FIRE RESISTANT BUILDING PANELS

Abstract

A fire resistant building panel comprising: a first major face; a second major face; and a fire resistant body comprising a binder, at least one additive, and at least one fiber material, wherein the binder comprises a calcareous material and a siliceous material; and wherein the fire resistant body is disposed between the first major face and the second major face. The fire resistant body provides a fire rating of at least 45 minutes as tested in accordance with Australian Standard AS1530.4-2005.

Claims

1. A fire resistant building panel comprising: a first major face; a second major face; a fire resistant body, said fire resistant body comprising: a binder comprising a calcareous material and a siliceous material, wherein the calcareous material comprises Portland cement, the Portland cement comprising 25-35 parts by weight of the total weight of the fire resistant body, and wherein the siliceous material comprises ground silica, the ground silica comprising 40-60 parts by weight of the total weight of the fire resistant body; at least one additive comprising a density modifying additive in the form of an expanded mineral, the expanded mineral comprising 15-20 parts by weight and an air entrainment agent in the form of aluminum powder, the air entrainment agent comprising 0.05-1 parts by weight of the total weight of fire resistant body; and at least one fiber material comprising cellulose fibers, the cellulose fibers comprising approximately 0.05 parts by weight of the total weight of the fire resistant body; a finishing layer secured to either the first major face of the fire resistant building panel or the second major face of the fire resistant building panel; and wherein the fire resistant body is disposed between the first major face and the second major face.

2. The fire resistant building panel according to claim 1, wherein the fire resistant body has a thickness of greater than or equal to 15 mm and less than or equal to 60 mm.

3. The fire resistant building panel according to claim 1, wherein the first major face of the fire resistant building panel is configured for engaging with a building substrate.

4. The fire resistant building panel according to claim 1, wherein either one or other, or both of the first major face and second major face of the fire resistant building panel are integrally formed with the fire resistant body of the fire resistant building panel.

5. A fire resistant building panel comprising: a first major face configured for engaging with a building substrate; a second major face configured to form a cladding face; a finishing layer secured to at least one of the first major face of the fire resistant building panel and the second major face of the fire resistant building panel; and a fire resistant body comprising a binder, at least one additive, and at least one fiber material, wherein the binder comprises a calcareous material and a siliceous material; wherein the fire resistant body is disposed between the first major face and the second major face.

6. The fire resistant building panel according to claim 5, wherein either one or other, or both of the first major face and second major face of the fire resistant building panel are integrally formed with the fire resistant body of the fire resistant building panel.

7. The fire resistant building panel according to claim 5, wherein the fire resistant body has a thickness of greater than or equal to 15 mm and less than or equal to 60 mm.

8. The fire resistant building panel according to claim 5, wherein the finishing layer comprises a fiber cement layer.

9. The fire resistant building panel according to claim 5, wherein the finishing layer comprises a thickness greater than or equal to 3 mm and less than or equal to 8 mm.

10. The fire resistant building panel according to claim 5, wherein the finishing layer comprises one or more layers, wherein, when the one or more layers are applied to the fire resistant body, the combined thickness of the fire resistant body and the one or more finishing layers ranges between 18 mm and 76 mm.

11. The fire resistant building panel according to claim 5, wherein the calcareous material comprises hydrated lime between approximately 35 and 40 parts by weight of the total weight of the fire resistant body.

12. The fire resistant building panel according to claim 5, wherein the siliceous material comprises between approximately 5 and 60 parts by weight of the total weight of the fire resistant body.

13. The fire resistant building panel according to claim 5, wherein the at least one additive is a density modifying additive, the density modifying additive comprising at least one of expanded minerals, hollow microspheres, and air.

14. The fire resistant building panel according to claim 5, wherein the at least one fiber material comprises at least one of natural organic fibers, synthetic organic fibers, and synthetic inorganic fibers.

15. The fire resistant building panel according to claim 5, wherein the calcareous material comprises Portland cement, Portland cement comprising 10-20 parts by weight of the total weight of the fire resistant body; wherein the siliceous material comprises micro silica, the micro silica comprising 5-15 parts by weight of the total weight of the fire resistant body; wherein the at least one additive comprises a density modifying additive and a filler, wherein the density modifying additive is in the form of microspheres having a density of less than 1 gm/cc and the filler is in the form of anhydrous calcium magnesium carbonate mineral, wherein the ratio of the density modifying additive and the filler is such that the density of the fire resistant body is between approximately 0.40-0.50 gm/cc and wherein the at least one additive comprises 20-70 parts by weight of the total weight of the fire resistant body; and wherein the at least one fiber material comprises a mixture of cellulose fibers and basalt fibers, wherein the cellulose fibers and basalt fibers are provided in a ratio of approximately 2:1 and comprise between approximately 3 and 10 parts by weight of the total weight of the fire resistant body.

