Fire-resistant load-bearing floor and ceiling system

Abstract

There is provided a fire-resistant floor and ceiling system (10), comprising a support structure (100) having a first side and a second side. A flooring sub-system (200) is provided at the first side of the support structure (10). The flooring sub-system (200) comprises a first layer (202) comprising a sheet material coupled to the first side of the support structure (100), and a second layer (204) coupled to the first layer (202). A ceiling sub-system (300) is provided at the second side of the support structure (100). The ceiling sub-system (300) comprises a third layer (302) comprising combustion resistant insulation material, and a fourth layer (304) comprising at least one layer of gypsum board. The system (10) thereby providing a fire-resistant and load-bearing structure for use as an intermediate level of a building.

Description

[0001] FIRE-RESISTANT LOAD-BEARING FLOOR AND CEILING SYSTEM

[0002] FIELD

[0003] The invention relates to a floor and ceiling system, and more specifically to a floor and ceiling system which is fire-resistant and load-bearing for use as an intermediate floor of a building.

[0004] BACKGROUND

[0005] It is often desired or mandated for a structure, or parts thereof, to be fire-resistant so that in case of a fire, a building can be evacuated with relative safety. For example, high-rise buildings pose challenges related to evacuation times, and so an escape route needs to be available for an amount of time suitable for total evacuation of occupants.

[0006] In commercial buildings, it is not only evacuation that is important. In a modern world where so much data is stored digitally, on servers for example, it is preferable to protect the integrity of any data against fire for as long as possible. This increases the likelihood of the data remaining intact after any fire related incident has been managed.

[0007] The long-standing method of creating fire-resistant, load-bearing flooring systems within buildings is to pour concrete onto a reinforcement mesh, thereby creating a reinforced concrete floor once cured.

[0008] Although the abovementioned conventional solution is fire-resistant and able to withstand high loads when reinforced, a significant disadvantage is that the resulting floor is typically very heavy owing to the volume of concrete. Concrete also has a short pot life, i.e. , the time from which the material is mixed to the time at which it is unusable. Before pouring concrete, significant time is required to prepare the reinforcing material, which is typically steel bar. Further, the concrete takes a long time to cure; a common estimate in the concrete industry is that full strength is not reached until approximately 28 days after pouring. Further still, pouring concrete as intermediate floors of a building requires specialist contractors and equipment such as pumps and vibrators, all of which require significant space on the building site while concrete pouring is occurring. This task is especially challenging in the case of high-rise buildings and skyscrapers.

[0009] Other concerns of concrete pouring methods include consistency and quality of the final product, which may vary per contractor.

[0010] There is a need for an improved fire-resistant floor and ceiling system and an improved method of constructing a fire-resistant floor and ceiling system that alleviates the problems described herein.

[0011] BRIEF DESCRIPTION OF THE INVENTION

[0012] The present invention provides a fire-resistant floor and ceiling system as claimed in claim 1 and a method of constructing a fire-resistant floor and ceiling system as claimed in claim 13.

[0013] Preferred embodiments of the invention are presented in the dependent claims.

[0014] The system according to examples of the invention seeks to overcome the disadvantages of conventional methods in that the system provides a lightweight floor and ceiling for use as an intermediate floor or level of a building, while also providing high load-bearing capabilities, all without the long curing or preparation times and expense associated with conventional methods of construction.

[0015] BRIEF DESCRIPTION OF THE FIGURES

[0016] In order that the present disclosure may be more readily understood, preferable embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a schematic view of a floor and ceiling system of an example of the present disclosure,

[0017] Figure 2 is an isometric diagrammatic view of a support structure of the floor and ceiling system of an example of the present disclosure,

[0018] Figure 3 is a detail diagrammatic view of a joist of the support structure of figure 2, Figure 4 is a schematic view of a flooring sub-system of an example of the present disclosure, and

[0019] Figure 5 is a schematic view of a ceiling sub-system of an example of the present disclosure.

[0020] DETAILED DESCRIPTION OF THE DISCLOSURE

[0021] Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is noted that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion.

