Patent Application
20170328057
Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference herein.
The present invention generally relates to fire-rated building structures. In particular, the present invention relates to fire-rated joint systems, wall assemblies, and other building structures that incorporate fire block angles, straps, reveals, and related assemblies.
Fire-rated construction components and assemblies are commonly used in the construction industry. These components and assemblies are aimed at preventing fire, heat, and smoke from leaving one room or other portion of a building and entering another room or portion of a building. The fire, heat or smoke usually moves between rooms through vents, joints in walls, or other openings. The fire-rated components often incorporate fire-retardant materials which substantially block the path of the fire, heat or smoke for at least some period of time. Intumescent materials work well for this purpose, because they swell and char when exposed to flames helping to create a barrier to the fire, heat, and/or smoke.
One particular wall joint with a high potential for allowing fire, heat or smoke to pass from one room to another is the joint between the top of a wall and the ceiling, which can be referred to as a head-of-wall joint. Another wall joint with a high potential for allowing fire, heat or smoke to pass from one room to another is the joint between the bottom of a wall and the floor, which can be referred to as a bottom-of-wall joint. In modern multi-story or multi-level buildings, the head-of-wall joint is often a dynamic joint in which relative movement between the ceiling and the wall is permitted. This relative movement is configured to accommodate deflection in the building due to loading of the ceiling or seismic forces. The conventional method for creating a fire-rated head-of-wall joint is to stuff a fire-resistant mineral wool material into the head-of-wall joint and then spray an elastomeric material over the joint to retain the mineral wool in place. This conventional construction of a fire-rated head-of-wall joint is time-consuming, expensive and has other disadvantages that are described herein.
A wall assembly commonly used in the construction industry includes a header track, bottom track, a plurality of wall studs and a plurality of wall board members, possibly among other components. A typical header track resembles a generally U-shaped (or some other similarly shaped) elongated channel capable of receiving or covering the ends of wall studs and holding the wall studs in place. The header track also permits the wall assembly to be coupled to an upper horizontal support structure, such as a ceiling or floor of a higher level floor of a multi-level building.
Header tracks generally have a web and at least one flange extending from the web. Typically, the header track includes a pair of flanges, which extend in the same direction from opposing edges of the web. The header track can be slotted header track, which includes a plurality of slots spaced along the length of the track and extending in a vertical direction. When the wall studs are placed into the slotted track, each of the plurality of slots accommodates a fastener used to connect the wall stud to the slotted track. The slots allow the wall studs to move generally orthogonally relative to the track. In those areas of the world where earthquakes are common, movement of the wall studs is important. If the wall studs are rigidly attached to the slotted track and not allowed to move freely in at least one direction, the stability of the wall and the building might be compromised. With the plurality of slots, the wall studs are free to move. Even in locations in which earthquakes are not common, movement between the studs and the header track can be desirable to accommodate movement of the building structure due to other loads, such as stationary or moving overhead loads, as described above. Similarly, bottom tracks generally have a web and at least one flange extending from the web. Typically, the bottom track includes a pair of flanges, which extend in the same direction from opposing edges of the web. The bottom track typically is not slotted and the studs are fixed relative to the bottom track.
Recently, improved methods of providing a fire-rated head-of-wall joint have been developed. One example of a fire-rated wall construction component is a head-of-wall fire block device sold by the Assignee of the present application under the trademark FireStik®. The FireStik® fire block product incorporates a metal profile with a layer of intumescent material on its inner surface. The metal profile of the FireStik® fire block product is independently and rigidly attached to a structure, such as the bottom of a floor or ceiling, at a position adjacent to the gap between the wallboard (e.g., drywall) and the ceiling on the opposite side (i.e., outside) of the wallboard relative to the studs and header track. The intumescent material, which is adhered to the inner surface of the metal profile, faces the wallboard, stud and header track. The space created in between the wallboard and ceiling, and the space between the stud and header track, allows for independent vertical movement of the stud in the header track when no fire is present.
When temperatures rise, the intumescent material on the FireStik® fire block product expands rapidly and chars. This expansion creates a barrier which fills the head-of-wall gap and inhibits or at least substantially prevents fire, heat and smoke from moving through the head-of-wall joint and entering an adjacent room for at least some period of time.
