GB2417736A - Building panel with fire resistance - Google Patents

Building panel with fire resistance Download PDF

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Publication number
GB2417736A
GB2417736A GB0517909A GB0517909A GB2417736A GB 2417736 A GB2417736 A GB 2417736A GB 0517909 A GB0517909 A GB 0517909A GB 0517909 A GB0517909 A GB 0517909A GB 2417736 A GB2417736 A GB 2417736A
Authority
GB
United Kingdom
Prior art keywords
building panel
board
tray
steel sheet
zinc
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
GB0517909A
Other versions
GB2417736B (en
GB0517909D0 (en
Inventor
Edward Martin Lunham
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.)
Furmanite International Ltd
Original Assignee
Furmanite International 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 Furmanite International Ltd filed Critical Furmanite International Ltd
Publication of GB0517909D0 publication Critical patent/GB0517909D0/en
Publication of GB2417736A publication Critical patent/GB2417736A/en
Application granted granted Critical
Publication of GB2417736B publication Critical patent/GB2417736B/en
Expired - Fee Related legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92Protection against other undesired influences or dangers
    • E04B1/94Protection against other undesired influences or dangers against fire
    • E04B1/941Building elements specially adapted therefor
    • E04B1/942Building elements specially adapted therefor slab-shaped
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/28Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups combinations of materials fully covered by groups E04C2/04 and E04C2/08

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Building Environments (AREA)
  • Laminated Bodies (AREA)

Abstract

A building panel comprises a tray 12, a board 14 bonded to the tray, and a top sheet bonded to the board. The tray may be of steel coated with Zn/Al/Si alloy: a sheet of this may be bonded, e.g. with a fire-rated water based contact adhesive, to a board, e.g. of cementitious material or inorganic material such as magnesium- or calcium silicate, optionally fibre reinforced, and the edges of the sheet bent up to form the tray 12, the top sheet 16, e.g. of similar alloy-coated steel, then being bonded to the board 14.