[0022] The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components, concentrations, applications and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. For example, the attachment of a first feature and a second feature in the description that follows may include embodiments in which the first feature and the second feature are attached in direct contact, and may also include embodiments in which additional features may be positioned between the first feature and the second feature, such that the first feature and the second feature may not be in direct contact. In addition, the present disclosure may repeat reference numerals and / or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and / or configurations discussed. The following disclosure describes representative examples. Each example may be considered to be an embodiment and any reference to an “example” may be changed to “embodiment” in the present disclosure.

[0023] Referring now to Figure 1 of the accompanying drawings, there is provided a fire- resistant floor and ceiling system 10 comprising a support structure 100 having a first (upper) side and a second (lower) side. A flooring sub-system 200 is provided at the first side of the support structure 100, and a ceiling sub-system 300 is provided at the second side of the support structure 100. Each of the support structure 100, the flooring sub-system 200, and the ceiling sub-system 300 may be implemented in any of many configurations, some of which will be described below. It should be noted that any of the configurations of the support structure 100, the flooring sub-system 200, and the ceiling sub-system 300, or elements thereof, may be implemented separately or combined with any configuration of the others of the support structure 100, flooring sub-system 200, and ceiling sub-system 300.

[0024] Figure 2 shows an exemplary support structure 100 already coupled to the structure of a building. The main structure of the building may feature main support beams 12 as dictated by the engineering design of the building. For the purpose of these examples, the main support beams are l-section beams, however the term “beam” is, in relation to any of the beams of the building or the support structure 100 and unless specified otherwise, to be interpreted as meaning elongate elements of any material, dimension, or cross-sectional shape.

[0025] The support structure 100 comprises primary support beams 102 which span the gap between adjacent main support beams 12. The primary support beams 102 are connected at each axial end to adjacent main support beams 12. The primary support beams 102 are preferably I-beams. The spacing, measured from the centre of one beam to the centre of the adjacent beam, between the primary support beams 102 is preferably approximately 1220 mm. The support structure further comprises joists 104 connected at each axial end to adjacent primary support beams 102. The joists 104 are preferably steel joists, and may be welded to the primary support beams 102. The upper surface of the joist 104 as shown in figure 2 may be planar, or close to planar, in relation to an upper surface of the primary support beams 102. A planar or close to planar surface provides a substantially flat structure on which the flooring sub-system 200 can be laid whilst overlapping the primary support beams 102. Where the primary support beams 102 are I-beams, the joists may be attached to the underside of the upper horizontal section of the “I”. In embodiments where the attachment of the joists 104 to the primary support beams 102 means that the upper surface of the joist 104 lies in a plane substantially below the upper surface of the primary support beams 102, the joist 104 may be notched so as to elevate its upper surface to be planar in relation to the upper surface of the primary support beams 102. Such an embodiment is shown in figure 3. The spacing between centres of adjacent joists 104 may be approximately 610 mm.

[0026] The support structure 100 may further comprise support struts 106. The support struts 106 are positioned parallel to and spaced vertically from the primary support beams 102. In other words, the support struts 106 are spaced from the primary support beams 102 in a direction normal to a plane defined by the major axes primary support beams 102 and the main support beams 12. The support struts 106 may be connected at each axial end to the main support beams 12 of the building. The purpose of the support struts 106 is preferably to provide a structure on which to attach the ceiling sub-system 300, and preferably not to provide structural integrity to the support structure 100. In such embodiments, the support struts 106 are preferably of light gauge steel. The support struts 106 preferably have an “I” or “C” cross section, or a mixture thereof. The support strut 106 at each extreme end of the run of support struts 106 may be a C section strut, with each intermediate support strut 106 being an I section strut. The centre to centre spacing of the support struts may be approximately 610 mm. It will be appreciated that although the support struts 106 are described above as being parallel to the primary support beams 102, the support struts 106 may be transverse to that shown in figure 2, or indeed extend diagonally or any intermediate angle providing there is an attachment point for each axial end of the support strut 106.

