BARRICADING AND/OR GUARDING MESH PANEL

TECHNICAL FIELD

[0001 ] The present invention relates to a polymer mesh panel for barricading and/or guarding applications. In particular, the present invention relates to a polymer mesh panel for use in barricading, guarding, shielding, under stairway guarding, fencing and scaffolding applications. However, it will be appreciated by those skilled in the art that the mesh panel may be utilised in numerous alternative applications.

BACKGROUND OF THE INVENTION

[0002] The following discussion of the background to the invention is intended to facilitate an understanding of the invention. However, it should be appreciated that the discussion is not an acknowledgement or admission that any of the material referred to was published, known or part of the common general knowledge as at the priority date of the application.

[0003] Barricading and screening is widely used in applications such as guarding, temporary fencing and scaffolding to provide a physical barrier to impede persons or objects from falling.

[0004] Many barricading and screening arrangements make use of panels. These panels are constructed to generic standards and therefore can be widely used in other technology areas and in many situations where a physical barrier or screen is required. Examples include privacy screening, light or wind screening, traffic control, partitioning, security screening and other applications.

[0005] Furthermore, most conventional panels used in screening and guarding applications are currently manufactured from steel, aluminium or other metals or alloys thereof. One example is described in Australian Patent Publication 2012200673A1.

[0006] Metallic panels are not suited for use in all environments, for example in corrosive environments, such as some plants and factories. Metal panels are also often susceptible to oxidisation unless heavily galvanised with regular maintenance, especially in outdoor applications. In environments where the panel may be deployed in a salt laden atmosphere for example in vicinity to the ocean, the oxidisation rate may be severe and reduce the effectiveness or viability of such panels. In addition, in some hospitality, commercial, industrial and defence applications the use of certain metals may be prohibited. [0007] A further disadvantage inherent with metal panels is that they are typically heavy to transport and install. This can add to the cost of the project, and potentially exposes persons involved with the assembly and disassembly to physical injury from heavy lifting, such as back related injuries. As a result, significant manual and/or mechanical power may be required to install metal panels which increase the cost of the project to the end user.

[0008] Additional disadvantages include that the metal panel may conduct electricity in the event of a short circuit, and produces carbon dioxide gas during manufacture.

[0009] A still further disadvantage with metal panels is that they are inherently rigid and difficult or not suitable for mounting in any configuration where the panel is required to flex or bend to accommodate non-planar mounting points.

[0010] Extruded lengths of plastic netting have also been used for barrier material. One example disclosed in United States Patent 4,928,929 describes a safety netting for use at construction sites. The netting comprises an extruded high density polyethylene flexible unitary web including a main portion provided with an array of apertures to form a net-like lattice and a continuous bendable toeboard portion. The netting is flexible enough to allow the toeboard portion to be deformed and bent, but has a tensile strength sufficient to prevent motion of objects such as tools, bricks and other large construction materials past the safety netting at low to moderate speeds. The flexibility and material strength of this netting would not be sufficient to prevent a number of objects damaging the barrier.

[001 1 ] Other existing mesh products manufactured from polymeric material are produced for use in applications such as garden lattice. Such panels have physical and/or configuration properties unsuitable for barricading and screening applications. For example, a number of garden lattice panels are manufactured in a woven manner, similar to a fabric having weft and warp strands. Alternatively, they may be manufactured from extruded tubes which are overlayed in a horizontally and vertically extending matrix and heated to affect local bonding of the joins. This construction makes the joins between the vertical and horizontal portions weak, and prone to failure when loaded. In addition, the two stage manufacturing process is complicated which adds to manufacture costs.

[0012] A further disadvantage with existing polymer mesh products is that they typically suffer from problems such as distortion caused by the joint welding process, and inconsistency of joint quality. [0013] It would therefore be desirable to substantially overcome or at least ameliorate one or more of the above disadvantages, or to provide an alternative.

SUMMARY OF THE INVENTION

[0014] In a first aspect, the present invention provides an integrally formed polymer mesh panel for barricading and/or guarding applications, the polymer mesh panel having a tensile strength of at least 20 MPa and able to withstand an impact force of at least 200 N.

[0015] The polymer mesh panel according to the present invention comprises a mesh structure which has advantageous strength and impact properties particularly suitable for barricading, shielding and/or guarding applications. Advantageously, the mesh panel can be designed to provide the following benefits:

• absorb the impact of falling objects;

• decelerate the rate of fall and impede further fall;

• return to proximity of original state after impact; and

• restrain egress through the panel of a displaced object;

[0016] The configuration, dimensions, physical and compositional properties of the mesh panel contribute to provide these advantageous properties.

[0017] In this respect, the polymer mesh panel has a tensile strength of at least 20 MPa, more preferably at least 30 MPa, and even more preferably at least 40 MPa. In some embodiments, the tensile strength is between 20 and 200 MPa, preferably between 30 and 100MPa, and more preferably between 40 and 75 MPa.

[0018] The polymer mesh panel is also configured to be able to withstand an impact force of at least 200N, more preferably at least 300 N, yet more preferably 400 N, and even more preferably at least 500 N. In some embodiments, polymer mesh panel is also configured to be able to withstand an impact force of between 300 N and 1500 N, preferably between 400 N and 100 N, and more preferably between 500 N and 800 N.

[0019] Embodiments of the polymer mesh panel can also include other desirable properties.

