Frame for an access panel or door

Abstract

A frame for an access panel or door comprises a plurality of linear frame members 8, each linear frame member being provided with a liner member 4 located, in use, between the frame and the opening in a building surface in which the frame is to be installed. Each liner member 4 has a flange 4c upstanding therefrom inwardly of the opening, whereby the frame is located against the flange 4c of each liner member. At least one adjustment means 9 is provided on each frame member extending between the frame member and the liner member, whereby the position of the frame member relative to the liner member may be adjusted. The invention also provides a method of fixing a frame for an access panel or door in an opening in a wall or ceiling of a building.

Description

Field of the Invention This invention relates to a frame for an access panel or door, for example for use where fire resistance and / or sound insulation is important, and to a method of fixing a frame for an access panel or door. Background to the Invention Installing four-sided framed access panels or doors in fire rated situations requires accurate fitting of the door in the wall and the closing of the fitting gap between the wall and frame to prevent fire passing around the door. The process of closing the gap between wall and frame is known as Firestopping and is traditionally achieved by stuffing the gap with a noncombustible fire-resistant insulation material such as mineral fibre loft insulation and then capping the insulation with a fire resistant mastic. Unlike timber door sets and frames, where architraves bridge and close off the gaps, a preformed access panel frame is intended to be fitted into an aperture in a wall or ceiling with no additional framing to the face. Most access panels are designed to fit flat to the surface of the wall or ceiling so the firestopping has to be done from the back, making it difficult to pack gaps that may be as little as 5mm wide between wall and frame. Additionally, installation requires packers at the position where the fixing screws secure the frame to the wall or ceiling. Without packers, overtightening the fixing screws can easily deform metal or plastic frames by pulling the frame into the gaps at the aperture sides where the aperture is not the exact size for the frame. This distortion of the frame being pulled to the aperture sides leads to the frame being forced out of square. Traditionally timber, plastic, or metal packers are used to fit in the gap between the door and frame which support the frame at the fixing point, preventing the frame from being distorted. Fitting the packers is awkward and timeconsuming, and expensive if metal packers have to be used because of fire reasons. Where an acoustic rating is to be achieved, this requires the gap between the frame and aperture to be sealed, which is traditionally achieved using a skeleton gun to caulk the gap between frame and wall or ceiling. This is a messy process and liable to drops in performance if areas cannot be reached. Some existing solutions using slide-out or expanding frame options require the slide out part to be the primary fixing to the aperture sides. The frame of the access panel or door is then fixed to the slide out or expanded frame section. This is adding a step in the fixing time and relying on the interconnecting screws or bolts to perform as well as fixings that would be into the wall or ceiling section. A further problem when using loose supplied slide-out or expanding frame sections is that there is a gap to the corners. Some solutions have triangular parts that also separately slide out and are in turn screwed in place. This method limits the corner cover size and adds a further step to fix the slide-out corners in place. Additionally, when using loose supplied slide-out or expanding frame sections, separately supplied wind-out bolts are required to locate the slide-out parts against the aperture before fixing the slide-out sections. Wind-out bolts need to be removed before the door can be closed and this adds another process to the fixing procedure. When using traditional style personnel metal door frame fixings, these fixings are threaded into the frame to extend out from the frame to locate against the aperture sides. The fixings are hollow so that fixing screws can then fix through the fixing. Access panels and doors have thinner frames than personnel style doors, so the frame is liable to distort at the hollow fixing point load point. Also, when using hollow fix wind-out fixed through bolts the wind-out mechanism is limited in its length, as access panels and doors have shallower frames than personnel doors. The mechanism can drop out of the frame if it is overextended. Squaring an access panel or door into an aperture that may not be perfectly square requires the packers to support the panel or door differently in different fixing positions to hold the panel or door square. This is achieved on site with different size packers used in different positions, which extends the fitting time in uneven apertures. Frames with profiles that present a void to the aperture edge are difficult to fix. Not seen in solid timber sections, the steel frame is a folded profile that, depending on the wall or ceiling thickness, may present a hollow part at the aperture edge. This has the fixing effect of unevenly supporting the frame so it can twist during fitting. Fitting larger frames into walls can be difficult where the aperture is not cut into a wall that is flat. Where a wall is not flat the frame legs fitted into either side of the aperture will not enable the door to be lined up correctly resulting in corners either sticking out or laying too deep within the frame. This misalignment is not obvious until the final steps of the fitting process resulting in the frame having to be removed and essentially starting again. The present invention provides a frame system for an access panel or door that seeks to overcome these problems. Summary of the Invention According to the invention, there is provided a frame for an access panel or door, comprising a plurality of linear frame members, each linear frame member being provided with a liner member located, in use, between the frame and the opening in a building surface in which the frame is to be installed, each liner member having a flange upstanding there-from inwardly of the opening, whereby the frame is located against the flange of each liner member, at least one adjustment means being provided on each frame member extending between the frame member and the liner member, whereby the position of the liner member relative to the frame member may be adjusted. The invention further provides a method of fixing a frame for an access panel or door in an opening in a wall or ceiling of a building, comprising securing a plurality of liner members into the opening, each liner member having a flange upstanding therefrom inwardly of the opening, and locating the frame into the opening against the liner member flanges, and adjusting at least one adjustment means provided on each frame member extending between the frame member and the liner member to bear against the respective sides of the liner member, and then securing the frame in the opening through the liner members. Other features of the frame are set out in the claims. Advantages of the frame and method of the invention include: • No firestopping is required. The frame and liner fill the gap, negating the need for mineral wool packing. The built in layers of