GB2625635A

GB2625635A - Prefabricated structure

Info

Publication number: GB2625635A
Application number: GB2317066.5A
Authority: GB
Inventors: Hart William
Original assignee: Taylor Hart Ltd
Current assignee: Taylor Hart Ltd
Priority date: 2023-11-07
Filing date: 2023-11-07
Publication date: 2024-06-26
Also published as: GB202317066D0

Abstract

A prefabricated structure 100 for forming an opening in a dry wall, the structure having a track member 112 arranged to form a frame defining an aperture and having a plurality of sections defining sides of the frame and a top surface facing into the aperture. A plurality of gypsum-based board sections 120 are secured on the top surface and surround the aperture. A fire resistant material 113 is secured to the boards and fill the aperture defined by the track member. Further disclosed is a wall comprising the structure and a method of making the dry wall. In use a builder can cut an opening in the fire resistant material on site to route pipework and cables.

Description

PREFABRICATED STRUCTURE

The present invention relates to a prefabricated structure for a dry wall. In particular, the present invention relates to a preformed frame for forming an opening in a dry wall, with a fire-resistant or fireproof material provided in the opening. The present invention also relates to a dry-wall or partition wall including the prefabricated structure, and to a method of making the dry-wall or partition wall.

Dry walls (or stud walls) are used to partition a large internal space into smaller areas.

Typically, a dry wall dividing wall includes an arrangement of studs forming a frame, with plasterboard secured to the studs.

Various services may be provided throughout the spaces separated by dry walls. These include power cables; data communications cables; cold or hot air conduits; gas pipes; heating or hot water pipes; and dean or waste water pipes. in order to connect services, openings (referred to as builders' work openings) are provided in walls. Builder's work openings include a structure attached to the studs, the structure defining an aperture. The services are provided through the opening, when the rest of the frame is covered with plasterboard.

In order to prevent spread of fire between adjoining spaces through the work opening, a fireproof (or fire-resistant) material (for example a fireproof batt) is provided in the opening During construction, the wall is made, with the opening formed in it. The services arc then provided through the opening. Fireproof batt is then provided in the work opening and secured to the frame of the work opening and to services conduits using a fireproof mastic. Typically, in order to fill the gaps in the work opening, several pieces of batt are needed, which are also joined together using mastic.

The process is slow, and inefficient. In a large project, there may be hundreds of builders' work openings which need to be closed in this way. There is therefore a need to provide for a quick way of making builders' work openings fireproof, whilst allowing services to be installed.

According to a first aspect of the invention, there is provided a prefabricated structure for forming an opening in a dry wall, the prefabricated structure including: a track member arranged to form a frame defining an aperture, the track member having a plurality of sections defining sides of the frame, and a top surface facing into the aperture: a plurality of gypsum-based board sections secured on the top surface of the track member, the gypsum-based board sections surrounding at least part of the aperture: and a fire-resistant or fireproof material secured to the gypsum-based board sections, the fire-resistant or fire-proof material filling the aperture defined by the track member.

Each section of the track member may be provided with at least one gypsum-based board section extending along at least part of the length of the section of the track. Gypsum-based board may be provided along the full length of each track section.

The fire-resistant or fireproof material may be secured along at least a portion of each side of the aperture. The fire-resistant or fireproof material may be secured along the full length of each side of the aperture The fire-resistant or fireproof material may be secured to the gypsum-based board sections by a fire-resistant or fireproof adhesive. The fire-resistant or fireproof adhesive may be an intumescent material, preferably intumescent mastic. The fire-resistant or fireproof adhesive may be cured to provide a rigid connection of the fire-resistant or fireproof material to the gypsum-based board sections.

A single piece of fire-resistant or fireproof material may be used to fill the aperture.

The track member may be a single piece, with corners formed therein.

The frame may fully surround the aperture.

The corners may be ninety degrees, or substantially ninety degrees.

The fire-resistant or fireproof material may comprise an ablative fire batt.

The prefabricated structure may comprise a packaging material to secure and protect the structure during transport The prefabricated structure may be formed off-site.

According to a second aspect of the invention, there is provided a dry-wall or partition wall comprising: a frame, defining opposing surfaces; gypsum-based board panels secured on one or both of the opposing surfaces: and a prefabricated structure according to the first aspect. forming an aperture extending between the opposing surfaces.