Still another example of an improved construction component for creating a fire-rated head-of-wall joint is a header track with integrated intumescent material strips sold by the Assignee of the present application under the trademark FAS Track®. In contrast to the FireStik® fire block product, the FAS Track® header track product incorporates the intumescent material directly on the header track so that the fire block material is installed during the framing process. Both the FireStik® and the FAS Track® fire block products are typically installed by the framing crew. The integration of the intumescent material into the FAS Track® header track product eliminates the need to install an additional fire block product after the wall board has been installed, which is typically done by a different crew than the framing crew.
Although the FireStik® and the FAS Track® products represent an improvement over the conventional method of stuffing mineral wool material into the head-of-wall joint and applying the elastomeric spray material over the mineral wool, there still exists room for improved products and methods for efficiently and cost-effectively creating fire-rated wall joints. Certain embodiments of the present invention involve a fire-rated wall joint product, such as a reveal piece, that incorporates a fire-resistant or intumescent material on at least one surface of the reveal piece. The reveal piece can be installed prior to the installation of the wall board and, preferably, during the framing process. The reveal piece may be installed directly against the studs to allow a wood or aluminum base trim piece to be recessed such that the trim piece is flush with the drywall. In some embodiments, the reveal piece includes a wallboard support to hold the wallboard or drywall in place.
Drywall reveals have been utilized in wall assembly design for decades. Whether at the base of wall, head of wall or somewhere in the middle of the wall, drywall reveals are commonly used as an architectural feature. When drywall reveals are utilized on a fire-rated wall, the wall assembly has a much higher cost. On current fire-rated walls, the drywall is installed without breaks from floor to ceiling. This requires a full layer of drywall to be installed first and then the reveals are installed followed by a second layer of drywall with the drywall breaking on both sides of the reveal. For this reason, the contractor basically needs to put two layers of drywall to maintain fire rating that would typically only require one layer for the fire rating.
Certain embodiments of the present invention involve a fire-rated reveal that combines steel (or another suitable reveal material) and fire-retardant or intumescent material. The steel profile is bent in a profile that, in some arrangements, allows a termination point for the drywall, a portion for an exposed reveal, and a fire block that will provide a fire rating without requiring an extra layer of drywall.
In some configurations, the fire-blocking feature is achieved by placing fire-retardant material or intumescent tape between two layers of steel of the reveal. When fire is introduced, the fire retardant material will expand between the two layers of steel, creating a separation between the two layers and thereby insulating the steel profile area of the wall that does not have drywall. In some embodiments, fire-retardant material may be placed on an exterior surface of the reveal piece such that at least a portion of the fire-retardant material extends beyond the corner of the reveal piece. The fire-retardant material is then pressed against the ceiling or floor, depending on the installation location of the reveal piece, to provide fire-blocking at a head- or bottom-of-wall joint. In some configurations, fire retardant material may not be necessary as the two layers of material may be sufficient.
In one aspect, a fire-rated assembly for a linear wall gap includes a track that has a web, a first flange and a second flange, wherein the web is substantially planar and has a first side edge and a second side edge, the first flange and the second flange extend in the same direction from the first and second side edges, respectively, wherein each of the first and second flanges is substantially planar such that the track defines a substantially U-shaped cross section; a strap piece comprising having a first free end and a second free end, a first bend and a second bend defined between the first free and the second free end, the first bend and the second bend defining a first vertical leg portion and a second vertical leg portion forming a gap therebetween, the first and second vertical leg portions formed from a single piece of material; a heat-expandable intumescent strip attached to the strap piece and extending lengthwise along an interior-facing surface of the strap piece, the intumescent strip adjacent the second bend; wherein, in use, the strap is positioned adjacent to one of the first flange and the second flange of the track structure such that the intumescent strip is between the strap piece and one of the first flange and the second flange of the track.
