GB2607112A - A lightweight composite structural construction panel - Google Patents
A lightweight composite structural construction panel Download PDFInfo
- Publication number
- GB2607112A GB2607112A GB2107735.9A GB202107735A GB2607112A GB 2607112 A GB2607112 A GB 2607112A GB 202107735 A GB202107735 A GB 202107735A GB 2607112 A GB2607112 A GB 2607112A
- Authority
- GB
- United Kingdom
- Prior art keywords
- panel
- fibre
- composite structural
- lightweight composite
- structural construction
- 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.)
- Withdrawn
Links
- 238000010276 construction Methods 0.000 title claims abstract description 46
- 239000002131 composite material Substances 0.000 title claims abstract description 45
- 239000000835 fiber Substances 0.000 claims abstract description 140
- 229910052500 inorganic mineral Inorganic materials 0.000 claims abstract description 86
- 239000011707 mineral Substances 0.000 claims abstract description 86
- 239000011435 rock Substances 0.000 claims abstract description 80
- 239000000463 material Substances 0.000 claims abstract description 19
- 239000013521 mastic Substances 0.000 claims abstract description 10
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims abstract description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 9
- 239000000853 adhesive Substances 0.000 claims abstract description 6
- 230000001070 adhesive effect Effects 0.000 claims abstract description 6
- 230000009970 fire resistant effect Effects 0.000 claims abstract description 4
- 239000011230 binding agent Substances 0.000 claims description 19
- 239000011248 coating agent Substances 0.000 claims description 15
- 238000000576 coating method Methods 0.000 claims description 15
- 230000003014 reinforcing effect Effects 0.000 claims description 6
- 238000003780 insertion Methods 0.000 claims description 3
- 230000037431 insertion Effects 0.000 claims description 3
- 238000003475 lamination Methods 0.000 claims description 3
- 239000000203 mixture Substances 0.000 claims description 3
- 239000000565 sealant Substances 0.000 claims description 3
- 230000002787 reinforcement Effects 0.000 abstract description 2
- 239000011490 mineral wool Substances 0.000 abstract 1
- 238000009413 insulation Methods 0.000 description 12
- 239000010410 layer Substances 0.000 description 8
- 230000009977 dual effect Effects 0.000 description 2
- 238000011065 in-situ storage Methods 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 238000005303 weighing Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910000746 Structural steel Inorganic materials 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000010811 mineral waste Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000002344 surface layer Substances 0.000 description 1
- 239000013585 weight reducing agent Substances 0.000 description 1
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
- E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
- E04B5/04—Load-carrying floor structures formed substantially of prefabricated units with beams or slabs of concrete or other stone-like material, e.g. asbestos cement
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building 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
- E04C2/284—Building 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 at least one of the materials being insulating
- E04C2/288—Building 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 at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
- E04B1/80—Heat insulating elements slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
- E04B1/941—Building elements specially adapted therefor
- E04B1/942—Building elements specially adapted therefor slab-shaped
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
- E04B9/001—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation characterised by provisions for heat or sound insulation
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
- E04B9/04—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation comprising slabs, panels, sheets or the like
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
- E04B9/22—Connection of slabs, panels, sheets or the like to the supporting construction
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B5/00—Floors; Floor construction with regard to insulation; Connections specially adapted therefor
- E04B5/02—Load-carrying floor structures formed substantially of prefabricated units
- E04B5/023—Separate connecting devices for prefabricated floor-slabs
Abstract
A lightweight composite structural construction panel comprises a concrete core portion having a first major surface and a second opposed major surface and a compressed mineral fibre or rock fibre panel laminated to at least one of the first major surface and a second opposed major surface and attached thereto using at least one elongate fastener. The concrete core portion may be a concrete slab incorporating reinforcement. An adhesive or other material, possibly a mastic or a water or acrylic based fire resistant material, may be provided between the concrete and the mineral fibre or rock wool panel.
Description
A LIGHTWEIGHT COMPOSITE STRUCTURAL CONSTRUCTION PANEL Technical Field of the Invention The present invention relates generally to building systems and particularly to a lightweight composite structural construction panel.
Background to the Invention
Relevant building standards typically provide a guideline for the attributes of a concrete slab to be used as a floor.
