Patent Grant
10415238
The present invention relates generally to a corner bead for cementitious fireproofing of structural steel members and, more particularly, to a device that is self-aligning in installation and allows the accurate gauging of the thickness of the fireproofing material along three surfaces.
In the art of a corner bead for fireproofing structural steel, prior approaches conventionally include a v-bend corner bead having adjustable legs (flanges). This type of corner bead is mostly used in the plastering and stucco trades. The previously utilized corner bead is constructed of wires welded into a lattice that is v-shaped in section as shown in
In installation, the longitudinal base wires of the v-shaped corner bead are attached with a tie wire either onto a metal lath or onto a wire mesh, and further attached to the steel member to be fireproofed as shown in
The prior art includes many problems, including the difficulty of properly adjusting the traditional corner bead to the adjacent surface, the uneven application of fireproofing material, and the lack of a dam for the wet cement material. Despite these well-known and long-existing problems, and a readily apparent market for a solution, the prior art does not disclose or suggest a viable, cost-effective solution to the aforementioned problems of the prior art.
Accordingly, a need exists for an improved corner bead to avoid inaccuracy in gauging the thickness of the fireproofing material and to allow easy installation along three surfaces. An improved self-aligning double wire corner bead is inexpensive to manufacture and easy to install.
The present invention provides a self-aligning, double wire corner bead that allows to make, in an accurate and quick manner, corners of a fireproofing material around structural steel members, said fireproofing material having uniform thickness around the structural steel member. This is accomplished by bending a single strip of welded wire fabric of pre-determined width along a plurality of longitudinally extending lines (axes) to provide a profile of a metal sheet having a plurality of dihedral angles, two wings of the desired width, a single wire membrane and a double wire membrane, said double wire membrane comprising a first leg and a second leg as substantially shown in
The angle at which each wing meets the single wire membrane and a second leg of the double wire membrane of the device, respectively, determines the thickness of the fireproofing material distributed around the structural steel member along three surfaces. Further, said thickness may be modified by changing the width of each respective wing. The uniformity in thickness of the fireproofing material distributed around three surfaces of the structural steel member is achieved by bending the first wing and the second wing at approximately the same angle in relation to the single wire membrane and the second leg of the double wire membrane, respectively. The uniformity in thickness of the fireproofing material distributed around all surfaces of the structural steel member in a contour type application is achieved by using the same width of the single metal strip bent to create an identical single metal sheet profile for all corners of the structural steel member.
It is further an object of the present invention to provide an improved corner bead for fireproofing structural steel without the need of adjusting the legs.
Another object of the present invention is to provide novel means of installing the corner bead by easier attachment to the structural steel.
Another object of the present invention is to provide an improved technique for application of accurate thickness of fireproofing material along three surfaces under any construction condition for making said fireproofing of structural steel members.
A further object of the present invention is to provide a dam to form a roughened surface on the first application of fireproofing material until it hardens along three surfaces.
While satisfying these and other related objectives, the present invention provides an improved, self-aligning, double wire corner bead for fireproofing structural steel which is very competitive from a mere economic standpoint. The corner bead of the present invention consists of a single strip of welded wire fabric cut to a desired width for the fireproofing thickness and bent along a plurality of longitudinal axes to form a set of wings, a single wire membrane, and a double wire membrane, said double wire membrane having a first leg and a second leg, said first leg seamlessly becoming said second leg through a process of bending of said double wire membrane such that said first leg is substantially parallel to said second leg, and wherein said single wire membrane and said double wire membrane are attached by the attachment means to the lath distributed around the structural steel member.
In accordance with the present invention, the corner bead includes a single elongated strip of welded wire fabric of pre-determined width, said single strip of welded wire fabric comprising a set of flexible mesh strips as shown in
According to one embodiment of the present invention, the improved double wire corner bead allows each element of the bent wire mesh of the corner bead to perform different functions that are essential for the successful completion of the fireproofing process along three surfaces.
The single wire membrane and the double wire membrane provide a flat portion of a grid (mesh) through which pneumatic or screw type fasteners attach the mesh to the structural steel at the appropriate location. In addition, the double-wire membrane provides additional support for two wings positioned at the opposite corners of the steel structure member, hence facilitating one piece of wire mesh to cover two corners and three surfaces of the structure. This easy application establishes automatic alignment of the corner bead along three surfaces, eliminates the cumbersome process of shrinking or expanding the distance between the legs of the traditional bead, as well as provides only one strip of metal of the desired width to allow fireproofing of two corners of the steel structure member along three surfaces at the same time in a contour-method application of the fireproofing material.