16. The fire resistant building panel according to claim 5, wherein the calcareous material comprises Portland cement, the Portland cement comprising 25-35 parts by weight of the total weight of the fire resistant body; wherein the siliceous material comprises ground silica, the ground silica comprising 40-60 parts by weight of the total weight of the fire resistant body; wherein the at least one additive comprises a density modifying additive in the form of an expanded mineral, the expanded mineral comprising 15-20 parts by weight of the total weight of the fire resistant body and an air entrainment agent in the form of aluminum powder, wherein the air entrainment agent comprises 0.05-1 parts by weight of the total weight of the fire resistant body; and wherein the at least one fiber material comprises cellulose fibers, wherein the cellulose fibers comprise approximately 0.05 parts by weight of the total weight of the fire resistant body.

17. A method of making a fire resistant building panel comprising the steps of: (a) providing a finishing layer of suitable dimensions; (b) placing a frame on the finishing layer to define boundaries of a fire resistant body; (c) mixing a binder, wherein the binder comprises a calcareous material and a siliceous material, at least one additive, and at least one fiber material together with water to form a slurry; (d) introducing the slurry onto the finishing layer in the frame until the slurry has reached a required depth; (e) allowing the slurry to sit for an initial period of time to allow the slurry to form a partially cured fire resistant body; (f) removing the frame; and (g) allowing the partially cured slurry to fully cure.

18. The method of making a fire resistant building panel according to claim 17, wherein the method further comprises applying a second finishing layer to the partially cured fire resistant body after the removing of the frame and before allowing the partially cured slurry to fully cure.

19. The method of making a fire resistant building panel according to claim 17, wherein the finishing layer is an uncured (green sheet) fiber cement layer.

20. The method of making a fire resistant building panel according to claim 19, wherein the slurry and uncured fiber cement finishing layer or layers are co-cured to form an integrally formed fire resistant building panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0045] Certain embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings. From figure to figure, the same or similar reference numerals are used to designate similar components of an illustrated embodiment.

[0046] FIG. 1 shows a cross-sectional side view of a fire resistant building panel according to one embodiment of the present disclosure, including an expanded schematic view of the composition of the fire resistant body (not to scale).

[0047] FIG. 2 shows a cross-sectional side view of a fire resistant building panel according to one embodiment of the present disclosure.

[0048] FIG. 3 shows a cross-sectional side view of a fire resistant building panel according to one embodiment of the present disclosure.

[0049] FIG. 4 shows a cross-sectional side view of a fire resistance test panel construction suitable for use in testing a fire resistant building panel produced according to one embodiment of the present disclosure;

[0050] FIG. 5 is a graph of fire resistance test results of a fire resistant building panel produced according to one embodiment of the present disclosure.

[0051] FIG. 6 is a graph of fire resistance test results of a fire resistant building panel produced according to one embodiment of the present disclosure.

DETAILED DESCRIPTION

[0052] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative embodiments described in the detailed description and drawings are not meant to be limiting. Other embodiments may be used, and other changes may be made, without departing from the spirit or scope of the subject matter presented here. It will be readily understood that the embodiments of the present disclosure, as generally described herein, and illustrated in the figures, can be arranged, substituted, combined, and designed in a wide variety of different configurations, all of which are explicitly contemplated and made part of this disclosure. The drawing figures are not necessarily to scale and certain features may be shown exaggerated in scale or in somewhat generalized or schematic form in the interest of clarity and conciseness.

[0053] Although the present disclosure is described with reference to specific examples, it will be appreciated by those skilled in the art that the present disclosure may be embodied in many other forms. The embodiments discussed herein are merely illustrative and do not limit the scope of the present disclosure.

[0054] Referring now to the drawings, FIG. 1 shows an example embodiment of a fire resistant building panel 100 comprising a fire resistant body 110 having a first major face 150 for engaging with building substrate 160, and a second major face 170 for providing an exposed cladding face remote from the building substrate 160. In the example embodiment shown, fire resistant building panel 100 is shown face fixed to one surface 165 of building substrate 160 using suitable mechanical fixings, for example, nails 250. It is understood that in this embodiment and in other example embodiments that other suitable mechanical and/or chemical fixings could also be used to attach fire resistant building panel 100 to building substrate 160.

[0055] As will be discussed in greater detail below, FIG. 1 shows an enlarged schematic of the composition of the example embodiment fire resistant body 110. The components shown in FIG. 1 are not drawn to scale and should be taken as a general representation of the arrangement of materials, according to the example embodiment of the present disclosure, and not an accurate or exact drawing of a material. Fire resistant building panel 100 can comprise a binder 120 comprising a calcareous material and a siliceous material, at least one additive 130, and/or at least one fiber 140. One advantage of certain embodiments of the fire resistant building panel 100, is that the composition of the fire resistant building panel 100 provides fire resistance together with the physical and mechanical properties normally associated with a building cladding material.