In particular, the relevant building standards typically provide a minimum concrete slab thickness to be used to comply with the requirements of structural adequacy or loadbearing capacity. Other attributes may be prescribed as well, such as minimum thickness of concrete coverage under the lowest part of the rebar mesh (steel) reinforcement.
The minimum thickness (and any other parameters) is provided to comply with a minimum Fire Resistance Level (FRL) Fire Resistance is expressed in minutes as Loadbearing Capacity/Integrity/Insulation in accordance with BS476 Parts 20, 21 and 22 or in minutes as Integrity/Insulation in accordance with BS476 Parts 20 and 22. For example, a slab that is not tested for Loadbearing Capacity but is tested for Integrity and Insulation may have an FRL expressed as 4180/60 which means that it maintained integrity for at least 180 minutes and maintained insulation for at least 60. The initial dash means that the slab was not tested for loadbearing capacity.
FRLs such as these are only applicable to the tested orientation and contain no information other than the time attained (which is in 30-minute increments to 120 minutes and then in 60-minute increments with the maximum time in the standard of 240 minutes, even if the slab lasted longer). They also contain no information as to the ultimate failure of the slab nor at what time mark In Australia, a concrete structural floor/ceiling or wall can be designed in accordance with AS3600-2018 Concrete Structures whereby an FRP Fire Resistance Period can be determined. The Australian standard provides a minimum thickness of a concrete slab and a minimum axis distance (distance from surface of concrete slab to any internal reinforcing) in Table 55.2 below:
TABLE
SISTANCE PERIODS (ERN) STRUCTURAL ADEQUACY
OR FIAT SLABS INCLUDING FLAT PLATES
This table shows that to attain a 240 minute FRP for structural adequacy, the minimum slab thickness for a concrete slab, is 200mm. In fact, the minimum concrete slab thickness to attain an FRP of 90 minutes and above, is 200mm
Summary of the Invention
According to a first aspect of the invention there is provided a lightweight composite structural construction panel comprising a concrete core portion having a first major surface and a second opposed major surface and at least one compressed mineral fibre or rock fibre panel laminated to at least one of the first major surface and a second opposed major surface and attached thereto using at least one elongate fastener.
According to a second aspect of the invention there is provided a lightweight composite structural floor slab comprising a concrete slab portion having an upper surface and a lower surface and at least one compressed mineral fibre or rock fibre panel laminated to at least one of the upper surface and the lower surface and attached thereto using at least one elongate fastener.
Providing a lightweight composite structural floor slab or construction panel of this makeup allows a reduction in the thickness of the concrete portion of the slab or panel, which also decreases the amount of material used and weight, whilst at least maintaining the level of fire resistance, particularly for loadbearing capacity, required by the relevant building standards.
In the context of the present description, the term 'structural' means loadbearing. Typically, the lightweight composite structural construction panel will find application or use as a structural floor slab provided at a lower side of a building level to function as a floor and a second structural floor slab is provided at an upper side of the same level to function as a ceiling in that level and a floor in the level above.
A structural panel can also be used as a loadbearing wall The concrete slab or core portion will normally be substantially rectangular prism shaped The major surfaces are typically larger in area and minor surfaces extend between the major surfaces at the edges thereof. The concrete slab or core portion will normally have a length between two spaced apart, substantially parallel minor surfaces, a width between two spaced apart, substantially parallel minor surfaces and a thickness between the major surfaces.
One or more compressed mineral fibre or rock fibre panel may be fitted relative to each concrete slab portion. The one or more compressed mineral fibre or rock fibre panel may be fitted relative to each concrete slab portion in a retrofit situation, with the concrete slab portion already in situ. Alternatively, and more preferred, is the provision of a composite structural floor slab with one or more compressed mineral fibre or rock fibre panel fitted relative to each concrete slab portion as an OEM product.
Each of the concrete slab or core portion and the compressed mineral fibre or rock fibre panel will typically have two major surfaces, the upper and lower surfaces (for a floor panel) or inner and outer surfaces for wall panel, being approximately parallel to each other, and four minor surfaces forming the side or edge surfaces of the respective panel The concrete slab or core portion may be preformed before the lamination of the compressed mineral fibre or rock fibre panel.