The width of the set of wings and/or the angle at which the first and the second wing meet the single wire membrane and the second leg of the double wire membrane, respectively, determines the thickness of the fireproofing material distributed along three surfaces by providing a rigid screed edge along a nose. Therefore, the correct amount of fireproofing material is distributed adjacent to the corner bead creating a leveled application throughout the surface.
The width of the set of wings also provides a dam to form a roughened surface on the first application of the fireproofing material until the fireproofing material hardens. This forming action allows successive application of the cement material to the adjacent surface.
In another aspect, the present invention includes a method of manufacturing an improved self-aligning, double wire corner bead for fireproofing structural steel comprising a single strip of welded wire fabric cut to the desired width for the fireproofing thickness and bent along a plurality of longitudinally extending lines (axes) to form a profile of a metal sheet, a first longitudinal line to define a first wing and a single wire membrane extending laterally therefrom at a first angle of approximately greater than 90 degrees but less than approximately 180 degrees relative to each other and wherein said single wire membrane is secured to a structural steel member and said first wing is configured to establish a desired thickness of the fireproofing material along two surfaces by providing a rigid screed edge along the nose, a second longitudinal line to define said single wire membrane and a first leg of a double wire membrane extending from said single wire membrane in a continuous manner and at a second angle of approximately 90 degrees relative to each other, a third longitudinal line to define said first leg of said double wire membrane and a second leg of said double wire membrane such that said first leg is positioned substantially parallel to said second leg (the second leg substantially overlaps the first leg), and wherein said double wire membrane is secured to said structural steel member, and a fourth longitudinal line to define a second wing and said second leg of said double wire membrane, said second leg extending downwardly from said second wing at a third angle of approximately greater than 90 degrees but less than approximately 180 degrees relative to each other, and wherein said third angle is substantially equal to said first angle.
In a further aspect, the present invention includes a method of finishing a set of corners for cementitious fireproofing in a contour application of a set of structural steel members, the method comprising the steps of: selecting a corner bead comprising a single strip of welded wire fabric cut to the appropriate width for the fireproofing thickness and bent along a plurality of longitudinally extending lines, to provide a profile having a plurality of dihedral angles, wherein a first longitudinal line to define a first wing and a single wire membrane extending laterally therefrom at a first angle of approximately greater than 90 degrees but less than approximately 180 degrees relative to each other and wherein, said single wire membrane is secured to a structural steel member and a first wing is configured to establish a desired thickness of the fireproofing material along two surfaces by providing a rigid screed edge along the nose, a second longitudinal line to define said single wire membrane and a first leg of a double wire membrane extending from said single wire membrane in a continuous manner and at a second angle of approximately 90 degrees relative to each other, a third longitudinal line to define said first leg of said double wire membrane and a second leg of said double wire membrane such that said second leg is extending from said first leg of said double wire membrane in a continuous manner in such a way that said first leg is positioned substantially parallel to the second leg (the second leg substantially overlaps the first leg), and wherein said double wire membrane is secured to said structural steel member, and a fourth longitudinal line to define a second wing and said second leg of said double wire membrane, said second leg extending downwardly from said second wing at a third angle of approximately greater than 90 degrees but less than approximately 180 degrees relative to each other, and wherein said third angle is substantially equal to said first angle.
A dihedral angle (also called a face angle) is the internal angle at which two adjacent faces of each section member of the double wire corner bead is delimited by the two inner faces, e.g., angle α1 formed between adjacent faces of the first wing and the single wire membrane, angle α2 formed between adjacent faces of the second wing and the second leg of the double wire membrane and angle β formed between adjacent faces of the single wire membrane and the first leg of the double wire membrane. The fourth angle created along the third longitudinal line between the first and the second leg of the double wire membrane is substantially zero (0) degrees so that the first leg and the second leg substantially overlap each other, and are approximately parallel, with respect to each other.
In another embodiment, the aim of the present invention is to provide a self-aligning corner bead which allows to make, in an accurate and quick manner, corners of the fireproofing material around structural steel members, said fireproofing material having uniform thickness around the structural steel. This aim is achieved owing to the fact that a strip of welded wire fabric having pre-determined width is bent along its longitudinal axis forming two wings of the desired width. The width of the second wing as well as the angle at which the two wings meet along the longitudinal axis determine the thickness of the fireproofing material strip disposed around the structural steel member along two surfaces. The uniformity in thickness of the fireproofing material distributed around the structural steel member is achieved by using the same width of the second wing bent at the same angle in relation to the first wing for all utilized corner beads, whether in a contour or a hollow-box type application.
It is further an object of the present invention to provide an improved corner bead for fireproofing structural steel without the need of adjusting the legs.