The dry-wall or partition wall may comprise: one or more service conduits extending through the aperture, the service conduits extending through openings in the fire-resistant or fireproof material.

The openings in the fire-resistant or fireproof material may be formed on site.

The fire-resistant or fireproof material may be sealed around the one or more service conduits. The fire-resistant or fireproof material may be sealed around the one or more service conduits by a fire-resistant or fireproof adhesive. The fire-resistant or fireproof adhesive may be an intumescent material, preferably intumescent mastic.

The one or more service conduits may comprise at least one of: power cables; data communications cables; cold or hot air conduits; gas pipes heating or hot water pipes; and clean or waste water pipes.

According to a third aspect of the invention,there is provided a method of making the dry-wall or partition wall of the second aspect, the method comprising: forming a dry wall frame; fitting a prefabricated structure according to the first aspect into the frame to define an aperture; securing gypsum-based board panels to one or both opposing faces of the frame. leaving the aperture open; cutting one or more slits into the fire-resistant or fireproof material, after it has been fitted into the frame; and providing one or more service conduits through the slits.

The method may comprise: sealing the fire-resistant or fireproof material around to the one or more service conduits.

The prefabricated structure may be made off-site and transported to where needed once completed.

The prefabricated work opening has a batt securely fitted inside the aperture. The ready-made structure is fitted into place and the batt is then cut to form slits or openings, and the services fitted through the openings. By securely fitting the batt into the frame before providing the services, it is held into place whilst the services are fitted. This process is quicker that fitting the batt around the services. By maintaining the integrity of a single piece of batt, less mastic is needed and potential weak points in the fire-resistant properties (where separate pieces of batt are joined) are removed.

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure I schematically illustrates an example of a dividing wall formed by a dry wall, with a cutaway section to show the components of the wall; Figure 2 schematically illustrates a prefabricated builders' work opening for I5 providing a services opening in a dividing wall; Figure 3 illustrates a method of assembling a dry wall; Figure 4 illustrates a builders' work opening installed in a dry wall with services extending through the opening; Figure 5 illustrates a method of making the prefabricated builders' work opening of Figure 2; Figure 6A shows the track member used to form the prefabricated builders' work opening of Figure 2; and Figure 68 illustrates a cross-section view taken through the track of the prefabricated builders' work opening, as indicated in Figure 6A: Figure 7A schematically illustrates a first step of forming an inline corner in the structure of Figure 2; Figure 78 schematically illustrates a second step of forming an inline corner in the structure of Figure 2; Figure 8 schematically shows the steps for joining the ends of the track member of Figure 2; and Figure 9 schematically illustrates an alternative embodiment of the structure of Figure 2.

In the following description, reference will be made to plasterboard. However, it will be appreciated that this may refer to any gypsum-based board used as a wall covering in dry walls. Similarly, whilst the following refers to a builders' work opening, it will be appreciated that it may refer to any form of opening that is filled by a fireproof material.

Figure 1 schematically illustrates an example of a dry wall 1 used to form partitions in an interior space. A cutaway section A shows the internal components of the wall 1.

In this example, the dry wall 1 is formed of a frame 3 fixed between a floor 5 and a ceiling 7. The frame 3 is made up of vertically extending studs 9a and horizontally extending studs 9b. In one example, the studs 9a,9b are metal, such as steel, with a C-shaped cross section. In other cases, any suitable shape and material stud can be used. Plasterboard panels I I are fixed to the studs 9a.,b.

The dividing wall 1 shown in Figure 1 is a simple planar wall with a planar first face 2 I5 on one side, and an opposing second face (not shown) on the opposite side. A builders' work opening 4 is provided in the wall 1, extending from the first side 2 to the second side. The builders' working opening is defined by a structure 100 fitted to the stud frame 3.

The structure 100 maintains the structural integrity of the frame 3 and wall 1, and also the fire safety and acoustic damping of the wall 1, It will be appreciated that various other openings and features (not shown) may be formed in the wall 1, also formed by different structures. For example, there may be openings for doors or windows or hatches. Also, dry walls 1 are often formed with deflection heads at the top of the frame 3.

Figure 2 illustrates the structure 100 that defines the builders' work opening.

