Fire-blast resistant door assembly and methods for installing the same

Abstract

A fire-blast resistant door assembly comprises a door frame and a door leaf. The front part of the door leaf comprises a front panel and a front stiffener that delimits a cavity from the inside of the front panel, wherein a sheet refractory material is installed in said cavity. The rear part of the door leaf comprises a rear panel and a rear stiffener that delimits a cavity from the inside of the rear panel. A support structure made of metal is installed in said cavity. The front and the rear parts of the door leaf are mutually connected through the layer of the refractory material, forming the thermal break therebetween, so that said support structure abuts against said sheet refractory material. The door frame, in its turn, comprises a front part and a rear part mutually connected through a layer of the refractory material forming a thermal break.

Claims

1. A fire-blast resistant door assembly comprising: a door frame made of metal and designed to be installed in a door opening, a door leaf pivotally hinged in the door frame and having a front part and a rear part, characterized in that the front part of the door leaf comprises a metallic front panel and a front stiffener extending along the perimeter of the internal side of the front panel so as to form a closed loop that delimits a first mounting cavity, and a first refractory material disposed in the first mounting cavity, the rear part of the door leaf comprises a metallic rear panel and rear stiffener extending along the perimeter of the internal side of the rear panel so as to form a closed loop that delimits a second mounting cavity, and a metallic support structure mounted in the second mounting cavity, wherein the front and the rear parts of the door leaf are mutually connected by fastening the front and the rear stiffeners to each other such that said support structure abuts against said first refractory material, wherein a layer of a second refractory material is interposed between the front and the rear stiffeners, wherein said layer forms a thermal break between the front and the rear parts of the door leaf, and the door frame comprises a front part and a rear part, mutually connected through a layer of a third refractory material, forming the thermal break therebetween.

2. The fire-blast resistant door assembly according to claim 1, characterized in that said first refractory material is mineral basalt wool.

3. The fire-blast resistant door assembly according to claim 1, characterized in that at least one of the second refractory material and the third refractory material forming the thermal break in the door leaf and the door frame is mullite silica cardboard.

4. The fire-blast resistant door assembly according to claim 1, characterized in that the front and the rear stiffeners of the door leaf are made of hollow pipe sections with rectangular cross-section.

5. The fire-blast resistant door assembly according to claim 1, characterized in that said support structure is a grid made of horizontal and vertical elements.

6. The fire-blast resistant door assembly according to claim 5, characterized in that said horizontal and vertical grid elements of the support structure are hollow pipe sections with rectangular cross-section.

7. The fire-blast resistant door assembly according to claim 5, characterized in that said grid of the support structure has a constant vertical and/or horizontal spacing.

8. The fire-blast resistant door assembly according to claim 1, characterized in that the front and the rear stiffeners of the door leaf are fastened together by means of bolted connections.

9. The fire-blast resistant door assembly according to claim 8, characterized in that a number of bolted connections and/or the material of the bolts in said connections are defined so that the thermal effect on the external part of the door assembly, essentially is fully dissipated in the interior of the door assembly.

10. The fire-blast resistant door assembly according to claim 1, characterized in that the front panel of the door leaf is bigger, along its length and width, than the opening of the door frame and comprises a sealing element mounted along the perimeter of the internal edge of the front panel of the door leaf and providing a sealing between the door leaf and door frame in the door's closed position.

11. A method for installing the fire-blast resistant door assembly according to any of claims 1-10 in the door opening with a metallic casing, said method comprising the following steps: welding a first clamping frame made of a metallic angular profile to the casing of the door opening so that one of the profile flanges bears against the casing, while the other profile flange forms a support lug, protruding inside the door opening, installing the door frame with the door leaf in the door opening so that the door frame abuts against said support lug, and welding a second clamping frame made of a metallic angular profile to the casing of the door opening so that one of the profile flanges bears against the casing, while the other profile flange forms a closure lug protruding inside the door opening, the door frame being fixed between said support and closure lugs, wherein during the installation of the door frame, a layer of the third refractory material is interposed between the door frame and said support and closure lugs, wherein said layer forms a thermal break therebetween.