[0056] In an alternative exemplary embodiment of fire resistant building panel 100, as best shown in FIG. 2, fire resistant body 110 further comprises finishing layer 190 secured to surface 210 of fire resistant body 110 to form second major face 170. In the embodiment shown, surface 210 of fire resistant body 110 is remote or not adjacent or proximate to first major face 150. First major surface 200 of finishing layer 190 can be configured for providing a cladding face. In the exemplary embodiment shown, finishing layer 190 can have a thickness of between approximately 3 mm and 8 mm. It is also possible for finishing layer 190 to have a thickness of between approximately 4 mm and 6 mm. It is advantageous for finishing layer 190 to be formed from a material that is physically and chemically compatible with fire rated body 110. Accordingly, in one embodiment, finishing layer 190 can be formed from fiber cement. In alternative embodiments, finishing layer 190 can be formed from any suitable exterior durable cladding material.

[0057] In a further alternative exemplary embodiment of fire resistant building panel 100, as best shown in FIG. 3, fire resistant body 110 can comprise separate finishing layers 190 and 220 secured to opposing faces of fire resistant body 110 to form the first major face 150 and second major face 170 of the fire resistant building panel 100. Similar to as that described above, first major surface 200 can be configured for providing a cladding face. In the exemplary embodiment shown, each of finishing layers 190 and/or 220 can have a thickness of between approximately 3 mm and 8 mm. In the embodiment shown, finishing layers 190 and 220 can be formed from fiber cement respectively. Alternatively, finishing layers 190 and 220 can be formed from non-fiber cement, and can be formed of the same or different materials. In alternative embodiments, finishing layers 190 and 220 can be formed from any suitable exterior durable cladding material as previously described.

[0058] In each of the exemplary embodiments shown in FIGS. 2 and 3, finishing layer 190 may be formed from any suitable durable cladding material, but is preferably formed from a material that is physically and chemically compatible with fire rated body 110. In the exemplary embodiments shown, finishing layer 190 is formed from fiber cement and can be suitably formulated for exposure during service as an interior or an exterior cladding material.

[0059] In one embodiment of the fire resistant building panel 100 of FIG. 2 or 3, wherein the fire resistant building panel 100 comprises either or both of finishing layers 190 and 220, finishing layers 190 and/or 220 can be secured to the fire resistant body 110 using either mechanical or chemical fixings and/o attachments.

[0060] In an alternative embodiment of fire resistant building panel 100, either or both of finishing layers 190 and 220 can comprise fiber cement finishing layers. The fiber cement finishing layers 190, 220 can be a cured or an uncured (green sheet) fiber cement layer. The advantage of using an uncured fiber cement finishing layer is that during the formation process the fire resistant body 110 and the uncured fiber cement finishing layer or layers can be co-cured to form fire resistant building panel in which the finishing layer(s) and fire resistant body can be integrally formed with each other.

[0061] In a further embodiment of the present disclosure, it is also possible to apply a coating to provide a functional and/or aesthetic finish onto the second major face of the fire resistant building panel.

EXAMPLES

[0062] As will be discussed in greater detail below, in some embodiments of the present disclosure provided herein, the composition of fire resistant body 110 can be formed from a binder 120, at least one additive 130 and/or at least one fiber 140, wherein the binder can comprise a calcareous material and a siliceous material. Formation of fire resistant body 110 can be achieved by blending the components of the composition together with water to form a slurry and casting in a mold, frame or formwork.

[0063] In each of Examples 1 to 3 below, samples of compositions of a fire resistant building panel of the type exemplified in FIGS. 1, 2 and 3 above were formed. Sample 1 of each of examples 1 to 3 comprises a fire resistant body 110. Sample 2 of each of examples 1 to 3 comprises a fire resistant body 110 together with a finishing layer 190 secured to at least one face of the fire resistant body 110. Sample 3 of each of examples 1 to 3 comprises a fire resistant body 110 together with finishing layers 190 and 220 secured to opposing faces of the fire resistant body 110.

Example 1. Hydrated Lime and Silica

[0064]

TABLE-US-00001 TABLE 1 Example 1 Formulation Range/ Specific Example/ Component parts by weight parts by weight Calcareous material 35-40 37 Siliceous Material 20-30 23 Additive 30-35 32 Fiber 3-10 8

TABLE-US-00002 TABLE 1(a) Density results DENSITY (gm/cc) 0.35-0.50 0.46

[0065] Sample 1: The calcareous material in the formulation for the fire resistant body of Example 1 is hydrated lime and the siliceous material is micro silica. The at least one additive in the formulation for the fire resistant body is a density modifying additive in the form of an expanded mineral, such as, for example, expanded perlite. The at least one fiber material in the formulation for the fire resistant body comprises a mixture of cellulose fibers and basalt fibers, wherein the cellulose fibers and basalt fibers are provided in a ratio of approximately 2:1. The cellulose fibers comprises one or more of softwood kraft cellulose pulp, hardwood pulp, straw derived and the like. Each of the components are provided as dry components in parts by weight as outlined in Table 1 wherein the dry components total approximately 100 parts by weight.