The structure 100 has a frame 101 that is rectangular in shape, having two opposing sides 102, 104, a bottom 106, and a top 108. The sides 102, 104 are spaced such that the frame 101 can be secured between two vertical studs 9a in a partition wall I. An opening 110 is formed between the sides 102, 104, bottom 106 and top 108 through which services are provided.

The sides 102. 104. bottom 106 and top 108 of the structure 100 are straight sections, formed by a track member 112.

The track member 112 includes a planar base 13 defining a bottom surface 15 and a top surface 17. Sidcwalls 19, 21 extend from the bottom surface 15, on opposing sides of the base 13. thus defining a channel 23. The base 13 and sidewalls 19, 21 thus form the "C" shaped section of the track 112 A plasterboard section 120 is fixed on the top surface 17 of the track member 112 on each of the sides 102, 104, bottom 106 and top 108. Each plasterboard section 120 is a simple rectangle in shape, and overlies the top surface, with a top face 122 facing inwards towards the opening 110 (i.e. perpendicular to an axis through the opening 110).

The plasterboard sections 120 are sized to be the same width as the base 13 of the track member 112, and are secured by screws (not shown) which pass through the plasterboard section 116 and base 13, into the channel 23 of the track member 112. The plasterboard sections 116 arc sized so that plasterboard sections 116 from neighbouring straight sections 102. 104_ 106. 108 abut at the corners (as best shown in Figure 7B discussed below).

A fireproof batt 113 is provided to fill the opening 110. The batt 113 is a single piece of material that is secured along the full length of the sides 102. 104. a bottom 106, and a top 108 of the frame 101 with an intumescent mastic 123 used as an adhesive. This provides a rigid adhesion, in particular if the mastic is cured after application and fitting the batt 113.

Figure 3 schematically illustrates a method 200 of forming a dry wall 1.

In a first step 202, the prefabricated structure 100 for forming the builders work opening 4 is provided.

In a second step 204, the frame 3 of the dry wall 1 is formed. The prefabricated structure 100 is then secured to the frame 3 in a third step 206.

The structure 100 is secured to the vertical studs 9a,b by screws 121 (such as nr screws) passing through the sidcwalls 102, 104 of the track member 112, into the sidewalls of the studs 9a, 9b, in a direction parallel to the axis through the opening 110.

It should be noted that the screws used to secure the plasterboard section 120 to the track sections 114 in the prefabricated structure 100 are sufficiently short that they do not interfere with the studs 9a in the frame 3. For example, the screws may only be 10mm. To further accomplish this, there may be an offset between the studs 9a and the structure 100. Furthermore, the screws 121 used to secure the structure 100 to the studs 9a arc sufficiently short that the structure 100 can be secure from both sides, and the screws 121 do not interfere within the channel of the stud 9a.

The plasterboard panels 11 arc fixed to the frame 3 in the usual manner, in the next step 208. The plasterboard panels 11 are cut to size to ensure the opening 110 remains clear. 15 The plasterboard panels 11 of the wall 1 have an outward facing surface perpendicular to the plasterboard sections 116 in the structure 100 (i.e, perpendicular to the axis passing through the opening 110). These form the first face 2 and the second face of the wall 1. The plasterboard panels 11 of the wall are cut to size such that the tops of the panels are level with the top surface 122 of the plasterboard sections in the builders' work opening 100, to form a sharp edge at the opening 110.

The service conduits 140 are then provided through the batt 113 in a next step 210. One or more service conduits 140 may be provided. Figure 4 illustrates an example builders' work opening 100 with one service conduit 140 in place, and a cut or opening 142 formed for a second.

Fitting the services 140 may include several sub-steps 210a,b,c In a first sub-step 210a a slit 142 is cut into the batt 113 for each services conduit 140.

This may be cut by a knife or any suitable cutting tool to score a straight line cut through the batt 113.

In a second sub-step 20 lb. a service conduit 140 is provided through each slit 142. The flexibility of the material of the batt 113 is such that the slit will open up but remain a tight fit around the conduit 140.

The rigid adhesion between the batt 113 and the plasterboard sections 120/frame 101 of the work opening 100 ensures the batt 113 is securely held in place while the cut is made, and conduit fitted.

In a final sub-step 210c, the material of the batt 113 is secured to the conduit(s) 140 using intumescent mastic 144.