One or more reinforcing members or structures may be provided within the concrete slab portion. If provided, the one or more reinforcing members or structures are preferably provided within the thickness of the slab portion, spaced from the major surfaces by at least 25 mm. The one or more reinforcing members or structures will normally be spaced from the minor surfaces on each side of the compressed mineral fibre or rock fibre panel.
The concrete slab or core or core portion will normally be substantially rectangular prism shaped. The concrete slab portion will normally have a length between two spaced apart, substantially parallel minor surfaces, a width between two spaced apart, substantially parallel minor surfaces and a thickness between the major surfaces The major surfaces are typically substantially planar.
The concrete slab or core portion will normally be provided in a standard size The concrete slab or core portion will normally be provided in a fixed or consistent thickness over its size. A thickness such as 120mm or 100mm could be used, although a lesser or greater thickness may be used depending upon requirements The compressed mineral fibre or rock fibre panel will normally be formed from mineral fibres and/or rock fibres and at least one binder. The binder may be a multicomponent binder.
A mineral fibre panel typically uses mineral waste residue as a raw material, whereas a rock fibre panel will normally use basalt as a raw material.
The binder is normally added to the mineral fibres and/or rock fibres The mineral fibres and/or rock fibres may be compressed before or after the binder is added. The mixture of binder and mineral fibres and/or rock fibres is normally then cured to 25 form the panel The binder content of the compressed mineral fibre or rock fibre panel according to the invention is at least 2%, preferably at least 3%, and even more preferably at least 4% When the compressed mineral fibre or rock fibre panels are intended for fire protection purposes the binder content may be down to 0.8%, preferably down to 1.4%.
The fibre orientation will usually be substantially parallel to the major surfaces of the compressed mineral fibre or rock fibre panel when compressed mineral fibre or rock fibre panels of one mono density are applied. If the compressed mineral fibre or rock fibre panel is a dual density panel, the fibre orientation will be more complex.
A dual density insulation compressed mineral fibre or rock fibre panel will typically have two closely connected layers of mineral fibres where the density of the one layer is different from the density of the other. Typically, the layer with the highest density will make up the smallest fraction of the total thickness of the compressed mineral fibre or rock fibre panel. This would be beneficial in the case of building facade insulation where a higher density of the outer layer of the insulation would make the insulation layer more resistant to mechanical damages during installation of the outer visible surface layer on the facade. If the outer layer is a render layer applied directly to the surface of the mineral fibre insulation layer, a high insulation density in the surface will be preferable.
The density of the compressed mineral fibre or rock fibre panel is typically more than 100 kg/m3, preferably at least 140 kg/m', and even more preferably at least 180 kg/m3. A density of 180 kg/m3 equates to a density of 9kg/m2 at a 50mm thickness. The density may be greater than this, but this does increase the weight of the compressed mineral fibre or rock fibre panel.
A compressed mineral fibre or rock fibre panel will normally be applied to at least one of the major surfaces of the slab or panel. A compressed mineral fibre or rock fibre panel may be applied to both of the major surfaces of the slab or panel. A compressed mineral fibre or rock fibre panel may be provided relative to some or all of the minor surfaces as well.
The compressed mineral fibre or rock fibre panel is normally laminated to at least one the major surfaces of the concrete slab or core. Typically, a major surface of the compressed mineral fibre or rock fibre panel will abut a major surface of the concrete slab or core The minor surfaces of the respective compressed mineral fibre or rock fibre panel and the concrete slab or core will normally be coplanar.
An adhesive or other material may be provided between the respective major surfaces of the respective compressed mineral fibre or rock fibre panel and the concrete slab or core. A mastic material may be used. A mastic material, may be used between adjacent panels. The mastic material may be or include a water based or acrylic fire-resistant mastic.
The material used may be flexible, even when set or dry.
The compressed mineral fibre or rock fibre panel is normally attached to at least one the major surfaces of the concrete slab or core using at least one elongate fastener.
Usually, multiple elongate fasteners will be used. The multiple elongate fasteners may be provided in a regular array. Multiple elongate fasteners may be provided spaced about the periphery of the or each compressed mineral fibre or rock fibre panel, spaced inwardly from the periphery. The fasteners are typically spaced inwardly at least 50mm from the edge of the slab or panel.