[0020] For example, the polymer mesh panel preferably has a tensile modulus at least 1 GPa, more preferable at least 1.5GPa, even more preferably at least 2 GPa, and even more preferably at least 2.5 GPa. In some embodiments, the tensile modulus is between 1 GPa and 6 GPa, more preferably between 2 GPa and 5 GPa, and even more preferably between 2.5 GPa and 3.5 GPa. [0021 ] Furthermore, the polymer mesh preferably has an aerodynamic drag C _fig of less than 20, preferably less than 15, more preferably less than 10, even more preferably less than 7, even more preferably less than 3, yet even more preferably less than 1 . In some embodiments, the polymer mesh preferably has an aerodynamic drag C _fig of less than 0.5, and more preferably less than 0.4. In preferred embodiments, the polymer mesh preferably has an aerodynamic drag C _fig of between 0.1 and 20, more preferably between 0.2 and 5, and even more preferably between 0.3 and 1 .

[0022] The size, dimension and mass of the mesh panel can also influence the suitability of the mesh panel to barricading, shielding and/or guarding applications.

[0023] Preferred embodiments of the polymer mesh panel have a width by height of from 300 mm by 300 mm to 2 m by 2 m, more preferably from 500 mm by 500 mm to 1 .5 m by 1.5 m, and even more preferably between 800 mm by 800 mm to 1.2 m by 1 .2 m.

[0024] Furthermore, the polymer mesh preferably has a thickness from 2 mm to 20 mm, more preferably from 2 to 15 mm, even more preferably from 2 to 15 mm, and yet even more preferably from 3 mm to 7 mm. In one preferred embodiment the polymer mesh has a thickness of about 5 mm.

[0025] The polymer mesh panel preferably has a mass from 0.5 to 10 kg/m ² , more preferably from 0.5 to 5 kg/m ² , and yet more preferably between 1 and 3 kg/m ² .

[0026] The composition of the polymer can also have an influence. Preferably, the mesh panel is manufactured from one or more thermoplastic, thermosets, or elastomers. More preferably, the polymer comprises at least one homopolymer, copolymer, blend or alloy including polycarbonate, polyvinyl chloride, or polyacrylonitrile. In some embodiments, the polymer is an impact modified and UV stabilised polymer. Exemplary examples include impact modified polycarbonate, acrylonitrile butadiene styrene (ABS) and blends thereof with polycarbide, styrene polycarbide blends, Styrene maleic anhydride (SMA) and blends thereof with polycarbide, Styrene Methyl Methacrylate (S-MMA) and blends thereof with polycarbide, Acrylonitrile Ethylene Styrene (AES) and blends thereof with polycarbide, acrylonitrile styrene acrylate (ASA) and blends thereof with polycarbide, in particular an ASA/ polycarbide alloy. In an exemplary embodiment, the mesh panel is manufactured from Geloy HRA222F, Geloy HRA170D and/or UPVC. [0027] A large variety of mesh panel configurations can be utilised for the present invention. In some embodiments, the mesh panel comprises a matrix of longitudinal members integrally connected at a plurality of nodes. Each node at a non-edge or corner portion of the matrix is preferably the junction of four of said longitudinal members, such that the matrix defines a plurality of quadrilateral shaped units. Each quadrilateral shaped unit preferably comprises a regular polygon, preferably a four sided polygon, for example a square or a rectangle.

[0028] Each quadrilateral shaped unit is preferably sized from 5 mm x 5 mm to 100 mm x 100 mm, more preferably from 10 mm x 10 mm to 50 mm x 50 mm, and even more preferably from 20 mm x 20 mm to 35 mm to 35 mm. In one embodiment, quadrilateral shaped unit is sized 25 mm x 25 mm. In other embodiments, the quadrilateral shaped unit has a mean diameter between 10 mm and 100 mm, and preferably between 20 mm and 50 mm. In some embodiments, each quadrilateral shaped unit defines an aperture.

[0029] In these embodiments, each of the longitudinal members each can have a substantially constant cross-sectional shape and cross-sectional area. While the longitudinal member can have any particular cross-sectional shape, it is preferred that the longitudinal members each have a generally circular, generally square or generally rectangular cross- section.

[0030] The thickness of the longitudinal members can also influence the mechanical properties of the mesh. The longitudinal members preferably have a mean cross-sectional thickness from 2 mm to 20 mm, more preferably from 3 to 15 mm, and yet more preferably from 4 to 10 mm. In one preferred embodiment, the longitudinal members have a mean cross-sectional thickness of 5 mm.

[0031 ] The connecting nodes can also have a preferred configuration. Each of the nodes preferably has a common thickness and a common minimum abutment radius between adjacent longitudinal members.

[0032] In some embodiments, a web can be located in each quadrilateral shaped unit, the web extending between the longitudinal members. In some embodiments, the web has a thickness which is less than a cross-sectional width of each longitudinal member. In other embodiments, the web has a thickness which is greater than a cross-sectional width of each longitudinal member. [0033] In some embodiments, an aperture may be located in each web. The aperture is preferably located in a generally central portion of said web. The aperture can have a variety of shapes. For example, the aperture may have a generally, curved, polygon, square, rectangular shape, circle, ellipse, triangle or hexagon. However, it should be appreciated that the invention should not be limited to any one of those specific aperture shapes. In some embodiments, the aperture has a keyhole shape defined by a generally circular portion and an adjoining cut-out which is smaller in width than a diameter of the generally circular portion. In other embodiments, the aperture has a keyhole shape defined by a generally circular portion and an adjoining cut-out which is larger in width than a diameter of the generally circular portion.

[0034] Some embodiments of the mesh panel may further comprise a self-illuminating photo luminescent strip attached adjacent to the top and/or bottom of the mesh panel. This self- illuminating photo luminescent strip can be used to provide walkway evacuation guidance during a power outage in the area the mesh panel is installed.

[0035] The mesh panel of the first aspect of the present invention can be manufactured using a number of manufacturing methods.