In some aspects, the strap further comprises a hem defined between the first bend and the first free end, the hem substantially parallel to the first and second vertical leg portions. In some aspects, the first and second vertical leg portions and the hem are each planar and substantially parallel to each other. In some aspects, the first and second vertical leg portions and the hem are formed from a single piece of material. In some aspects, the strap further comprises a second intumescent material applied to one of the first vertical leg portion and the second vertical leg portion such that the intumescent material is within the gap between the first vertical leg portion and the second vertical leg portion. In some aspects, the strap further comprises a wallboard support defined between the first bend and the first free end, the wallboard support having a substantially J-shaped profile and extending outwards from the first and second vertical leg portions.
In another aspect, a fire-rated wall joint product includes a strap piece comprising having a first free end and a second free end, a first bend and a second bend defined between the first free and the second free end, the first bend and the second bend defining a first vertical leg portion and a second vertical leg portion forming a gap therebetween, the first and second vertical leg portions being formed from a single piece of material; and a heat-expandable intumescent strip attached to the strap piece and extending lengthwise along an interior-facing surface of the strap piece, the intumescent strip adjacent the second bend.
In some aspects, the joint product further includes a second intumescent material applied to one of the first vertical leg portion and the second vertical leg portion such that the intumescent material is between the first vertical leg portion and the second vertical leg portion. In some aspects, the strap further comprises a hem defined between the first bend and the first free end, the hem substantially parallel to the first and second vertical leg portions. In some aspects, the first and second vertical leg portions and the hem are each planar and substantially parallel to each other. In some aspects, the first and second vertical leg portions and the hem are formed from a single piece of material. In some aspects, the strap further includes a second intumescent material applied to one of the first vertical leg portion and the second vertical leg portion such that the intumescent material is between the first vertical leg portion and the second vertical leg portion. In some aspects, the strap further includes a wallboard support defined between the first bend and the first free end, the wallboard support having a substantially J-shaped profile and extending outwards from the first and second vertical leg portions. In some aspects, the strap further includes a kickout portion such that the kickout portion forms an approximately 100 degree angle with the first and second vertical leg portions.
In yet another aspect, a fire-rated wall joint product includes an elongated piece comprising a strap having a first bend, a second bend, a free edge and a hem, the strap and the hem being formed from a single piece of material; and an intumescent material strip applied to an exterior surface of the strap and extending beyond the second bend of the strap, wherein a length of the intumescent material strip is equal to or less than about one-half a height of the strap.
In some aspects, the strap has a two-ply section having a first layer and a second layer such that the free edge of the strap is adjacent the hem, the two-ply section forming a gap between the first layer and the second layer. In some aspects, an intumescent material is applied within the gap.
Certain features, aspects and advantages of the various devices, systems and methods presented herein are described with reference to drawings of certain embodiments, which are intended to illustrate, but not to limit, such devices, systems, and methods. It is to be understood that the drawings are for the purpose of illustrating concepts of the embodiments discussed herein and may not be to scale. For example, certain gaps or spaces between components illustrated herein may be exaggerated to assist in the understanding of the embodiments. Dimensions, if provided in the specification, are merely for the purpose of example in the context of the specific arrangements shown and are not intended to limit the disclosure. The drawings contain twelve (12) figures.
Several preferred embodiments of the fire-rated reveal pieces and fire-rated reveal systems are described herein, typically in the context of a wall assembly and, in particular, a bottom-of-wall assembly. However, the fire-rated reveal pieces and fire-rated reveal systems can also be used in other applications, such as at the head or sides of a wall or a joint in an intermediate location of a wall. The fire-rated reveal pieces and fire-rated reveal systems can also be used in non-wall applications. In view of the bottom-of-wall assembly being but one of the multiple applications for the fire-rated reveal pieces and fire-rated reveal systems, the use of relative or directional terminology, or other such descriptions, is for convenience in describing the particular embodiments, arrangements or orientations shown. Therefore, such terms are not intended to be limiting, unless specifically designated as such.