Another object of the present invention is to provide novel means of installation of the corner bead by easier attachment to the structural steel.
Another object of the present invention is to provide an improved technique for application of accurate thickness of fireproofing material along two surfaces under any construction condition for making said fireproofing of structural steel members.
A further object of the present invention is to provide a dam to form a roughened surface on the first application of fireproofing material until it hardens.
In satisfaction of these and related objectives, applicant's present invention provides an improved corner bead for fireproofing structural steel which is very competitive from a mere economic standpoint. The corner bead of the present invention consists of a strip of welded wire fabric cut to the appropriate width for the fireproofing thickness and bent longitudinally to form an obtuse V-shaped device.
In accordance with the present invention, the corner bead includes an elongated strip of welded wire fabric of pre-determined width, said strip bent along its longitudinal axis to define a pair of laterally extending wings, said wings comprising a flexible mesh strip.
According to one embodiment of the present invention, the improved corner bead allows each wing of the corner bead to perform different functions that are essential for the successful completion of the fireproofing process along two surfaces.
The width of the first wing provides a flat portion of metal grid (mesh) through which pneumatic or screw type fasteners attach the mesh to the lath disposed over the structural steel at the appropriate location. This easy application establishes automatic alignment and eliminates the cumbersome process of shrinking or expanding the distance between the legs of the traditional bead.
The width of the second wing and/or the angle at which the first and the second wing meet determines the thickness of the fireproofing material along two surfaces. The location of the rigid screed edge along the plastic nosing allows the correct amount of material to be distributed alongside the corner bead creating a leveled application throughout the surface.
The width of the second wing also provides a dam to form a roughened surface on the first application of the fireproofing material until it hardens. This forming action allows successive application of the cement material to the adjacent surface.
In another aspect, the present invention resides in a method of manufacturing an improved corner bead for fireproofing structural steel comprising a strip of welded wire fabric cut to the appropriate width for the fireproofing thickness and bent along the longitudinal axis to form an obtuse V-shaped device, said longitudinal axis to define a pair of wings extending laterally therefrom at an angle of approximately more than 90 disagrees but less than approximately 180 degrees relative to each other and, wherein said first wing is secured to a structural steel member through a lath, said lath disposed around the structural steel member to hold the fireproofing material to said structural steel member, and a second wing configured to establish a desired thickness of the fireproofing material along two surfaces by providing a rigid screed edge along the plastic nosing.
In a further aspect, the present invention resides in a method of finishing the corners for cementitious fireproofing (whether in a hollow box or a contour application) of structural steel members, the method comprising: selecting a corner bead comprising a strip of welded wire fabric cut to the appropriate width for the fireproofing thickness and bent along its longitudinal axis to form an obtuse V-shaped device, said longitudinal axis to define a pair of wings extending laterally therefrom at an angle of approximately more than 90 degrees but less than approximately 180 degrees relative to each other; said first wing attached by joining means (attachment means) for securing said corner bead's first wing to a lath or mesh previously attached to a structural steel member and a second wing configured to establish a desired thickness of the fireproofing material along two surfaces by providing a rigid screed edge along the plastic nosing; attaching said first wing through said lath to the structural steel member; and applying successive layers of the fireproofing material to allow creation of the roughened cementitious surface, and tapering to the outward extending width of the second wing.
Applicant's approach to the problem described above is certainly simple, but it is equally unobvious. With over twenty years of experience in the field of fireproofing services, applicant is well educated on the challenges involved such as the difficulty of properly adjusting the traditional corner bead to the adjacent surface, the uneven application of fireproofing material, and the lack of dam for the wet cement material. Despite these well-known and long-existing problems, and a readily apparent market for a solution, no one has presented a viable, cost-effective solution such as applicant here provides.
Referring to
In a preferred embodiment, corner bead 10 is made of a suitable metal, such as 16 gauge wire. Other suitable materials known in the art may be employed, including suitable plastics. In a preferred embodiment, corner bead 10 is a double welded wire fabric.
In a preferred embodiment, corner bead 10 has a set of bends integrally formed in corner bead 10 along the plurality of longitudinal axes. Any number of bends may be employed. Longitudinal axis A defines first wing 12 and single wire membrane 11. First wing 12 and single wire membrane 11 form angle α1 of approximately greater than 90 degrees, but less than approximately 180 degrees as further illustrated in
In a preferred embodiment, nose 14 is made of a suitable plastic, such as polyvinyl chloride. Other suitable materials known in the art may be employed.