[0036] In a second aspect, the mesh panel of the first aspect of the present invention is manufactured using an injection moulding process. In this aspect, the present invention provides a method of forming a mesh panel as described above, the method comprising the steps of:

heating a granular or pellet polymeric thermoplastic or thermoset material until the polymeric material is plastic and fluid enough to be extruded, formed or moulded;

injecting the heated polymeric material under pressure into a mould; and

ejecting the mesh panel from the mould after a cooling period has elapsed.

[0037] It should be appreciated that the mesh panel can be manufactured using other plastic moulding process, such as extrusion and/or calendaring.

[0038] In one example, an extrusion process could be used in which the mesh panel according to the first aspect is formed using a method comprising the steps of:

heating a granular or pellet polymeric thermoplastic or thermoset material until the polymeric material is plastic and fluid enough to be extruded, formed or moulded;

extruding the heated polymeric material through a profile tool,

cooling the extruded polymeric material in a liquid bath. [0039] The extrusion method can include the further steps of cutting the extruded polymeric material to required lengths. Apertures may be formed in the mesh panel by one or more of chemical, heat, microwave, ultra-sonic or vibration welding processes.

[0040] In another example, a calendaring process is used. The method of manufacturing the panel may therefore comprise the following steps:

heating a granular or pellet polymeric thermoplastic or thermoset material until the polymeric material is plastic and fluid enough to be extruded, formed or moulded;

calendaring the plastic fluid polymeric material from a Banbury mixer or large extruder;

shaping the polymeric material using two or more crowned rollers to form a generally flat sheet form; and

die cutting, stamping or routing the flat sheet form define apertures in the mesh panel.

BRIEF DESCRIPTION OF THE DRAWINGS

[0041 ] Preferred embodiments of the invention will now be described by way of specific examples with reference to the accompanying drawings, in which:

Figure 1 is a partial perspective view of a mesh panel according to a first embodiment;

Figure 2 is a front detail showing a portion of the mesh panel of the first embodiment depicted in Figure 1 .

Figure 3 is a partial perspective view of a mesh panel according to a second embodiment;

Figure 4 is a partial perspective view of a mesh panel according to a third embodiment;

Figure 5 is a partial perspective view of a mesh panel according to a fourth embodiment;

Figure 6 is a partial perspective view of a mesh panel according to a fifth embodiment;

Figure 7 is a partial perspective view of a mesh panel according to a sixth embodiment;

Figure 8 is a partial perspective view of a mesh panel according to a seventh embodiment;

Figure 9 is a partial perspective view of a mesh panel according to an eighth embodiment; Figure 10 is a partial perspective view of a mesh panel according to a ninth embodiment;

Figure 1 1 is a partial perspective view of a mesh panel according to a tenth embodiment;

Figure 12 is a partial perspective view of a mesh panel according to an eleventh embodiment; and

Figure 13 depicts an injection moulding process which can be utilised in manufacturing a mesh panel illustrated in each of Figures 1 to 12.

DETAILED DESCRIPTION PANEL CONFIGURATIONS

[0042] Figures 1 to 12 illustrate various possible configurations of mesh panel 20 according to the present invention. Each embodiment of the mesh panel 20 includes a grid matrix pattern therein, which prevents objects larger than the spacing of the matrix from falling off of an elevated surface or structure when installed. It should be appreciated that a mesh panel according to the present invention may be embodied in many different forms, and some embodiments of the panel 20 will be discussed below. However, the present invention should not be strictly limited to those embodiments.

[0043] Figure 1 is a partial view of an embodiment of a polymer mesh panel 20 defined by a matrix of panel members 52 each having a generally circular cross-section. A detailed front view showing a portion of the mesh panel 20 is included in Figure 2. A longitudinal axis of each panel member 52 is either generally perpendicular or generally co-axial with a longitudinal axis of each adjacent panel member 52, such that the mesh panel 20 defines a plurality of mesh units 53. In this embodiment, the entirety of the mesh units 53 form apertures in the mesh. The mesh units 53 can be generally square or generally rectangular depending on the height and width dimensions of the comprising panel member 52.

[0044] Figure 3 depicts an alternative embodiment of a mesh panel 20 defined by a matrix of generally rectangular members 52.

[0045] Figure 4 is an embodiment of a mesh panel 20 defined by a matrix of members 52 each having generally circular cross-sections. A web 54 is located in each mesh unit 53 extending between four panel members 52, and the webs 54 are formed between each repeating mesh unit 53 of the matrix defined by four of the members 52. [0046] In the embodiment of Figure 4, a circular aperture 56 is located in each web 54. The circular aperture 56 enables items to be secured to the panel 20, such as a mounting bracket for fastening the panel 20 to a support structure. In addition, the aperture 56 permits air to pass therethrough, facilitating a reduction in the wind loading on the structure.

[0047] Figure 5 is a further embodiment of a mesh panel 20. In this embodiment, the panel 20 is similar to the panel 20 described above with respect to Figure 4, however the members 52 have generally rectangular cross-sections.

[0048] Figure 6 is a further embodiment of a mesh panel 20. In this embodiment, the panel 20 is similar to the panel 20 described above with respect to Figure 4, however the apertures 56 are hexagonal.

[0049] Figure 7 is a further embodiment of a mesh panel 20. In this embodiment, the panel 20 is similar to the panel described above with respect to Figure 6, however the members 52 have generally rectangular cross-sections.

[0050] Figure 8 is a further embodiment of a mesh panel 20. In this embodiment, the panel 20 is similar to the panel 20 described above with respect to Figure 4, however the apertures 56 are triangular.

[0051 ] Figure 9 is a further embodiment of a mesh panel 20. In this embodiment, the panel 20 is similar to the panel described above with respect to Figure 8, however the members 52 have generally rectangular cross-sections.