Any opening formed for or by the insertion of the elongate fasteners may be provided with a sealant such as a mastic material to help seal the opening.
In an embodiment, a high-density inert mineral fibreboard coated on one or both sides with a water-based or acrylic coating may be used as the compressed mineral fibre or rock fibre panel. The thickness of the coating may vary. The coating may be an ablative coating.
An example of a compressed mineral fibre or rock fibre panel which may be used is sold under the trade name IntubattO, but any panel of similar characteristics may be used.
Benefits to the construction industry & the environment: A single concrete manufacturing plant produces more VOC's than every aeroplane in the air over the same period of time. Less concrete required in the design, less VOC' s to the environment.
1m3 of concrete weighs approximately 2.4 ton A composite slab according to an embodiment of the invention capable of attaining a FRL120/120/120, includes a 100mm thick concrete core portion weighing 240kgm2 and a 50mm thick mineral panel weighing 9kgm2 for a total weight of 249kgm2 and a total thickness 150mm. A Standard 200mm thick concrete slab to attain the same FRL FRL120/120/120, weighs 480kgm2 (50mm thicker and almost twice the weight of the lightweight composite structural construction panel Use of the lightweight composite structural construction panel of the invention results in a saving of approximately 23 lkgm2. So, if a single floor level is 500m2, this results in a weight reduction of 115,500 kg per floor.
I 0 The structural steel/concrete vertical support between each floor level will also not have to be as strong, as is has much less load to carry, which in turn reduces material, and weight of material.
At 150mm thick, floors formed using a lightweight composite structural construction panel according to an embodiment, are 50mm thinner than IS the comparable concrete slab, meaning that a high-rise building could be designed so that it ends up with an extra floor level compared to a building designed with 200mm thick concrete slabs of the same height (use of composite slab according to an embodiment gives an extra 500mm per 10 levels, 2m per 40 levels etc).
Whilst the disclosure above is mainly directed to general building applications, particularly multi-storey building applications, specialist constructions such as petrochemical plants, some military establishments, large road tunnels and other types of specialist construction, are typically required to meet a far higher fire standard The lightweight composite structural construction panel of the invention may also be suitable for applications requiring loadbearing capacity, integrity and/or insulation performance in excess of FRL240/240/240 or other aspects of performance.
Detailed Description of the Invention
In order that the invention may be more clearly understood one or more embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which: Figure 1 is a side view of a lightweight composite structural floor slab according to an embodiment Figure 2 is an isometric view from the underside of the floor slab illustrated in Figure 1 during assembly.
Figure 3 is an isometric view from the underside of the floor slab illustrated in Figure 2 during fastening With reference to the accompanying figures, a lightweight composite structural floor slab 10 is provided. The structural floor slab 10 illustrated in the Figures comprises a concrete slab portion 11 having an upper surface 12 and a lower surface 13 arid a number of compressed mineral fibre or rock fibre panels 14 laminated to the lower surface 13 and attached thereto using elongate fasteners 15.
The concrete slab 10 will normally be substantially rectangular prism shaped. The major surfaces of the concrete slab are typically larger in area and minor surfaces extend between the major surfaces at the edges thereof The concrete slab 10 will normally have a length between two spaced apart, substantially parallel minor surfaces, a width between two spaced apart, substantially parallel minor surfaces and a thickness between the major surfaces.
Typically, the lightweight composite structural construction panel will find application or use as a structural floor slab as shown in Figures 1 to 3, provided at a lower side of a building level to function as a floor and a second structural floor slab is provided at an upper side of the same level to function as a ceiling in that level and a floor in the level above.
However, the structural panel can also be used as a loadbearing wall. Typically, though not always, if used as a loadbearing wall, the compressed mineral fibre or rock fibre panels 14 will be provided on both major surfaces.
One or more compressed mineral fibre or rock fibre panel may be fitted relative to each concrete slab portion. The one or more compressed mineral fibre or rock fibre panel may be fitted relative to each concrete slab portion in a retrofit situation, with the concrete slab portion already in situ, to form the lightweight panel of the invention.
Alternatively, and more preferred, is the provision of a composite structural floor slab 10 with one or more compressed mineral fibre or rock fibre panels 14 fitted relative to each concrete slab portion 10, as an OEM product.
