GB2289270A - Intumescent and fire resistant compositions - Google Patents

Intumescent and fire resistant compositions Download PDF

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Publication number
GB2289270A
GB2289270A GB9409172A GB9409172A GB2289270A GB 2289270 A GB2289270 A GB 2289270A GB 9409172 A GB9409172 A GB 9409172A GB 9409172 A GB9409172 A GB 9409172A GB 2289270 A GB2289270 A GB 2289270A
Authority
GB
United Kingdom
Prior art keywords
fire
weight
resistant mortar
particulate
ceramic
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.)
Granted
Application number
GB9409172A
Other versions
GB9409172D0 (en
GB2289270B (en
Inventor
Derek Alfred Ward
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Environmental Seals Ltd
Original Assignee
Environmental Seals Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Environmental Seals Ltd filed Critical Environmental Seals Ltd
Priority to GB9409172A priority Critical patent/GB2289270B/en
Publication of GB9409172D0 publication Critical patent/GB9409172D0/en
Priority to IE950314A priority patent/IE80585B1/en
Publication of GB2289270A publication Critical patent/GB2289270A/en
Application granted granted Critical
Publication of GB2289270B publication Critical patent/GB2289270B/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

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Classifications

    • 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
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/16—Waste materials; Refuse from building or ceramic industry
    • 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
    • C04B28/06—Aluminous cements
    • 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
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • 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
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • C04B2111/285—Intumescent materials
    • 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
    • C04B2111/60—Flooring materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Abstract

A particulate ceramic material containing at least 75% by weight of a non-fibrous ceramic shot material is used to make fire seals, fire barrier products and mortars. The fire-resistant mortars are particularly suitable for the preparation of light weight load-bearing slabs, for example flooring slabs or ceilings, and in the preparation of panels for use in the construction of ceilings and walls. The panels may optionally contain a layer of intumescent material. <IMAGE>