Description

24 1 7736 TITLE: Building Panels
DESCRIPTION
This invention concerns building panels and, in particular, concerns heat resistant building panels as well as panels having impact resistance.
Heat resistant building panels are known which comprise a central core of fibre- reinforced Portland cement and outer skins of galvanised steel sheet mechanically bonded to the central core by locking tongues pressed from the material of the steel .sheets. The locking tongues are created by punching generally circular holes through the A. . galvanised steel sheets.
2. The manufacturing process enables blemishes, some of which are known as :. black rust, to develop on the exposed surfaces of the galvanised steel sheets. The outer skins of the panels are also susceptible to marking during handling. The exposed areas c..
of core, where the steel sheet has been punched are easily damaged.
Thus, the appearance of such panels can be impaired, so they do not lend themselves to use in situations where appearance may be an issue in spite of their robustness and resistance to mechanical damage.
An object of this invention is to provide building panels, especially heat and impact resistant building panels, that may have an attractive appearance.
According to this invention there is provided a building parcel comprising a tray having a base and sides, a board bonded in the tray and a top sheet bonded to the board.
The board is preferably of a heat resistant material. The heat resistant material may be chosen from inorganic fillers or cementitious materials. The board may be made of reinforced material. Suitable reinforcement materials include fibres.
When the board is of inorganic filler material magnesium silicate and calcium silicate may be suitable choices, of which magnesium silicate is preferred.
The materials for the tray and the top sheet are preferably chosen from alloy coated steel sheet. Particularly suitable for use in making the trays and top sheets for panels of the invention is zinc/aluminium alloy coated mild steel sheet, especially alloy coated steel sheet sold under the trade mark ALUZINK, which is mild steel sheet coated .
: .: 8, with an alloy of zinc, aluminium and silicon. Typically, the alloy coating is applied by a ...
.. hot dipping (galvanizing) process. The preferred alloy coating contains 55% aluminium, 43.4% zinc and 1.6% silicon. The alloy coating thickness may be in the range 20 to 25 .e microns. The alloy coated steel sheet may have a thickness of from 0. 4mm to 2.0mm, 8.
. . . although a thickness of 0.5mm is preferred for use in the present invention. ...
. The board is preferably bonded to the tray by means of adhesive as is the top sheet preferably bonded to the board. The adhesive is preferably a fire-rated adhesive.
The adhesive is also preferably a water-based contact adhesive.
A preferred building panel according to the invention comprises a tray of zinc/aluminium alloy coated steel containing a magnesium silicate board bonded therein and a top sheet of zinc/aluminium alloy coated steel sheet bonded to the board.
Bonding of the board to the tray and of the top sheet to the board is preferably by means of a water-based contact adhesive.
Building panels of the invention are preferably produced by preparing a former for the tray in flat form, bonding a piece of board to the former, folding up the tray around the board and bonding the top sheet onto the board.
By forming the panels using a tray the sides of the tray will provide protection for edges of the board, which in the prior art panels are exposed. Also, because the sides of the panel are formed by relatively rigid tray sides, there is less likelihood of panels being or becoming misshapen at the sides and consequently less likelihood of misalignment arising where panels are butted together.
This invention will now be further described, by way of example only, with reference to the accompanying drawings, in which: ...
. Figure 1 shows a building panel according to the invention; and ...
Figure 2 is a section through the building panel of Figure 1. e.
Referring to the accompanying drawings, a heat resistant building panel 10 . comprises a tray 12 of mild steel sheet coated with an alloy of zinc, aluminium and . silicon, such as that sold under the trade mark ALUZINK, a board 14 of magnesium silicate bonded into the tray and a top sheet 16 bonded to the board 14, also of zinc coated aluminium.
The panel 10 is formed by bonding the magnesium silicate board 14 to a shaped sheet of the alloy coated steel by means of a fire-rated waterbased contact adhesive, such as 3M4M FastCure 2000. The sheet of alloy coated steel is generally rectangular with a flap on each side and the flaps are then folded up to the edges of the board to form the tray.
The top sheet 16 is similarly bonded to the board 14 using an adhesive, such as fire-rated water-based contact adhesive 3M'M FastCure 2000.
A panel of the type illustrated was tested under the Fire Resistance Performance of a Partition Assembly, in accordance with BS476: Part 2.2: Clause 5.
A specimen partition was installed into the opening of a concrete reinforced test frame to form the test construction. The specimen panel was a partition assembly having overall dimensions of 3035mm high by 3000mm wide and 150mm thick. The framing comprised lOOmm by 44mm by 2mm thick galvanised steel "C-section" studs, at a maximum 1200mm centres, friction fitted into galvanised steel "U-section" head and ë base channels. The cavity was insulated with lOOmm thick mineral fibre. Each side of ..
. the stud frame was covered with a ceramic fibre insulating gasket and then faced with a single layer of 12.5mm heat resistant panel according to the invention.
The panel was based on a board of magnesium silicate with a combination of inorganic materials, wood fibre, glass fibre and non-woven cloths and water with facings ...
.. of steel coated with an alloy of aluminium and zinc adhered to the board by Fastbond 2000 impact adhesive.
The test was carried out in a furnace controlled so that its mean temperature complied with the requirements of BS 476: Part 20: 1987, Clause 3.1 using nine mineral thermocouples distributed over a plane l OOmm from the surface of the test construction.
Thermocouples were provided to monitor the unexposed surface of the specimen and the output of all instrumentation was recorded at no less than one minute intervals.
Cotton pads and gap gauges were available to evaluate the impermeability of the specimen to hot gases.
After the first five minutes of testing and for the remainder of the test the furnace atmospheric pressure was controlled so that it complied with the requirements of BS 476: Part 20: 1987, Clause 3.2.2. The calculated pressure differential relative to the laboratory atmosphere at the top of the specimen was 17 ( + ) Pa.
Tests were carried out to evaluate integrity and insulation. For integrity it is required that there is no collapse of the specimen, no sustained flaming on the unexposed surface and no loss of impermeability. The specimen tested satisfied these requirements for a period of 240 minutes.
For insulation it is required that the mean temperature rise of the unexposed . surface of the specimen under test shall not be greater than 140 and that the maximum .
temperature rise shall not be greater than 180 . These requirements were satisfied for a period of 165 minutes.
The alloy coated steel sheet material that may be used in forming the panel of :. . Figures I and 2 has an attractive surface appearance. It can also be provided in patterned eve .. surface forms for improved surface appearance as well as improved rigidity.
Furthermore, the alloy coated steel sheet generally has a reflective surface particularly to heat, which aids heat resistance.
Other advantages of building panels according to the invention compared to prior art may include the following: panels can have relatively even surface enabling them to be handled using vacuum lifting apparatus; panels can be resistant to finger marks and other markings as well as being scratch resistant; the panels have improved resistance to delamination; panels of the invention can be made to non-standard sizes, whilst retaining the protection to the edges of the panels through the use of a tray; using magnesium silicate board can produce a lighter weight panel and magnesium silicate has greater fire resistance than calcium silicate; there are no noxious gas emissions from preferred panels of the invention; zinc/aluminium alloy coated steel has improved corrosion resistance compared to zinc galvanised steel and there are no cut edges in panels of the invention that need special treatment to avoid corrosion or the formation of black rust; . panels of the invention may be of lighter weight than prior art panels based on ë .. galvanised steel skins and a cementitious core. Thus, the panels of the invention may be easier to handle and may require a thinner supporting framework; zinc/aluminium alloy coated steel sheets can be painted; panels of the invention may have improved impact resistance due to the strength . of the magnesium silicate board in steel facings.