[0066] The dry components are mixed together with water to form a slurry using conventional mixing means. Approximately 30 to 50 parts by weight of water are added to the dry components to form a slurry of the desired consistency which depends on the forming method to be used. Separately a frame is positioned on a supporting substrate such that a seal is formed between the frame and the substrate. The slurry is then cast into the frame on top of the substrate until the slurry has reached a pre-determined depth of between approximately 15 mm (0.6 inch) and 60 mm (2.4 inch) within the frame structure. The slurry was then allowed to rest at ambient conditions for approximately 1 hour. The resting time is calculated to allow the slurry to partially cure such that it is possible to remove the frame structure without the partially cured slurry losing its shape. The partially cured slurry is then allowed to rest for a period of time in which it is allowed to complete curing. The time required to complete the curing process is variable. In the above exemplary embodiment, the partially cured slurry is allowed to rest for a period of 24 hours at ambient temperature to complete curing. In one embodiment, the fire resistant body of Example 1 is designed to be less than 60 mm thick (2.4 inch) and have a mass of less than 30 kg/square meter (712 lb/ft.sup.2). The density of the fire resistant body of Example 1 is between 0.35 and 0.5 gm/cc (21.8 and 31.2 lb/ft.sup.3) as outlined in Table 1(a).

[0067] In an alternate embodiment, the fire resistant building panels may be formed from the same formulation and forming method, but using steam curing or autoclave curing. For example, in one alternate embodiment, the fire resistant building panel may be cured at a minimum of 50 degrees Celsius (122 degrees Fahrenheit) for a minimum of 6 hours, or autoclave cured by heating in an autoclave to a temperature of 170 to 180 degrees Celsius (338 to 356 Fahrenheit).

[0068] Sample 2: In a second set of samples, a slurry is formed in accordance with the method and formulation of Example 1, sample 1 and Table 1. Separately a frame is positioned around an autoclaved 4.5 mm (0.2 inch) fiber cement layer. The slurry is then cast into the frame on top of the fiber cement layer until the slurry has reached a depth of approximately 40 mm (1.6 inch) within the frame structure. The slurry was then allowed to rest at ambient conditions for approximately 1 hour. The resting time is calculated to allow the curing reaction to proceed sufficiently so that the slurry is partially cured and that it is possible to remove the frame structure without the slurry losing its shape. After resting and allowing the slurry to partially cure, the frame was removed and the composite fire resistant building panel is allowed to sit and air cure for 24 hours at ambient temperature. The resultant fire resistant building panel is of the type exemplified in FIG. 2 above which comprises an integrally formed finishing layer 190 secured to fire resistant body 110 to form the second major face 170.

[0069] Sample 3: In a third set of samples, a slurry is formed in accordance with the method and formulation of Example 1, sample 1 and Table 1. Similarly to sample 2, a frame is positioned around an autoclaved 4.5 mm fiber cement layer. The slurry is then cast into the frame on top of the fiber cement layer until the slurry has reached a depth of approximately 40 mm within the frame structure. The slurry was then allowed to rest at ambient conditions for approximately 1 hour. The resting time is calculated to allow the slurry to partially cure such that it is possible to remove the frame structure without the slurry losing its shape. A second 4.5 mm (0.2 inch) fiber cement layer was applied to the surface of the slurry and the composite fire resistant building panel was allowed to sit and air cure for 24 hours at ambient temperature. The resultant fire resistant building panel is of the type exemplified in FIG. 3 above which comprises an integrally formed finishing layers 190 and 220 bonded to opposing faces of fire resistant body 110 to form the first major face 150 and second major face 170.

[0070] In alternate embodiments, the frame may be sized relatively smaller than a first layer, or positioned asymmetrically on the first layer to provide a formed edge profile such as complementary interlocking edge formations in the final formed fire resistant building panel.

Example 2. Portland Cement

[0071] The compositions of Examples 2 and 3 are similar in that the calcareous material of the fire resistant body is a Portland cement based hydraulic binder system. The compositions of Example 3 provide an alternative to the compositions of Example 2. In Example 2, a low density additive is a component added to the formulation. In contrast, in Example 3, density modification takes the form of an in-situ chemical reaction caused by the presence of an air entrainment agent. Representative formulation ranges and specific formulations for each of Examples 2 and 3 are shown in Tables 2 and 3 respectively below.

TABLE-US-00003 TABLE 2 Example 2 Formulation Range/ Specific Example/ Component parts by weight parts by weight Calcareous Material 10-20 17 Siliceous material 5-15 10 Additive 20-70 65 Fiber 3-10 8

TABLE-US-00004 TABLE 2(a) Density results DENSITY (gm/cc) 0.40-0.50 0.48

[0072] Sample 1: In sample 1 of Example 2, the calcareous material in the formulation for the fire resistant body is ordinary Portland cement and the siliceous material is micro silica. The at least one additive in the formulation for the fire resistant body comprises a density modifying additive and a filler. The density modifying additive is in the form of microspheres having a density of less than 1 gm/cc (62.4 lb/ft3). The filler is in the form of anhydrous calcium magnesium carbonate mineral. The ratio of the first and second additive is variable and is adjusted in order to maintain the density of the fire resistant body so that it is within the desired density range of 0.40-0.50 gm/cc (25-31.2 lb/ft3).