intumescent to the Liner expand during a fire ensuing the seal. • No Shims are required. The frame adjustment screws brace the fixing screws against the aperture. • There is no frame deformation during fixing. The fixing positions are adjacent to the captive screw or bolt that adjust the members out so the frame is supported at the exact position the wall fixing screw is trying to deform the frame. • Seals can be built-in. The frame can be fitted with a flexible acoustic seal that will seal itself against the aperture sides. • Installation requires fewer fixings. The frame does not require extra fixings into the wall or to other frame sections. • There are no open corners. The corner parts cover the corner gaps and can be provided in larger sizes for larger gaps. • Captive adjustment screws are included, so no additional bolts are required to wind out the adjustable members, the captive screws remaining in place after the installation. • There is no frame distortion. The liner members are substantially the full length of the frame side distributing the load so there are no point loads to distort the frame. • The frame can adjust for larger door to liner gaps. The adjusting screws are captive and will not fall out once they are at the end of their travel. Longer bolts can be specified to cover larger gaps. • A greater degree of adjustment is provided. The adjustable members can be wound out to level and position the access panel or door in its aperture. • There is less adjustment of heavy components. The liner fitted around the frame present a lightweight solution to correct the opening aperture for flat ness avoiding later install issue that only present themselves at a late stage in the installation. Brief Description of the Drawings In the drawings, which illustrate an exemplary embodiment of the invention: Figure 1 is a sectional view of a portion of a wall with an opening therein, into which a liner member in accordance with the invention has been located; Figure 2 is a view corresponding to that of Figure 1, showing the first stage of fixing of the frame, placing the frame in the opening; Figure 3 is a view corresponding to that of Figures 1 and 2, showing the second stage of fixing, using the adjustment screws to align the frame; Figure 4 is a view corresponding to that of 1,2 &3, showing the third stage of fixing, screwing the frame into the liner and / or opening; Figure 5 is a perspective view from one side of a portion of an opening and frame inserted therein; Figure 6 is a perspective view from the other side, showing a portion of the completed frame with a corner member in position.; Figure 7 is a perspective view of a section of the liner member without seals; and Figure 8 is a perspective view of a section of the liner member with seals. Detailed Description of the Illustrated Embodiment Figure 1 illustrates a first step in installation of the frame of the invention into an opening in a building structure, for example a wall 1 with double plasterboard 2 on each side and with a metal section component 3 enclosing the edge of the wall 1 at the face of the opening. It will be appreciated that the building structure could be of any form, for example brickwork, timber partition, and steel stud, typically faced with plasterboard, although other optional finishing surfaces may be used. A liner 4 is formed from linear members fabricated from sheet steel with a length appropriate to the length of the opening and width appropriate to the width of the corresponding frame, having a planar main portion 4a which is located against the surface of the opening and a face flange 4b extending normally thereto to be located against the face of the wall surrounding the opening and stop flange 4c extending normally from the main portion 4a into the opening. The main portion 4a is provided with spaced apart holes along the length thereof through which pilot holes can be drilled through the metal section 3 into the wall 1 to receive fixing screws 5. The main portion 4a is pierced with a longitudinal series of holes or slots 6 over which is adhered a strip 7 of intumescent material, the holes or slots 6 allowing the intumescent material to come into contact with the side of the opening in the event of a fire causing the material to expand. These may be seen more clearly in Figure 7, described hereinafter. Referring now to Figure 2, the frame 8 is formed from linear frame members fabricated from sheet steel with a channel section 8a and an inner member 8b secured by welding or rivetting within the channel section 8a and having spaced apart screw-threaded holes therethrough to receive respective adjustment screws 9. The inner member 8b thus serves to stiffen the channel section 8a and provide a support for the adjusting screws 9. The frame 8 is provided with face flange 10 along one edge thereof which in use rests against the surface of the wall surrounding the opening and over the liner face flange 4b. The frame face flange 10 is conveniently configured as a perforated bead frame to provide a guide and an anchoring key for plastering on the wall face. The side of the channel section 8a remote from the face flange 10 is configured to rest against the stop flange 4c, thereby providing a physical firestop. Figure 3 illustrates the configuration after the adjusting screws 9 have been screwed to their final positions. Each screw has a corresponding access hole formed in the channel section 8a to permit access for a screwdriver or Allen key or the like for driving the screws. The screws 9 are rotated to drive them outwardly of the frame and into contact with the liner member 4. As shown in Figure 4, frame screws 11 are then driven through the liner member and into the surrounding building structure through apertures provided at intervals along the frame members. The frame screws are preferably located adjacent to the adjusting screws 9 to avoid distortion of the frame locally. Figure 5 shows a portion of the frame located in the opening, the view being from the side where the face flanges 10 are in contact with the plasterboard 2 surrounding the opening. Referring to Figure 6, it will be observed that there might be a potential vulnerability at the corners, but the solution is through the use of corner parts 12, each consisting of a triangular steel member with flanges extending normally thereto along each of the shorter sides thereof. These flanges are inserted, in use, between the liner members 4 and the sides of the opening. Screwing down the Liner members into contact with the side of the opening serves to trap the corner parts 12 in position, sealing the corners. The corner parts 12 also serve to set the position in the Z-axis of the face of the door relative to the wall. Intumescent seals may be provided on the flanges of the corner seals to ensure continuity of sealing though the corners. It will also be seen from Figures 5 and 6 that the frame members are joined together at the corners of the frame by means of angle pieces 13 which serve to ensure that the frames are right angles at the corners. It will be appreciated, however, that the invention could be applied to other shapes with linear sides, rather than just rectangles. Referring to Figure 7, the liner members 4 each have a series of slots or holes 6 that will allow an intumescent seal 7 located over the slots or holes 6 to expand under the influence of fire to both sides of the liner face filling any gaps that may arise. Figure 8 illustrates the liner member 4 with a strip of intumescent or other seal 7 applied to the face.