Referring to
In use, the improved, self-aligning, double wire corner bead 10 of the present disclosure is utilized in a contour-like manner, surrounding a structural steel member with fireproofing material. Referring to
Referring to
In a preferred embodiment, the determination of angles α1 and α2 should be such that a uniform thickness of fireproofing material 22 along surface S1 is achieved.
In one embodiment, lath 26 is distributed around structural steel member 24. Single wire membrane 11 is attached through lath 26 into structural steel member 24 by pneumatic fastener 28 at a single fastening position on single wire membrane 11. Other joining or attaching means known in the art, such as welded pins or screws, may be employed.
In another embodiment, each of single wire membrane 11 and double wire membrane 30 is attached to structural steel member 24 by pneumatic fastener 28 at a single fastening position on double wire membrane 30.
In another embodiment, leg 31 and leg 31′ of double wire membrane 30 are attached through lath 26 into structural steel member 24 by pneumatic fastener 28 at a single fastening position on double wire membrane 30. Other joining or attaching means known in the art, such as welded pins or screws, may be employed. According to one embodiment of the present invention, lath 26 is optionally distributed along the entire perimeter of structural steel member 24 to be fireproofed (not shown). In another embodiment, lath 26 is distributed along a portion of the perimeter of structural steel member 24.
In other embodiments, any number of fastening positions and locations may be employed.
The width of first wing 12 and second wing 12′ along with nose 14 attached to the outer edges of both wings serves as a dam during the process of fireproofing. Fireproofing material 22 is then sprayed onto lath 26 and screened off using the location of nose 14 to determine the finished thickness of fireproofing material 22.
Referring to
It will be appreciated by those skilled in the art that any type of member may be employed.
In a field application on a job site, structural steel members 24 are erected into a structure prior to fireproofing, and all surfaces of structural steel member 24 may be sprayed or troweled onto the surface of lath 26 at the same time (not shown).
Referring to
As further shown in
In general, two methods of enveloping the structural steel member with the fireproofing material may be utilized. As shown in
As shown in
As can be seen most clearly in
In a further development of the subject matter described with reference to
In a shop application (i.e., fireproofing is applied in a facility of the applicant to individual steel members), the cementitious composition is sprayed or poured one at a time on one horizontal surface 632 of lath 628 as shown in
In a field application (outside of applicant's facility), where the members are erected into a structure prior to fireproofing, all surfaces of the steel member may be sprayed or troweled onto the lath surfaces at the same time (not shown). The process is similar regardless of whether the contour or hollow-box application is utilized.
It will be appreciated that the invention is not restricted to the particular embodiment that has been described, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims, as interpreted in accordance with principles of prevailing law, including the doctrine of equivalents or any other principle that enlarges the enforceable scope of a claim beyond its literal scope. Unless the context indicates otherwise, a reference in a claim to the number of instances of an element, be it a reference to one instance or greater than one instance, requires at least the stated number of instances of the element, but is not intended to exclude from the scope of the claim a structure or method having more instances of that element than stated. The word “comprise” or a derivative thereof, when used in a claim, is used in a nonexclusive sense that is not intended to exclude the presence of other elements or steps in acclaimed structure or method.
This application is a divisional application of U.S. application Ser. No. 15/382,687, filed Dec. 18, 2016, which is a continuation of U.S. application Ser. No. 14/832,074, filed Aug. 21, 2015, now U.S. Pat. No. 9,540,813, issued Jan. 10, 2017, which claims priority to U.S. Provisional Application No. 62/040,182, filed Aug. 21, 2014. U.S. application Ser. No. 14/832,074 is also a continuation-in-part of U.S. application Ser. No. 14/292,881, filed May 31, 2014, now U.S. Pat. No. 9,140,005, issued Sep. 22, 2015, which claims priority to U.S. Provisional Application No. 61/830,257, filed Jun. 3, 2013. Each of the above patent applications is incorporated by reference herein in its entirety to provide continuity of disclosure.
