1. Field of the Invention
The invention relates generally to a shaft wall construction comprising of triangular studs used to hold wall panels in place during construction and service life of shaft walls in buildings. The system includes triangular shaped steel studs with one or more layers of gypsum board secured to one side of the triangular shaped steel studs. The triangular steel studs rest in a notched floor and ceiling runner. The one or more layers of gypsum board are then directly attached to a flat side of the triangular stud with properly sized steel screws. This system will typically be used as a shaft wall system or constructed in locations where attachment of gypsum board to both sides of a wall system is not feasible.
2. Background of the Invention
Walls around shafts, such as elevator shafts, were traditionally formed from concrete. Such installations required personnel working inside the shaft to have to wait until the walls were completed, then remove debris and other material from the concrete erection.
As an improvement to the concrete systems, the assignee of the present invention developed a system whereby drywall (such as SHEETROCK brand gypsum board, available from United States Gypsum Corporation of Chicago, Ill.) or other wall panels can be installed from outside the shaft, thereby significantly reducing any scaffolding, and construction debris inside the shaft. Such present day shaft wall assemblies are constructed from one side only, namely outside the shaft. By installing the wall panels from the outside, personnel working inside the shaft no longer needed to wait until the construction was completed to begin their work.
Such systems typically include a pair of J-runners into which a first wall panel is inserted, with the first J-runner along the top of the wall panel and a second J-runner along the bottom as well as both ends of the wall. The J-runner generally is formed from metals, such as steel, and typically includes a first short upstanding section and a second tall upstanding section in a substantially parallel configuration, each forming a substantially right angle with a middle section. Such a configuration allows for a first wall panel (or shaft panel) to be inserted between the upstanding sections to form the interior of the shaft. Additional wall panels can be affixed to the outside of the J-runners, typically to the outer surfaces of the short upstanding sections to form the interior of the room. In typical shaft wall constructions, wall studs, such as C-H studs and E-studs, are used to hold the wall panel in place. This type of construction is described by U.S. Pat. Nos. 3,943,680; 3,940,899; and 4,152,878, all to Balinski, each of which is hereby incorporated by reference in its entirety.
Shaft walls fasteners are not permitted to penetrate from the outermost wall through the assembly according to Fire Tests of Building Construction and Materials, UL 263, Jun. 21, 2011. ASTM E119-15 also limits fastener penetration in shaft wall assemblies. In other words the fastener, such as a nail or screw, cannot penetrate from the outer wall of the shaft wall assembly to the exposed inner space of the shaft. If fasteners do penetrate the assembly, temperature measurements are required to be measured on the heads of the fasteners.
To avoid fastener penetration into exposed inner space of the shaft a conventional shaft wall assembly employs a C-H stud 10 as shown in
Positioned between the first J-runner 10 and the second J-runner 11, and between each of the studs 12 is a single shaft liner panel 13. Each shaft liner panel 13 has opposed vertical edges 16 (one shown) inserted into a respective cavity of a stud 12.
Located outside the J-runners 10 and 11 are a pair of wall boards 14 and 15. When fully installed as an inner surface of the shaft, shaft liner panel 13 forms the inside 28 (
Typical gypsum wallboard panels and liner panels are made of Type X gypsum wallboard or Type C gypsum wallboard. ⅝″ Type X gypsum board provides one-hour fire protection when used on both sides of a steel partition.
U.S. Pat. No. 7,712,267 to Lehane discloses a modification to the shaft wall assembly of
Preferably the lifting elements 21 form a flattened surface (ledge) 22 upon which the studs 12 and/or the shaft liner panel 13 can rest. Generally, shaft liner panel 13 is inserted into the J-runner 10, pushed up the ramping edge 23 until it rests upon the ledge 22 and then slid horizontally until a first vertical edge of the shaft panel 13 is properly seated in a first stud 12. Then the next stud 12 is put into place between the lower J-runner 10 and upper J-runner 11 and pushed against the shaft liner panel 13 to have a second vertical edge of the shaft panel 13 seat in a cavity of the second stud 12. The lifting elements also provide a space 24 to define a drain.
Conventional shaft wall assemblies with C-H studs and panels have many benefits. For example, they are constructed from one side only, fire ratings are applicable from either side, they are proven by years of tests and real world use, and they provide relatively quick construction. However, a disadvantage of conventional shaft wall assemblies with C-H studs and panels is they require liner panels which can be difficult to produce and transport. Also, there is generally a limitation in size and gauge of C-H studs, for example they are employed with 24 inch wide liner panels. It would be beneficial to develop a construction that did not require liner panels.