[0027] To increase the structural integrity of the support struts 106, one or more strut bracing beams 108 may be provided. The strut bracing beams 108 may be connected at one axial end to one of the plurality of support struts, and at the other axial end to another of the plurality of support struts 106. The bending resistance of the support strut 106 is thereby increased.

[0028] The connections, attachments and couplings between the numerous elements described above may be by any means known in the art, including but not limited to welding, brazing, brackets, threaded fasteners, rivets, adhesives (mechanical or chemical) and the like, or a combination thereof.

[0029] Figure 4 shows the flooring sub-system 200. The flooring sub-system 200 comprises a first layer 202, and a second layer 204. The first layer 202 is a sheet material and preferably serves to provide strength to the flooring sub-system 200. The first layer 202 may be a steel plate, and may have a thickness of 5 mm. The first layer may instead be or incorporate a steel mesh. Other materials, both metallic and non-metallic are contemplated. The metal sheet can be perforated. Depending on the material chosen, the minimum thickness may vary in order to support the desired load of an intermediate floor within a building. It is envisaged that the embodiment comprising a 5 mm steel plate can safely withstand a load of 15 kN / m2, a pressure that may be exerted by a structure such as a high-density data hall. It will be clear to the skilled person, however, that the teachings of the present disclosure are equally as applicable to a flooring for any building and purpose. In embodiments where the joists 104 are notched, the plate may be sized to couple to the primary support beams 102. Alternatively, in embodiments where the joists 104 are not planar with the top surface of the primary support beams 102, the plate may be sized such that it does not couple with the top surface of the primary support beams 102, but instead lies on only the top surface of the joists 104. The second layer 204 is a fibre cement board, gypsum fibre board, or combination thereof. The fibre cement board may be a PRIMAflex® board, as produced by Saint-Gobain, or similar fire-resistant board. One example of a similar board would be a high density compressed cement fibre board, which can achieve similar load ratings as the PRIMAflex® board whilst having a lower thickness dimension. In embodiments using the PRIMAflex® board, the board may have a thickness of 20 mm. The second layer 204 is preferably secured to the first layer 202 mechanically, and more preferably by nails (using a nail gun in embodiments having a metallic or relatively hard first layer 202). The second layer 204 may be one layer, but alternatively may comprise multiple layers of any thickness deemed appropriate for the specific use case of the present disclosure. Additionally, the flooring sub-system 200 may comprise multiples of either or both of the first layer 202 and the second layer 204. In one embodiment, one layer of the second layer 204 (fibre cement board) may be sandwiched between two layers of the first layer 202 (sheet material).

[0030] When constructing the floor and ceiling system 10, the first layer 202 may be attached to the first side of the support structure 100, and then the second layer 204 coupled to the first layer 202. Alternatively, the second layer 204 may be coupled to the first layer 202 before the first layer 202 is attached to the first side of the support structure 100. Attachment of the first layer 202 to the first side of the support structure 100 may be by any means known in the art, such as but not limited to threaded fasteners, rivets, nails, welding or brazing.

[0031] Figure 5 illustrates an exemplary ceiling subsystem 300 which comprises a third layer 302 and a plurality of layers of a fourth layer 304.

[0032] The third layer 302 comprises a combustion resistant insulation material, such as StoneWool® as produced by llnilin Insulation. Other materials, which may be Euro class A1 rated (or equivalently rated), are also suitable for the third layer 302. The third layer may have a thickness of 100 mm, or any other thickness as required by the design requirements of a specific implementation. Similarly, the third layer may have a density of 40 kg / m3, but may be of any commercially available density as required for a specific implementation. In a preferred embodiment, the third layer 302 is retained by the support struts 106 of the support structure 100. Alternatively, the third layer 302 may be retained by the primary support beams 102 of the support structure 100. As a further alternative, the third layer 302 may not be retained by any element of the support structure 100, but instead held in place by the fourth layer 304 positioned below the third layer 302. It will also be readily apparent that fixing means such as adhesives and clamps may be used to attach the third layer 302 to the second side of the support structure 100.