Each of the concrete slab 11 and compressed mineral fibre or rock fibre panel 14 will typically have two major surfaces, the upper and lower surfaces (for a floor panel) or inner and outer surfaces for wall panel, being approximately parallel to each other, and four minor surfaces forming the side or edge surfaces of the respective panel.
Where more than one compressed mineral fibre or rock fibre panel 14 is provided relative to a concrete slab or core portion, at least some of the side edges of at least some of the compressed mineral fibre or rock fibre panels 14 will typically be coplanar with the side or edge surfaces of the concrete slab or core portion.
The concrete slab 11 is normally pre-formed before the lamination of the compressed mineral fibre or rock fibre panel 14 thereto.
The major surfaces of the concrete slab 10 are typically substantially planar.
The concrete slab 11 will normally be provided in a standard size. The concrete slab 11 will normally be provided in a fixed or consistent thickness over its size. A thickness such as 120mm or 100mm could be used, although a lesser or greater thickness may be used depending upon requirements, particularly the structural requirements to be achieved The compressed mineral fibre or rock fibre panel 14 will normally be formed from mineral fibres and/or rock fibres and a binder. The binder may be a multi component binder.
The binder is normally added to the mineral fibres and/or rock fibres The mineral fibres and/or rock fibres may be compressed before or after the binder is added The mixture of binder and mineral fibres and/or rock fibres is normally then cured to form the panel.
An example of a compressed mineral fibre or rock fibre panel which may be used is sold under the trade name Intubatt®, but any panel of similar characteristics may be used.
The binder content of the compressed mineral fibre or rock fibre panel according to the invention is at least 2%, preferably at least 3%, and even more preferably at least 4%. When the compressed mineral fibre or rock fibre panels are intended for fire protection purposes the binder content may be down to 0.8%, preferably down to 1.4%.
The density of the compressed mineral fibre or rock fibre panel is typically more than 100 kg/m3, preferably at least 140 kg/m3, and even more preferably at least 180 kg/e. A density of 180 kg/m3 equates to a density of 9kg/m2 at a 50mm thickness. The density may be greater than this, but this does increase the weight of the compressed mineral fibre or rock fibre panel.
A compressed mineral fibre or rock fibre panel 14 will normally be applied to at least one of the major surfaces of the slab, usually the lower side as shown in the Figures. A compressed mineral fibre or rock fibre panel 14 may be applied to both of the major surfaces of the slab or panel, particularly when the panel is used as a structural wall panel.
In an embodiment, a high-density inert mineral or rock fibre board 17 can be coated on one or both sides with a water-based acrylic coating 16 may be provided as the compressed mineral fibre or rock fibre panel. The thickness of the coating may vary.
The coating 16 may be an ablative coating. The water-based acrylic coating 16 may be provided relative to some or all of the minor surfaces as well, as shown in Figure 2 in particular to cover the edges of the mineral or rock fibre board 17.
The compressed mineral fibre or rock fibre panel is normally laminated to at least one the major surfaces of the concrete slab 11 or core Typically, a major surface of the compressed mineral fibre or rock fibre panel 14 will abut a major surface of the concrete slab 11 or core. The minor surfaces of the respective compressed mineral fibre or rock fibre panel 14 and the concrete slab 11 or core will normally be coplanar as shown.
An adhesive or other material (not shown in the Figures) may be provided between the respective major surfaces of the respective compressed mineral fibre or rock fibre panel 14 and the concrete slab 11 or core. The adhesive material may be include a water based or acrylic fire resistant mastic. A mastic material may be used between adjacent panels.
The adhesive or other material used may be flexible, even when set or dry.
Usually, multiple elongate fasteners 15 will be used as shown. The multiple elongate fasteners 15 may be provided in a regular array. Multiple elongate fasteners are usually provided spaced about the periphery of the or each compressed mineral fibre or rock fibre panel 14, spaced inwardly from the periphery. The fasteners 15 are typically spaced inwardly at least 50mm from the edge of the slab or panel.
Any opening formed for or by the insertion of the elongate fasteners 15 may be provided with a sealant such as a mastic material to help seal the opening.