It will be appreciated that provided the prefabricated builders work opening is fitted into the frame 3, before the services conduits 140 are fitted, the method 200 may occur in any order.

Figure 5 schematically illustrates a method 300 of forming the prefabricated builders work opening structure 100. This is manufactured off-site, packaged and then shipped to the site where it is needed in a first step 302, the track members 112 is cut to length 302. The frame 101 of the structure 100 is formed by a single length of track member 112, that is later bent to form the frame 101. as discussed below.

The track member 112 has a length extending from a first end 116 to a second end 118.

in the assembled state (Figure 2), the length of the track member 112 extends around the perimeter of the opening 110. The track member 112 is the same C-section track as used to form the studs 9a,b of the frame 3 of the dividing wall I. Once the track member 112 is cut to size, the method 300 then includes cutting the plasterboard sections to size 304, securing 306 the plasterboard section 120 to the track member 112, and forming 308 the shape of the frame.

Figure 6A shows the track member 112 in a partially assembled state, partway through forming the shape. Figure 6B shows a cross section through the frame 100, perpendicular to the length of the track member 112, as shown by the dashed line in Figure 6A.

As discussed above, the rectangular shape of the frame 101 is formed by bending the single track member 112 at three "in-line-corners 114 to form the desired shape. The in-line corners 114 are the corners formed part way along the length of the track section 112.

Figures 7A and 7B illustrate how the in-line corners 114 in the structure 100 are formed, in more detail. The plasterboard sections 120 are secured to the base 13 of the track member 112 prior to bending. A gap 124 is left between adjacent plasterboard section 120. A cut 126 is formed in the sidewalls 19, 21 of the track 112. The cut 126 extends the full height of the sidewall 19, 21 up to the base 13, but the base 13 itself is kept intact.

IS

By forming the cut 126 in this way, a pivot point (or live hinge) is formed in the track member 126, around which it can be bent to form the corner 114. By correctly sizing the gap 124. and aligning the cut 126 at or near one end of the gap 124, the track member 112 is free to rotate whilst the plasterboard sections 120 properly align and abut each other when the corner I 14 is formed.

The opposite ends 116, 118 of the track member 112 join together to form the fourth corner 115 of the rectangle (the overlapping corner 115). Figure 8 shows the fourth corner 115 in more detail.

To form the fourth corner 115, the second end 118 of the track section 112 overlaps the first end 116. At an end portion 117 of the track section 1 -I 2 formed at the second end 1 I 8, the base 13 of the track section 112 is cut away, leaving only the walls 19, 21. This allows the first end 116 of the track section 112 to be received within the channel 23 at the second end 118 of the track section. Therefore the sidewalls 19, 21 at the first end 116 overlap the sidewalls 19, 21 at the second end 118 The first end 116 and second end 118 are secured to each other by screws 119 extending through the corresponding side walls 19, 21, Screws 119 are provided in both sidewalls 19, 21, although only one sidewall 19 is shown in Figure 8, in one example, the screw 119 may be a wafer head screw.

The screw 119 used to form the overlapping corner 115 may be used to secure the prefabricated structure 100 to the frame 3 of the wall 1. For example, the prefabricated structure 100 may be shipped with the screw partway inserted, to a length sufficient to hold the ends 117, 118 together but to not inhibit placement of the prefabricated structure 100 relative to the frame 3. The screw then be fully screwed into place to secure the prefabricated structure 100 to the frame 3.

In other examples, the prefabricated structure 100 may be transported without the screw in place, in the overlapping corner. The screw is then inserted when the prefabricated structure is fitted.

in other examples, the screw 119 at the overlapping corner may be short enough that it does not inhibit placement of the prefabricated structure 100 on the frame, and a separate screw 119 in a different location may be used to secure the prefabricated structure 100 to the frame 3. Alternatively, welding, adhesive or other means may be used to secure the overlapping corner 115, and a separate screw 119 in a different location may be used to secure the prefabricated structure 100 to the frame 3, In a next step 310 of the method 300, the batt 113 is fitted into the opening 110. As discussed above, the batt 113 is secured by intumescent mastic 123. This is cured (e.g. by heat and/or time) to provide rigid adhesion of the batt 113.