[0033] The fourth layer 304 comprises a plurality of layers of fire-resistant gypsum board, such as the Gyproc® FireLine® board as produced by British Gypsum. Any other fire-resistant gypsum board (also known as fire-resistant plasterboard) or calcium silicate ceiling system may also be used. Each layer of the fourth layer 304 preferably has a thickness of 15 mm, but may be of any commercially available thickness. Although four layers of gypsum board are shown in figure 5, it will be appreciated that any number (that is to say, one or more) of layers of gypsum board may be used according to the design requirements of the specific implementation. It should also be noted that depending on the span of the ceiling or design preference, more than one gypsum board may be used per layer. The gypsum boards for the fourth layer can bring various functions or performance, for example, acoustic property, water proof performance.

[0034] The plurality of layers of board may be called a board stack. The board stack may also include the third layer 302 insulating layer.

[0035] To restrict the passage of heat, smoke, and flames through the fourth layer 304, any gaps between boards (lying in the same layer or adjacent layers), may be at least partially filled with a jointing compound. Gaps between boards and surrounding walls may also be at least partially filled with the jointing compound. One such compound is Gyproc® ProTop© ready-mixed jointing compound, as produced by Saint-Gobain. It will, however, be clear to the skilled person that other jointing compounds may be used. In embodiments of the fourth layer 304 featuring more than one layer, the boards of each of the layers are preferably staggered so as to avoid the gaps between boards of the same layer overlapping with those of an adjacent layer as much as possible. In doing so, this practice allows for greater fire-resistance as there is no direct flow path for fire to circumnavigate the boards of the fourth layer 304. The gaps between boards on the layer of the fourth layer 304 furthest from the support structure 100 may be filled with a mesh tape before applying the jointing compound so as to form a seamless finishing appearance. Preferably, a Gyproc® reinforcement mesh tape is used. The gypsum boards of the fourth layer 304 may be coupled to the support structure, or adjacent layers of the fourth layer 304, using any means known in the art as discussed above. Preferably, the fixing means are self-drilling drywall screws.

[0036] When constructing the above-described system, a builder constructs the support structure such that it has a first side for holding the flooring sub-system, and a second side for supporting the ceiling sub-system. The flooring sub-system can be fitted to the support structure by attaching the first layer of sheet material to the support structure, and then the second layer can be coupled to the first layer. The ceiling sub-system can be fitted to the support structure by attaching the third layer support structure, and then coupling the fourth layer to the support structure. A fire-resistant and load-bearing structure for use as an intermediate level of a building is thereby constructed.

[0037] Attaching the third layer to the support structure may comprise placing the third layer within the support structure, and then attaching the at least one layer of the fourth layer of gypsum board to the support structure.

[0038] Attaching the fourth layer to the support structure may comprise attaching the plurality of layers of the fourth layer of gypsum board to the support structure in a staggered pattern. Doing so ensures that the joints between boards do not overlap. Any gaps between the boards may then be at least partially filled with the jointing compound. When constructing the above-described fire-resistant floor and ceiling system 10 and assembling its many components, some or all of the components may be coupled, attached or fixed together before then attaching the fixed together components to the relevant section of the system 10. That is to say that the system 10 may be constructed from its component parts in a stepwise manner in situ, or it may be almost entirely pre-constructed before then installing a large portion of the system to an already installed portion. It will be apparent to the skilled person that any number of variations on the theme are possible, and all are intended to be covered by the disclosure.

[0039] For example, the support structure 100 may be built in situ, i.e., in a building. Then, a pre-constructed flooring sub-system 200 comprising the first layer 202 and second layer 204 may be positioned and fixed to the support structure 100.

[0040] It will be appreciated that the dimensions and / or number of layers of any of the layers may be increased or decreased as required to achieve the desired firerating.

[0041] Similarly, beam dimensions and spacing may be modified in order to meet the desired load-bearing rating.

[0042] A sub-system may also be partially built in situ, and partially pre-constructed. For example, the third layer 302 may be positioned in the support structure 100 in situ, and then a pre-constructed fourth layer 304 comprising a plurality of layers coupled to the support structure 100.

