GB2421037A

GB2421037A - Fire resistant panel

Info

Publication number: GB2421037A
Application number: GB0524302A
Authority: GB
Inventors: Aidan Mark Thomas Chippendale
Original assignee: Ancon Ltd
Current assignee: Leviat Ltd
Priority date: 2004-11-29
Filing date: 2005-11-29
Publication date: 2006-06-14
Anticipated expiration: 2025-11-29
Also published as: GB0426166D0; GB2421037B; GB0524302D0

Abstract

A fire resistant panel comprises a core 28 of fire-resistant material having on a first side thereof a metal layer 36 comprising stainless steel. The metal layer may comprise an innermost layer of stainless steel overlaid with ceramic-coated steel, and may be bonded to the core or may be not connected to the core, which may be calcium silicate. There may be a single or laminated layer 32 on the other side of the core, which may be ceramic-coated steel, or ceramic-coated steel overlying stainless steel, as for layer 36. The panels may be used for lining tunnels, and be attached as a cladding to elongate channel-form members: the panels may be flat or curved, and the core 28 may comprise a plurality of layers.

Description

fl 1 2421037 Improved Fire Resistant Panel The present invention relates

to a fire resistant panel and in particular to a fire resistant panel suitable for lining a substantially enclosed conduit such as a tunnel.

Fire resistant linings are often applied to the walls and roofs of tunnels such as road and rail tunnels. The lining typically comprises a plurality of panels of fire resistant material which are fixed to the roof and walls by appropriately configured fixing devices. In the event of a fire the lining prevents the flames reaching the walls and roof thereby reducing the possibility of structural damage to the tunnel in the vicinity of the fire. It has been observed that the intensity of certain types of fire can result in the structural failure of known linings.

According to the present invention there is provided a tire resistant panel comprising a core of fire resistant material having on a first side thereof a metal layer, wherein the metal layer at least partially comprises stainless steel.

The metal layer provides structural support for the fire resistant material and prevents the fire resistant material collapsing under its own weight when weakened during or after exposure to a fire.

The metal layer may fully comprise stainless steel. Alternatively, the metal layer may comprise a plurality of layers. In such an embodiment the metal layer may comprise a layer of stainless steel and a layer of another metal or alloy. The other metal may be steel and my be provided with a corrosion resistant coating. For example, the coating may be a ceramic coating or a galvanised coating of zinc. The layer of other metal is preferably provided outermost with respect to the core. In a preferred embodiment the layer of stainless steel extends fully over the side of the core to which it is applied. In an alternative embodiment the stainless steel layer may be perforated. n

The metal layer may be connected to the core, for example by adhesive. Alternatively the metal layer may be unconnected to the core. In such an embodiment the metal layer may be retained in associated with the core by the provision of fixing means provided around the periphery of the panel. The layer of stainless steel may have a thickness of between 1mm to 2mm, and more preferably a thickness of 1.2mm to 1.6mm.

The panel may be provided with a layer of stainless steel on both sides of the core.

Embodiments of the present invention will now be described with reference to the accompanying drawings in which: Figure 1 shows a simplified crosssectional view of a tunnel having a fire resistant lining attached to the roof thereof Figure 2 shows a part cross-sectional view of a fire resistant panel of a known construction; Figures 3 to 7 show part crosssectional views of fire resistant panels according to the present invention; and Figure 8 shows a cross-sectional view of a fixture for mounting panels to the wall or ceiling of a conduit such as a tunnel.

Referring firstly to figure 1 there is shown a simplified cross-sectional view of a tunnel generally designated 10. The tunnel 10 comprises a roof 12 and opposing walls 14,16.

The roof 12 is provided with a fire resistant lining generally designated 18. The lining 18 comprises a fire resistant panel 20 which is mounted to a backing member 22 which is in the from of an inverted tray. Typically a fire resistant infill (not shown) such as a fire blanket is provided in the space 24 between the panel and backing member 20,22 The panel and backing member 20,22 are attached to the roof 12 by fixing members 26 extending between the backing member 22 and the roof 12. Figure 2 shows a cross sectional view of the of the construction of the panel 20. The panel 20 comprises a core of fire board 28 which is sandwiched on opposing sides between thin sheets of ceramic coated steel 30,32 glued to the core with an appropriate adhesive. In a known example of such a panel 20 the core 28 has a thickness of approximately 25 mm and the steel sheets 30,32 a thickness of between 0.62 mm and 0.82 mm. fl

In the event of a fire, heat and flames are prevented from reaching roof 12 by the presence of the lining 18. It has been observed that in instances where the fire is particularly intense the lining 18 can fail thereby exposing the roof 12. In such instances the heat of the fire causes the outermost ceramic coated steel sheet 30 to disintegrate thereby exposing the fire board core 28 which subsequently fails structurally. Disintegration of the panel 20 in this manner is more likely to occur where the panel 20 is required to span distances in the region of 1200 mm. In such situations the disintegration of the outer sheet 30 causes the remainder of the panel 20 to collapse under its own weight.