The structure 100 is constructed off-site, away from the location where the dry wall 1 is installed. As such, the lengths required for the track member 112 can be cut from larger stock portions of tracks. Similarly, the plasterboard sections 120 can also be cut from larger stock plasterboard panels, and the batt 113 can be cut from larger stock of batt 113, In this way, wastage of batt, track length and plasterboard panels can be reduced, as a large number of structures can be constructed at the same time, and the required lengths and areas can be efficiently cut form the larger stock pieces. Furthermore, this reduces the work required on site. it also allows the cutting of the batt, track members and plasterboard sections to be automated, reducing labour required.

In at least some examples, the method 200 may also include the step of drilling or punching screw holes for securing the plasterboard sections 120 to the track member 112.

In at least some examples, the method 200 may further include the step of drilling or punching the screw holes for securing the structure 100 to the studs 9a,b of the dry wall 1 and at the overlapping corner 115. This may allow the structure 100 to be secured to the studs 9a,b at fixed points.

When the prefabricated builders' work opening 100 is completed, it is packaged. This may include a protective tape or wrapping, a covering film, and/or any other suitable packaging to protect and/or secure the prefabricated builders' work opening 100. The prefabricated builders' work opening 100 is then shipped to where needed.

It will be appreciated that the steps of manufacturing the prefabricated structure 100 may also be carried out in any particular order.

It will be appreciated that the dry wall 1 discussed above is given by way of example only. The dry wall I may be constructed in any different way, to have different shapes and/or features, as will be understood by the person skilled in the art.

Furthermore, it will also be understood that various aspects of the dry wall 1 may be specified by the manufacturer of the plasterboard or regulatory bodies. In particular, the spacing of the vertical studs 9a and/or the location of fixing points from weak points (such as the ends of studs 9a,b) may be specified, allowing the structure 100 to have certain specified dimensions.

In the example discussed above, the sharp edge where the structure 100 meets the plaster panels 11 is formed by having the plasterboard sections 120 the same width as the base 13, and the plasterboard panels 11 overlapping the plasterboard sections 120 in the vertical direction. It will be appreciated that this is by way of example only. In other examples, the plasterboard sections 120 may overhang the base by the same length as the width of the plasterboard panels 11. The plasterboard panels II are then fitted to abut the underside of the plasterboard section 120 at the overhang.

In the above examples, the plasterboard sections 120 are fixed to the track member 112 before the track member 112 is bent. This is by way of example only. Instead, the track member 112 may be bent first, and then the plasterboard sections 120 attached.

In the above example, the pivot for forming the corners 114 is formed by cutting through the sidewall 19,21 and leaving the base intact. It will be appreciated that the pivot may be formed in other ways. For example, the cut 126 may extend into the base 13 or alternatively, the cut 126 may only extend along a portion of the sidewall 19, 21. In further examples, a material weakness may be formed in the sidewall 19, 21 and/or base 13 to form the pivot.

At the overlapping corner 115, the base 13 of the top section is removed so that the side 102 can be received in the top section. The section of base removed can be any suitable size to allow the overlap. In other examples, the base 13 of the side 102 may be removed so that the top section 108 is received in the base 13. The corner 115 where the two ends 116, 118 meet may also be formed in any other suitable way. There need not necessarily be overlap at this corner.

The corners 114, 115 need not necessarily be right angles, and other shapes of corner 114 may also be formed.

In the above, screws are used to fix the plasterboard sections 120 to the track member 112, and the structure 100 to the frame 3 of the wall 1. This is by way of example only. Any suitable mechanical fixing means may be used. Alternatively, adhesive or other fixing means may also be used.

In the example discussed above, a rectangular frame 100 is formed. It will, however, be appreciated that the prefabricated structure may have different shapes.

The structure may have any polygonal shape.

In another example, a "U" shaped member may be formed. The "U" shaped member is similar to the structure 100 shown in Figure 2, but includes only the sides 102, 104 and base 106 (or top 108). In some examples, the two sides are of similar length, but this is not essential In the "U" shaped structure, the batt 113 is only secured along three sides.

When securing the "U" shaped member to the frame, a first side 102 is secured to a first vertical stud 9a, and a second side 104 is secured to a second vertical stud 9b, with the base 106 (to top 108) level. Each of the sides may be secured to the studs 9a by a pair of screws (not shown).