[0073] The at least one fiber material in the formulation for the fire resistant body comprises a mixture of cellulose fibers and basalt fibers, wherein the cellulose fibers and basalt fibers are provided in a ratio of approximately 2:1. The cellulose fibers comprise softwood kraft cellulose pulp. Each of the component are provided as dry components and are mixed with water to form a slurry. Each of the component are provided as dry components in parts by weight as outlined in Table 2 wherein the dry components total approximately 100 parts by weight. Approximately 30 to 50 parts by weight of water are mixed with the dry components to form a slurry of desired consistency which depends on the forming method to be used.

[0074] As before, the slurry of Example 2 is then cast into a frame on top of a substrate until the slurry has reached a pre-determined depth of between approximately 15 mm and 60 mm within the frame structure. The slurry was then allowed to rest at ambient conditions for approximately 1 hour. The resting time is calculated to allow the slurry to partially cure such that it is possible to remove the frame structure without the partially cured slurry losing its shape. The partially cured slurry is then allowed to rest for a period of time in which it is allowed to complete curing. The time required to complete the curing process is variable. In the above exemplary embodiment, the partially cured slurry is allowed to rest for a period of 24 hours at ambient temperature to complete curing. In one embodiment, the fire resistant body of Example 2 is designed to have a density between 0.4 and 0.5 gm/cc (25 and 31.2 lb/ft3) as outlined in Table 2(a).

[0075] As per Example 1, it is also possible to have alternate embodiments in which the fire resistant building panels may be formed from the same formulation and forming method, as outlined for Example 2 above, but using steam curing or autoclave curing. For example, in one alternate embodiment, the fire resistant building panel may be cured at a minimum of 50 degrees Celsius (122 degrees Fahrenheit) for a minimum of 6 hours, or autoclave cured by heating in an autoclave to a temperature of 170 to 180 degrees Celsius (338 to 356 Fahrenheit).

[0076] Sample 2: In a second set of samples, a slurry is formed in accordance with the method and formulation of Example 2, sample 1 and Table 2.

[0077] An uncured (green sheet) fiber cement layer is formed by mixing a fiber cement slurry with approximate ratios of cement to silica to cellulose pulp, wherein the ratio of cement to silica to cellulose pulp is 1:1:0.15. The fiber cement slurry is then formed into a green-sheet using a Hatschek machine or dewatered in a filter press or similar to form the uncured fiber cement having a thickness of approximately 4 to 5 mm (0.16 to 0.20 inch).

[0078] Separately a frame is positioned around the uncured (green sheet) fiber cement layer. The slurry of Example 2, sample 1 was cast into the frame on top of the fiber cement layer until the slurry reached a desired depth within the frame structure. The slurry was then allowed to rest at ambient conditions until such a time as the slurry is partially cured and it was possible to remove the frame structure without the slurry losing its shape. The frame was then removed from a composite panel comprising the partially cured green sheet fiber cement layer and the partially cured fire resistant body. The composite panel was then cured in an autoclave under normal conditions. The fiber cement green sheet and the fire resistant body react during curing to provide an integrally formed composite fire resistant building panel. The resultant fire resistant building panel is of the type exemplified in FIG. 2 above which comprises an integrally formed finishing layer 190 secured to fire resistant body 110 to form the second major face 170.

[0079] Sample 3: In a third set of samples, a slurry is formed in accordance with the method and formulation of Example 2, sample 1 and Table 2.

[0080] Similarly to Example 2, sample 2, an uncured (green sheet) fiber cement layer is formed by mixing a fiber cement slurry with approximate ratios of cement to silica to cellulose pulp, wherein the ratio of cement to silica to cellulose pulp is 1:1:0.15. The fiber cement slurry is then formed into a green-sheet using a Hatschek machine or dewatered in a filter press or similar to form the uncured fiber cement having a thickness of approximately 4 to 5 mm (0.16 to 0.20 inch).

[0081] A frame was positioned around the uncured (green sheet) fiber cement layer. The slurry of Example 2, sample 1 was cast into the frame on top of the fiber cement layer until the slurry reached a desired depth within the frame structure. The slurry was then allowed to rest at ambient conditions until such a time as the slurry is partially cured and it was possible to remove the frame structure without the slurry losing its shape. The frame was then removed from a composite panel comprising the partially cured green sheet fiber cement layer and the partially cured fire resistant body. A second 4.5 mm (0.18 inch) fiber cement layer was applied to the surface of the partially cured slurry. Pressure was applied to bring the second fiber cement layer into direct contact with the partially cured slurry to form the composite fire resistant building panel. The composite fire resistant building panel is allowed to sit and air cure for 24 hours at ambient temperature.