| Number | Name | Date | Kind |
|---|---|---|---|
| 131506 | Corbett | Sep 1872 | A |
| RE5179 | Corbett | Dec 1872 | E |
| 583413 | Meserve | May 1897 | A |
| 624076 | Parker | May 1899 | A |
| 632007 | Broome | Aug 1899 | A |
| 640409 | Parker | Jan 1900 | A |
| 658386 | Mitchell | Sep 1900 | A |
| 1110369 | Bagnall et al. | Sep 1914 | A |
| 1122076 | Collins | Dec 1914 | A |
| 1210560 | Tappen | Jan 1917 | A |
| 1419232 | Curtis | Jun 1922 | A |
| 1608475 | Dean | Nov 1926 | A |
| 1624121 | Thiem | Apr 1927 | A |
| 1782147 | Merryweather | Nov 1930 | A |
| 1858836 | Martell | May 1932 | A |
| 1907990 | Manske | May 1933 | A |
| 1988081 | Kemper | Jan 1935 | A |
| 2005572 | Vass | Jun 1935 | A |
| 2012203 | Peterson | Aug 1935 | A |
| 2061050 | Stafford | Nov 1936 | A |
| 2074463 | Davis | Mar 1937 | A |
| 2127806 | Burt | Aug 1938 | A |
| 2196086 | Sprouse | Apr 1940 | A |
| 2213603 | Young et al. | Sep 1940 | A |
| 2267002 | Turner | Dec 1941 | A |
| 2370052 | Lindelow | Feb 1945 | A |
| 2391581 | Markuson | Dec 1945 | A |
| 2465756 | Schepis | Mar 1949 | A |
| 2483888 | Danielson | Oct 1949 | A |
| 2702932 | Woodson | Mar 1955 | A |
| 2945329 | Schneller | Jul 1960 | A |
| 2969616 | Gustafson | Jan 1961 | A |
| 3175330 | Holson | Mar 1965 | A |
| 3217456 | Quigg | Nov 1965 | A |
| 3255561 | Cable | Jun 1966 | A |
| 3295268 | Alva | Jan 1967 | A |
| 3345788 | Holsman | Oct 1967 | A |
| 3412512 | Hollister | Nov 1968 | A |
| 3516213 | Sauer | Jun 1970 | A |
| 3748815 | Parker | Jul 1973 | A |
| 3772844 | Thorne | Nov 1973 | A |
| 3908327 | Quigg | Sep 1975 | A |
| 3913290 | Billing et al. | Oct 1975 | A |
| 4043092 | Paul et al. | Aug 1977 | A |
| 4069075 | Billing et al. | Jan 1978 | A |
| 4391074 | Holsman | Jul 1983 | A |
| 4493945 | Feldman | Jan 1985 | A |
| 4683019 | Motoki | Jul 1987 | A |
| 4729916 | Feldman | Mar 1988 | A |
| 4854107 | Roberts | Aug 1989 | A |
| 4955173 | Czechowski | Sep 1990 | A |
| 5073430 | Aidan | Dec 1991 | A |
| 5157887 | Watterworth, III et al. | Oct 1992 | A |
| 5398472 | Eichelkraut | Mar 1995 | A |
| 5433991 | Boyd | Jul 1995 | A |
| 5580648 | Castle et al. | Dec 1996 | A |
| 5625986 | Mansfield et al. | May 1997 | A |
| 5685116 | Bradshaw et al. | Nov 1997 | A |
| 5788403 | Dison et al. | Aug 1998 | A |
| 6330777 | Padley | Dec 2001 | B1 |
| 6591566 | Rodlin | Jul 2003 | B1 |
| 6698144 | Larson | Mar 2004 | B1 |
| 7921537 | Rodlin | Apr 2011 | B2 |
| 8291676 | Hong et al. | Oct 2012 | B2 |
| 8555593 | Ramos | Oct 2013 | B2 |
| 9140005 | Miller | Sep 2015 | B2 |
| 9540813 | Miller | Jan 2017 | B2 |
| 10060123 | Miller | Aug 2018 | B2 |
| 10087622 | Miller | Oct 2018 | B2 |
| 20020005023 | Ford | Jan 2002 | A1 |
| 20030024188 | Smythe | Feb 2003 | A1 |
| 20030079429 | Rodlin | May 2003 | A1 |
| 20040250488 | Rodlin | Dec 2004 | A1 |
| 20070119106 | Sacks et al. | May 2007 | A1 |
| 20080282644 | Hong et al. | Nov 2008 | A1 |
| 20120085047 | Hiscock et al. | Apr 2012 | A1 |
| 20120110936 | Egan et al. | May 2012 | A1 |
| 20130205696 | Little et al. | Aug 2013 | A1 |
| 20140352243 | Miller | Dec 2014 | A1 |
| 20160040428 | Miller | Feb 2016 | A1 |
| Number | Date | Country |
|---|---|---|
| 2012105858 | Aug 2012 | WO |
| Entry |
|---|
| Stockton Wire Products, “Plastic Nose Weep-Aid® for better construction”. Pages from brochure, printed 1989, 3 pages. |
| Number | Date | Country | |
|---|---|---|---|
| 62040182 | Aug 2014 | US | |
| 61830257 | Jun 2013 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15382687 | Dec 2016 | US |
| Child | 16131513 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14832074 | Aug 2015 | US |
| Child | 15382687 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 14292881 | May 2014 | US |
| Child | 14832074 | US |