12. The method for installing the fire-blast resistant door assembly according to any of claims 1-10 in the door opening having smaller size than the door frame of said assembly, said method comprising the following steps: welding a support frame made of an angular profile to the exterior perimeter of the door frame so that one of the profile flanges extends at a distance from the door frame surface on the inside of the door and is directed inwards the door opening, so as to form a groove between said flange and the door frame, putting the door frame against the wall essentially so that said profile flange of the door frame, protruding from an internal side of the door frame with formation of the groove, abuts against a wall around the door opening, mounting channel-shaped metallic fastening elements on end faces of the door opening, at least from the upper and lateral sides of the opening, so that the wall of each of said channels essentially bears against a respective end face of the opening, wherein one of the flanges encloses the wall of the opening from the inside, while the other flange is fitted into said groove formed by the profile flange of the support frame and the internal side of the door frame, wherein a layer of the third refractory material forming a thermal break is interposed between the wall of the opening and the surfaces of said channel flanges and of the support frame, adjoining each other in the region of said groove, and welding said channel-shaped fastening elements together.

13. The method for installing the fire-blast resistant door assembly according to claim 12, characterized in that the channel-shaped metallic fastening elements consist of two angular profiles and at least one strip designed for connecting said profiles and welded thereto.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The above-mentioned advantages of the present invention will be better understood from reading the following description of preferred embodiments thereof with reference to the appended drawings, in which:

(2) FIG. 1 shows a cutaway view of a fire-blast resistant door assembly installed in a door opening with a metallic casing according to an embodiment of the present invention;

(3) FIG. 2 shows an enlarged segment of the fire-blast resistant door assembly from FIG. 1;

(4) FIG. 3 shows a schematic cross-section view (top view) of the fire-blast resistant door assembly installed in the door frame having smaller dimensions than the door frame of said assembly according to the embodiment of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

(5) Hereafter, with reference to the accompanying drawings described is a fire-blast resistant door assembly, as well as methods for installing the same according to the preferred embodiments of the present invention.

(6) FIG. 1 schematically illustrates the section with the set of planes parallel to the plane A, of the fire-blast resistant assembly comprising a door frame (1) and a door leaf (2), which is installed in a door opening with a metallic casing (3). FIG. 2 shows the enlarged detail of the fire-blast resistant door assembly. The door leaf (2) is a structure consisting of a rear part and a front part. The rear part of the door leaf (2) comprises a metallic rear panel (20, see FIG. 3), wherein a rear stiffener (4) is welded along the perimeter of this panel, said stiffener being made of hollow pipe sections with rectangular cross-section and forming a closed loop that delimits a mounting cavity. In this cavity, hereinafter referred to as the second mounting cavity, a support structure (5) comprised of metal is installed; this support structure represents a grid consisting of horizontal and vertical elements. In turn, said grid elements preferably may be the hollow pipe sections with rectangular cross-section.

(7) Next, as shown in FIG. 2, the front part of the door leaf (2) comprises a metallic front panel (6), wherein a front stiffener (7) is welded along the perimeter of this panel, said stiffener preferably being made of hollow pipe sections with rectangular cross-section and forming a closed loop that delimits a mounting cavity. In this cavity, hereinafter referred to as the first mounting cavity, a mat of sheet refractory material (8), preferably, of a mineral basalt wool, is disposed.

(8) As noted above, in the preferred embodiment the stiffeners (4, 7) of the door assembly are made of hollow pipe sections with rectangular cross-section, thereby ensuring the lightweight of the assembly. However, the present invention is not limited in this respect, and said stiffeners may be, for example, made of pipe sections with nonrectangular section, or they may be solid.