Claims (39)

1. A building panel comprising a tray, a board bonded in the tray and a top sheet bonded to the board.
2. A building panel as claimed in claim 1, wherein the board is a heat resistant material.
3. A building panel as claimed in claim 1 or 2, wherein the board is made from inorganic fillers or cementitious material.
4. A building panel as claimed in claim 3, wherein the inorganic filler is selected ;. . from magnesium silicate and calcium silicate. -en
5. A building panel as claimed in claim 3 or 4, wherein the board material is :. reinforced.
:'
6. A building panel as claimed in claim 5, wherein the reinforcement is fibrous.
: .
7. A building panel as claimed in any one of claims I to 6, wherein the tray is made A. of alloy coated steel sheet.
8. A building panel as claimed in any one of claims 1 to 7, wherein the top sheet is made of alloy coated steel sheet.
9. A building panel as claimed in claim 7 or 8, wherein the alloy coated steel sheet comprises mild steel sheet coated with a zinc/aluminium alloy.
10. A building panel as claimed in claim 7, 8 or 9, wherein the zinc/aluminium alloy comprises zinc, aluminium and silicon.
I 1. A building panel as claimed in claim 10, wherein the alloy consists essentially of 55% aluminium, 43.4% zinc and 1.6% silicon.
12. A building panel as claimed in any one of claims 7 to 11, wherein the alloy coating has a thickness in the range of 20 to 25 microns.
13. A building panel as claimed in any one of claims 7 to 12, wherein the steel sheet has a thickness of from 0.4mm to 2.0mm.
14. A building panel as claimed in claim 13, wherein the steel sheet has a thickness of 0.5mm.
15. A building panel as claimed in any one of claims I to 14, wherein the board is bonded to the tray by means of adhesive.
16. A building panel as claimed in claim 15, wherein the adhesive is a water-based contact adhesive I,
17. A building panel as claimed in claim 15 or 16, wherein the adhesive is a fire ^. :.. rated adhesive. .
:
18. A building panel as claimed in any one of claims 1 to 17, wherein forming the : . panel includes the step of folding sheet material to form the tray around the board. .
19. A building panel comprising a tray of zinc/aluminium alloy coated steel containing a magnesium silicate board bonded therein and a top sheet of zinc/aluminium alloy coated steel bonded to the board.
20. A building panel as claimed in claim 19, wherein bonding is by means of a water-based contact adhesive.
21. A method of making a building panel comprising the steps of forming a tray having a base and sides of sheet metal about a board bonded to the sheet metal and bonding a top sheet of metal to the board to enclose the board.
22. A method as claimed in claim 21, wherein the board is a heat resistant material.
23. A method as claimed in claim 21 or 22, wherein the board is made from inorganic fillers or cementitious material.
24. A method as claimed in claim 23, wherein the inorganic filler is selected from magnesium silicate and calcium silicate.
25. A method as claimed in claim 23 or 24, wherein the board material is reinforced.
26. A method as claimed in claim 25, wherein the reinforcement is fibrous.
27. A method as claimed in any one of claims 21 to 26, wherein the tray is made of alloy coated steel sheet.
28. A method as claimed in any one of claims 21 to 27, wherein the top sheet is made of alloy coated steel sheet. .
,, '
29. A method as claimed in claim 27 or 28, wherein the alloy coated steel sheet : comprises mild steel sheet coated with a zinc/aluminium alloy. .
I'
30. A method as claimed in claim 27, 28 or 29, wherein the zinc/aluminium alloy : .. . comprises zinc, aluminium and silicon.
3 1. A method as claimed in claim 30, wherein the alloy consists essentially of 55% aluminium, 43.4% zinc and 1.6% silicon.
32. A method as claimed in any one of claims 27 to 31, wherein the alloy coating has a thickness in the range of 20 to 25 microns.
33. A method as claimed in any one of claims 27 to 32, wherein the steel sheet has a thickness of from 0.4mrn to 2.0mm.
34. A method as claimed in claim 33, wherein the steel sheet has a thickness of 0.5mm.
35. A method as claimed in any one of claims 21 to 34, wherein the board is bonded to the tray by means of adhesive.
36. A method as claimed in claim 35, wherein the adhesive is a waterbased contact adhesive.
37. A method as claimed in claim 35 or 36, wherein the adhesive is a firerated adhesive.
38. A building panel substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.
39. A method of making a building panel substantially as hereinbefore described with reference to the accompanying drawings. . ecu e
e a e e ë e e a e e A. ccee e
GB0517909A 2004-09-06 2005-09-05 Building panels Expired - Fee Related GB2417736B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GBGB0419655.6A GB0419655D0 (en) 2004-09-06 2004-09-06 Building panels