[0052] Figure 10 is a further embodiment of a mesh panel 20. In this embodiment, the apertures 56 are keyhole shaped apertures. The keyhole shaped apertures 56 are defined by a generally circular portion 58, and an adjoining cut-out or slot 60 which is depicted smaller although may be larger in width than the diameter of the circular portion 58. The keyhole shaped apertures 56 can be used to secure a product to the mesh panel 20. While the embodiment of Figure 10 is depicted with rectangular cross-section, it may also be produced with a generally circular cross-section.

[0053] Whilst the cut-out 60 of the keyhole shaped apertures 56 is shown in the drawings directed downwardly, in other embodiments not shown in the drawings, the cut-out 60 may be angularly orientated at any position relative to the circular portion 58. [0054] Figure 1 1 is a further embodiment of a mesh panel 20. In this embodiment, the panel 20 is similar to the panel 20 described above with respect to Figure 4, however the apertures 56 are elliptical or oval shaped.

[0055] Figure 12 is a further embodiment of a mesh panel 20. In this embodiment, the panel 20 is similar to the panel described above with respect to Figure 1 1 , however the members 52 have generally rectangular cross-sections.

[0056] In each of the mesh panels depicted in Figures 1 to 12, the webs 54 provide improved levels of impact absorption, visual, noise and light screening. In addition, the web 54 provides increased diagonal bracing to the panel 20. Furthermore, the small aperture size 56 in the webs 54 provide a significant reduction in dropped object risk, to workers operating at lower levels on a construction site, as the size of any object capable of fitting through the apertures 56 would have to be relatively small.

[0057] The apertures 56 provide a suitable mounting point to secure other items, or alternatively to secure the panels 20 to a support structure such as a vertical post or railing, or other adjacent panels 20.

[0058] The apertures 56 advantageously permit the flow of air through the mesh panel 20, thereby significantly reducing the wind loading which may be experienced in some locations, and accordingly reducing the load applied to the support structure. The apertures 56 may be provided in other shapes. In practice, the apertures 56 may be of any curved or polygon shape, such as a pentagon, octagon etc.

[0059] While not illustrated, it should be understood that any of the illustrated mesh panel 20 embodiments in Figures 1 to 12 may be provided with a self-illuminating photo luminescent strip attached adjacent to the top and/or bottom or some other portion of the mesh panel to provide walkway evacuation guidance during a power outage.

[0060] It should also be understood that the mesh panel 20 can be designed and have a composition (as described below) which enables the panel to act as an immediate emergency flame and radiation inhibitor (when fire initiates outside the mesh panel 20) to assist in the protection of persons evacuating from the installation in which the panels are installed. [0061 ] Furthermore, it should be appreciated that when installed on site in a guarding, barricading or shielding application, mesh panel 20 is installed as a modular system and thus can have shared sections and/or panel members.

PHYSICAL AND MATERIAL PROPERTIES

[0062] Advantageously, the mesh panel 20 can be designed to provide the following benefits:

• absorb the impact of falling objects;

• decelerate the rate of fall and impede further fall;

• return to proximity of original state after impact;

• restrain egress through the panel of a displaced object;

[0063] In preferred embodiments, the mesh panel 20 can also be designed to:

• impede the splash of spilt liquids;

• act as an insulation medium in the event of an electrical short-circuit;

• provide a partial lee area in high wind situations; and

• provide a noise abatement amenity.

[0064] The configuration, dimensions, physical and compositional properties of the mesh panel contribute to provide these advantageous properties.

Panel Size

[0065] The mesh panel 20 may be manufactured in a variety of sizes. For most applications, the mesh panel 20 is manufactured between 300 mm x 300 mm to 2 m x 2 m. However, it should be appreciated that the panel could be manufactured in any shape or size, and may be cut down to any desired size or shape. In this respect, the mesh panel may be manufactured as a square, rectangular, or other regular four sided polygon within the above dimensions. For example, when used as a barricade for a walkway having a top rail, middle rail and kick plate, the mesh panel is preferably sized to fit 150 mm from the top rail and adapted to fit to the kick plate and middle rail. For Australian standards for railing, this typically requires a mesh panel size of 885 mm x 995 mm. In other applications, a mesh panel size of 1990 mm x 1690 mm, or 1990 mm x 845 mm may be used.

[0066] The mesh aperture (the opening formed by the entire mesh unit 53 in Figures 1 , 2 and 3, and shaped aperture 56 in other embodiments) size can also influence the properties of the mesh. The mean dimensions of the mesh aperture can vary from 10 mm x 10 mm to 100 mm x 100 mm depending on the size and application of the mesh. In many instances the mesh aperture size is from 20mm x 20 mm to 60 mm to 60 mm. It should be appreciated that the actual width and height of each mesh aperture can vary within those limits depending on the shape of the mesh aperture. For example, rectangular apertures would have a different width and height.

[0067] In an exemplary embodiment, the mesh apertures are 30 mm from centre to centre, and have an inside square size of 25mm, and outside square size of 35mm.

[0068] The thickness of the panel member 52 can also influence the mechanical properties of the mesh. The panel member 52 preferably has a mean cross-sectional thickness of from 2 mm to 20 mm, more preferably from 3 to 15 mm, and yet more preferably from 4 and 10 mm. In exemplary embodiments, the thickness of the panel member 52 is about 5 mm.

Panel Mass/Weight

[0069] The mesh panel 20 is preferably constructed light weight, having an installed mass of between 0.5 and 5 kg/m ² and more preferably between 1 to 3 kg/m ² . In some embodiments the mesh panel 20 can have an installed weight/mass of about 2.6 kg per metre ² attached.