The "U" shaped structure may be used to form an opening where the top of the access hatch is formed by a building soffit (not shown) or floor, rather than the horizontal track 9b of the frame 3.

In the "U-shaped structure, the plasterboard sections 120 may extend longer than the sides 102. 104 of the track member 112, to form an overlap with adjacent features. For example, where the "U" shaped member forms a three sided hatch, and a break is provided in the horizontal stud 9b, the plaster panels 11 may overlap cut ends of the stud 9b (and optionally the deflection head, if provided).

Once the 'U" shaped prefabricated structure is installed in the frame 3 of the dry wall 1, the edge of the batt 113 not secured to the prefabricated structure 100 may be sealed to the frame 3 or another structure.

As discussed above, the plasterboard sections 120 (which face parallel to a direction through the opening) may extend longer than the sides 102, 104 of the track member 112, in the "U" shaped structure. The sides may be formed with plasterboard sections 120 that do not extend the full length of the track 112. Thus when the side tracks, and the "U" shaped members and sides are combined, a continuous plaster panel surface is formed. This may also help to accommodate overlap between the track sections 112. Alternatively, the plasterboard sections 120 may overlap the end of the side tracks 112, whilst the plasterboard sections 120 on the "U" shaped members do not reach the end of the track 112.

In a further example, the side tracks and/or -U" shaped member may have plaster panels 112 that extend to the ends of the track sections 112, such that the joins between the track sections and the joins between the plasterboard panels align In the above example_ ablative batt 113 is used to fille the aperture 110 in the prefabricated builders' working opening. However, this is just by way of example. Any suitable fireproof or fire-resistant material, which can be secured to the frame of the structure 100, and which can be cut, or drilled to fit the conduits 140 for services could be used.

In the example discussed above, the batt 113 is secured along the full length of all four sides. It will be appreciated that in some examples, the batt 113 may only be secured along a portion of one or more sides, at one or more different points.

IS

Whilst intumescent mastic is used in the examples discussed above, any suitable adhesive, retains adhesive properties at the temperatures the opening is intended to be used with, can be used. Furthermore, mechanical fixings may be used instead of or as well as adhesive.

In some examples, the adhesive is fireproof or fire resistant, to provide a seal against the spread of fire through the point where the batt 113 meets the plaster board sections. 120 Where mechanical fixings are used, or the adhesive does not provide fire resistant properties, or the adhesive is not provided along the full length of the sides, a fireproof or fire-resistant seal may be provided.

Similarly to how the batt 1 13 is secured around its outer edges, any suitable adhesive or fixing means can be used to secure the batt 113 to the conduits. This may be the same or different to how the batt 113 is secured around its edges.

The batt 113 may have any suitable thickness. It may be the same width as the track 112 or plasterboard sections 120, or be narrower or wider. Optionally, the sealing/securing of the batt 113 to the conduits 114 may be one or both sides of the batt 113.

In the example discussed above, slits 142 are cut through the but to insert the conduits 140. However, any shape cut or hole can be formed to providc an opening for the conduits 140.

In some examples, no conduits are provided through the open ng and the batt 113 is left intact.

In the example discussed above, the plasterboard sections 120 extend the full length of each side of the opening 110. This need not be the case, and the plasterboard may only extend a portion of the length of each side in one or more pieces. In this example, the batt 113 may close the opening 110 where the plasterboard sections 120 are omitted. The batt 113 may be secured to the track 112 where desired.

Figure 9 schematically illustrates an example of a structure 100 according to a further embodiment. In this example, the structure 100 includes three separate pre-formed parts.

The first part 100a is a builders' work opening. The builders' work opening 100a is similar to the builders' work opening 100 described in relation to Figure 2. and is formed of a single length of track section 112a. However, the width of the builders' work opening 100a in Figure 9 (i.e. the length of the bottom 106 and top 108 sections) is less than the spacing between the vertical studs 9a.

The second and third parts 110b,c of the structure 100 are mounting elements used to fix the hatch 100a to the frame 3 of the dry wall 1.