To solve the deficiencies of conventional constructions, the shaft wall assembly of the invention is provided with one or more supporting studs having a triangular cross-section. Thus, fasteners, such as screws (for example type S drywall screws) can be screwed into the void space within the triangular stud so they are not exposed to the exposed inner space of a shaft wall assembly. The triangular studs are sized to have a depth to fit into a standard floor runner and ceiling runner. The floor runner may be a J-shaped runner or a C-shaped runner. Also, the ceiling runner may be a J-shaped runner or a C-shaped runner. Preferably, the floor and ceiling runners are C-shaped.
The C-runner which may be employed in the assembly of the invention includes a front upstanding section and a back upstanding section in a parallel configuration, each forming a substantially right angle with a middle section, with optional lifting elements positioned on the middle section and/or upstanding sections. The front upstanding section and the back upstanding section have about the same height.
The J-runner if employed in the assembly of the invention includes a short upstanding section and a tall upstanding section in a parallel configuration, each forming a substantially right angle with a middle section, with optional lifting elements positioned on the middle section and/or upstanding sections.
Regardless of whether the runner is a C-runner or J-runner is employed, if desired a notched runner is employed with notches every 6 to 12 inches on center (OC), typically 8 inches OC to accommodate for multiple stud spacing scenarios. The notch is an indentation or a protrusion on one of the upstanding walls of the runner. One, two, three or even 4 layers of gypsum board are secured to only one side of the triangular studs. The system will be asymmetrical with gypsum board on only one side of the wall and one face of the triangle.
In particular the invention provides a shaft-wall assembly comprising:
a shaft wall having upper, lower, left and right sides;
a floor runner positioned adjacent to the lower side of the shaft wall, a ceiling runner, positioned adjacent to the upper side of the shaft wall,
wherein each of the floor runner and the ceiling runner comprises:
a substantially planar transverse middle section having opposed first and second longitudinal sides each having a length and opposed first and second ends each having a width, wherein the length of each longitudinal side is greater than the width of each end;
a first upstanding section and a second upstanding section, wherein the first upstanding section has a first height and the second upstanding section has a second height, the first upstanding section extending to the first height from the first longitudinal side of the middle section, and the second upstanding section extending to the second height from the second longitudinal side of the middle section
a triangular stud of the shaft wall between the floor runner and the ceiling runner, the triangular stud having a triangular polyhedron shape comprising three sidewalls defining a triangular bottom perimeter and a triangular top perimeter;
the floor runner and the triangular stud sized for a first said side of the triangular stud to contact the first upstanding section of the floor runner and a vertex of the triangular stud opposed to the first side of the triangular stud to contact the second upstanding section of the floor runner.
If a J-runner as a floor or ceiling runner is employed the first height is less than the second height. If a C-runner is employed as a floor or ceiling runner the first height and the second height are equal.
The invention also provides a triangular stud for a shaft wall, the triangular stud having a triangular polyhedron shape comprising three sidewalls defining a triangular bottom perimeter and a triangular top perimeter, a lower end portion of the triangular stud having a notch for mating with a protrusion of a J-runner.
The invention also provides a runner comprising:
a substantially planar transverse middle section having opposed first and second longitudinal sides each having a length and opposed first and second ends each having a width, wherein the length of each longitudinal side is greater than the width of each end;
a first upstanding section and a second upstanding section, wherein the first upstanding section has a first height and the second upstanding section has a second height, the first upstanding section extending to the first height from the first longitudinal side of the middle section, and the second upstanding section extending to the second height from the second longitudinal side of the middle section, wherein the first upstanding section and the second upstanding section are substantially parallel;
wherein the runner has at least one feature selected from the group consisting of vertically elongated indentations spaced along the first upstanding section and vertically elongated protrusions spaced along the first upstanding section.
If a J-runner is employed as a floor or ceiling runner the first height is less than the second height. If a C-runner is employed as a floor or ceiling runner the first height and the second height are equal.
In the figures, like numbered elements have the same configurations unless otherwise indicated.
With reference to the embodiment of shaft wall 101 of
The triangular stud 112 of the shaft wall is between the floor C-runner 10 and the ceiling C-runner 11. The triangular stud 112 has a triangular polyhedron shape comprising three sidewalls defining a triangular bottom perimeter and a triangular top perimeter. Preferably, all transverse cross-sections of the triangular stud 112 parallel to the top perimeter and the bottom perimeter are the same triangle.
Each C-runner 10, 11 has a horizontal middle wall (section) 6, a first vertical wall 2, and a second vertical wall 4 (
Unlike the conventional system 1 of
Located outside the C-runners 10 and 11 are a pair of wall boards 14 and 15. When fully installed an inner surface of wall board 15 forms the inside of the shaft, while an outer surface of the wall board 14 forms the interior wall of a room.