(9) As can be seen in FIG. 2 or FIG. 3, the front and the rear parts of the door leaf (2) are mutually connected by fastening the front (7) and the rear (4) stiffeners to each other by means of a given number of bolted connections so that the support structure (5), with its surface facing outwards, bears against the sheet refractory material (8) and abuts against it. Meanwhile, between said front (7) and the rear (4) stiffeners there is a layer of refractory material (9), preferably of mullite silica cardboard, that creates a thermal break between the front and the rear parts of the door leaf.

(10) The door leaf (2) is pivotally hinged in the door frame, the hinges being preferably installed outside of the door via a welding connection with the door leaf (2) and the door frame (1), respectively. The front panel (6) of the door leaf may be bigger, along its length and width, than the opening of the door frame and may be equipped with a sealing element installed along the perimeter of its internal edge. Therefore, the front panel (6) is partially superimposed on the door frame (1) in the door's closed position so as to obtain a sealing between the door leaf and the door frame. In other embodiment, as shown, for example, in FIG. 2, the dimensions of the front panel (6) of the door leaf may be increased due to the metallic strips welded along its perimeter and equipped with sealing elements. In this embodiment, said strips are superimposed on the edges of the door frame (1) in the door's closed position in order to obtain the sealing. Said sealing element or elements may be comprised of rubber or other suitable elastic material capable of providing the sealing.

(11) This door frame (1) also represents a structure having a front part (11) and a rear part (12), preferably made of hollow pipe sections with rectangular cross-section. Meanwhile, in different embodiments, each of the front (11) and the rear (12) parts of the door frame (1) may include more than one pipe section with different cross-sections, welded together, in order to provide the desired assembly rigidity. For example, FIG. 2 shows an embodiment where the front part of the door frame consists of two (11 and 11) welded together pipe sections with rectangular cross-section. In this case, between the front (11, 11) part and the rear part (12) of the door frame (1) there is also provided a layer of the refractory material (13), preferably of mullite silica cardboard, which creates a thermal break therebetween. Thus, the door assembly according to the present invention differs by providing the thermal break between all the elements of its front part, placed outside, and all the elements of its rear part, arranged from the room side.

(12) The door assembly according to the present invention is preferably installed in the following manner. A first clamping frame (14) made of a metallic angular profile is welded to the metallic casing (3) of the door opening, so that one of the profile flanges bears against the casing (3), and the other profile flange protrudes inwards the door opening and forms a support lug. The assembled door frame (1) with the door leaf (2) is installed such that it abuts against this lug, and is fixed by welding a second clamping frame (15) made of a metallic angular profile to the casing (3), on the other side of the door frame (1). The second frame (15) is welded such that one of the profile flanges of the frame (15) bears against the casing (3), and the other flange protrudes inside the door opening, thereby creating a closure lug and ensuring fixation of the door frame (1) between said support and closure lugs, as shown in FIG. 2.

(13) Then, during the described installation procedure of the door frame (1), between the door frame (1) and said support and closure lugs of the clamping frames (14 and 15), a layer of the refractory material (16), preferably of mullite silica cardboard, is interposed, wherein said layer forms a thermal break therebetween. It should be noted that the present invention is not limited in terms of choosing the refractory materials (9, 13, 16, 19), and in order to create thermal breaks in the door leaf, door frame and the fastening elements of the door assembly one can use any suitable refractory material or materials.

(14) As can be seen in FIG. 2, in addition to the refractory material layer (16), between the support and the closure lugs of the clamping frames (14, 15) it is possible to place at least one additional fastening element, preferably made of hollow pipe sections with rectangular cross-section, similar to the stiffeners of the door assembly, in order to ensure the fastening security of the door frame (1) between said lugs.