Figure 3 shows a partial cross-sectional view of a panel, generally designated 34, according to the present invention. The panel 34 comprises a core of fire board 28 upon which there is provided on one side a thin sheet 32 of corrosion resistant metal and on the other side of a thin sheet of stainless steel 36. The core is manufactured from a noncombustible material such as, for example, mineral bound calcium silicate. The sheets 32,36 may glued, bonded or otherwise mechanically connected to the core 28.

Alternatively, the sheets 32,36 may be loose with respect to the core 28 such that the sheets 32,36 overlie the core. By loose, it is meant that the sheets 32,36 are not glued or bonded to the core 28 nor are the sheets 32,36 retained in association with the core 28 by means of one or more fixings extending through the panel 34 or by projections of the sheets 32,36 extending into the core 28. Fixings may be provided around the periphery of the panel 34 to retain the sheets 32, 36 to the core 28.

In use, the panel 34 is mounted such that the stainless steel sheet 36 is outermost, which is to say that it is on the opposite side of the panel 36 to the tunnel roof 12. Stainless steel has a greater temperature resistance than ceramic coated steel and thus is able to remain intact when exposed to temperatures at which ceramic coated steel disintegrates.

By remaining intact the fire board core 28 of the panel 34 is prevented from structural failure under its own weight and hence the panel 34 prevents heat and flames reaching the tunnel roof 12. For a panel 34 having a core thickness of 25 mm and a 0.62 mm to 0.82 mm thick layer of ceramic coated steel 32 on the side facing the tunnel roof or n wall, it has been found that a stainless steel layer of between 1.2 mm to 1.6 mm provides sufficient protection to maintain the integrity of the panel when exposed to temperatures in the region of 1350 degrees centigrade.

Referring now to figure 4 there is shown a partial cross sectional view of an alternative panel generally designated 38. The panel 38 comprises a core of fire board 28 upon which there is provided on one side a thin sheet 32 of corrosion resistant metal and on the other side a stainless steel and ceramic coated steel laminate 40. As before, the sheet and laminate 32,40 may be glued, bonded or otherwise mechanically connected to the core 28 or, alternatively, one or both of the sheet and laminate 32,40 may be loose with respect to the core 28. The laminate 40 comprises an outer layer 42 of ceramic coated steel and an inner layer 44 of stainless steel. In use, the panel 38 is mounted such that the laminate 40 is outermost, which is to say that it is on the opposite side of the panel 38 to the tunnel roof or wall. In the event that the ceramic coated steel layer 42 disintegrates due to the action of a fire the presence of the stainless steel layer 44 maintains the integrity of the panel 38 as a whole.

Figure 5 shows a partial cross-sectional view of an alternative panel generally designated 46. The panel 46 comprises a core of fire board 28 upon one side of which there is provided a thin sheet 48 of stainless steel. The opposing side 50 of the core 28 is exposed. The sheet 48 may be glued, bonded or otherwise mechanically connected to the core 28 or, alternatively, the sheet 48 may not be loose with respect to the core 28.

In use, the panel 46 is mounted such that the sheet 48 is outermost, which is to say that it is on the opposite side of the panel 46 to the tunnel roof or wall. In the event of a fire the presence of the stainless steel sheet 48 maintains the integrity of the panel 46 as a whole.

Figure 6 shows a partial cross-sectional view of an alternative panel generally designated 52. The panel 52 comprises a core of fire board 28 upon one side of which there is provided a stainless steel and ceramic coated steel laminate 54. The opposing side 50 of the core 28 is exposed. The laminate 54 may be glued, bonded or otherwise mechanically connected to the core 28 or, alternatively, the laminate 54 may be loose with respect to the core 28. The laminate 54 comprises an outer layer 58 of ceramic coated steel and an inner layer 60 of stainless steel. In use, the panel 52 is mounted such that the laminate 54 is outermost, which is to say that it is on the opposite side of the panel 52 to the tunnel roof or wall. In the event that the ceramic coated steel layer 58 disintegrates due to the action of a fire the presence of the stainless steel layer 60 maintains the integrity of the panel 52 as a whole.

Figure 7 shows a partial cross-sectional view of a curved panel generally designated 62.

The panel 62 comprises a core of fire board 28 upon one side of which there is provided a thin sheet 64 of stainless steel. The core 28 is comprised of a plurality fire board layers 68. The layers 68 may be connected to one another, for example by a heat resistant adhesive. Alternatively, the layer 68 may be loose with respect to one another.

The opposing side 66 of the core 28 is exposed. The sheet 64 may be glued, bonded or otherwise mechanically connected to the core 28 or, alternatively, the sheet 64 may not be loose with respect to the core 28. In use, the panel 62 is mounted such that the sheet 64 is outermost, which is to say that it is on the opposite side of the panel 62 to the tunnel roof or wall. In the event of a fire the presence of the stainless steel sheet 64 maintains the integrity of the panel 62 as a whole.