[0043] It should be noted that each of the floor sub-system 200 and the ceiling subsystem 300 may be implemented separately. In doing so, the floor sub-system may be used as a ground floor of a building, and the ceiling sub-system 300 may be used between the top floor and a roof of a building.

[0044] Elements of the support structure may be defined as elements of either a floor system or a ceiling system without the requirement of the rest of the support structure. This is especially the case where, as described above, one of the floor sub-system and the ceiling sub-system is implemented independently. For example, the support struts 106 may be considered part of the ceiling system.

[0045] The above description outlines features of several examples or embodiments so that those of ordinary skill in the art may better understand various aspects of the present disclosure. Those of ordinary skill in the art should appreciate that they may readily use the present disclosure as a basis for designing or modifying other processes and structures for carrying out the same purposes and / or achieving the same advantages of various examples or embodiments introduced herein. Those of ordinary skill in the art should also realise that such equivalent constructions do not depart from the scope of the present disclosure, and that they may make various changes, substitutions, and alterations herein without departing from the scope of the present disclosure.

[0046] Although the subject matter has been described in language specific to structural features or methodological acts, it is to be understood that the subject matter of the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as example forms of implementing at least some of the claims.

[0047] Various operations of examples or embodiments are provided herein. The order in which some or all of the operations are described should not be construed to imply that these operations are necessarily order dependent. Alternative ordering will be appreciated having the benefit of this description. Further, it will be understood that not all operations are necessarily present in each embodiment provided herein. Also, it will be understood that not all operations are necessary in some examples or embodiments.

[0048] Moreover, "exemplary" is used herein to mean serving as an example, instance, illustration, etc., and not necessarily as advantageous. As used in this application, "or" is intended to mean an inclusive "or" rather than an exclusive "or". In addition, "a" and "an" as used in this application and the appended claims are generally be construed to mean "one or more" unless specified otherwise or clear from context to be directed to a singular form. Also, at least one of A and B and / or the like generally means A or B or both A and B. Furthermore, to the extent that "includes", "having", "has", "with", or variants thereof are used, such terms are intended to be inclusive in a manner similar to the term "comprising”. Also, unless specified otherwise, “first,” “second,” or the like are not intended to imply a temporal aspect, a spatial aspect, an ordering, etc. Rather, such terms are merely used as identifiers, names, etc. for features, elements, items, etc. For example, a first element and a second element generally correspond to element A and element B or two different or two identical elements or the same element.

[0049] When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

[0050] The terms “coupled to” or “attached to” mean either directly or indirectly coupled or attached to unless otherwise specified.

[0051] The invention may also broadly consist in the parts, elements, steps, examples and / or features referred to or indicated in the specification individually or collectively in any and all combinations of two or more said parts, elements, steps, examples and / or features. In particular, one or more features in any of the embodiments described herein may be combined with one or more features from any other embodiment(s) described herein.

[0052] Protection may be sought for any features disclosed in any one or more published documents referenced herein in combination with the present disclosure.

[0053] Although certain example embodiments of the invention have been described, the scope of the appended claims is not intended to be limited solely to these embodiments. The claims are to be construed literally, purposively, and / or to encompass equivalents. REPRESENTATIVE FEATURES

[0054] Representative features are set out in the following clauses, which stand alone or may be combined, in any combination, with one or more features disclosed in the text and / or drawings of the specification.

[0055] 1. A fire-resistant floor and ceiling system, comprising: a support structure having a first side and a second side; a flooring sub-system provided at the first side of the support structure, the flooring sub-system comprising: a first layer comprising a sheet material which is coupled to the first side of the support structure, and a second layer comprising fibre cement board and / or gypsum fibre board, the second layer being coupled to the first layer; and a ceiling sub-system provided at the second side of the support structure, the ceiling sub-system comprising: a third layer comprising combustion resistant insulation material which is coupled to the support structure, and a fourth layer comprising at least one layer of gypsum board, the fourth layer being coupled to the second side of the support structure, the system thereby providing a fire-resistant and load-bearing structure for use as an intermediate level of a building.