A lightweight composite structural construction panel of an embodiment described herein has been found to attain a Fire Resistance Level (FRL) at the thickness given below: * FRL240/240/240 Total construction panel thickness 170mm * FRL180/180/180 Total construction panel thickness 170mm * FRL120/120/120 Total construction panel thickness 150mm * FRL90/90/90 Total construction panel thickness 150mm (tested but may be even thinner) The Fire Resistance Level above is expressed in minutes as Loadbearing Capacity/Integrity/Insulation in accordance with B S476 Parts 20, 21 and 22. These total construction panel thicknesses for the same FRL, compare surprisingly favourably with a concrete slab which is 200mm.
The one or more embodiments are described above by way of example only. Many variations are possible without departing from the scope of protection afforded by the appended claims.
Claims (3)
- CLAIMSA lightweight composite structural construction panel comprising a concrete core portion having a first major surface and a second opposed major surface and at least one compressed mineral fibre or rock fibre panel laminated to at least one of the first major surface and a second opposed major surface and attached thereto using at least one elongate fastener.
- 2. A lightweight composite structural construction panel as claimed in claim I wherein the concrete core portion is a concrete slab portion with the first major surface being an upper surface and the second opposed major surface being a lower surface and the at least one compressed mineral fibre or rock fibre panel is laminated to at least one of the upper surface and lower surface and attached thereto using at least one elongate fastener.
- 3. A lightweight composite structural construction panel as claimed in claim 1 or claim 2 wherein the compressed mineral fibre or rock fibre panel is provided relative to both of the first major surface and a second opposed major surface A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein the concrete core portion is rectangular prism shaped A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein the concrete core portion preformed before the lamination of the compressed mineral fibre or rock fibre panel.A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein the concrete core portion comprises one or more reinforcing members or structures provided within the concrete core portion 7. A lightweight composite structural construction panel as claimed in claim 6 wherein the one or more reinforcing members or structures are provided within the concrete core portion, spaced from the respective major surfaces by at least 25 mm.A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein the major surfaces of the concrete core portion are substantially planar.A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein the concrete core portion is provided in a fixed or consistent thickness over its size 10. A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein the compressed mineral fibre or rock fibre panel is formed from mineral fibres and/or rock fibres and at least one binder.L A lightweight composite structural construction panel as claimed in claim 10 wherein the mineral fibres and/or rock fibres are compressed before or after the at least one binder is added.12. A lightweight composite structural construction panel as claimed in either one of claim 10 or claim 11 wherein a mixture of binder and mineral fibres and/or rock fibres is cured to form the compressed mineral fibre or rock fibre panel.13 A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein the density of the compressed mineral fibre or rock fibre panel is more than 100 kg/m3, preferably at least 140 kg/m3, and even more preferably at least 180 kg/n3.14. A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein a major surface of the compressed mineral fibre or rock fibre panel abuts a major surface of the concrete core portion.15. A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein an adhesive or other material is provided between the respective major surfaces of the respective compressed mineral fibre or rock fibre panel and the concrete core portion.16. A lightweight composite structural construction panel as claimed in claim 15 wherein a mastic material is used.17. A lightweight composite structural construction panel as claimed in claim 15 or claim 16 wherein an water based or acrylic fire resistant material is used.18. A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein multiple elongate fasteners are used for the or each compressed mineral fibre or rock fibre panel 19. A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein elongate fasteners are provided spaced about the periphery of the or each compressed mineral fibre or rock fibre panel, spaced inwardly from the periphery.20. A lightweight composite structural construction panel as claimed in claim 19 