Claims

1. A frame for an access panel or door, comprising a plurality of linear frame members, each linear frame member being provided with a liner member located, in use, between the frame and the opening in a building surface in which the frame is to be installed, each liner member having a flange upstanding therefrom inwardly of the opening, whereby the frame is located against the flange of each liner member, at least one adjustment means being provided on each frame member extending between the frame member and the liner member, whereby the position of the frame member relative to the liner member may be adjusted, wherein the frame is provided with a face flange along one edge thereof which, in use, rests against the surface of a wall surrounding the opening and over the flange of the respective liner member.

2. A frame according to Claim 1, wherein at least one strip of sealing material is located between each frame member and the corresponding liner member.

3. A frame according to Claim 2, wherein the sealing material is an acoustic sealing material.

4. A frame according to Claim 2, wherein the sealing material is an intumescent material.

5. A frame according to Claim 4, wherein each strip of intumescent material is adhered to the liner member.

6. A frame according to Claim 4 or 5, wherein apertures are provided through the planar section of the liner member, and the intumescent material is positioned such that, in the event of a fire in use, the intumescing material can contact the sides of the opening through the apertures.

7. A frame according to any preceding claim, wherein the adjustment means comprises at least one adjustment screw threaded through the frame member and engaging the liner member.

8. A frame according to Claim 7, wherein a plurality of adjustment screws are provided on each frame member.

9. A frame according to any preceding claim, wherein the liner members that are configured to overlap each other at the corners to close any gap.

10. A frame according to any preceding claim, wherein the liner members are formed from a resiliently bendable material.

11. A frame according to Claim 10, wherein the liner members are formed from metal.

12. A frame according to Claim 11, wherein each liner member is welded to an adjacent liner member.

13. A method of fixing a frame for an access panel or door in an opening in a wall or ceiling of a building, the frame having a face flange along on edge thereof, comprising securing a plurality of liner members into the opening, each liner member having a flange upstanding therefrom inwardly of the opening, and locating the frame into the opening against the liner member flanges, and adjusting at least one adjustment means provided on each frame member extending between the frame member and the liner member to bear against the respective sides of the liner member, and with the face flange against the surface of a wall surrounding the opening and over the flange of the respective liner member, and then securing the frame in the opening through the liner members.

14. A method according to Claim 13, comprising during the liner securing step locating at each corner of the frame a triangular corner piece having flanges extending normally to two sides of the triangle such that the flanges are located between the sides of the opening and the liner members.

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