CA1139075A - Economy stud for forming fire-rated wall and structure formed therewith - Google Patents
Economy stud for forming fire-rated wall and structure formed therewithInfo
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- CA1139075A CA1139075A CA000363653A CA363653A CA1139075A CA 1139075 A CA1139075 A CA 1139075A CA 000363653 A CA000363653 A CA 000363653A CA 363653 A CA363653 A CA 363653A CA 1139075 A CA1139075 A CA 1139075A
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Abstract
APPLICATION FOR
LETTERS PATENT
FOR
ECONOMY STUD FOR FORMING FIRE-RATED WALL
AND STRUCTURE FORMED THEREWITH
ABSTRACT OF THE DISCLOSURE
A metal stud for constructing a fire-rated wall and the wall structure formed of a plurality of the studs mounted in runners and having at least a pair of spaced-apart layers of wallboard panels with adjacent panels in abutting edge-to-edge relationship, the stud being formed of an integral piece of sheet metal and comprising a single layer web having a pair of continuous oppositely directed flange means at one edge thereof, the other edge being operatively connected with a panel in oblique relationship thereto, the oblique panel having a discontinuous flange-forming structure com-prising a plurality of spaced-apart tabs struck therefrom on both sides of the oblique panel and oriented substantially parallel with respect to the continuous oppositely directed flange means, the oblique panel being operatively connected to a wallboard-supporting panel spaced apart from the con-tinous oppositely directed flange means and substantially parallel thereto, the wallboard-supporting panel being adapted to have panels of a second layer affixed thereto in parallel spaced-apart relationship with regard to the first layer of wallboard panels. The continuous flange-forming structure cooperating with the continuous flange structure and the web to define a pair of oppositely directed channels for having the edges of the wallboard panel engaged therein.
LETTERS PATENT
FOR
ECONOMY STUD FOR FORMING FIRE-RATED WALL
AND STRUCTURE FORMED THEREWITH
ABSTRACT OF THE DISCLOSURE
A metal stud for constructing a fire-rated wall and the wall structure formed of a plurality of the studs mounted in runners and having at least a pair of spaced-apart layers of wallboard panels with adjacent panels in abutting edge-to-edge relationship, the stud being formed of an integral piece of sheet metal and comprising a single layer web having a pair of continuous oppositely directed flange means at one edge thereof, the other edge being operatively connected with a panel in oblique relationship thereto, the oblique panel having a discontinuous flange-forming structure com-prising a plurality of spaced-apart tabs struck therefrom on both sides of the oblique panel and oriented substantially parallel with respect to the continuous oppositely directed flange means, the oblique panel being operatively connected to a wallboard-supporting panel spaced apart from the con-tinous oppositely directed flange means and substantially parallel thereto, the wallboard-supporting panel being adapted to have panels of a second layer affixed thereto in parallel spaced-apart relationship with regard to the first layer of wallboard panels. The continuous flange-forming structure cooperating with the continuous flange structure and the web to define a pair of oppositely directed channels for having the edges of the wallboard panel engaged therein.
Description
BACKGROUND OF T~IE INVENTION
(1) Field of the Invention \
The present invention relates to wall construction, and more particularly refers to studs which may be utilized to form fire-retardant or ~ire-rated wall structures particularly for-use in enclosing open shafts in multi-story buildings such as offices and high-rise apartments, and to the wall structure formed therewith.
(1) Field of the Invention \
The present invention relates to wall construction, and more particularly refers to studs which may be utilized to form fire-retardant or ~ire-rated wall structures particularly for-use in enclosing open shafts in multi-story buildings such as offices and high-rise apartments, and to the wall structure formed therewith.
(2) Description of the Prior Art .
Walls enclosing shafts such as air return shafts, eleva-tor shafts, and stairwell shafts commonly separate the shafts from other rooms such as corridors, toilets, and utility rooms.
With increasing governmental concern for promoting safety for occupants of public buildings, manufacturers of building pro-ducts have sought to provide shaft walls meeting at least minimal safety requirements, whi.le at the same time, providing builders with materials that are both easy to install and low in cost.