The first mounting element 100b is "U" shaped, having a pair of parallel straight portions 128b 130b, connected by a straight joining portion I32b at respective corners 134b, 136b. The corners 134b, 136b are right angled. The corners 134b, 136b are internal corners such that the parallel end portions 128b, 130b of the mounting clement 100b extend away from the base 13 of the track section 112b in the opposite direction to the walls 19, 21 The corners 134b, 136b in the first mounting element 100b are in-line corners as discussed above in relation to Figures 7A and 7B. The first mounting clement 100b is formed of a single track element 112b. Therefore, the first mounting element 100b can be considered similar to a "U" shaped structure as discussed above, without the plasterboard.

The second mounting element 100c is of similar construction to the first mounting clement 10013, with a pair spaced parallel portions 128c, 130c, joined by a connecting portion 132c. The portions 128c, 130c, 132c, are joined at respective corners 134c, 136c.

In both the first and second mounting members 100b,c the length of the joining portion 132b,c (and hence the spacing between the parallel portions 128b,130b, 128c,130c) is the length of the spacing between the vertical studs 9a (which, as discussed above, may be standard).

In use, the mounting elements 100b,c are secured to the vertical studs 9a of the frame 3 using nr screws, in a similar manner to how the structure 100 discussed in relation to Figure 2 is fixed to the studs 9.

The first mounting element 100b is fixed with the parallel portions 128b,130b extending downward from the j oining portion 132b along the studs 9a, and the sidewalls 19,21 of the track section 112b in the joining portion 132b extending upward from the base 13.

The second mounting element 100c is vertically spaced above the first mounting element 100a, with the parallel straight portions 128c, 130c extending upward from the joining portion 132c, and the sidewalls 19,21 of the track section of the joining portion 132c extending downward from the base 13.

The reduced size hatch 100a is fixed between the joining portions 132b,c of the two mounting elements 100b,c, using screws 138 in a similar manner to the way the mounting elements 100b,c are fixed to the studs 9a.

During assembly of the frame 3, one of the mounting members 100b,c is fixed between two vertical studs 9a. The reduced size hatch 100a is then located at the correct position between the two studs 9a and secured to the mounting element 100b,c already fixed in place. The other mounting element 100bc is then secured to the hatch 100a and studs 9a. In this way, the hatch 100a can be provided at any position between the studs 9a.

Alternatively, both mounting elements 100b,c may be secured to one of the studs 9a, the hatch 100a is then located at the correct position between the two studs 9a and secured to the mounting elements 100b,c. The mounting elements 100b,c are then fixed to the other stud 9a. Again, the hatch 100a can be provided at any position between the studs 9a.

Once the frame 3 is assembled, the wall I can be completed in the same manner as discussed above In the examples discussed above, the corners 134b,c, 136b,c of the mounting elements 100b,c are in-line right angled corners. However, it will be appreciated that any method can be used to form the corners 134b,c, 136b,c and/or the corners may be any angle. Furthermore, the corners 134b,c, 136b,c need not necessarily be internal corners -instead, they may be external corners formed by being the track 112 in the opposite direction. A section of the sides of the track may be removed to allow this bending.

In the examples shown above, the parallel portions 128b,c, 130b,c of the mounting elements extend away from the gap between the mounting elements 100b,c where the hatch 100a is fixed. However, in other examples, this may not be the case. This may be especially useful when installing a hatch near a floor or ceiling, and there is not spaced to fit the mounting elements 100b,c.

In some examples, the two mounting elements 100b,c may be of different structure and/or the straight parallel portions 128b,c, 130b,c may both extend downward or upward, rather than in opposite directions.

In the example shown in Figure 9, two mounting members 100b,c are used. However, it will be appreciated that only a single mounting member may be used, or more than two 30 mounting members may be used.

In the example discussed above, the mounting member are "U" shaped members. However, in other examples, the mounting members may be L-shaped, square, or any other shape. The mounting members provide a structure between vertical studs to fix preformed structures 100 to.

It will be appreciated that where prefabricated structures 100 are secured to the frame 3, the various standards may require fixing screws to be a minimum distance from an end of the track members and from any corners, and from each other, and may require a minimum length of overlap. Thus the length of any side sections 102, 104 and the length of any overlap between a pre-formed structure 100 and the frame should be sufficient to match these requirements In some examples, the horizontal width of the structure may be wider than the defined spacing between the vertical studs 9a. In this case, the vertical studs 9a may be cut where the pre-fonned structures define an opening. and the cut ends of the studs 9a may be received in the track sections 112 forming the top and/or bottom 106, 108 of the frame.