Publications (3)

Publication Number Publication Date
GB0517909D0 GB0517909D0 (en) 2005-10-12
GB2417736A true GB2417736A (en) 2006-03-08
GB2417736B GB2417736B (en) 2009-09-02

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GBGB0419655.6A Ceased GB0419655D0 (en) 2004-09-06 2004-09-06 Building panels
GB0517909A Expired - Fee Related GB2417736B (en) 2004-09-06 2005-09-05 Building panels

Family Applications Before (1)

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GBGB0419655.6A Ceased GB0419655D0 (en) 2004-09-06 2004-09-06 Building panels

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITGE20080070A1 (en) * 2008-08-08 2010-02-09 Euroinsulite S R L INCOMBUSTIBLE LIGHT TILE FOR THE CREATION OF RAISED FLOORS.
CN102296713A (en) * 2011-07-11 2011-12-28 谷艮之 Heat-preservation, heat-insulation and fire-resistance composite board
WO2022012013A1 (en) * 2020-07-17 2022-01-20 山东安冷新材料科技有限公司 Fireproof composite thermal insulation board, and preparation method therefor and application thereof

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2092637A (en) * 1980-12-16 1982-08-18 Belge Revetements Dynamique Ba A composite floor slab
GB2130615A (en) * 1982-11-23 1984-06-06 Clifford Sidney Bundy Floor panels
GB2183689A (en) * 1985-11-20 1987-06-10 Rsm Ind Ltd Floor panel
GB2206140A (en) * 1987-05-28 1988-12-29 Floorplan Electrica Ltd Rectangular flooring panels for false floors
EP1304425A1 (en) * 2001-10-18 2003-04-23 Bresciana Graniti S.p.A. Composite panel for raised floors
WO2005021891A1 (en) * 2003-08-29 2005-03-10 Kingspan Holdings (Irl) Limited An access floor panel

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2092637A (en) * 1980-12-16 1982-08-18 Belge Revetements Dynamique Ba A composite floor slab
GB2130615A (en) * 1982-11-23 1984-06-06 Clifford Sidney Bundy Floor panels
GB2183689A (en) * 1985-11-20 1987-06-10 Rsm Ind Ltd Floor panel
GB2206140A (en) * 1987-05-28 1988-12-29 Floorplan Electrica Ltd Rectangular flooring panels for false floors
EP1304425A1 (en) * 2001-10-18 2003-04-23 Bresciana Graniti S.p.A. Composite panel for raised floors
WO2005021891A1 (en) * 2003-08-29 2005-03-10 Kingspan Holdings (Irl) Limited An access floor panel

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITGE20080070A1 (en) * 2008-08-08 2010-02-09 Euroinsulite S R L INCOMBUSTIBLE LIGHT TILE FOR THE CREATION OF RAISED FLOORS.
CN102296713A (en) * 2011-07-11 2011-12-28 谷艮之 Heat-preservation, heat-insulation and fire-resistance composite board
WO2022012013A1 (en) * 2020-07-17 2022-01-20 山东安冷新材料科技有限公司 Fireproof composite thermal insulation board, and preparation method therefor and application thereof

Also Published As

Publication number Publication date
GB0419655D0 (en) 2004-10-06
GB2417736B (en) 2009-09-02
GB0517909D0 (en) 2005-10-12

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Date Code Title Description
PCNP Patent ceased through non-payment of renewal fee

Effective date: 20091202