Preferably, as shown in
With continued reference to
The kickout portion 128 is formed from a second end 126 of the metal sheet 130, by bending the metal sheet 130 to form a corner 125. The portion of the vertical leg 122 adjacent to the corner 125 and vertically lower than the J-shaped wallboard support 136 is also called the reveal portion of the vertical reveal leg 122. The kickout portion 128 extends outward, that is, away from the bottom track 43, of the wall assembly 110, in the same direction as the wallboard support portion 136. While the wallboard support portion 136 is generally a single ply or single layer of material, the kickout portion 128, is formed from a two-ply, or double layer of material. The material 130 may be bent approximately 180 degrees to form bend 127 at the outward end of the kickout portion 128. As shown in
The material 130 of the reveal 120 is bent, at corner 125, to allow the material to extend upwards, forming part of the two-ply section of the vertical leg 122. In some embodiments, including the embodiment shown in
With further reference to
Since the reveal 120 is preferably made from a single sheet of material, the bending process to form the reveal 120 results in several two-ply, or double layer, sections. As shown in
For further fire protection, intumescent material may be placed on an exterior surface of the reveal 120 or between layers of material forming the two- or three-ply sections of the vertical leg 122 of the reveal 120. For example, as shown in
Preferably, as described above, the intumescent tape or strips 140, 142 are constructed with a material that expands in response to elevated heat or fire to create a fire-blocking char. One suitable material is marketed as BlazeSeal™ from Rectorseal of Houston, Tex. Other suitable intumescent materials are available from 3M Corporation, Hilti Corporation, Specified Technologies, Inc., or Grace Construction Products. The intumescent material expands to many times (e.g., up to 35 times or more) its original size when exposed to sufficient heat (e.g., 350 degrees Fahrenheit). Thus, intumescent materials are commonly used as a fire block because the expanding material tends to fill gaps. Once expanded, the intumescent material is resistant to smoke, heat and fire and inhibits fire from passing through the bottom-of-wall joint, head-of-wall joint or other wall joint. Thus, intumescent materials are preferred for many applications. However, other fire retardant materials can also be used. Therefore, the term intumescent strip is used for convenience in the present specification and that the term is to be interpreted to cover other expandable or non-expandable fire-resistant materials as well, such as intumescent paints (e.g., spray-on), fiberglass wool (preferably with a binder, such as cured urea-phenolic resin) or fire-rated dry mix products, unless otherwise indicated. The intumescent strips 140, 142 can have any suitable thickness that provides a sufficient volume of intumescent material to create an effective fire block for the particular application, while having small enough dimensions to be accommodated in a wall assembly. That is, preferably, the intumescent material strips 140, 142 do not cause unsightly protrusions or humps in the wall from excessive build-up of material. In one arrangement, the thickness of the intumescent strips 140, 142 is between about 1/16 (0.0625) inches and ⅛ (0.125) inches, or between about 0.065 inches and 0.090 inches. One preferred thickness is about 0.075 inches.
With reference to
Similar to the reveal 120 shown in
With continued reference to
The portion of the vertical leg 222 adjacent to the bend 225 is also called the reveal portion of the vertical reveal leg 222, and is preferably a two-ply or two layer section. The wallboard support portion 236 is generally a single ply or single layer of material.
During manufacture, the material 230 is bent, forming bend 225, to allow the material to extend upwards and form part of the two-ply section of the vertical leg 222. In some embodiments, including the embodiment shown in
The reveal 220 preferably has dimensions similar to those discussed above with respect to reveal 120. With further reference to
Since the reveal 220 is preferably made from a single sheet of material, the bending process to form the reveal 220 results in several two-ply, or double layer, sections. As shown in
For further fire protection, intumescent material may be placed on an exterior surface of the reveal 220 or between layers of material forming the two- or three-ply sections of the vertical leg 222 of the reveal 220. For example, as shown in
With reference to
Similar to the reveals 120, 220 discussed above, the reveal 320 includes a vertical reveal leg 322 and an inverted J-shaped wallboard support portion 336. The illustrated vertical leg 322 and inverted J-shaped wallboard support portion 336 are preferably unitarily formed. That is, the vertical leg 322 and the inverted J-shaped wallboard support portion 336 are constructed from a single piece of material. As described above, typically, the single piece of material is a flat piece of light gauge steel, which is then deformed into the shape of the reveal 320, such as through a roll-forming, bending (such as on a press brake) or other suitable process. Preferably, the vertical leg 322 is substantially planar.