Panel Thickness

[0070] The mesh panel 20 is preferably constructed to have a thickness of between 2 mm and 20 mm. In most cases, a thickness of less than 2 mm will not impart the desired mechanical properties to the mesh panel and a thickness of over 20mm would result in a heavy panel or a panel having too much wind drag. In most instances, it is desirable to have a mesh panel of between 2 mm and 10mm, and more preferably from 3 mm and 7 mm thickness.

Mechanical Properties

[0071 ] The mesh panel 20 can be manufactured and constructed from materials and in a particular configuration which has advantageous mechanical properties to meet the barricade and/or guarding function of the barricade or guarding arrangement the mesh panel 20 form a part. These mechanical properties are preferably:

• Tensile strength of at least 20 MPa;

• Tensile modulus of at least 1 GPa; and

• Impact resistance in which the panel is able to withstand an impact force of at least 200 N.

Other Properties [0072] The mesh panel 20 can be manufactured and constructed from materials and in a particular configuration which has other advantageous properties to meet the barricade and/or guarding function of the barricade or guarding arrangement the mesh panel 20 form a part. These other properties are preferably:

• An aerodynamic drag C _fig of less than 20, preferably less than 10. For an open mesh, as shown in Figures 1 and 2, it is preferably to have an aerodynamic drag C _fig of less than 1 .

• a wind loading of no greater than 2.5 times loading without the mesh. It is noted that wind loading will be greatly influenced by the shape and configuration of the mesh panel and apertures in the grid matrix of that panel;

• Meet fire resistance testing according to AS1530.2 and AS1530.3;

• Meets chemical resistance for Sulphuric Acid in accordance with ASTM D543, and for Shellsol Kerosene in accordance with ASTM D 543;

• Is resistant to ultraviolet degradation;

• Complies with UL94 Flame Rating;

• Complies with UL746C Outdoor suitability; and

• Complies with ISO 4589 Oxygen Index;

[0073] It should also be understood that relevant antistatic properties can be incorporated in to the mesh panel through the addition of an appropriate antistatic additive. Such an embodiment may be manufactured to meet require FRAS (Fire retardant anti-static) requirements for underground mining for example coal mines.

[0074] For applications in barricading, scaffolding and guarding, it is preferred that the mesh panel also meets the relevant standard for that application. Examples of relevant standards for Australia include AS1657 walkways Platforms and Stairways, Scaffolding AS 1576, Guidelines for Scaffolding AS 4576, and Safety of machinery AS 4024.1 and AS 4024.1601 - 2006.

[0075] Other embodiments of the mesh panel can be configured to meet the relevant United States Occupational Safety & Health Administration (OSHA) regulations including (but not limited to) Handrails etc - 1910.23, Machine Guarding - 1910.212 (General Requirements for all machines), Machine Guarding 1910.217 (Mechanical Power Presses), Scaffolding - 1910.28 - Safety Requirements. Additionally, embodiments of the mesh panel can be configured to meet the relevant United States Mine Safety & Health Administration (MSHA) Standards including (but not limited to) Guarding - 75.1722 Mechanical Equipment Guards, and Standard 56/57.141 12.

[0076] Similarly, embodiments of the mesh panel can be configured to meet the following ISO (International Organization for Standardization) standards: EN ISO 13857; ISO 13849.

[0077] Embodiments of the mesh panel can be configured to meet the following British Standards: EN 953; EN 954.

[0078] Embodiments of the mesh panel can be configured to meet Canadian Standards (CSA) Standard Z432.

[0079] Similarly, embodiments of the mesh panel can be configured to meet one or more of the relevant ASIA-OSH (Asian-Pacific Regional Network on Occupational Safety and Health Information) standards, including 1202 Provisions of Guards; 1203 Standard Machinery Guards; 1204 Machine Guard at Point of Operation; 1205 Transmission Machinery Guarding; 1206 Woodworking Machinery; 1207 Guarding Mechanical Power Presses and Foot and Hand Power Presses; 1068 Overhead Walks, Runways and Platforms; 1414 Scaffoldings; 1415 Construction Equipment; 1416 Plant and Equipment; 1061 Construction and Maintenance; 1062 Space Requirement; 1063 Walkway Surface; 1064 Floor and Wall Opening; 1065 Stairs; 1066 Window Openings; 1068 Overhead Walks, Runways and Platforms; 1069 Yards.

[0080] It should be appreciated that above list of standards is only a sample of the relevant standards that the mesh panel can be configured to meet, and the invention should not be limited to that list. The mesh panel can be configured to meet a number of other standards required for various jurisdictions, states, countries and/or regions in which that mesh panel is used.

MATERIAL COMPOSITION

[0081 ] The mesh panel 20 of the present invention can be manufactured from a large variety of polymer material compositions to provide the above referred advantageous properties.

[0082] It should be understood that a large number of polymers may be used, a number with selected polymer additives to enhance or provide specific desired properties. In addition, colorants may be added in the process to control the colour of the final part. Useful polymers include all thermoplastics, some thermosets, and some elastomers. [0083] The selection of a material for creating moulded parts is not solely based upon the desired characteristics of the final part. While each material has different properties that will affect the strength and function of the final part, these properties also dictate the parameters used in processing these materials. Each material requires a different set of processing parameters in the moulding process, including the temperature, pressure, mould temperature, ejection temperature, and cycle time.