[0082] The resultant fire resistant building panel is of the type exemplified in FIG. 3 above which comprises an integrally formed finishing layer 190 and 220 bonded to opposing faces of fire resistant body 110 to form the first major face 150 and second major face 170.

Example 3. Portland Cement and Aluminum Powder

[0083]

TABLE-US-00005 TABLE 3 Example 3 Formulation Range/ Specific Example/ Component parts by weight parts by weight Calcareous Material 25-35 32 Siliceous Material 40-60 47.9 1.sup.st Additive 15-20 20 2.sup.nd Additive 0.05-1 0.05 Fiber 0.05 0.05

[0084] Sample 1: In example 3, the formulation for the fire resistant body comprises a calcareous material in the form of Portland cement and a siliceous material in the form of ground silica. The at least one additive in the formulation for the fire resistant body comprises a first additive and a second additive. The first additive is a density modifying additive in the form of an expanded mineral, such as expanded perlite. The second additive comprises an air entrainment agent in the form of aluminum powder. The at least one fiber material in the formulation for the fire resistant body comprises cellulose fibers. The cellulose fibers comprise softwood kraft cellulose pulp. Each of the component are provided as dry components and are mixed with water to form a slurry. The dry components total approximately 100 parts by weight and are mixed with water in an approximate 2:1 ratio to form the slurry.

[0085] The slurry is then cast into a frame until the slurry has reached a pre-determined depth of between approximately 15 mm and 60 mm within the frame structure. The frame is provided with a temporary support substrate to support the slurry until it is partially cured. In one embodiment the temporary support substrate could be in the form of a releasable base plate. When the slurry composition is poured into frame, expansion of the slurry as a result of the chemical reaction of Portland cement binder 120 and aluminum powder in which resulting gas voids are formed throughout the fire resistant body 110 is visible. The slurry is allowed to rest at ambient conditions for approximately 1 hour until the slurry is partially cured and it is possible to remove the frame structure without the partially cured slurry losing its shape. The partially cured slurry is then allowed to rest for a period of time in which it is allowed to complete curing. The time required to complete the curing process is variable. In the above exemplary embodiment, the partially cured slurry is allowed to rest for a period of 24 hours at ambient temperature to complete curing. In an alternate embodiment, the fire resistant building panels may be formed from the same formulation, and forming method, but using steam curing or autoclave curing. For example, in one alternate embodiment, the fire resistant building panel may be cured at a minimum of 50 degrees Celsius (122 degrees Fahrenheit) for a minimum of 6 hours, or autoclave cured by heating in an autoclave to a temperature of 170 to 180 degrees Celsius (338 to 356 Fahrenheit).

Sample 2:

[0086]

TABLE-US-00006 TABLE 3(a) Example 3: Fire Resistant finishing layer Formulation Range/ Specific Example/ Component parts by weight parts by weight Calcareous Material 25-35 35 Siliceous Material 40-60 45 1.sup.st Additive 5-10 10 2.sup.nd Additive 3-5 3 Fiber 5-10 7

[0087] In a second set of samples, a slurry is formed in accordance with the method and formulation of Example 3, sample 1 and Table 3. Separately, a fiber cement layer is formed using a Hatschek machine or a filter press. The formulation for the fiber cement layer comprises a calcareous material comprising Portland cement, a siliceous material comprising ground silica, a first additive comprising calcium carbonate, a second additive comprising hydrated alumina and at least one fiber comprising cellulose pulp. The dry components are mixed in the amounts outlined in Table 3(a) with water in an approximate 2:1 ratio to form a slurry. In this example, the slurry was then formed into an uncured (green sheet) fiber cement layer using either a Hatschek machine or a filter press. In one embodiment, the uncured (green sheet) fiber cement layer is used as a first finishing layer 190 to form a composite fire resistant building panel. In an alternate embodiment, the fiber cement green sheet may be cured by air curing, steam curing or autoclave curing to form a cured fiber cement sheet prior to being used to provide first finishing layer.

[0088] As for the previous examples, a frame is provided on the first finishing layer. The slurry composition for fire resistant body is poured into frame onto the first finishing layer. When the slurry composition is poured into frame, expansion of the slurry as a result of the chemical reaction of Portland cement binder and aluminum powder in which resulting gas voids are formed throughout the fire resistant body is visible. The fire resistant body is allowed to cure as previously described.

[0089] Sample 3: In a third set of samples, a second finishing layer is applied to the second major face of the fire resistant body of Example 3, sample 2. The second finishing layer is also an uncured (green sheet) or cured fiber cement layer of the kind described in Example 3, Sample 2. In one exemplary embodiment, the second finishing layer is restrained in position, such that the expansion of fire resistant body between first layer and second layer and frame is constrained. Consequently voids formed near each of the first and second major faces adjacent the respective finishing layers, and/or at the edges of the frame structure, will collapse and leave a densified area in these portions relative to other areas of the fire resistant body. The result of the constraint will be that voids will be preferentially distributed in fire resistant body.