Two of the most important of these safe~y requirements concern wind loading and fire ratings. Destructi~e wind loading is of particular concern where the shaft is an air return shaft or an elevator shaft, where pressures or vacuums are developed which load the shaft wall up to 15 pounds per square foot in excess of atmospheric pressureO
Cavity walls, and particularly those utilized for en-closing elevator shafts, stairwells, and air return shafts, are continually being subjected to increasingly stringent fire code requirements. The trend is to require such walls ;9;
to meet or surpass certain fire ratings measu.red pursuant to ASTM E-ll9 Fire Rating Test. Elevator shaft walls require, for example at least a 2-hour rating. Where the wall system is "unbalanced'l, increasingly, code enforcement organizations are requiring that the rating be achieved from both sides of the wall. To pass such tests, heat trans~er through the metal studs used to construct such walls must be substantially re-duced~ At the same time, however, the stud must still retain a sufficient degree of structural strength, and in addition, must meet economic requirements. Moreover, the enga~ement of the stud with the wall panels which they support must be of such nature that construction is achieved with a minimum of required labor and materials. The structure must, never-theless, withstand the requirements of accurate and complete en~agement of the panels and studs, to ensure that the fire rating will be achieved.
The above fire problems concerni.ng shafts can also be said to.apply to long corridors in buildings, which in effect are horizontal, rather than vertical, shafts. Thus, without adequate fire ratings, a corridor wall easily transmits the fire throughout the floor as the fire proceeds along the corridor.
To solve these and other problems, early building shaft walls were commonly built up and lined with various types of block masonry, including both concrete and gypsum block.
~hile block masonry has proved suitable for many applications 9 it has been found to be undesirable in those situations where the shaf~ rises to great heights. Further~ block masonry structures cannot withstand high wind loading. Because of their great weight, concrete block masonry materials require supporting structures of great weight and strength. An additional problem is that these heavy materials give rise to problems in their installation. Those skilled in install-ing the above-described shaft lining materials are forced to handle them at dangerously high levels.
Walls of the type described and related structures have been disclosed in the prior art, and particularly in U.S.
Patent Nos. 3,740,912, 3,702,044, 3,609,93~, 3,016,116,
Walls enclosing shafts such as air return shafts, eleva-tor shafts, and stairwell shafts commonly separate the shafts from other rooms such as corridors, toilets, and utility rooms.
With increasing governmental concern for promoting safety for occupants of public buildings, manufacturers of building pro-ducts have sought to provide shaft walls meeting at least minimal safety requirements, whi.le at the same time, providing builders with materials that are both easy to install and low in cost.
Two of the most important of these safe~y requirements concern wind loading and fire ratings. Destructi~e wind loading is of particular concern where the shaft is an air return shaft or an elevator shaft, where pressures or vacuums are developed which load the shaft wall up to 15 pounds per square foot in excess of atmospheric pressureO
Cavity walls, and particularly those utilized for en-closing elevator shafts, stairwells, and air return shafts, are continually being subjected to increasingly stringent fire code requirements. The trend is to require such walls ;9;
to meet or surpass certain fire ratings measu.red pursuant to ASTM E-ll9 Fire Rating Test. Elevator shaft walls require, for example at least a 2-hour rating. Where the wall system is "unbalanced'l, increasingly, code enforcement organizations are requiring that the rating be achieved from both sides of the wall. To pass such tests, heat trans~er through the metal studs used to construct such walls must be substantially re-duced~ At the same time, however, the stud must still retain a sufficient degree of structural strength, and in addition, must meet economic requirements. Moreover, the enga~ement of the stud with the wall panels which they support must be of such nature that construction is achieved with a minimum of required labor and materials. The structure must, never-theless, withstand the requirements of accurate and complete en~agement of the panels and studs, to ensure that the fire rating will be achieved.
The above fire problems concerni.ng shafts can also be said to.apply to long corridors in buildings, which in effect are horizontal, rather than vertical, shafts. Thus, without adequate fire ratings, a corridor wall easily transmits the fire throughout the floor as the fire proceeds along the corridor.
To solve these and other problems, early building shaft walls were commonly built up and lined with various types of block masonry, including both concrete and gypsum block.