[0084] The following polymer materials, including homopolymers, copolymers, blends, alloys and/or other combinations may be used in manufacturing the mesh panel 20 of the present invention:

• Acetal (POM)

• Acrylic (PMMA)

• Acrylonitrile Butadiene Styrene (ABS)

• Cellulose Acetate (CA)

• Polyamide 6 (Nylon) (PA6)

• Polyamide 6/6 (Nylon) (PA6/6)

• Polyamide 1 1 +12 (Nylon) (PA1 1 +12)

• Polycarbonate (PC)

• Polyester - Thermoplastic (PBT, PET)

• Polyether Sulphone (PES)

• Polyether Ether Ketone (PEEKEEK)

• Polyetherimide (PEI)

• Polyethylene - Low Density (LDPE)

- High Density (HDPE)

• Polyphenylene Oxide (PPO)

• Polyphenylene Sulphide (PPS)

• Polypropylene (PP)

• Polystyrene - General Purpose (GPPS)

- High Impact (HIPS)

• Polyvinyl Chloride - Plasticised (PVC)

- Rigid (UPVC)

• Styrene Acrylonitrile (SAN)

• Thermoplastic Elastomer/ Rubber (TPE/R) [0085] In addition to the materials listed above, the following materials may also be used to produce the mesh panel 20:

• Polypropylene = PP, PP CS, any PP random copolymers;

• Geloy resins, blends and alloys = ASA, ASA+AMSAN, ASA+PC, ASA+SAN;

• Geloy HRA222F resin;

• Geloy HRA170D resin;

• Nylon and/or blends;

• Acrylics - PMMA materials;

• ABS;

• Polyesters - PET, PES, APET;

• Polystyrene - EPS, PS, also any blends;

• Polyethylene - LLDPE, HDPE, LDPE;

• Polycarbonate blends - Lexan, Calibre, Makrolon, PBT+ PC, PC, PC+ABS, PEC, PPC, PPC+PC;

• PEEKEEK, PET, PES blends;

• PVC and/or UPVC blends, SPVC;

• All Cycolac resins;

• ASA/PVC blends; and/or

• Ultra High Molecular Weight Polyethylene, UHMWPE, UHMW, HMPE, HPPE

[0086] In an exemplary embodiment, the mesh panel 20 is manufactured from Geloy HRA222F/HRA170D and/or UPVC. Geloy HRA222F is a multi-purpose, chlorine and bromine free flame retardant ASA-PC alloy for injection moulding processes. Geloy HRA222F is advantageous because the base Polycarbonate (PC) polymer has a high tensile strength and Impact Resistance. The addition of Acrylonitrile Styrene Acrylate (ASA) gives good UV resistance, flame resistance and chemical resistance properties. These properties are desirable in the mining and construction industries.

MANUFACTURING PROCESSES

[0087] The mesh panel 20 may be manufactured through a number of polymer forming processes, some of which are described in more detail below:

Injection moulding

[0088] Each mesh panel 20 of the present invention is preferably manufactured using an injection moulding process. A general schematic of an injection moulding process which can be used to manufacture a mesh panel 20 is depicted in Figure 13. In this process, a selected polymer/ plastic (as previously described) typically commences as granular particles or pellets 22 which are melted in an injection moulding machine 24. The melted plastic is then injected under pressure into a mould 30, where it cools and solidifies in a short period of time. The mould 30 is typically manufactured from steel or aluminium or other metal.

[0089] The mesh panel 20 of the present invention is preferably is currently injection moulded as a unitary product in a single mould. The mesh panels 20 are typically large elements, measuring anywhere between 300mm x 300mm to 2m x 2m. A single unitary moulded panel unit therefore requires a large mould 30.

[0090] The stages of the injection moulding process will now be described in more detail.

[0091 ] Prior to the injection of the material into the mould 30, the two halves 32, 34 of the mould 30 are securely closed by the clamping unit. Each of the two halves 32, 34 of the mould 30 is attached to the injection moulding machine 24 and one half is permitted to slide (open and close). A hydraulic or electric powered clamping unit closes the mould 30 halves 32, 34 together and exerts sufficient force to keep the mould 30 securely closed while the required volume of plastic material 22 is injected.

[0092] The raw plastic material 22, usually in the form of granules or pellets, is fed into the injection moulding machine and may be coloured by using pre-coloured master batch or a colour dosing attachment to the moulding machine 24, and advances towards the mould 30 by the injection unit, ram injector or reciprocating screw. During this process, the material is melted by a combination of heat and/or pressure. The molten plastic fluid is then injected into the mould 30 and the build-up of pressure packs and moulds the material. The amount of material that is injected is referred to as the shot.

[0093] The molten plastic 22 that is inside the mould 30 begins to cool (via water channels which keep the mould at a desired temperature) as soon as it makes contact with the interior mould 30 surfaces. As the plastic 22 cools within the mould 30, it will solidify into the shape of the mesh panel 20. However, during cooling some shrinkage of the moulded component will occur and is catered for in the mould design.

[0094] After sufficient time has elapsed, the cooled mesh panel 20 is ejected from the mould 30 by an ejection system, which is attached to the rear half of the mould 30. When the mould 30 is opened, a mechanism is used to push the mesh panel 20 out of the mould 30. Force must be applied to eject the part because during cooling the mesh panel 20 may shrink and adhere to the mould 30. In order to facilitate the ejection of the mesh panel 20, a mould release agent may be sprayed onto the inner surfaces of the mould 30 cavity prior to injection of the plastic material 22. Once the part is ejected, the mould 30 can be again clamped shut for the next shot to be injected. After the injection moulding cycle, some post processing may be applied to the mesh panel 20 to remove any seam lines, sprue or ejector pin marks or other visible manufacturing marks.

Compression Moulding

[0095] Various embodiments of the mesh panel may be manufactured using a compression moulding process. In this process (not illustrated), the polymer material to be moulded is placed in the mould cavity and the heated platens are closed by hydraulic ram. Thermoset resins, either bulk moulding compound (BMC) or sheet moulding compound (SMC), are conformed to the mould shape by the applied pressure and heated until a curing reaction occurs. SMC feed material usually is cut to conform to the surface area of the mould. The mould is then cooled and the part removed.

