Universal Fireproofing Patch Kit for Steel Structural Integrity
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Solution Overview
Problem
Existing fireproofing methods for structural steel are labor-intensive, expensive, and lack versatility, failing to maintain structural integrity and UL fire rating requirements in various environmental conditions.
Innovation Solution
A spreadable or sprayable cementitious fireproofing composition, packaged as a kit with a hydrating agent and mixing tool, that can be applied to any substrate, maintaining UL fire rating requirements and providing superior thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional spray fireproofing materials are used, then fire resistance is achieved, but the materials are labor-intensive and expensive to apply
Solution Approach 1:
The fireproofing system is divided into discrete patches that can be independently applied to steel surfaces. Each patch is a self-contained unit with fire-resistant properties, allowing for localized application rather than requiring complete surface coverage with traditional spray materials. This segmentation enables faster, more efficient installation while maintaining fire resistance ratings.
Solution Approach 2:
The patent employs disposable or easily replaceable fireproofing patches that can be quickly installed and removed if needed. These patches are designed as single-use or limited-life components that simplify the application process and reduce labor requirements compared to traditional spray systems that require extensive preparation and application time.
2Reliability
If masonry materials are used to encase steel, then fire protection is provided, but the process is slow and expensive with significant weight concerns
Solution Approach 1:
Instead of uniformly encasing steel members with heavy masonry materials, the invention applies fireproofing patches only to specific locations where fire protection is needed. This localized approach provides adequate fire protection while minimizing the addition of structural weight, as patches are applied selectively rather than covering entire surfaces with dense materials.
Solution Approach 2:
The fireproofing patches utilize composite material constructions that combine fire-resistant properties with lightweight characteristics. By using composite formulations rather than traditional heavy masonry, the patches achieve effective fire protection with significantly reduced weight, maintaining structural efficiency while meeting fire safety requirements.
3Reliability
If deluge sprinkler systems are installed, then structural integrity is protected, but water supply and runoff difficulties arise
Solution Approach 1:
The invention extracts the fire protection function from complex active sprinkler systems and embeds it directly into passive fireproofing patches applied to steel surfaces. This eliminates the need for water distribution networks, valves, and control systems while maintaining structural integrity protection during fires. The fire resistance is inherent in the patches themselves rather than requiring an active water-based system.
4Reliability
If spray fireproofing is applied to maintain structural integrity, then steel temperature is controlled, but the material must be applied correctly to function
Solution Approach 1:
The fireproofing patches are pre-manufactured with fire-resistant properties and proper thickness specifications before field installation. This preliminary preparation ensures that when patches are applied to steel surfaces, the correct fire protection level is achieved without requiring complex application procedures or specialized skills. The fire resistance is built into the patches during manufacturing, simplifying the installation process.
Solution Approach 2:
The invention changes the physical state or form of fireproofing material from spray-applied coatings to pre-formed patches with controlled dimensions and properties. This parameter change allows for easier handling and application while ensuring consistent fire protection performance. The patches can be directly installed without requiring spray equipment or specialized application techniques, reducing operational complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution offers a cost-effective, easy-to-use, and universally applicable fireproofing system that maintains structural integrity and exceeds 2-hour fire resistance ratings, outperforming existing methods in thermal protection and labor efficiency.
Implementation Method 1
The fire resistive material is designed to keep elevated temperatures away from the steel substrate by converting the captured water within the material to steam, over a specified period of time
Implementation Method 2
Spray applied fireproofing is designed to preserve the structural integrity of the 'assembly' that it seeks to protect by keeping the substrate, usually steel, at temperatures that are relatively cool
Implementation Method 3
Supplementing this basic water conversion process compliments additional reactions that contribute to this time delay including for example, reflection or deflection, absorption, self-combustion, and other endothermic reactions
Data Source
AI summary
Techniques and methods are disclosed for facilitating the fireproofing application process to the structural members of buildings (e.g., houses, apartment buildings, office buildings, sky-rises, etc.) and for improving the structural integrity of steel when exposed to extreme temperatures. The components of the Universal Fireproofing Patch provide a fireproofing protection product that exceeds Underwriters Laboratories fireproofing guidelines, which may be used under any circumstances (i.e., in the event the existing material to be fire-patched is either unknown or unavailable). The components of the Universal Fireproofing Patch enable a user the ability to coat a non-conforming area quickly, easily and for a fraction of the price compared to commercial patching services. Finally, the Universal Fireproofing Patch is sold as a kit that is comprised of a container, a premeasured quantity of water and fireproofing mix, a mixer, a trowel and an instrument capable of measuring liquids. The container provided in the kit stores the fireproofing mix, serves as a housing for when a user mixes the components together and is readily mobile for transporting purposes.