[0090] In an alternate embodiment of Example 3, sample 1 or sample 2, it is also possible to constrain expansion of the slurry as a result of the chemical reaction of Portland cement binder 120 and aluminum powder using releasable base plates with the frame structure. The releasable base plates will constrain the expansion of the slurry in a similar way to that of the finishing layers such that voids formed near each of the releasable base plates, and/or at the edges of the frame structure, will collapse and leave a densified area in these portions relative to other areas of the fire resistant body. Densification of the fire resistant body at either one or other, or both, of the first major face and second major face is beneficial in providing an integrally formed weather durable cladding face on fire resistant body.

[0091] Fire resistance tests were conducted for a range of different panel thicknesses manufactured using the formulations of Examples 1 to 3 as provided in tables 1 to 3 above. Comparisons were made with other commercially available materials tested under the same conditions. A fire test panel assembly was constructed using the fire resistant building panel according to any one Examples 1 to 3, to test the sample in accordance with Australian Standard AS1530.4-2005. A cross sectional side view of the fire test panel assembly 270, showing the direction from which the fire is applied by the furnace during the test is shown in FIG. 4.

[0092] The fire test requires making a building wall test section of approximately 1.2 meters high1.2 meters wide (4 ft high4 ft wide). The test section is constructed using a timber frame 280, where timber framing members are 90 mm35 mm spaced at 60 mm centers (3.5 inch1.4 inch spaced at 2.4 inch centers). The frame is clad on the side to be exposed to the fire with the fire resistant building panel and fixed to the frame at 200 mm (8 inch) centers. In the example shown in FIG. 4, a fire resistant panel in accordance with the exemplary embodiment of FIG. 2 comprising a fire resistant body 110 and first finishing layer 190 is attached to timber frame 280. The cavities in the frame, between framing members, are filled with insulating material 300 in the form of an R2.5 fibrous insulation batt. The rear face (non-fire side) is clad with a second cladding material 240, such as an interior lining board, for example a 6 mm fiber cement panel or a 16 mm plasterboard panel. Altogether, the test panel is approximately 120 mm (4.7 inch) thick. The test provides a rating in the form of a time. The time is the time required for the temperature measured on the rear face (non-fire side) panel to reach 140 degrees Celsius (284 degrees Fahrenheit) above ambient temperature. For example, a 2 hour fire rating means that it took 2 hours for the rear face of a test panel to reach ambient temperature+140 degrees Celsius (284 degrees Fahrenheit).

[0093] Fire resistance testing of current commercially available panels were carried out concurrently with fire resistant building panels made according to samples 1 of Examples 1 and 2 of the present disclosure. The results below in Table 4 provide a comparison of the Fire Ratings achieved by each.

TABLE-US-00007 TABLE 4 Fire Resistance Tests Results and Fire Ratings Fire Thickness Time to 140 deg C. above Rating Product (mm) ambient (minutes) (minutes) Plasterboard 16 164 deg @ 30 28 25 164 deg @ 50 48 32 164 deg @ 97 95 AAC 16 164 deg @ 25 23 25 164 deg @ 42 40 Example 1, Sample 1 16 164 deg @ 52 50 Example 2, Sample 1 16 164 deg @ 54 52 Example 1, Sample 1 25 164 deg @ 78 75 Example 2, Sample 1 28 164 deg @ 82 80 Example 1, Sample 1 32 164 deg @ 119 118 Example 2, Sample 1 35 164 deg @ 125 125 Example 1, Sample 1 40 82 deg @ 119test stopped 142 Example 2, Sample 1 40 82 deg @ 119test stopped 142

[0094] A trace of the Fire Rating test for a 40 mm (1.6 inch) fire resistant building panel manufactured using Example 1 is shown in FIG. 5, where the trace of the fire side temperature provided by the fire test furnace apparatus is shown reaching 1000 degrees Celsius (1832 degrees Fahrenheit) and holding until approximately 120 minutes. On the same trace, a temperature reading on the rear face of second cladding material 240 on the rear face of fire test panel assembly 270 is shown, reaching only 82 degrees Celsius (180 degrees Fahrenheit) after a test time of 119 minutes, after which the test was stopped.

[0095] Similarly, a trace of Fire Rating test for a 40 mm thick fire resistant building panel manufactured using example 2 is shown in FIG. 6, showing the furnace temperature during the test, and the temperature measured on the rear face of fire resistant building panel assembly 270.

[0096] Fire resistance testing of current commercially available panels were carried out concurrently with fire resistant building panels made according to samples 2 of Examples 1 and 2 of the present disclosure. The results below in Table 5 provide a comparison of the Fire Ratings achieved by each. In the exemplary embodiments the finishing layer comprises a fiber cement layer having a thickness of approximately 4.5 mm (0.2 inch).