[0056] 2. The system of clause 1 , wherein the ceiling sub-system is positioned at least partially within the support structure.

[0057] 3. The system of clause 1 or clause 2, wherein the fourth layer comprises a plurality of layers of gypsum board.

[0058] 4. The system of any one of the preceding clauses, wherein each layer in the fourth layer comprises two or more boards positioned in the same plane. 5. The system of clause 4, wherein the plurality of boards in each layer of the fourth layer are staggered to prevent gaps in adjacent layers of the fourth layer overlapping.

[0059] 6. The system of any one of the preceding clauses, wherein gaps around edges of the boards of the fourth layer are filled at least partially with a jointing compound.

[0060] 7. The system of any one of the preceding clauses, wherein the sheet material of the first layer is of steel.

[0061] 8. The system of any one of the preceding clauses, wherein the sheet material of the first layer incorporates a mesh.

[0062] 9. The system of any one of the preceding clauses, wherein the support structure comprises primary support beams connected at each axial end to adjacent main support beams of the building.

[0063] 10. The system of clause 9, wherein the support structure further comprises joists connected at each axial end to adjacent primary support beams.

[0064] 11 . The system of any one of clauses 9 or 10, wherein the support structure further comprises a plurality of support struts positioned parallel to the primary support beams and spaced in a direction normal to a plane defined by the major axes of both the primary support beams and the main support beams.

[0065] 12. The system of clause 11 , wherein the support structure further comprises support strut bracing beams connected at one axial end to one of the plurality of support struts, and at the other axial end to another of the plurality of support struts. 13. A method of constructing a fire-resistant floor and ceiling system, comprising: providing a support structure having a first side and a second side; providing a flooring sub-system at the first side of the support structure by: attaching a first layer to the first side of the support structure, the first layer comprising a sheet material; and coupling a second layer to the first layer, the second layer comprising fibre cement board and / or gypsum fibre board; providing a ceiling sub-system at the second side of the support structure by: attaching a third layer to the second side of the support structure, the third layer comprising a combustion resistant insulation material; and coupling a fourth layer to the support structure, the fourth layer comprising at least one layer of gypsum board, thereby providing a fire-resistant and load-bearing structure for use as an intermediate level of a building.

[0066] 14. The method of clause 13, wherein attaching the third layer to the support structure comprises placing the third layer of non-combustible insulation within the support structure, and then attaching the at least one layer of the fourth layer of gypsum board to the support structure.

[0067] 15. The method of any one of clauses 13 and 14, wherein attaching the fourth layer to the support structure comprises: attaching the first layer of a plurality of layers of the fourth layer of gypsum board to the support structure; attaching each of the other of the plurality of layers of the fourth layer of gypsum board to an adjacent layer of the fourth layer in a staggered pattern such that the joints between boards do not overlap; and at least partially filling the joints between boards with a fire rated jointing compound. 16. A building comprising the fire-resistant floor and ceiling system of any one of clauses 1 to 12.

[0068] 17. A fire-resistant floor system for attaching to a plurality of main support beams of a building, the floor system comprising: a support structure, having a first side and a second side, and comprising primary support beams for connection at each axial end to adjacent main support beams of the building; a flooring sub-system provided at the first side of the support structure, the flooring sub-system comprising: a first layer comprising a sheet material which is coupled to the first side of the support structure, and a second layer coupled to the first layer, at least one of the first layer and the second layer being fire-resistant, the floor system thereby providing a fire-resistant and load-bearing structure for use as a floor of the building.

[0069] 18. The fire-resistant floor system of clause 17, wherein, the sheet material of the first layer is of steel.

[0070] 19. The fire-resistant floor system of clause 17 or 18, wherein the sheet material of the first layer incorporates a mesh.

[0071] 20. The fire-resistant floor system of any one of clauses 17 to 19, wherein the second layer comprises fibre cement board and / or gypsum fibre board.