~hile block masonry has proved suitable for many applications 9 it has been found to be undesirable in those situations where the shaf~ rises to great heights. Further~ block masonry structures cannot withstand high wind loading. Because of their great weight, concrete block masonry materials require supporting structures of great weight and strength. An additional problem is that these heavy materials give rise to problems in their installation. Those skilled in install-ing the above-described shaft lining materials are forced to handle them at dangerously high levels.
Walls of the type described and related structures have been disclosed in the prior art, and particularly in U.S.
Patent Nos. 3,740,912, 3,702,044, 3,609,93~, 3,016,116,
3,094,197, 999,752, 3,495,417, 3r271,920, 3,839,839, and many others. However, even though many of the structures disclosed in these patents have proven to be highly satis-factory, the search has continued to provide wall structures of the type described of greater strength, and greater fire-retardant properties.
In U.S. Patent No. 4,152,878 there is disc]osed a highly satisfactoxy stud and fire-rated shaft wall structure. How-ever, the stud is somewhat expensive to construct since it uses a substantial amount of metal.
SUMMARY OF THE INVENTION
It is accordingly, an object of the invention to provide a stud for the construction of a cavity shaft wall for mul-ti story buildings, which walls meet safety standards of wind loading.
It is a further object to provide a stud for the proauc-tion of a cavity shaft wall, which wall can meet required fire rating tests even when utilizing relatively thin wall-board panels.
It is an additional object to provide a stud for the production of a cavity shaft wall which is relatively inexpensive, lightweight, and relatively easy to install.
It is a further object to provide a building structure utilizing studs of the type described wherein both layers of wallboard panels can be inserted from the outside or corridor side, thereby obviating the need for workmen to erect scaffolding and to work within an elevator shaft around which the shaft wall is beiny installedO
Other objects and advantages will become apparent upon reference to the drawings and detailed description.
According to the invention~ a fire-rated cavity shaft wall structure is provided utilizing a plurality of metal studs according to the invention and a plurality of gypsum wallboard panels to form two spaced-apart rows with each of the panels having two opposed vertical edges, a stud being interposed between adjacent panels, and mounting the panels.
Each of th~ studs has a web portion formed of a single layer of metal, a pair of oppositely directed continuous flanges provided at one edge of the web, an oblique panel integrally connected with the web, and a supporting panel spaced apart from the oppositely directed flanges and in substan-tially parallel relationship thereto~ Additionally, tabs are struck out on both sides of the oblique panel to provide oppositely direct~d discontinuous flanges sub-stantially parallel to the oppositely directed contin-uous flanges. The oppositely directed continuous flanges and the oppositely directed discontinuous flanges CQ-operate to define oppositely directed channels in which the edges of adjacent gypsum board panels may be inserted from the corridor side of the shaft wall. In assembling the structuxe, one layer of wallboard is inserted in the oppositely directed channels formed by the flanges, and another layer of-wallboard panels is subsequen~ly affixed to the wallboard-supporting panels by nails or screws. The entire structure may be assembled by workmen positioned in the corridor side of the shaft wall. Additionally, slots may be provided in the web to improve the fire-rated proper-ties~
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side elevational view of a stud according to the invention.
FI&~ 2 is a cross-s~ctional view taken at the line 22 of FIG. 1, looking in the direction of the arrows.
FIG. 3 is a cross-sectional view of a stud similar to that of FIGS. 1 and 2, but wherein the orientation of the oppositely directed flanges and the base panel are reversed.
PIG. 4 is a perspective view of a portion of a cavity shaft wall embodying the stud of FIGS~ 1 and 2.
FIG. 5 is a fragmentary cross-sectional view taken at the line 5--5 of FIG. 4, looking in the direction of the arrows.
FIG. 6 is a perspective view of a portion of a wall suitable for use in stairwells, and FIG. 7 is a fragmentary cross-sectional view taken at the line 7--7 of FIG. 6, looking in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, a stud 10 is shown formed of a unitary int.egral sheet of metal such as steel or aluminum. The stud comprises a continuous flange-forminc3 panel 11 comprising an outer panel member 12 terminating at a first fold 13, and an inner panel member 14 connected to the first fold 13, folded over onto the outer panel member 12, and extending to a second fold 15, thereby defining a pair of oppositely directed flanges 16 and 17.
