The present invention relates generally to building construction using cement-based wallboard panels, and more specifically relates to apparatus for securing adjacent panels to building frames.
Exterior walls of buildings serve a number of different functions. Specifically, exterior walls provide structural support and resist uniform, lateral, axial and concentrated loads applied to the building. Additionally, exterior walls act as a water, vapor and air barrier for the building. Further, exterior walls provide protection from flying debris during storms and are noncombustible. While providing these functions, it is desired to reduce the overall thickness of the exterior walls.
Many modern buildings use a steel frame within the exterior structural walls. Typically, noncombustible paneling is attached to the steel frame members. Such panels are also used to form sub-floors and as such are secured to building frame members or to concrete floor pads. This noncombustible paneling sometimes includes cement panels. For example, U.S. Pat. No. 8,079,198 to Tonyan et al., incorporated herein by reference, discloses a residential and commercial construction including a metal frame and lightweight cement panel shear wall. The shear wall is made from a mixture of inorganic binder and lightweight fillers. The combination of a metal frame with cement panels results in the noncombustible shear wall system.
Additionally, U.S. Pat. No. 8,122,679 to Tonyan et al., incorporated herein by reference, discloses wall systems having cement panels employed on metal frames. In particular, the disclosed wall system includes structural cement panels which are mechanically and/or adhesively fastened to a fire wall or other fire resistive assembly light gauge cold formed metal framing system, which acts as a shear resistant diaphragm. Moreover, U.S. Pat. No. 8,061,108 to Tonyan et al., incorporated herein by reference, discloses a foundation system which includes metal framing members that support a reinforced, lightweight, dimensionally stable cementitious panel.
However, conventional buildings which utilize a steel frame with noncombustible panels also include sheet steel cross-strapping or complete sheets of steel, referred to as shear walls, to resist lateral loading. Moreover, the steel frame typically includes high gauge studs for accommodating axial loading. In some cases, especially when used to form sub-floors, the cement panels are provided with tongue-in-groove edge construction for enhancing stability of the resulting assembled sub-floor. In such construction, adjacent panels support neighboring panels when loads are applied. However, the creation of panels with tongue-in-groove edges is relatively expensive and time consuming.
In conventional construction, wall panels, whether made of conventional wallboard or the relatively heavier duty cement fiber panels discussed above, are secured to underlying building frames using fasteners. The building frames are traditionally wood, but more frequently, steel “C”-shaped studs are employed. Building panels are dimensioned to be attached to frame members, including vertical studs and horizontal headers and footers. The vertical studs are spaced according to local building codes, such as 16-inch on center spacing.
In the case of buildings constructed using cement fiber panels, which are often in an exterior application, due to environmental factors such as high winds, the panels are often subject to shear forces that induce vertical and or horizontal movement of the panel against the holding force of the fasteners. In many cases, this movement of the panels causes the fasteners to pull out of the frame, or the panel to pull away from the fastener.
Another drawback of conventional building systems is that especially when the building frame has an irregular shape, the dimensions of the panel may not coincide with the spacing of the vertical frame members. As such, it is not unusual for two adjacent panels to meet at a place where there is no properly positioned vertical frame member. In such cases installers need to install a supplemental vertical frame member, which adds to the cost of the building in both material and labor to achieve the desired building strength integrity.
In other cases, when two adjacent panels meet at a vertical frame member, they share the relatively narrow space provided for receiving a fastener to retain the panel to the frame. Operators are often challenged to install the fasteners to properly engage the frame member, while not placing the fastener overly close to the edge of the panel in a way that causes panel fracture. In some cases, placement of fasteners too close to the panel edge has been known to weaken the panel. The required additional installer attention to the assembly process delays the building construction and as such adds to the costs.
Thus, there is a need for an improved building system that accommodates the attachment of adjacent building panels to avoid the drawbacks discussed above.
The above-listed need is met or exceeded by the present building systems which provide specialized brackets for securing adjacent cement-based wallboard panels together. In some cases, adjacent panels of this type are attachable without the use of a supporting vertical frame member or stud. Upon assembly, the two adjacent panels act physically as one continuous panel. In a floor application, the assembled panels provide a joint that is stronger than a conventional tongue-in-groove joint. When used as a shearwall on an interior or exterior of a building, the present system provides a blocked panel configuration to increase the assembled load carrying capabilities.
Included in one embodiment of the present system are brackets having a rough “H”-shape when viewed from above, creating back-to-back recesses dimensioned for accommodating edges of adjacent cement-based wallboard panels. Specialized threaded fasteners are used to secure the edges of each panel between arms of the adjacent recess.