Description

INTUMESCENT AND FIRE RESISTANT COMPOSITIONS The present invention relates to intumescent and fireresistant compositions containing a ceramic material and to their use in, inter alia, the construction of flooring materials, and wall and ceiling panels, for buildings.
Our earlier British Patent Application No. 9207659.5 (Publication No. 2254609) describes the use of ceramic fibres in the preparation of intumescent and fire resistant products. Commercially available ceramic fibre of the type used in the process described in GB 2254609 contains a proportion of non-fibrous ceramic material in particulate form, which we refer to as "shot". In processes such as the process described in GB 2254609, the particulate ceramic shot tends to become separated from the fibrous materials and accumulates as waste which is usually simply discarded. It has now been found that the ceramic shot material can be used in fire-resistant compositions, and in certain instances is advantageous with regard to the ceramic fibre used hitherto.
In a first aspect therefore, the invention provides the use of ceramic particulate material wherein at least 75% by weight of the said material is in non-fibrous shot form, for the manufacture for a fire seal or fire barrier product.
Preferably the ceramic particulate material contains at least 85% non-fibrous shot material, and more preferably contains at least 90% non-fibrous shot material.
The ceramic particulate material may contain up to 25% by weight of a fibrous ceramic material, preferably up to 15% by weight, and more preferably no more than 10% by weight ceramic fibrous material.
The ceramic fibrous materials from which the ceramic shot of the present invention is obtained are commercially available and typically comprise an alumina silicate material.
In one embodiment of the present invention, there is provided a fire-resistant mortar comprising a calcium aluminate cement and a particulate ceramic material containing at least 75% by weight of a non-fibrous ceramic shot material as hereinbefore defined.
It is preferred that in relation to the total weight of the mixture of calcium aluminate cement and particulate ceramic material, the particulate ceramic material constitutes up to about 85% by weight, and more preferably between 60% and 80% by weight. Conversely, it is preferred that the calcium aluminate cement constitutes at least 15% by weight of the mixture and preferably between 20% and 30% by weight of the total weight of the mixture.
The fire-resistant mortar may be formulated together with a binder, for example a polymeric binder such as a polyacrylate or a polyvinyl acetate. The binder may be present in an amount of up to about 15% by weight relative to the total weight of the mixture of calcium aluminate cement and particulate ceramic material. Preferably the binder constitutes less than 10% by weight relative to the total weight of the said mixture, and more preferably no more than 5% by weight relative to the total weight of said mixture.
The calcium aluminate cements used in the fireresistant mortars of the present invention are examples of high alumina cements and one particular high alumina cement is "Ciment Fondu" (Trade Mark) manufactured by the Lafarge Aluminous Cement Company of Grays, Essex, United Kingdom.
The typical composition of a calcium aluminate cement, as determined by chemical analysis, can be 38-40% Al203, 37-39% CaO, 3-5% SiO2 and 15-18% Fe203/FeO.
The fire mortars of the present invention can readily be cast to form lightweight load-bearing slabs, for example, flooring slabs or ceilings. Whereas, normally, during the preparation of a cement floor or ceiling, it is necessary to support the drying cement on a shuttering structure, in the present case, it is sufficient to provide a lightweight support formed of Rockwool fibre slabs.
In a further aspect, the invention provides a method of constructing a floor or ceiling slab, comprising providing a layer of fire resistant fibre blocks, eg.
rockwool fibre blocks, to form a support surface, optionally laying on the support surface one or more reinforcing bars or a reinforcing mesh, and casting onto the support surface a fire mortar as hereinbefore defined.
The fire mortars of the present invention can include an accelerator to accelerate the hardening of the cement.
In one embodiment, the fire mortar compositions can contain a mixture of accelerated and non-accelerated calcium aluminate cement. For example the accelerated calcium aluminate cement can be an accelerated form of Ciment Fondu Lafarge available from Lafarge Aluminous Cements of Grays, Essex, United Kingdom.
In a further aspect, the invention provides for the use of a particulate ceramic material containing at least 75% by weight non-fibrous ceramic shot in the manufacture of a fire mortar comprising a calcium aluminate cement.
The fire mortars of the present invention typically are formed by mixing a quantity of particulate ceramic material with water and then adding the cement.
An advantage of the fire mortars of the present invention is that they possess not only good fire resistant properties, but also they are relatively light, yet are nevertheless load-bearing, which makes them ideally suited for use in the formation of suspended floors or ceilings.
Tests carried out on a 50mm thick slab of set fire mortar formed from a mixture of 70% particulate ceramic material, 15% non-accelerated Ciment Fondu Lafarge and 15% accelerated Ciment Fondu Lafarge illustrated that the slab can withstand temperatures of 12000C for in excess of two hours.
A further advantage of the fire mortars of the invention is that they can be drilled more easily using conventional tools and thus panels mad from the fire mortars can readily be fastened to other building components.
In a still further aspect, the invention provides a panel suitable, for example, for use in constructing a ceiling, wall or like structure, the panel comprising a pair of cover sheets and, disposed therebetween, a layer of fire mortar as hereinbefore defined.
In a preferred arrangement, there is provided a panel of the aforesaid type wherein a layer of intumescent material is interposed between the fire mortar layer and a cover sheet.
The panels of the invention can be constructed with dimensions broadly equivalent to conventional plasterboard sheet, and thus may be employed in place of plasterboard in, for example, the construction of ceilings and walls.
Typically, such panels can be of 9mm to about 30mm thickness. The cover sheets can be simply paper or cardboard layers of the type conventionally used in the facings of plasterboard.
The intumescent substance can be, for example, an alkali metal silicate or exfoliating graphite, and preferably it is exfoliating graphite.
The intumescent substance can be applied to the fire mortar layer before the fire mortar has set, such that it is firmly bonded thereto upon setting of the fire mortar.
Alternatively, or additionally, the intumescent substance can be mixed with a binder (e.g. a polyacrylate binder) to assist adhesion of the fire mortar layer to the intumescent substance, and adhesion of the intumescent substance to the cover layer.
One form of panel in accordance with the present invention is illustrated in Figure 1 which is a side sectional elevation through a portion of the panel.
As shown in Figure 1, the panel comprises a pair of covering layers of sheets 1 and 2 formed of card or a heavy duty paper material, between which are sandwiched a layer of fire mortar 3 of a composition substantially as described above, and an intumescent layer 4, which in this embodiment is formed of exfoliating graphite.
To prepare a panel of the aforesaid type, cover sheet 2 is supported on a suitable support surface (not shown) and a layer of fire mortar of the desired thickness is poured onto the sheet 2 whilst the mortar is still wet, exfoliating graphite is sprinkled onto the surface to the desired depth and the cover paper 1 is then applied. In order to ensure better adhesion, an aqueous solution or suspension of a binder (e.g. an acrylate binder) can be mixed with the exfoliating graphite and the resulting slurry poured onto the fire mortar layer 3 prior to applying the cover layer 1.
Tests carried out on a panel prepared as described above have shown that by incorporating a layer of intumescent material into the panel, the fire resistance of the panel is increased by several hours.
The example given above is by way of illustration only, and it will be apparent that numerous modifications and alterations could be made without to the illustrated without departing from the principles underlying this invention. All such modifications and alterations are intended to be embraced by this application.

