WO2020252538A1

WO2020252538A1 - Fire resistant block

Info

Publication number: WO2020252538A1
Application number: PCT/AU2020/050627
Authority: WO
Inventors: Neil Pinchers
Original assignee: Our Plan B Pty Ltd
Priority date: 2019-06-20
Filing date: 2020-06-19
Publication date: 2020-12-24
Also published as: AU2019100675A4

Abstract

Disclosed is a block for creating through holes in buildings, such as in walls and floors. The block has an upper surface, a lower surface, and a plurality of through holes extending between the upper and lower surfaces. The block is constructed from a non-combustible material and is tapered so that the upper surface is a different size to the lower surface. The block can be made from aerated concrete and may not have any steel reinforcing or any other metal components. Also disclosed is a system for housing cables that uses the block and a plug that is sized to fit into and substantially close one of the through holes. Finally, a method of creating a floor and wall with through holes by using the blocks is also disclosed.

Description

FIRE RESISTANT BLOCK

Background of the Invention

[0001] The present invention generally relates to devices and methods used for routing cables in a building, and particularly the implications and considerations of the fire safety of these systems.

Description of the Prior Art

[0002] In buildings, it is generally necessary for cables to pass through floors, particularly between levels of a multiple storey building. Currently, concrete slabs are commonly poured without the provision for holes for cables. Holes must then be core drilled into the concrete. Alternatively, large rectangular holes may be left open for the cables.

[0003] A similar situation also occurs with walls in the buildings. If the walls are designed to be fire rated then, currently, cables are passed through these penetrations (core holes or large rectangular holes).

[0004] Australian Standards require that the penetrations are also fire rated and that the cables are separated and spaced at correct intervals. Therefore, these factors need to be taken into consideration when drilling the holes in the concrete or when leaving the large rectangular holes and then fireproofing these holes at a later stage.

[0005] These current systems are not ideal, as they can be labour intensive and expensive, due to the difficulty in core drilling concrete slabs. They can also result in unsafe fire spaces if large penetrations are not then adequately closed in an appropriate way.

[0006] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that the prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates. Summary of the Present Invention

[0007] According to an aspect of the invention, there is provided a block comprising an upper surface, a lower surface, and a plurality of through holes extending between the upper and lower surfaces, wherein the block is constructed from a non-combustible material and the block is tapered so that the upper surface is a different size to the lower surface.

[0008] In an embodiment, the upper surface is larger than the lower surface.

[0009] In an embodiment, the block has at least three through holes.

[0010] In an embodiment, the block has at least six through holes.

[0011] In an embodiment, a distance separating adjacent through holes is equal to or greater than 50mm.

[0012] In an embodiment, the holes have a diameter of between 97mm and 202mm.

[0013] In one example form, the block is made from aerated concrete. In another example form, the block has no steel reinforcing. In yet another example form, the block does not include any metal components.

[0014] According to another aspect, there is provided a system for housing cables, comprising a block substantially as herein defined and a plug that is sized to fit into and substantially close one of the through holes.

[0015] In an embodiment, the plug is adapted for a cable to be passed through.

[0016] In an embodiment, the plug is made from a non-combustible material.

[0017] According to yet another aspect, there is provided a method of creating a floor with through holes, the method comprising the steps of: providing a prefabricated block that has a plurality of through holes; placing the block so that the through holes are in a desired position; pouring concrete around the block; and allowing the block to become fixed in place within the concrete. [0018] In an embodiment, the method further includes the step of passing a cable through one of the through holes and sealing around the cable using a plug.

[0019] In an embodiment, the block is substantially as defined herein.

[0020] It will be appreciated that the broad forms of the invention and their respective features can be used in conjunction and/or independently, and reference to separate broad forms is not intended to be limiting. Furthermore, it will be appreciated that features of the method can be performed using the system or apparatus and that features of the system or apparatus can be implemented using the method.