It will be appreciated that the curved core 28 described with reference to figure 7 may be used in conjunction with facing layer and/or laminate arrangements described with reference to figures 3, 4 and 6.

Figure 8 shows a cross-sectional view of a mounting arrangement, generally designated 70, for mounting panels 38 to as surface 72 of a conduit such as a tunnel. In the embodiment shown the panels 38 are of the type described with reference to figure 4 having a sheet of corrosion resistant metal on one side and a laminate of stainless steel and ceramic coated steel on the other side. It will be appreciated that the mounting arrangement 70 may be employed with other board configurations.

The arrangement 70 includes a channel 74 mounted to the surface 72 within which is located a bolt 76. The head 78 of the bolt 76 is sized such that the underside thereof n rests against respective edges 80 of the channel 74 and the shank 82 of the bolt 76 extends outwardly from the channel 74. Mounted to the bolt shank 82 is a clamp arrangement generally designated 84. The shank 82 is positioned between the edges 86 of two panels 38. It will be appreciated that the channel 74 may be provided with a plurality of bolts 76 and clamp arrangements 84 along its length.

The clamp arrangement 84 includes an inner backing strip 88 and a ceramic gasket 90 disposed between the panels 38 and the channel 74 and through which the bolt shank 84 extends. The strip and gasket 88,90 are retained to the bolt shank 84 by a nut 92. The clamp arrangement 84 further includes an outer cover strip 94 and ceramic gasket 96.

the cover strip and gasket 94,96 are retained by inner and outer nuts 98, 100. The inner nut 98 is received in a top hat section of channel 102. In instances where the metal layers of the panels are not connected to the cores, it will be appreciated that the clamp arrangements 84 serve to both connect the panels 32 to the surface 72 and retain the metal layers to the cores. n

Claims

Claims 1. A fire resistant panel comprising a core of fire resistant

material having on a first side thereof a metal layer, wherein the metal layer at least partially comprises stainless steel.
2. A fire resistant panel as claimed in claim I wherein the metal layer is fully comprised of stainless steel.
3. A fire resistant panel as claimed in claim I wherein the metal layer comprises a plurality of layers.
4. A fire resistant panel as claimed in claim 3 wherein the metal layer comprises a layer of stainless steel and a layer of another metal or alloy.
5. A fire resistant panel as claimed in claim 4 wherein said other metal is steel.
6. A fire resistant panel as claimed in claim 4 or claim 5 wherein the layer of other metal is provided with a ceramic coating.
7. A fire resistant panel as claimed in any of claims 4 to 7 wherein the layer of other metal is provided outermost.
8. A fire resistant panel as claimed in any preceding claim wherein the metal layer is connected to the core.
9. A fire resistant panel as claimed in claim 8 wherein the metal layer is connected to the core with adhesive.
10. A fire resistant panel as claimed in any of claims I to 7 wherein the metal layer is not connected to the core. n
11. A fire resistant panel as claimed in any preceding claim wherein the layer of stainless steel has a thickness of between 1 mm to 2mm.
12. A fire resistant panel as claimed in claim 11 wherein the layer of stainless steel has a thickness of between 1.2mm to 1.6mm.
13. A fire resistant panel as claimed in any preceding claim wherein the panel includes a further metal layer on a second side thereof.
14. A fire resistant panel as claimed in claim 11 wherein said further metal layer at least partially comprises stainless steel.
15. A fire resistant panel as claimed in claim 1 wherein said further metal layer is fully comprised of stainless steel.
16. A fire resistant panel as claimed in claim 13 or claim 14 wherein said further metal layer comprises a plurality of layers.
17. A fire resistant panel as claimed in claim 16 wherein the metal layer comprises a layer of stainless steel and a layer of another metal or alloy.
18. A fire resistant pane! as claimed in claim 17 wherein said other metal is steel.
19. A fire resistant panel as claimed in claim 17 or claim 18 wherein the layer of other metal is provided with a ceramic coating.
20. A fire resistant panel as claimed in any of claims 17 to 19 wherein the layer of other metal is provided outermost.
21. A fire resistant panel as claimed in any of claims 13 to 20 wherein said further metal layer is connected to the core.
22. A fire resistant panel as claimed in claim 21 wherein said further metal layer is cotmected to the core with adhesive.
23 A fire resistant panel as claimed in any of claims 13 to 20 wherein the metal layer is not connected to the core.
24. A fire resistant panel as claimed in any preceding claim wherein the panel is substantially planar.
25. A fire resistant panel as claimed in any of claims 1 to 23 wherein the panel is curved.
26. A lire resistant panel as claimed in any preceding claim wherein the panel is of substantially uniform thickness.
27. A fire resistant panel as claimed in any preceding claim wherein the core is comprised of a plurality of layers of fire resistant material.
28. A fire resistant panel substantially as hereinbefore described with reference to or as shown in figures 3 to 7 of the accompanying drawings.