A web 18 is connected at the second fold 15 and e~tends substantially perpendicularly with respect to the outer panel member 12 to a third fold 19. An oblique panel 20 which is acutely angled with respect to the plane of the web 18 extencls from the third fold 19 and is connected by means of a portion thereof or connecting panel 27 to a wallboard supporting panel 21 which is disposed at an acute angle with respect to 7~
the oblique panel 20, perpendicular to the connecting panel 27, and substantially para~lel to the oppositely directed flanges 16 and 17. The wallboard-supporting panel 21 may be provided with a turned-over edge or flange 22. The outer panel member 12 may also be provided with a turned-over edge 23. Additionally/ in a preferred embodiment, a groove 24 may be proviaed in the outer panel member 12 in order to increase structural rigidity thereof. Further, a conventional circular aperture 25 may be provided in the oblique panel 20 to permit cables, wires and ducts to pass through the stud. The web 18 is preferably provided with elongate apertures 26, similar to those shown in U.S. Patent
In U.S. Patent No. 4,152,878 there is disc]osed a highly satisfactoxy stud and fire-rated shaft wall structure. How-ever, the stud is somewhat expensive to construct since it uses a substantial amount of metal.
SUMMARY OF THE INVENTION
It is accordingly, an object of the invention to provide a stud for the construction of a cavity shaft wall for mul-ti story buildings, which walls meet safety standards of wind loading.
It is a further object to provide a stud for the proauc-tion of a cavity shaft wall, which wall can meet required fire rating tests even when utilizing relatively thin wall-board panels.
It is an additional object to provide a stud for the production of a cavity shaft wall which is relatively inexpensive, lightweight, and relatively easy to install.
It is a further object to provide a building structure utilizing studs of the type described wherein both layers of wallboard panels can be inserted from the outside or corridor side, thereby obviating the need for workmen to erect scaffolding and to work within an elevator shaft around which the shaft wall is beiny installedO
Other objects and advantages will become apparent upon reference to the drawings and detailed description.
According to the invention~ a fire-rated cavity shaft wall structure is provided utilizing a plurality of metal studs according to the invention and a plurality of gypsum wallboard panels to form two spaced-apart rows with each of the panels having two opposed vertical edges, a stud being interposed between adjacent panels, and mounting the panels.
Each of th~ studs has a web portion formed of a single layer of metal, a pair of oppositely directed continuous flanges provided at one edge of the web, an oblique panel integrally connected with the web, and a supporting panel spaced apart from the oppositely directed flanges and in substan-tially parallel relationship thereto~ Additionally, tabs are struck out on both sides of the oblique panel to provide oppositely direct~d discontinuous flanges sub-stantially parallel to the oppositely directed contin-uous flanges. The oppositely directed continuous flanges and the oppositely directed discontinuous flanges CQ-operate to define oppositely directed channels in which the edges of adjacent gypsum board panels may be inserted from the corridor side of the shaft wall. In assembling the structuxe, one layer of wallboard is inserted in the oppositely directed channels formed by the flanges, and another layer of-wallboard panels is subsequen~ly affixed to the wallboard-supporting panels by nails or screws. The entire structure may be assembled by workmen positioned in the corridor side of the shaft wall. Additionally, slots may be provided in the web to improve the fire-rated proper-ties~
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a side elevational view of a stud according to the invention.
FI&~ 2 is a cross-s~ctional view taken at the line 22 of FIG. 1, looking in the direction of the arrows.
FIG. 3 is a cross-sectional view of a stud similar to that of FIGS. 1 and 2, but wherein the orientation of the oppositely directed flanges and the base panel are reversed.
PIG. 4 is a perspective view of a portion of a cavity shaft wall embodying the stud of FIGS~ 1 and 2.
FIG. 5 is a fragmentary cross-sectional view taken at the line 5--5 of FIG. 4, looking in the direction of the arrows.