With continued reference to
With reference to
In some embodiments, as shown in
The reveal 320 can have similar dimensions as those discussed above with respect to reveals 120 and 220. With further reference to
For further fire protection, intumescent material may be placed on an exterior surface of the reveal 320. For example, as shown in
In some embodiments, preferably the thickness of the fire-stopping or intumescent material 142 is such that the outermost edge of the intumescent material 142 aligns with the attachment flange 240. This alignment allows the intumescent material 142 to be pressed against the header track 42 to provide a fire-blocking barrier. While one embodiment of the reveal 320 is shown in
Another embodiment of a reveal 420 is shown in
In some embodiments, the reveal 420 has a strap or plate profile, with the J-shaped drywall support profile shown in reveals 120, 220, and 320 removed. As the concrete floor is rarely perfectly straight, use of a strap or plate profile reveal can facilitate installation, allowing the installer to, for example, snap a level caulk line of the face of the steel strap or reveal as a reference point for the drywall location. Similar to the reveals 120, 220, and 320 discussed above, the reveal 420 includes a vertical reveal leg 422 forming a fire-blocking strap or plate. The reveal 420 also includes a hem 460 to help hold the reveal 420 in place as part of the wall assembly. The illustrated vertical leg 422 and hem 460 are unitarily formed by bending or shaping a single sheet of material, preferably steel. As described above, typically, the single piece of material is a flat piece of light gauge steel, which is then deformed into the shape of the reveal 420, such as through a roll-forming, bending (such as on a press brake) or other suitable process. Preferably, the vertical leg 422 is substantially planar.
With continued reference to
With reference to
Preferably, the vertical leg 422 of the reveal 420 is a two-ply or double layer construction of two layers of material. As noted above, the double layers of material forming the vertical leg 422 are beneficial for fire protection and for passing the UL fire-rating test.
During manufacture, the material 430 is bent, forming bend 425, to allow the material to extend upwards and form part of the two-ply section of the vertical leg 422. A free end of the metal sheet 430 extends vertically upward from the bend 425 at the second end 426 of the vertical leg 422, substantially parallel to the vertical leg 422. In some embodiments, as shown in
With further reference to
As discussed above, since the reveal 420 is preferably made from a single sheet of material, the bending process to form the reveal 420 results in a two-ply, or double layer, section. As shown in
In some embodiments, the reveal 520 has a strap or plate profile, similar to reveal 420, with the J-shaped drywall support profile shown in reveals 120, 220, and 320 removed. As the concrete floor is rarely perfectly straight, use of a strap or plate profile reveal can facilitate installation, allowing the installer to, for example, snap a level caulk line of the face of the steel strap or reveal as a reference point for the drywall location. Similar to the reveals 120, 220, 320, and 420 discussed above, the reveal 520 includes a vertical reveal leg 522 forming a fire-blocking strap or plate formed from a single sheet of material such as sheet metal. As described above, typically, the single piece of material is a flat piece of light gauge steel. Preferably, the vertical leg 522 is substantially planar.
With continued reference to
With reference to
With further reference to
The above-described arrangements can also be utilized at a gap at the bottom of the wall assembly and at a gap at the side of the wall assembly. Preferably, each such assembly is similar to the head-of-wall assemblies described above. In particular, preferably, each such assembly creates a fire-resistant structure at the respective wall gap. Any of the embodiments of a reveal discussed above can be attached adjacent to a corner, flange, or leg of a framing member, such as metal tracks, headers, header tracks, sill plates, bottom tracks, metal studs, wood studs or wall partitions, and placed between the framing member and a wall board member at a perimeter of a wall assembly to create a fire block arrangement.
The reveal 620 has a central portion 640 and a pair of side portions 642 that extend in opposite directions from the central portion 640. The central portion 640 is located between the first edge 652 and the second edge 654 of the first and second wallboard members 15A, 15B. The pair of side portions 642 is positioned on the surface of the first and second wallboard members 15A, 15B, such that the reveal 620 is positioned adjacent to and over the reveal gap 650. The reveal 620 is fastened to the stud 46 and/or the first and second wallboard members 15A, 15B by fasteners 48. The fasteners 48 may penetrate the side portions 642 of the reveal 620.