As the fasteners are fully installed and tightened, the opposing arms, webs or flanges of the H-bracket are pulled together around the panel edge, creating a pinching effect that more securely holds the panels in position. In some applications, the resulting assembly is strong enough that a corresponding vertical building frame stud is not needed at the seam defined by adjacent cement-based panels. Accordingly, when constructing a building using cement-based panels and the present bracket system, there is less cutting and fitting of panels to correspond to existing vertical stud spacing on the building frame. As such, construction speed is increased.
Once the adjacent panel edges are secured in this manner, the resulting assembly is relatively resistant to vertical or lateral shear forces exerted on the building by severe weather. Also, the panels are held more securely than in conventional construction systems, as the fasteners are less prone to loosening and unwanted falling out, as well as less prone to causing local panel failure at the point of fastener attachment. When used in the construction of a building having a conventional steel frame, the present system provides an alternative procedure for securing adjacent panels without the need for attachment of the panels at their seam to an adjacent frame member.
More specifically, a building system for attaching adjacent wallboard panels together during building construction involving attachment of wallboard panels to members of a building frame, is provided, including a first wallboard panel having a first panel edge; a second wallboard panel having a second panel edge, the second panel edge being adjacent the first panel edge; a bracket defining a first attachment location for the first panel edge, and a second panel attachment location for the second panel edge so that second panel edge is held adjacent the first panel edge; and at least one first fastener securing the first panel edge in the first attachment location, and at least one second fastener securing the second panel edge in the second attachment location.
In an embodiment, the bracket is “H”-shaped when viewed from above. In another embodiment, the bracket is “Z”-shaped when viewed from above. In still another embodiment, the bracket is “T”-shaped when viewed from above.
In an embodiment, the bracket is provided in two, “U”-shaped components having clips for releasable fastening to each other in back-to-back configuration. In an embodiment, the fastener has a self-drilling tip. In a preferred embodiment, the fastener is a TEK™-type or Simpson Strong-Tie™ fastener. In a preferred embodiment, the bracket secures the first panel edge to the second panel edge independently of attachment of the panels to the building frame.
In another embodiment, a bracket is provided for use in a building system for attaching adjacent wallboard panels together during building construction involving attachment of wallboard panels to members of a building frame, the system including a first wallboard panel having a first panel edge, a second wallboard panel having a second panel edge, the second panel edge being adjacent the first panel edge. The bracket includes a first attachment location configured for accommodating the first panel edge, and a second panel attachment location configured for accommodating the second panel edge so that second panel edge is held adjacent the first panel edge; and each attachment location is configured for accommodating at least one first fastener securing the first panel edge in the first attachment location, and at least one second fastener securing the second panel edge in the second attachment location.
In an embodiment, the bracket is one of “H”-shaped, “Z”-shaped and “T”-shaped when viewed from above. In an embodiment, the bracket is provided in two “U”-shaped components having clip formations for releasably fastening the components together in back-to-back configuration.
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When wallboard panels 18 are secured to the building frame 12 as through the use of fasteners 20, it often occurs that the dimensions of a particular wallboard panel 18a do not fully line up with the studs 14 of the building frame 12. In such cases, the panels 18a need to be trimmed so that an edge of the panel overlaps one half of an adjacent stud 14, allowing sufficient space for the next adjacent panel to be secured in place on the frame. Alternately, an additional stud is inserted into the frame to support the panel edge.
While in the present application, “wallboard panel” is generally understood to mean fiber-reinforced cement panels used for exterior construction, also referred to as “cement panels,” it is also contemplated that the term is applicable to paper-faced gypsum wallboard panels or other modified types of construction panels, whether used for interior or exterior construction. Regarding the fiber-reinforced cement panels, they are in one embodiment disclosed in commonly-assigned U.S. Pat. Nos. 8,079,198; 8,122,679; and. 8,061,108, all of which are incorporated herein by reference.
A feature of the present building system 10 is that adjacent wallboard panels 18a and 18b have respective first and second edges 22 and 24 that are adjacent each other and intersect at a point distant from the next adjacent vertical studs 14. In such situations, a bracket 30 is employed to securely join the adjacent edges 22, 24 to provide sufficient support that the resulting building construction strength integrity is maintained.
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An advantage of the action of the fastener 40 is that during installation, it draws the separated flanges 38 together in a pinching action about the panel edge 22, 24. The resulting assembly is sufficiently strong that the adjacent panel edges 22, 24 are positively secured in a self-supporting manner so that a respective frame stud 14 is not needed at that location. In other words, the bracket 30 secures the first panel edge 22 to the second panel edge 24 independently of attachment of the panels to the building frame 12.
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While a particular embodiment of the present building system enhancing attachment of adjacent panels has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.
The present application is a Non-Provisional of, and claims 35 U.S.C. 119 priority from, U.S. Provisional Application Ser. No. 63/506,163 filed Jun. 5, 2023, the entire contents of which are incorporated by reference herein.
Number | Date | Country | |
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63506163 | Jun 2023 | US |