Brief Description of the Drawings

[0021] Various examples and embodiments of the present invention will now be described with reference to the accompanying drawings, in which: -

[0022] Figure l is a top view of an embodiment of a block according to the present invention; [0023] Figure 2 is an end view of the block from Figure 1;

[0024] Figure 3 is a cross sectional end view of the block from Figure 1;

[0025] Figure 4 is a side view of the block from Figure 1;

[0026] Figure 5 is a cross sectional side view of the block from Figure 1;

[0027] Figure 6 is an isometric view of the block from Figure 1;

[0028] Figure 7 is a top view of another embodiment of a block according to the present invention;

[0029] Figure 8 is an end view of the block from Figure 7;

[0030] Figure 9 is a cross sectional end view of the block from Figure 7;

[0031] Figure 10 is a side view of the block from Figure 7;

[0032] Figure 11 is a cross sectional side view of the block from Figure 7; [0033] Figure 12 is an isometric view of the block from Figure 7;

[0034] Figure 13 is a front view of a typical wall with an embodiment of a block installed; [0035] Figure 14 is a cross sectional side view of the wall from Figure 13;

[0036] Figure 15 is a front view of a typical wall with an embodiment of a block installed; and [0037] Figure 16 is a cross sectional side view of the wall from Figure 15.

Detailed Description of the Preferred Embodiments

[0038] The following modes, given by way of example only, are described in order to provide a more precise understanding of the subject matter of a preferred embodiment or embodiments.

[0039] In the Figures, incorporated to illustrate features of an example embodiment, like reference numerals are used to identify like parts throughout the Figures.

[0040] An example embodiment of a block according to the invention will now be described. The block has an upper surface, a lower surface, and a plurality of through holes extending between the upper and lower surfaces. The block is constructed from a non-combustible material and is tapered so that the upper surface is a different size to the lower surface.

[0041] A non-combustible material is intended to refer to a substance that will not ignite, bum, support combustion, or release flammable vapours when subject to fire or heat under certain conditions. These conditions may be determined in accordance with one of a range of standard test methods that are used in various jurisdictions.

[0042] Throughout this specification, as in the general known state of the art, various terms may be used to describe the combustibility of materials. Such terms may include non combustible, non-flammable, ignition resistant, fire-resistant, and fireproof, for example. These various terms may relate to the same or different levels of combustibility in comparison to the term“non-combustible”, and are not necessarily used interchangeably.

[0043] The block described is advantageous because it can provide a prefabricated solution to creating cable passages in floors and other concrete slabs. That is, the block can be provided and concrete poured around the block, so that the finished slab has holes already in place. As the block is made from non-combustible material, the final concrete slab also remains of a non combustible nature.

[0044] Using the block in this way makes it a very simple process to provide the holes at the correct location, size and spacing. The block may have any number of holes and can be manufactured according to any particular size and spacing regulations, thereby ensuring that any applicable local standards can be adhered to. For example, some standards require that cables be separated and spaced at particular intervals, so the block allows this to be easily achieved using the various holes provided.

[0045] A number of other features will now be described, which may be optional or advantageous aspects of some example embodiments.

[0046] In some embodiments, the block is installed so that the upper surface is larger than the lower surface. If this is in a floor, for example, it ensures that loads placed on the block cannot cause the block to be pushed out of the floor into a space below. Even if the block comes loose over time for some reason, it will still be supported by the surrounding floor.

[0047] In various alternative embodiments, the block may have any suitable number of holes. For example, the block may have three through holes, six through holes, or any other number as is appropriate for a particular application.

[0048] In some alternative embodiments, the distance between the holes may be varied. As discussed above, this distance may be important for ensuring minimum separation between cables when the block is in use. In one example, the distance separating adjacent through holes is 50mm. That is, there is at least 50mm of material at the closest point between adjacent holes. In another example, this distance may be higher, such as 60mm, 70mm, or more. Of course, if particular standards or regulations allow, the distance may also be less.