(15) In another embodiment of the present invention, the described door assembly is installed in the door opening having smaller dimensions than the door frame (1), as illustrated in FIG. 3, where in a plan view shown is a cross-section of a part of the door assembly and one of the walls of the door opening. For such installation procedure, a support frame (17) made of an angular profile is welded to the outer perimeter of the door frame (1), such that one of the profile flanges extends at a distance from the door frame surface on the inside of the door and is directed inwards the door opening, thereby forming a groove between said flange and the door frame (1). Then, the door frame is pressed against the wall of the opening such that said protruding profile flange of the support frame (17) abuts against the wall around the door opening. After that, channel-shaped metallic fastening elements (18) are mounted on the end faces of the door opening, at least from the upper and lateral sides of the opening, so that at each of said channels (18) the wall essentially bears against the respective end face of the opening, wherein one of the flanges encloses the wall of the opening from the inside, and other flange is fitted into said groove formed by the profile flange of the support frame (17) and the internal side of the door frame, as shown in FIG. 3. Moreover, a layer of the refractory material (19), preferably of mullite silica cardboard, is interposed between the wall of the opening and the surfaces of said channel (18) flanges and of the support frame (17), adjoining each other in the region of said groove, wherein said layer creates a thermal break therebetween. Next, said channel-shaped fastening elements (18) are welded together.

(16) As mentioned above, the channel-shaped fastening elements (18) are installed on the end faces of the door opening, at least from the upper and lateral sides of the opening. This is caused by that the door opening can be delimited, from bellow, by the floor surface, where the installation of the fastening element is not required. However, the present invention is not limited in this regard, and the channel-shaped fastening elements (18) may be installed on the end faces of the wall from each side of the door opening. In the preferred embodiment, but not limited thereto, the channel-shaped metallic fastening elements (18) are made of two angular profiles and at least one metallic strip designed for connecting said profiles and welded thereto as shown in FIGS. 2 and 3. Due to the composed structure of these channels it is possible to decrease their weight and thus simplify the installation procedure of the door assembly.

(17) The substantial advantage of the described method for installing the door assembly is that the mounting contour for the door frame, defined by the support frame (17), has dimensions that exceed the dimensions of the door opening. The use of such support frame (17) essentially removes all requirements for equipping the door opening for installing the door so that the door assembly according to the present invention may be installed essentially in any door opening.

(18) Let's consider an explosion scenario outside the room where the described door assembly is installed. The air blast exposes from outside on the front panel (6) of the door leaf (2), respectively, and the load is carried by the front panel (6) and is transmitted, firstly, to the layer of the sheet refractory material (8). The refractory material (8) due to its porosity is pressed into the rigidly fastened grid support structure (5) and, therefore, some part of the air-blast is dissipated in the interior of the door. Concurrently, after the air blast exposure, the refractory material (8), due to flexibility, can restore its original position, thereby improving the door reliability as regards its tightness. Next, the rigid support structure (5) carries the major part of the excessive pressure and, thanks to the fact that it is designed as a grid, as described above, it ensures as high yield strength as possible. Meanwhile, the support structure (5) stabilizes the position of the porous internal part of the door leaf. Concurrently, the parts of the front panel (6) superimposed on the door frame in the door's closed position, as described above, transfer a part of the bending force form the air-blast exposure on the frame (1) of the door assembly, which is rigidly fixed in the opening by means of solid metallic clamping frames (14, 15) welded to the metallic casing (3) of the opening. That provides an additional relief of the structural elements of the door leaf, thereby reducing the risk of unrecoverable deformation of the whole assembly.

(19) A door sample realized in accordance with the preferred embodiment of the fire-blast resistant door assembly, as described above, and installed in a test opening with a metallic casing according to the described embodiment of the method for installing the fire-blast resistant assembly, passed the blast resistance test and withstood the load level Pf=1.5 kg/sm.sup.2 (150 kPa) without visual damages of the sample and impairment of functional properties, and without displacement when exploding the trinitrotoluene charge weighing 50 kg in a cube form on the ground surface from a distance of 12 m at the primary test, wherein at the secondary test the fire-blast resistant door withstood the load level of Pf=3.5 kg/sm.sup.2 (350 kPa) from a distance of 9 m without changing the functional properties of the sample.

(20) It should be noted that exemplary preferred embodiments of the present invention which have just been described, do not limit the scope of the present invention. Upon reading the present description the one skilled in the art may propose numerous modifications and supplements to the described embodiments, all of which would fall under the scope of patent protection defined by the appended claims of the invention.