[0096] Thermoplastic resins may be loaded into the mould either in the form of pellets or sheet, or the mould may be loaded from a plasticating extruder. Thermoplastic materials are heated above their melting points, formed by the mould and cooled.

Calendering

[0097] Calendering describes a process of feeding a molten plastic material between two or more crowned calender rollers from a Banbury mixer or a large extruder, the resultant sheet is fed onto a table to cool. For the present mesh panel, a plastic sheet can be formed using this process and on cooling the sheet may be punched or die cut into a mesh formatted appearance.

[0098] PVC is the major calendared material. However, it should be appreciated that other thermoplastics may be used.

Extrusion

[0099] While moulding parts using thermoplastics is widely understood, the extrusion of thermoplastic into profiles is less understood. Profile extrusion produces primarily constant cross-section parts that are subsequently cut into finite lengths. [00100] A basic description of the process is melt the raw material, shape it into the required profile by pushing the plastic material through a die, on leaving the die cool the profile while hauling the profile to a docking saw and cutting to required length.

[00101] In the extrusion process, the thermoplastic materials in pellet or powder form, are heated using electrical heat or frictional heat in an extruder until in a molten plastic state and then by single or twin screw auger feed fed through a die with an opening or openings that shape the material into the designed profile configuration.

[00102] As the material (extrudate) exits the die the profile is cooled by vacuum or calibration or water bath or air template systems with the extrudate being hauled by the haul- off to the cutting or docking unit.

[00103] Following extrusion the profile may be fabricated into a permanent mesh form by the use of a template and heat for example hot plate, or chemical or laser or microwave or radio frequency or ultrasonic or vibration welding.

[00104] Extrusion materials are generally similar to those used in moulding - except as moulding materials flow easily and fill moulds they are difficult to extrude as extrusion materials must exit the die in a very stiff state known as the melt flow index (mfi) melt strength, melt stiffness, etc with the melt viscosity commonly shown as the material melt flow rate. Extrusion materials generally have a melt flow index of less than 1 while injection moulding materials typically exceed 8. Materials commonly extruded include PVC, ABS, Polypropylene, Polyethylene, Thermoplastic Elastomers, Polycarbonate, Aramids and many others.

Other Moulding Processes

[00105] It should be appreciated that it may be possible to use other established plastic moulding manufacturing process, including rotational moulding, contact moulding, blow moulding and/or thermoforming to manufacture a mesh panel 20 according to the present invention.

EXAMPLES

[00106] A test mesh panel was constructed in accordance with the mesh panel 20 embodiment illustrated in Figures 1 and 2. The test mesh panel comprised a panel section having the dimensions of 885 mm x 995 mm, 5 mm thickness. The test mesh panel included mesh apertures (mesh units 52 in Figure 1 ) which are spaced apart 30 mm from centre to centre, and have an inside square size of 25mm, and outside square size of 35mm. The test mesh panel was also formed from a matrix of panel members (component 52 in Figure 1 ) having a thickness of 5 mm. The mesh panel was manufactured from polymer comprising Geloy HRA222F/HRA170D.

[00107] The test mesh panel or representative parts thereof were tested according to a number of standard tests for the relevant properties.

Example 1 - Mechanical Properties

[00108] The test mesh panel or representative parts thereof were tested according to a number of standard tests for desired mechanical properties. The results for mechanical properties, including tensile strength - break and yield, elongation - break and yield, and Tensile modulus are provided in Table 1.

[00109] Table 1 : Mesh Panel material data.

Example 2 - Impact Resistance

[001 10] A mesh panel of the subject test mesh panel configuration was tested according to a four different standard tests to provide impact resistance data. The most applicable Australian Standard was AS 1 170.2, which specifies speed, mass and face dimensions for impact based on the requirement to withstand flying debris in cyclone conditions. This level was used as a guideline to determine the impact test level attained by mesh panel 20.

Method 1 : Pressure deflection test.

[001 1 1] A distributed load was applied to the test mesh panel to replicate the design test case of 1 .8kPa pressure on the barrier. The load was applied using water filled 'sand' bags of 154kg total mass. This load was applied to the mesh panel in typical configuration attached to the handrail, from the outward face of the mesh. Failure of the mesh panel was considered to be the point where a mesh element of the test mesh panel was broken.

[001 12] Peak deflection of the test mesh panel with and without loading was measured to determine the deflection under this load. Peak deflection of 130mm was measured. The ability or otherwise of the mesh panel to return to its original position prior to deflection was also noted. The mesh panel returned to its original position after the 'sand' bags were removed and no damage to the mesh panel was noted.

Method 2: Vertical drop test on Mesh Panel simply supported.

[001 13] Impact testing was performed on a single test mesh panel of the subject configuration laying horizontally, supported at the edges only with masses dropped from vertically above. Masses of 1 to 7 kg in increments of 1 kg were dropped on the test mesh panel.

[001 14] The test mesh panel did not fail under loads up to 7kg. The maximum deflection of the mesh panel was for the 7kg load at 130mm and the mesh panel returned to the undeflected position when the mass was removed. The impact force and impact energy sustained by the test mesh panel is summarised in Table 2.

[001 15] Table 2: Impact force applied to mesh panel, impact speed for 5 m/s

Mass (kg) Deflection (mm) Impact Energy (J) Impact force (N)

1 50 12.5 250

2 25

3 37.5

4 1 10 50 454

5 62.5

6 75

7 130 87.5 673 Method 3: Vertical drop test on Mesh Panel attached to a Handrail Section.

