environmental conditions, layer (c) advantageously incorporates aromatic polyamide fibres as hereinbefore described.
    The method according to the invention is capable of a wide variety of applications, such as on ships' bulkheads and on oil drilling platforms and installations. It may be used in road construction where, for example, a roadway has to pass across a steel bridge, so as to form a fire insulation and a flexible base layer reducing the need for expansion and contraction joints.
    WHAT WE CLAIM IS: 1. A method of insulating a substrate against fire, which comprises coating the substrate on one or both sides first with a layer of foamed cementitious mass comprising a calcium silicate hydrate matrix having variously sized air-filled cavities therein, said cavities having diameters from 20 to 100 microns, said mass having a bulk density of 180 to 1800 kg/m3, and the distance between said cavities being not less than 5 microns, and then with a further layer of said cementitious foam, and finally applying an outer layer of said foam containing alkali-resistant glass fibres, said glass fibres having a length of 25 to 38 mm, a diameter of 9 to 15 microns, and constituting 3.5 to 7% by weight of said outer layer.
  2. 2. A method according to claim 1, wherein said outer layer includes up to 0.8% by weight of fibres of an aromatic polyamide.
  3. 3. A method according to clam 1 or 2, wherein said outer layer has a thickness of 3 to 6 mm and a bulk density substantially in excess of the base layer of cementitious foam.
  4. 4. A method according to claim 3, wherein said bulk density is in the range of
    1400 to 2200 kg/m3.
  5. 5. A method of insulating a substrate against fire, substantially as hereinbefore described.
GB48473/77A 1978-05-31 1978-05-31 Methods of fire insulation Expired GB1604052A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB48473/77A GB1604052A (en) 1978-05-31 1978-05-31 Methods of fire insulation

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB48473/77A GB1604052A (en) 1978-05-31 1978-05-31 Methods of fire insulation

Publications (1)

Publication Number Publication Date
GB1604052A true GB1604052A (en) 1981-12-02

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Family Applications (1)

Application Number Title Priority Date Filing Date
GB48473/77A Expired GB1604052A (en) 1978-05-31 1978-05-31 Methods of fire insulation

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2164330A (en) * 1984-08-27 1986-03-19 Tatsuo Kitano Shaped bodies of calcium silicate

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2164330A (en) * 1984-08-27 1986-03-19 Tatsuo Kitano Shaped bodies of calcium silicate

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PS Patent sealed
PCNP Patent ceased through non-payment of renewal fee