[0049] In some alternative embodiments, the size of the holes may also be varied. The size of the holes may be important depending on exactly what cables or other services are to be passed through the hole, and the size may also be important to ensure that appropriately sized plugs are readily available. Typically, the holes have a diameter of between 97mm and 202mm. For example, a 138mm hole or a 168mm hole may be suitable to allow a snug fit of an off the shelf plug. In other examples, however, sizes above or below this range may also be provided.

[0050] In one example embodiment, the block is made from aerated concrete. It will be understood that the term“aerated concrete” may refer to a range of materials that are produced and/or sold under this and other generic and/or trade names, such as but not limited to autoclaved aerated concrete (AAC), Aircrete, Hebei™, and many other names. This term is also intended to encompass other similar materials that may be made from a substance that may not technically fall under the definition of“concrete”.

[0051] Using aerated concrete to make the block is advantageous due to the properties of this material. In particular, aerated concrete is long lasting, sound resistant, highly thermally insulating and highly fire resistant. Additionally, it has a low environmental impact due to the reduced raw materials, reduced solid waste at the end of its life, and reduced cost and energy required in transportation and labour due to the lighter weight when compared to regular solid concrete. Blocks of aerated concrete are also able to be produced with very high dimensional accuracy, or alternatively can be easily cut and shaped if necessary.

[0052] In an example embodiment, the block has no steel reinforcing. This may assist with the fire resistance of the block and may also be beneficial in reducing any risk of interference with cabling that passes through the holes. In one particularly advantageous embodiment, the block does not comprise any metal components at all.

[0053] In some embodiments, the block may be used together with a plug or“muffin” to form a system for housing cables. In this system, the plug is sized to fit into and substantially close one of the through holes. Preferably, the plug is also fire resistant or even non-combustible, in order to form a strong fire barrier together with the block. The plug may also be adapted for a cable to be passed through, such as by drilling or cutting a small hole through the plug.

[0054] An example embodiment of a method of creating a floor with through holes will now be described. The method involves providing a prefabricated block, such as one similar to that described previously, that has a plurality of through holes. The block is placed at a location where a concrete slab is to be poured, so that the through holes are in a desired position. The concrete is then poured around the block, so that when the concrete sets the block is fixed in place within the concrete.

[0055] When the block is installed in this way, the concrete surrounds the sides of the block, leaving the upper and lower surfaces exposed so that the holes effectively pass through the concrete slab. One or more cables can then be passed through the holes. The space around the cable can sealed using a plug, completing the fireproof barrier.

[0056] An example embodiment of a block will now be described with reference to Figures 1 to 6. Referring in particular to Figure 6, a block 10 according to a first embodiment of the invention is shown. The block 10 includes an upper surface 12 and a lower surface 13. Three through holes 15 extend between the upper surface 12 and lower surface 13.

[0057] The block is preferably constructed from a non-combustible material. In a preferred embodiment, this material is aerated concrete. It will be appreciated, however, that alternative forms of the invention may use any other suitable material, such as but not limited to solid or reinforced concrete, composites, foams, and synthetic materials. The preferred embodiment has no steel reinforcing or any other metal components, however it will be appreciated that these may be included in some alternative embodiments.

[0058] The block 10 is tapered so that the upper surface 12 is larger than the lower surface 13. For example, in the embodiment shown, the lower surface may have dimensions of 460mm x 200mm, while the upper surface may have dimensions of 500mm x 240mm.

[0059] The block 10 has the holes 15 located at appropriate distances from one another to ensure it conforms to appropriate standards. For example, in one embodiment the holes are 85mm in diameter and are separated from one another by at least 50mm.