TABLE-US-00008 TABLE 5 Fire Resistance Tests Results and Fire Ratings Thickness Time to 140 deg C. above Fire Rating Product (mm) ambient (minutes) (minutes) Example 1, 16 169 deg @ 52 55 Sample 2 25 164 deg @ 83 80 32 163 deg @ 119 121 40 82 deg @ 123test stopped 147 Example 2, 16 168 deg @ 54 56 Sample 2 28 164 deg @ 87 87 35 164 deg @ 130 130 40 82 deg @ 124test stopped 145

[0097] Fire resistance testing of current commercially available panels were carried out concurrently with fire resistant building panels made according to samples 3 of Examples 1 and 2 of the present disclosure. The results below in Table 6 provide a comparison of the Fire Ratings achieved by each. In the exemplary embodiments, each of the finishing layers comprise a fiber cement layer having a thickness of approximately 4.5 mm (0.2 inch).

TABLE-US-00009 TABLE 6 Fire Resistance Tests Results and Fire Ratings Thickness Time to 140 deg C. above Fire Rating Product (mm) ambient (minutes) (minutes) Example 1, 16 164 deg @ 61 59 Sample 3 25 164 deg @ 87 83 32 164 deg @ 129 128 40 82 deg @ 128 151 Example 2, 16 168 deg @ 63 61 Sample 3 28 164 deg @ 92 90 35 164 deg @ 135 135 40 82 deg @ 128 149

[0098] Fire resistance testing of current commercially available panels were carried out concurrently with fire resistant building panels made according to samples 2 and 3 of Example 3 of the present disclosure. The results below in Table 7 provide a comparison of the Fire Ratings achieved by each. In the exemplary embodiments the finishing layer comprises a fiber cement layer having a thickness of approximately 4.5 mm (0.2 inch).

TABLE-US-00010 TABLE 7 Fire resistance tests results and Fire Ratings Thickness Time to 140 deg C. Fire Rating Product (mm) (minutes) (minutes) Example 3, 16 169 C. @ 51 53 Sample 2 25 164 C. @ 80 78 32 163 C. @ 120 119 40 81 C. @ 123 143 Example 3, 16 163 C. @ 60 60 Sample 3 28 164 C. @ 81 82 35 164 C. @ 124 126 40 82 C. @ 128 147

[0099] It will be appreciated that the illustrated fire resistant building panel provides a single, integrally formed product capable of providing both fire resistance and the mechanical and physical properties required by a building cladding material.

[0100] Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as any subcombination or variation of any subcombination.

[0101] Moreover, while methods may be depicted in the drawings or described in the specification in a particular order, such methods need not be performed in the particular order shown or in sequential order, and not all methods need not be performed, to achieve desirable results. Other methods that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional methods can be performed before, after, simultaneously, or between any of the described methods. Further, the methods may be rearranged or reordered in other implementations. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. Additionally, other implementations are within the scope of this disclosure.

[0102] It will of course be understood that the disclosure is not limited to the specific details described herein, which are given by way of example only, and that various modifications and alterations are possible within the scope of the disclosure as defined in the appended claims.

[0103] Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation can also be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can, in some cases, be excised from the combination, and the combination may be claimed as any subcombination or variation of any subcombination.

[0104] Moreover, while methods may be depicted in the drawings or described in the specification in a particular order, such methods need not be performed in the particular order shown or in sequential order, and that all methods need not be performed, to achieve desirable results. Other methods that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional methods can be performed before, after, simultaneously, or between any of the described methods. Further, the methods may be rearranged or reordered in other implementations. Also, the separation of various system components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. Additionally, other implementations are within the scope of this disclosure.

[0105] Conditional language, such as can, could, might, or may, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include or do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.

[0106] Conjunctive language, such as the phrase at least one of X, Y, and Z unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y or Z. Thus, such conjunctive language is not generally intended to imply that certain embodiments require the presence of at least one of X, at least one of Y, and at least one of Z.

[0107] Although making and using various embodiments are discussed in detail below, it should be appreciated that the description provides many inventive concepts that may be embodied in a wide variety of contexts. The specific aspects and embodiments discussed herein are merely illustrative of ways to make and use the systems and methods disclosed herein and do not limit the scope of the disclosure. The systems and methods described herein may be used in conjunction with fire resistant building panels and are described herein with reference to this application. However, it will be appreciated that the disclosure is not limited to this particular field of use.

[0108] Some embodiments have been described in connection with the accompanying drawings. Distances, angles, etc. are merely illustrative and do not necessarily bear an exact relationship to actual dimensions and layout of the devices illustrated. Components can be added, removed, and/or rearranged. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with various embodiments can be used in all other embodiments set forth herein. Additionally, it will be recognized that any methods described herein may be practiced using any device suitable for performing the recited steps.

[0109] While a number of embodiments and variations thereof have been described in detail, other modifications and methods of using the same will be apparent to those of skill in the art. Accordingly, it should be understood that various applications, modifications, materials, and substitutions can be made of equivalents without departing from the unique and inventive disclosure herein or the scope of the claims.