[001 16] A single test mesh panel of the subject configuration was fixed to a horizontal handrail section of a test rig and was tested with the mesh in the horizontal positions and masses dropped from vertically above. Masses of 1 to 4 kg at impact speed of 5m/s were applied without failure of the mesh. A summary of the test results is provided in Table 3.

[001 17] Table 3: Impact force applied to mesh panel installed on handrail, impact speed 5 m/s

Method 4: Pendulum test on Mesh Panel attached to a Handrail Section.

[001 18] Masses fixed to a 4 m pendulum were applied to a handrail mounted in the usual, upright position in a test rig. A mesh panel of the subject test mesh panel configuration was affixed to the handrail and was tested with typical hand tools fixed to a pendulum. As a result of these tests, the Barrier was shown to withstand impact loads typical of its in service use. The Barrier was shown to withstand a 4kg load travelling at 0.1 VR for VR = 50 ms-1. A summary of the results is provided in table 4.

[001 19] Table 4: Impact force applied to mesh panel applied to handrail, via pendulum

[00120] When the mass struck the mesh horizontally, affixed to a pendulum, the maximum impact energy sustained was 50.6 J at 4.5 ms ^"1 resulting in an impact force of 723 N.

[00121] These loads indicate that the Barrier will resist windborne debris at a level suitable for its purpose. The impact loads tested are also in excess of expected tool loads.

Example 3 - Wind testing

[00122] A test mesh panel of the subject configuration was subjected to wind tunnel testing to measure drag and C _fig (aerodynamic shape factor) values of the barrier attached to a standard handrail system, as well as the strength of the panel connection clips and force exerted on the platform to which they are attached in wind conditions between 0 and 50 m/s (180km/h).

[00123] A baseline assessment of the handrail section was taken without the test mesh panel installed and compared against the results from the test on a combined mesh and handrail section. The test mesh panel was also tested in conjunction with a vertical joiner strip and mounting clips, for example as described and illustrated in the applicant's copending international patent application PCT/AU201 1/001 165, the contents of should be understood to be incorporated into this specification by this reference.

[00124] The impact of the mesh panel attached with standard mounting clips (for example as described and illustrated in the applicant's co-pending international patent application PCT/AU201 1/001 165) on the wind loading of a handrail section is to increase the wind load by 75 - 85% of the wind load without the mesh for wind speeds between 0 and 50 m/s (0 - 180 km/h). A conservative estimate of wind load increase due to the mesh panel was 1 .85 times loading without mesh.

[00125] For a typical design arrangement with vertical joining strips (for example as described and illustrated in the applicant's co-pending international patent application PCT/AU201 1/001 165) the wind load is increased to between 2 and 2.1 times the loading without safety barricading.

[00126] The single panel and handrail assembly and an L-shaped assembly were tested for strength under a constant 50m/s (180 km/h) wind. The L-shaped assembly was rotated through 360° over 12 minutes under the constant 180 km/h wind flow.

[00127] The aerodynamic drag (C _fig ) for the various test configurations were determined for comparison. C _fig for the mesh panel is determined based on reference area, Az, which, for wind normal to the mesh panel, is 0.841 m ² (0.995 x 0.845 m ² ) the area enclosed by the external dimensions of the mesh panel. The reference area for wind at an angle other than normal to the mesh panel is the projection of the area in the direction normal to the wind direction.

[00128] The highest drag resulted from a yaw angle of 0 degrees, equating to the mesh panel on the leeward side of the handrail assembly. This force is also the worst case for failure of the mesh panel (tending to 'blow' the mesh off the handrail assembly). This configuration was be used to determine C _d and C _fig for calculations according to AS 1 170.2. [00129] A summary of Wind Testing Results is provided in Table 5.

[00130] Table 5: Wind drag force on single mesh panel with clip fittings but no solid joiners.

[00131] Both assemblies withstood the wind without failure of standard components (mounting clips or mesh panel).

[00132] The mesh panel deformed at least 50mm under maximum applied wind load but did not sustain any damage. The mounting clips did not fail under this load. Significant (>10mm) deflection of the mesh panel only occurred for wind speeds of 40 m/s and above.

Example 4 - Fire Resistance according to BCA, AS 1530.2, AS1530.3, UL94

[00133] The subject test mesh panel was found to meet the fire resistance testing according to AS1530.2 and AS1530.3. This indicates an equivalent or better result than standard building materials and below limits required by the Building Code of Australia

(BCA).

• Flammability Index: 1 (Range 0 - 100 for most material)

• Spread Factor: 0 (Range 0-40)

• Heat Factor: 1 (Range 0 - upward) Maximum height (d) mean 1.8

• Heat (a) mean 1.5 °C min

• No of specimens tested 6

Example 5 - Test Results Summary

[00134] Table 6 provides a summary of the properties and tests that the subject test mesh panel achieved: [00135] Table 6: Test Result Summary

[00136] It is to be understood that the polymer mesh panel of the present invention comprises a mesh structure which has advantageous strength and impact properties particularly suitable for barricading, shielding and/or guarding applications, including barrier guarding applications. Each specific application includes specific local, state and national specification and/or standards to which that barrier or shield must comply. For example barrier guarding applications of the mesh do not completely surround danger zones but rather restrict or prevent access by their size and separation from the danger zone, and there must be no wilful act to reach the danger zone. Such barrier guards must be placed at a safe distance in accordance with the relevant minimum standards that may apply to the country or state.

[00137] Those skilled in the art will appreciate that the invention described herein is susceptible to variations and modifications other than those specifically described. It is understood that the invention includes all such variations and modifications which fall within the spirit and scope of the present invention.

[00138] Where the terms "comprise", "comprises", "comprised" or "comprising" are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other feature, integer, step, component or group thereof.