[0072] 21 . The fire-resistant floor system of any one of clauses 17 to 20, wherein the support structure further comprises joists connected at each axial end to adjacent primary support beams.

[0073] 22. A building comprising the fire-resistant floor system of any one of clauses 17 to 21. 23. A fire-resistant ceiling system for attaching to a plurality of main support beams of a building, the ceiling system comprising: a plurality of support struts coupled to the plurality of main support beams; a board stack comprising a plurality of layers of board, the board stack coupled to the support struts, each board of the board stack selected from a group comprising fibre cement board, gypsum board, or a combination thereof.

[0074] 24. The fire-resistant ceiling system of clause 23, wherein the board stack comprises a layer of combustion resistant insulation material coupled to the support struts.

[0075] 25. The fire-resistant ceiling system of clause 23 or clause 24, wherein the board stack is positioned at least partially within the support structure.

[0076] 26. The fire-resistant ceiling system of any one of clauses 23 to 25, wherein each layer in the board stack comprises two or more boards positioned in the same plane.

[0077] 27. The fire-resistant ceiling system of clause 26, wherein the plurality of boards in each layer of the board stack are staggered to prevent gaps in adjacent layers of the board stack overlapping.

[0078] 28. The fire-resistant ceiling system of clause 27, wherein gaps around edges of the boards of the board stack are filled at least partially with a jointing compound.

[0079] 29. The fire-resistant ceiling system of any one of clauses 23 to 28, further comprising support strut bracing beams connected at one axial end to one of the plurality of support struts, and at the other axial end to another of the plurality of support struts. ethod for constructing the fire-resistant floor system of any one of clauses1 , comprising: providing the support structure having a first side and a second side; and providing a flooring sub-system at the first side of the support structure by: attaching a first layer to the first side of the support structure, the first layer comprising a sheet material; and coupling a second layer to the first layer. uilding comprising the fire-resistant ceiling system of any one of clauses 23

Claims

CLAIMS1. A fire-resistant floor and ceiling system, comprising: a support structure having a first side and a second side; a flooring sub-system provided at the first side of the support structure, the flooring sub-system comprising: a first layer comprising a sheet material which is coupled to the first side of the support structure, and a second layer comprising fibre cement board and / or gypsum fibre board, the second layer being coupled to the first layer; and a ceiling sub-system provided at the second side of the support structure, the ceiling sub-system comprising: a third layer comprising combustion resistant insulation material which is coupled to the support structure, and a fourth layer comprising at least one layer of gypsum board, the fourth layer being coupled to the second side of the support structure, the system thereby providing a fire-resistant and load-bearing structure for use as an intermediate level of a building.

2. The system of claim 1 , wherein the ceiling sub-system is positioned at least partially within the support structure.

3. The system of claim 1 or claim 2, wherein the fourth layer comprises a plurality of layers of gypsum board.

4. The system of any one of the preceding claims, wherein each layer in the fourth layer comprises two or more boards positioned in the same plane.

5. The system of claim 4, wherein the plurality of boards in each layer of the fourth layer are staggered to prevent gaps in adjacent layers of the fourth layer overlapping.

6. The system of any one of the preceding claims, wherein gaps around edges of the boards of the fourth layer are filled at least partially with a jointing compound.

7. The system of any one of the preceding claims, wherein the sheet material of the first layer is of steel.

8. The system of any one of the preceding claims, wherein the sheet material of the first layer incorporates a mesh.

9. The system of any one of the preceding claims, wherein the support structure comprises primary support beams connected at each axial end to adjacent main support beams of the building.

10. The system of claim 9, wherein the support structure further comprises joists connected at each axial end to adjacent primary support beams.11 . The system of any one of claims 9 or 10, wherein the support structure further comprises a plurality of support struts positioned parallel to the primary support beams and spaced in a direction normal to a plane defined by the major axes of both the primary support beams and the main support beams.

12. The system of claim 11 , wherein the support structure further comprises support strut bracing beams connected at one axial end to one of the plurality of support struts, and at the other axial end to another of the plurality of support struts.