Claims

Claims 1. A prefabricated structure for forming an opening in a dry wall, the prefabricated structure including: a track member arranged to form a frame defining an aperture, the track member having a plurality of sections defining sides of the frame, and a top surface facing into the aperture: a plurality of gypsum-based board sections secured on the top surface of the track member, the gypsum-based board sections surrounding at least part of the aperture, and a fire-resistant or fireproof material secured to the gypsum-based board sections, the fire-resistant or fire-proof material filling the aperture defined by the track member.
IS 2. The prefabricated structure of claim I, wherein each section of the track member is provided with at least one gypsum-based board section extending along at least part of the length of the section of the track.
3. The prefabricated structure of claim 2, wherein gypsum-based board is provided along the full length of each track section.
The prefabricated structure of any preceding claim, wherein the fire-resistant or fireproof material is secured along at least a portion of each side of the aperture.
The prefabricated structure of claim 4, wherein the fire-resistant or fireproof material is secured along the full length of each side of the aperture.
6. The prefabricated structure of any preceding claim, wherein the fire-resistant or fireproof material is secured to the gypsum-based board sections by a fire-resistant or fireproof adhesive The prefabricated structure of claim 6, wherein the fire-resistant or fireproof adhesive is an intumescent material, preferably intumescent mastic.The prefabricated structure of claim 6 or claim 7, wherein the fire-resistant or fireproof adhesive is cured to provide a rigid connection of the fire-resistant or fireproof material to the gypsum-based board sections.9. The prefabricated structure of any preceding claim, wherein a single piece of fire-resistant or fireproof material is used to fill the aperture.10. The prefabricated structure of any preceding claim herein the track member is a single piece, with corners formed therein.11. The prefabricated structure of any preceding claim, wherein the frame fully surrounds the aperture.12. The prefabricated structure of any preceding claim, wherein the corners are I5 ninety degrees, or substantially ninety degrees.13. The prefabricated structure of any preceding claim 'herein the fire-resistant or fireproof material comprises an ablative fire batt.14. The prefabricated structure of any preceding claim, comprising a packaging material to secure and protect the structure during transport.15. The prefabricated structure of any preceding claim, wherein the prefabricated structure is formed off-site. 25 16. A dry-wall or partition wall comprising: a frame, defining opposing surfaces; gypsum-based board panels secured on one or both of the opposing surfaces; and a prefabricated structure as claimed in any preceding claim, forming an aperture extending between the opposing surfaces.17. The dry-wall or partition wall as claimed in claim 16, comprising: one or more service conduits extending through the aperture, the service conduits extending through openings in the fire-resistant or fireproof material 18. 19. 20. 21. 22. 23.The dry-wall or partition wall as claimed in claim 17, wherein the openings in the fire-resistant or fireproof material are formed on site.The dry-wall or partition wall as claimed in claim 17 or claim 18, wherein the fire-resistant or fireproof material is sealed around the one or more service conduits The dry-wall or partition wall as claimed in claim 19, wherein the fire-resistant or fireproof material is scaled around the one or more service conduits by a fire-resistant or fireproof adhesive.The dry-wall or partition wall as claimed in claim 20, wherein the fire-resistant or fireproof adhesive is an intumescent material, preferably intumescent mastic.The dry-wall or partition wall as claimed in any of claims 17 to 21 wherein the one or more service conduits comprise at least one of: power cables; data communications cables; cold or hot air conduits; gas pipes; heating or hot water pipes and clean or waste water pipes A method of making the dry-wall or partition wall as claimed in any of claims 17 to 22, comprising: forming a dry wall frame; fitting a prefabricated structure as claimed in any of claims 1 to 15 into the frame to define an aperture; securing gypsum-based board panels to one or both opposing faces of the frame, leaving the aperture open; cutting one or more slits into the fire-resistant or fireproof material, after it has been fitted into the frame; and providing one or more service conduits through the slits.24. The method of claim 23, comprising: sealing the fire-resistant or fireproof material around to the one or more service conduits.25. The method of claim 23 or claim 24, wherein the prefabricated structure is made off-site and transported to where needed once completed.