Claims (20)

1. The use of ceramic particulate material wherein at least 75% by weight of the said material is in a non fibrous shot form, for the manufacture of a fire seal or fire barrier product.
2. The use according to claim 1 wherein the ceramic particulate material contains at least 90% non-fibrous shot material.
3. A fire-resistant mortar comprising a calcium aluminate cement and a particulate ceramic material containing at least 75% by weight of a non-fibrous ceramic shot material.
4. A fire-resistant mortar according to claim 3 wherein the ceramic particulate material contains at least 90% non-fibrous shot material.
5. A fire-resistant mortar according to claim 4 wherein the particulate ceramic material constitutes up to about 85% by weight of the total weight of the mixture of calcium aluminate cement and particulate ceramic material.
6. A fire-resistant mortar according to claim 5 wherein the particulate ceramic material constitutes between 60% and 80% by weight of the said total weight.
7. A fire-resistant mortar according to any one of claims 3 to 6 which contains a binder.
8. A fire-resistant mortar according to claim 7 wherein the binder is a polymeric binder.
9. A fire-resistant mortar according to claim 8 wherein the polymeric binder is a polyacrylate or a polyvinyl acetate binder.
10. A fire-resistant mortar according to any one of claims 7 to 9 wherein the binder is present in an amount of up to about 15% by weight relative to the total weight of the mixture of calcium aluminate cement and particulate ceramic material.
11. A fire-resistant mortar according to claim 10 wherein the binder constitutes less than 10% by weight relative to the said total weight.
12. A fire-resistant mortar according to any one of claims 3 to 11 wherein the calcium aluminate cement has a composition, as determined by chemical analysis, of 38%-40% A1203, 37%-39% CaO, 3%-5% SiO2 and 15%-18% Fe203-FeO.
13. A light weight load-bearing slab formed from a fire resistant mortar as defined in any one of claims 3 to 12.
14. A method of constructing a floor or ceiling slab, comprising providing a layer of fire-resistant fibre blocks to form a support surface, optionally laying on the support surface one or more reinforcing bars or a reinforcing mesh, and casting onto the support surface a fire-resistant mortar as defined in any one of claims 3 to 12.
15. The use of a particulate ceramic material containing at least 75% by weight non-fibrous ceramic shot for the manufacture of a fire mortar comprising a calcium aluminate cement.
16. A panel suitable for use in constructing a ceiling, wall or like structure, the panel comprising a pair of cover sheets and, disposed therebetween, a layer of fire-resistant mortar as defined in any one of claims 3 to 12.
17. A panel according to claim 16 wherein a layer of intumescent material is interposed between the fire resistant mortar layer and a cover sheet.
18. A panel as defined in either of claims 16 or 17 having a thickness in the range 9mm to about 30mm.
19. A panel according to claim 17 or claim 18 wherein a layer of alkaline metal silicate or exfoliating graphite is interposed between the fire mortar layer and a cover sheet.
20. A panel substantially as described herein with reference to the accompanying drawings.
GB9409172A 1994-05-09 1994-05-09 Intumescent and fire resistant compositions Expired - Fee Related GB2289270B (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
GB9409172A GB2289270B (en) 1994-05-09 1994-05-09 Intumescent and fire resistant compositions
IE950314A IE80585B1 (en) 1994-05-09 1995-05-04 Intumescent and fire resistant compositions