13. A method of constructing a fire-resistant floor and ceiling system, comprising: providing a support structure having a first side and a second side; providing a flooring sub-system at the first side of the support structure by:attaching a first layer to the first side of the support structure, the first layer comprising a sheet material; and coupling a second layer to the first layer, the second layer comprising fibre cement board and / or gypsum fibre board; providing a ceiling sub-system at the second side of the support structure by: attaching a third layer to the second side of the support structure, the third layer comprising a combustion resistant insulation material; and coupling a fourth layer to the support structure, the fourth layer comprising at least one layer of gypsum board, thereby providing a fire-resistant and load-bearing structure for use as an intermediate level of a building.

14. The method of claim 13, wherein attaching the third layer to the support structure comprises placing the third layer of non-combustible insulation within the support structure, and then attaching the at least one layer of the fourth layer of gypsum board to the support structure.

15. The method of any one of claims 13 and 14, wherein attaching the fourth layer to the support structure comprises: attaching the first layer of a plurality of layers of the fourth layer of gypsum board to the support structure; attaching each of the other of the plurality of layers of the fourth layer of gypsum board to an adjacent layer of the fourth layer in a staggered pattern such that the joints between boards do not overlap; and at least partially filling the joints between boards with a fire rated jointing compound.

16. A building comprising the fire-resistant floor and ceiling system of any one of claims 1 to 12.2217. A fire-resistant floor system for attaching to a plurality of main support beams of a building, the floor system comprising: a support structure, having a first side and a second side, and comprising primary support beams for connection at each axial end to adjacent main support beams of the building; a flooring sub-system provided at the first side of the support structure, the flooring sub-system comprising: a first layer comprising a sheet material which is coupled to the first side of the support structure, and a second layer coupled to the first layer, at least one of the first layer and the second layer being fire-resistant, the floor system thereby providing a fire-resistant and load-bearing structure for use as a floor of the building.

18. The fire-resistant floor system of claim 17, wherein, the sheet material of the first layer is of steel.

19. The fire-resistant floor system of claim 17 or 18, wherein the sheet material of the first layer incorporates a mesh.

20. The fire-resistant floor system of any one of claims 17 to 19, wherein the second layer comprises fibre cement board and / or gypsum fibre board.21 . The fire-resistant floor system of any one of claims 17 to 20, wherein the support structure further comprises joists connected at each axial end to adjacent primary support beams.

22. A building comprising the fire-resistant floor system of any one of claims 17 to 21.

23. A fire-resistant ceiling system for attaching to a plurality of main support beams of a building, the ceiling system comprising: a plurality of support struts coupled to the plurality of main support beams;23 a board stack comprising a plurality of layers of board, the board stack coupled to the support struts, each board of the board stack selected from a group comprising fibre cement board, gypsum board, or a combination thereof.

24. The fire-resistant ceiling system of claim 23, wherein the board stack comprises a layer of combustion resistant insulation material coupled to the support struts.

25. The fire-resistant ceiling system of claim 23 or claim 24, wherein the board stack is positioned at least partially within the support structure.

26. The fire-resistant ceiling system of any one of claims 23 to 25, wherein each layer in the board stack comprises two or more boards positioned in the same plane.

27. The fire-resistant ceiling system of claim 26, wherein the plurality of boards in each layer of the board stack are staggered to prevent gaps in adjacent layers of the board stack overlapping.

28. The fire-resistant ceiling system of claim 27, wherein gaps around edges of the boards of the board stack are filled at least partially with a jointing compound.

29. The fire-resistant ceiling system of any one of claims 23 to 28, further comprising support strut bracing beams connected at one axial end to one of the plurality of support struts, and at the other axial end to another of the plurality of support struts.

30. A method for constructing the fire-resistant floor system of any one of claims 17 to 21 , comprising: providing the support structure having a first side and a second side; and providing a flooring sub-system at the first side of the support structure by:attaching a first layer to the first side of the support structure, the first layer comprising a sheet material; and coupling a second layer to the first layer. 31 . A building comprising the fire-resistant ceiling system of any one of claims 23-

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