wherein the elongate fasteners are spaced inwardly at least 50mm from the periphery of the or each compressed mineral fibre or rock fibre panel 2k A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein any opening formed for or by insertion of the at least one elongate fastener is provided with a sealant to help seal the opening.22 A lightweight composite structural construction panel as claimed in any one of the preceding claims wherein the compressed mineral fibre or rock fibre panel is a high-density inert mineral fibreboard coated on at least one side thereof.23. A lightweight composite structural construction panel as claimed in claim 22 wherein the coating is a water-based acrylic coating.24. A lightweight composite structural construction panel as claimed in claim 22 or claim 23 wherein the coating is an ablative coating.25. A lightweight composite structural construction panel as claimed in any one of claims 22 to 24 wherein the coating is a water based or acrylic coating.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2107735.9A GB2607112A (en) | 2021-05-29 | 2021-05-29 | A lightweight composite structural construction panel |
| GB2114778.0A GB2607644A (en) | 2021-05-29 | 2021-10-15 | A lightweight composite structural construction panel |
| PCT/GB2022/051347 WO2022254190A1 (en) | 2021-05-29 | 2022-05-26 | A lightweight composite structural construction panel |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB2107735.9A GB2607112A (en) | 2021-05-29 | 2021-05-29 | A lightweight composite structural construction panel |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB202107735D0 GB202107735D0 (en) | 2021-07-14 |
| GB2607112A true GB2607112A (en) | 2022-11-30 |
Family
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Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB2107735.9A Withdrawn GB2607112A (en) | 2021-05-29 | 2021-05-29 | A lightweight composite structural construction panel |
| GB2114778.0A Pending GB2607644A (en) | 2021-05-29 | 2021-10-15 | A lightweight composite structural construction panel |
Family Applications After (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB2114778.0A Pending GB2607644A (en) | 2021-05-29 | 2021-10-15 | A lightweight composite structural construction panel |
Country Status (1)
| Country | Link |
|---|---|
| GB (2) | GB2607112A (en) |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2294289A2 (en) * | 1974-12-13 | 1976-07-09 | Paillat Maurice | Precast reinforced concrete insulated floor slab mfr. - has mould base lined with mineral fibre retained by spiked metal strips |
| EP1754842A2 (en) * | 2005-08-16 | 2007-02-21 | ALHO Holding GmbH & Co.KG | Composite floor element |
| FR2931496A1 (en) * | 2008-05-20 | 2009-11-27 | Modulaire Innovation | Prefabricated multi-layer monoblock panel e.g. wall panel, for forming e.g. wythe of modular dwelling, has core formed by ultra high performance fiber concrete with ribs, and thermo-acoustic insulant placed inside ribs |
Family Cites Families (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP2584111B1 (en) * | 2011-10-18 | 2015-08-26 | Rockwool International A/S | Reinforced concrete wall provided with insulating panels on the underside and a method of making such wall |
| CN209723379U (en) * | 2019-03-13 | 2019-12-03 | 锦萧建筑科技有限公司 | Prefabricated load-bearing shear wall plate |
| CN110258914A (en) * | 2019-07-23 | 2019-09-20 | 华美节能科技集团玻璃棉制品有限公司 | A kind of mineral wool Side fascia and its installation and application |
| CN212353118U (en) * | 2020-03-07 | 2021-01-15 | 山西德诺聚鑫建材科技有限公司 | Building energy-saving insulation board |
| CN212927058U (en) * | 2020-03-19 | 2021-04-09 | 巴中市华兴建筑有限公司 | Bulky concrete double-deck template presss from both sides outer heat preservation maintenance structure of rock wool board |
| CN111519813A (en) * | 2020-05-09 | 2020-08-11 | 中交三航局第三工程有限公司 | MF heat-preservation sound-insulation assembled concrete laminated slab |
-
2021
- 2021-05-29 GB GB2107735.9A patent/GB2607112A/en not_active Withdrawn
- 2021-10-15 GB GB2114778.0A patent/GB2607644A/en active Pending
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2294289A2 (en) * | 1974-12-13 | 1976-07-09 | Paillat Maurice | Precast reinforced concrete insulated floor slab mfr. - has mould base lined with mineral fibre retained by spiked metal strips |
| EP1754842A2 (en) * | 2005-08-16 | 2007-02-21 | ALHO Holding GmbH & Co.KG | Composite floor element |
| FR2931496A1 (en) * | 2008-05-20 | 2009-11-27 | Modulaire Innovation | Prefabricated multi-layer monoblock panel e.g. wall panel, for forming e.g. wythe of modular dwelling, has core formed by ultra high performance fiber concrete with ribs, and thermo-acoustic insulant placed inside ribs |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2607644A (en) | 2022-12-14 |
| GB202114778D0 (en) | 2021-12-01 |
| GB202107735D0 (en) | 2021-07-14 |
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