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9409172A GB2289270B (en) 1994-05-09 1994-05-09 Intumescent and fire resistant compositions

Publications (3)

Publication Number Publication Date
GB9409172D0 GB9409172D0 (en) 1994-06-29
GB2289270A true GB2289270A (en) 1995-11-15
GB2289270B GB2289270B (en) 1998-03-11

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Family Applications (1)

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GB9409172A Expired - Fee Related GB2289270B (en) 1994-05-09 1994-05-09 Intumescent and fire resistant compositions

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IE (1) IE80585B1 (en)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016102116A1 (en) * 2014-12-22 2016-06-30 Fermacell Gmbh Fire protection panel and method for producing same

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3615783A (en) * 1970-06-24 1971-10-26 John Wilfred Howard Hydraulic cement compositions
JPS58208178A (en) * 1982-05-24 1983-12-03 イビデン株式会社 Heat resistant resilient sheet article and manufacture
US4863700A (en) * 1985-04-16 1989-09-05 Stemcor Monolithic catalytic converter mounting arrangement
US5028397A (en) * 1988-02-11 1991-07-02 Minnesota Mining And Manufacturing Company Catalytic converter
GB2254609A (en) * 1991-04-09 1992-10-14 Environmental Seals Ltd Intumescent fire seals
US5250269A (en) * 1992-05-21 1993-10-05 Minnesota Mining And Manufacturing Company Catalytic converter having a metallic monolith mounted by a heat-insulating mat of refractory ceramic fibers
WO1994002545A1 (en) * 1992-07-17 1994-02-03 Alcan International Limited Intumescent compositions

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3615783A (en) * 1970-06-24 1971-10-26 John Wilfred Howard Hydraulic cement compositions
JPS58208178A (en) * 1982-05-24 1983-12-03 イビデン株式会社 Heat resistant resilient sheet article and manufacture
US4863700A (en) * 1985-04-16 1989-09-05 Stemcor Monolithic catalytic converter mounting arrangement
US5028397A (en) * 1988-02-11 1991-07-02 Minnesota Mining And Manufacturing Company Catalytic converter
GB2254609A (en) * 1991-04-09 1992-10-14 Environmental Seals Ltd Intumescent fire seals
US5250269A (en) * 1992-05-21 1993-10-05 Minnesota Mining And Manufacturing Company Catalytic converter having a metallic monolith mounted by a heat-insulating mat of refractory ceramic fibers
WO1994002545A1 (en) * 1992-07-17 1994-02-03 Alcan International Limited Intumescent compositions

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
WPI Abstract Accession No 84-014891/03 & JP 58 208 178 A *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2016102116A1 (en) * 2014-12-22 2016-06-30 Fermacell Gmbh Fire protection panel and method for producing same

Also Published As

Publication number Publication date
IE80585B1 (en) 1998-10-07
GB9409172D0 (en) 1994-06-29
IE950314A1 (en) 1995-11-29
GB2289270B (en) 1998-03-11

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PCNP Patent ceased through non-payment of renewal fee

Effective date: 20020509