[0060] When constructing a concrete slab, the block 10 can be placed in position so that it will form part of the slab once complete. That is, the concrete will be poured around the block 10 so that it abuts side surfaces 18 and end surfaces 19, but leaves the upper surface 12 and lower surface 13 exposed. In this way, the holes 15 will provide access through the completed concrete slab. [0061] When the block 10 is used in a floor, for example, the side surfaces 18 and end surfaces 19 tapering in towards the bottom of the block 10 ensures that loads placed on the block 10 cannot cause the block 10 to be pushed out of the floor into a space below. Even if the block comes loose over time for some reason, it will still be supported by the surrounding floor. It will be appreciated that in alternative embodiments, however, that only some of the surfaces 18, 19 might taper or they might be tapered in a different way or a different amount.

[0062] Cables can be passed through the holes 15 once the slab is completed, the plugs being used to fill the remaining space around the cables. If any holes 15 are not used for routing cables for some reason, then these can be completely closed by a plug.

[0063] Another example embodiment of a block will now be described with reference to Figures 7 to 12. Referring in particular to Figure 12, the block 10 is similar to that described previously, having an upper surface 12 and a lower surface 13. This block 10, however, is much longer and has six through holes 15, rather than only three from the previous example.

[0064] Referring now to Figures 13 to 16, it can be seen that the block 10 is also suitable for use in a structural masonry wall 20. The wall is typically made using bricks 21 stacked on a floor 22. Mortar 23 is used to accommodate the tapered shape of the block 10, with the holes 15 extending through the wall 20 and providing a passage from one side of the wall 20 to the other.

[0065] The block 10 in the embodiment shown is different in size to the bricks 21, requiring bricks to be cut to fill the space around the block 10. In fact, Figures 13 and 14 show a block 10 of a first size, while Figures 15 and 16 show a block 10 of a second size. In each case, the surrounding bricks 21 are sized accordingly.

[0066] In the foregoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as“front” and“rear”,“inner” and“outer”,“above” and“below” and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

[0067] Throughout this specification and claims which follow, unless the context requires otherwise, the word“comprise”, and variations such as“comprises” or“comprising”, will be understood to imply the inclusion of a stated integer or group of integers or steps but not the exclusion of any other integer or group of integers. As used herein and unless otherwise stated, the term“approximately” means ±20%.

[0068] Persons skilled in the art will appreciate that numerous variations and modifications will become apparent. All such variations and modifications which become apparent to persons skilled in the art, should be considered to fall within the spirit and scope that the invention broadly appearing before described.

Claims

THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1) A block comprising an upper surface, a lower surface, and a plurality of through holes extending between the upper and lower surfaces, wherein the block is constructed from a non-combustible material and the block is tapered so that the upper surface is a different size to the lower surface.

2) The block according to claim 1, wherein the upper surface is larger than the lower surface.

3) The block according to any one of the preceding claims, wherein the block has at least three through holes.

4) The block according to any one of the preceding claims, wherein the block has at least six through holes.

5) The block according to any one of the preceding claims, wherein a distance separating adjacent through holes is equal to or greater than 50mm.

6) The block according to any one of the preceding claim, wherein the holes have a diameter of between 97mm and 202mm.

7) The block according to any one of the preceding claims, wherein the block is made from aerated concrete.

8) The block according to any one of the preceding claims, wherein the block has no steel reinforcing.

9) The block according to any one of the preceding claims, wherein the block does not comprise any metal components.

10)A system for housing cables, comprising a block according to any one of the preceding claims and a plug that is sized to fit into and substantially close one of the through holes.

11) The system according to claim 10, wherein the plug is adapted for a cable to be passed through. 12) The system according to any one of claims 10 or 11, wherein the plug is made from a non combustible material.

13)A method of creating a floor with through holes, the method comprising the steps of: providing a prefabricated block that has a plurality of through holes;

placing the block so that the through holes are in a desired position;

pouring concrete around the block; and

allowing the block to become fixed in place within the concrete.

14) The method according to claim 13, further comprising the step of passing a cable through one of the through holes and sealing around the cable using a plug.

15) The method according to any one of claims 13 or 14, wherein the block is defined according to any one of claims 1 to 9.