As shown in
Similar to the reveals 120, 220, 320, 420, 520 the reveal 620 is preferably formed from a light gauge steel material by any suitable process, such as roll forming, for example. Preferably, the reveal 620 is an elongated member having a consistent or substantially consistent cross-sectional shape throughout its length. One or more preferred embodiments of the reveal 620 are generally or substantially strap or plate like in cross-section. In one embodiment, the reveal 620 may have a width 22 of approximately 2.5 to 3 inches and a length of between about 5 feet and 25 feet. In some configurations, the reveal 620 can also be between 2.5 to 6 inches in width. In some configurations, the reveal 620 can also be between about 10 and 20 feet in length. Preferably, the reveal 620 is about 10-12 feet in length to facilitate shipping and storage.
As shown in
It should be understood to one of ordinary skill in the art that the reveal 620 is not limited to being formed by bending of sheet metal. In some configurations, the reveal 620 may be formed by bonding multiple pieces of material. In some configurations, first and second vertical legs 622, 632 may have unequal lengths such that a portion of the reveal 620 is two-ply and a portion of the reveal 620 is single-ply.
In alternative configurations, the reveal 620 may have at least one intumescent strip (not shown) applied to at least one of the vertical legs 622, 632. The intumescent strip may be applied to surfaces of the reveal 620 that face the stud 46 and/or the first and second wallboard members 15A, 15B. The at least one intumescent strip may be positioned on the central portion 640 within the reveal gap 650. In some configurations, the intumescent strip can be positioned at or near an edge of the vertical leg 622, 632 similar to the arrangements of
The described assemblies provide convenient and adaptable fire block structures for a variety of linear wall gap applications, which in at least some embodiments permit the creation of a fire rated joint according to UL 2079. In some arrangements, the separate angles and reveal pieces include fire-retardant materials (e.g., intumescent material strips) secured (e.g., adhesively attached or bonded) to appropriate locations on the angles or reveal pieces and can be used with a variety of headers, footers (bottom tracks or sill plates) and studs to create a customizable assembly. Thus, one particular type of angle or reveal can be combined with multiple sizes or types of base tracks, headers, sill plates or studs to result a large number of possible combinations. The angles and reveals can be configured for use with commonly-available tracks, headers, sill plates or studs, in addition to customized tracks, headers, sill plates or studs specifically designed for use with the angles. Thus, the advantages of the described systems can be applied to existing wall assemblies. Therefore, the angles and reveals can be stocked in bulk and used as needed with an appropriate framing component.
Language of degree used herein, such as the terms “approximately,” “about,” “generally,” and “substantially” as used herein, represent a value, amount, or characteristic close to the stated value, amount, or characteristic that still performs a desired function or achieves a desired result. For example, the terms “approximately,” “about,” “generally,” and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount. As another example, in certain embodiments, the term “substantially parallel” refers to a value, amount, or characteristic that is exactly parallel or departs from exactly parallel by less than or equal to 15 degrees, 10 degrees, 5 degrees, 3 degrees, 1 degree, 0.1 degree, or otherwise. As another example, in certain embodiments, that a first object is “substantially adjacent” to a second object may mean that the first object is directly next to and touching the second object, is directly next to but not touching due to manufacturing variations or inherent spring back or resiliency of the materials or may mean that the first object is within 0.5 inch, 0.2 inch, and 0.1 inch from the second object.
Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In particular, while the present angle piece and assemblies have been described in the context of particularly preferred embodiments, the skilled artisan will appreciate, in view of the present disclosure, that certain advantages, features and aspects of the angle and reveal pieces and assemblies may be realized in a variety of other applications, many of which have been noted above. Additionally, it is contemplated that various aspects and features of the invention described can be practiced separately, combined together, or substituted for one another, and that a variety of combination and subcombinations of the features and aspects can be made and still fall within the scope of the invention. For example, the specific locations of the intumescent strips can be utilized with the variety of different embodiments of the angle and reveal pieces disclosed herein in addition to those embodiments specifically illustrated. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims.
| Number | Date | Country | |
|---|---|---|---|
| 62364775 | Jul 2016 | US | |
| 62104627 | Jan 2015 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14997291 | Jan 2016 | US |
| Child | 15655688 | US |