Located outside the J-runners 10 and 11 are a pair of wall boards 14 and 15. When fully installed an inner surface of wall board 15 forms the inside of the shaft, while an outer surface of the wall board 14 forms the interior wall of a room.
The embodiment of shaft wall 101A of
The triangular stud 112 of the shaft wall is between the floor J-runner 10A and the ceiling J-runner 11A. The triangular stud 112 has a triangular polyhedron shape comprising three sidewalls defining a triangular bottom perimeter and a triangular top perimeter. Preferably, all transverse cross-sections of the triangular stud 112 parallel to the top perimeter and the bottom perimeter are the same triangle.
Each J-runner 10A, 11A has a horizontal middle wall (section) 6, a shorter first vertical wall 2A, and a taller second vertical wall 4A (
Unlike the conventional system 1 of
Located outside the J-runners 10A and 11A are a pair of wall boards 14 and 15. When fully installed an inner surface of wall board 15 forms the inside of the shaft, while an outer surface of the wall board 14 forms the interior wall of a room.
A first end of the lifting element 151 is proximal to the shorter vertical wall 152 and a second end of the lifting element 151 is distal to the shorter vertical wall 152. At least one triangular stud 142 is positioned on the lifting element 159. Also, preferably the lifting element 151 defines a drain in the horizontal middle wall 156 below the lifting element 151.
The studs 12 can take the form of any stud having a triangular cross section suitable for placing in the present C-runner or J-runner. Typical materials for the studs include steel.
For beginning or terminating a wall, typically a metal framing member with a C or L profile is used.
The C-runners, J-runners, and the triangular studs of the invention can be formed of any suitable material. Typical materials include steel, for example 24 gauge (0.024 in, 0.6 cm) or 20 gauge (0.035 in, 0.9 cm) or other suitable gauges. The C-runners and J-runners and triangular studs can be formed by stamping or roll forming. To form the lifting elements, e.g. lifting element 151 or protrusions 158 of a runner, the runner can be lanced, stamped, pierced or notched.
C-runners and J-runners employed in the present invention including a bottom (middle) section 71, a shorter wall 69, and lifting elements 129. With reference to
J-runners are the same except the shorter upstanding wall typically has a height of from about 0.75 to 2.0 inches (1.9 to 5.1 cm), preferably approximately 1 inch (2.54 cm), while the taller upstanding wall typically has a height of from about 1.5 to 4 inches (3.8 to 10.2 cm), preferably about 2.0 to 2.5 inches (5.1 to 6.4 cm), more preferably about 2.1 inches (5.3 cm).
Although
The invention has many advantages. It employs one or more, preferably two or more, most preferably 2 or 3, layers of wall board attached to one side of the triangular studs. The studs are triangular so the pointed end of the screw goes into the stud and is not exposed. Thus, the shaft wall of the invention does not need an inner liner panel wall as do shaft walls made with C-H studs. All the wall boards of the present shaft wall assembly are actually attached to studs rather than having some attached and others slidingly held by a runner and C-H studs.
Generally in assembling the shaft wall assembly the triangular studs are not attached to the top or bottom J-runner. Thus, to assist in placing the triangular stud, preferably the triangular stud has the notch described above for mating with an indentation on the inner shorter wall of the J-runner. Another preferred enhancement to assist in placing the triangular stud is for the J-runner to have the above-described protrusions along its outer taller wall to form cavities in which to locate an edge of the triangular stud.
Triangular studs are stronger than C-H studs for a given composition and gage of metal from which they are made. Thus, the shaft wall assemblies of the present invention can be made taller than shaft wall assemblies made with C-H studs.
A Computer Assisted Design (CAD) simulation was run to compare a conventional 20 Gauge C-Stud with a 25 Gauge Triangle Studs of the present invention. The 25 Gauge Triangle Studs of the present invention was notched as shown by
TABLE 1 shows mechanical properties achieved out of the CAD computer simulations. This data shows the 25 Gauge triangular stud at 3⅝″ was equivalent to a 20 Gauge C-Stud at 3⅝″ deep.
The CAD simulation showed the triangular stud configuration has multiple advantages. It has greater moment of inertia about strong “X” access allowing for increase in limiting heights. It also has much greater weak moment of inertia about “Y” access allowing for greater unbraced lengths, especially in instances where wallboard sheathing is only on one side. The stud allows easy of installation in case of a vertical board joint since there is more space for two rows of fasteners.
It should be apparent that embodiments other than those specifically described above may come within the spirit and scope of the present invention. Hence, the present invention is not limited by the above description.
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