FIG. 6 is a perspective view of a portion of a wall suitable for use in stairwells, and FIG. 7 is a fragmentary cross-sectional view taken at the line 7--7 of FIG. 6, looking in the direction of the arrows.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, a stud 10 is shown formed of a unitary int.egral sheet of metal such as steel or aluminum. The stud comprises a continuous flange-forminc3 panel 11 comprising an outer panel member 12 terminating at a first fold 13, and an inner panel member 14 connected to the first fold 13, folded over onto the outer panel member 12, and extending to a second fold 15, thereby defining a pair of oppositely directed flanges 16 and 17.
A web 18 is connected at the second fold 15 and e~tends substantially perpendicularly with respect to the outer panel member 12 to a third fold 19. An oblique panel 20 which is acutely angled with respect to the plane of the web 18 extencls from the third fold 19 and is connected by means of a portion thereof or connecting panel 27 to a wallboard supporting panel 21 which is disposed at an acute angle with respect to 7~
the oblique panel 20, perpendicular to the connecting panel 27, and substantially para~lel to the oppositely directed flanges 16 and 17. The wallboard-supporting panel 21 may be provided with a turned-over edge or flange 22. The outer panel member 12 may also be provided with a turned-over edge 23. Additionally/ in a preferred embodiment, a groove 24 may be proviaed in the outer panel member 12 in order to increase structural rigidity thereof. Further, a conventional circular aperture 25 may be provided in the oblique panel 20 to permit cables, wires and ducts to pass through the stud. The web 18 is preferably provided with elongate apertures 26, similar to those shown in U.S. Patent
4,152,878, issued May 8? 1979 to the present inventor. ~s disclosed therein, the apertures have several functions.
First, they break up the heat conduction path transversely through the web. Second, they facilitate heat dissipation into the wallboards, and enhance the fire-rating properties of a wall formed from a plurality of the studs and wallboards.
Although only a single row of apertures has been shown in the structure of FIGS. 1 and 2, if desired two or more rows may be utilized with the apertures preferably in staggexed relationship. Additionally, if desired, apertures may be placed in the outer panel member 12.
A pair of discontinuous flanges 28 and 29 are formed, one on each side of the web 18, by striking tabs 31 and 32 from the web 18. The tabs alternate from one side to the other of the web and are oriented substantially parallel to the flange-forming panel 11. The discontinuous flanges ~3~ 75 28 and 29 comprised of the tabs 31 ana 32 ~ooperate with the web 18 to define a pair of oppositely directea channels 33 and 34 in which the edges of adjacent wallboard liner panels are inserted and retained.
In the studs shown in FIGS. 1 and 2 the folded-over flange 17 is on the same side of the web 18 as the turned-over flange 22 of the wallboard-supporting panel 21.
Alternatively~ the stud 30 shown in ~IG. 3 may be utilized in which the folded-over flange 17' is on an opposite side of the web 18 as the turned-over flange 22 of the wallboard-supporting panel 21. In FIG. 3 the same numerals have been utilized to show the structures which are the same as those of FIG. 2, while prime numerals are utilized to show the structures which are reversed. As can be seen, in addition to the identical structures, the stud 30 comprises an outer panel member 12' extending to a fold 13l, and an inner panel member 14' extending to a second fold 15l and web 18.
Referring to FIGS. 4 and 5, a wall structure suitable for use as a cavity shaft wall is shown utilizing stud 10 as shown in FIGS. 1 and 2. The structure is in the form of a cavity shaft wall structure 35 suitable for assembly from the outer or corridor side with respect to the cavity around which the wall is assembled, and comprises an upper 3-runner 36 having a web 37, a major or lar~e flange 38 on the shaft side, and a minor or smaller flange 39 on the outer wall side. The runner 36 may be affixed to a ceiling structure.
s On the floor structure is mounted a lower J-runner 40ihaving a web 41, a major flange 42 on the shat side, an~ a minor flange 43 on the outer or corridor side. A plurality of studs 10 are mounted inside the runners 36 and 40. As shown in FIGS. 4 and 5, a layer or row of gypsum wallboard or liner panels 44 is retained within the channels 33 and,34 of each stud and restrained by the web 18, the flanges 16 and 17 and the tabs 31 and 32. The liner panels are provided with beveled panel corners 45 to facilitate insertion into the channels 33 and 34, and additionally, to clear the grooves 24 of the studs.
A first outer layer of wallboard panels 46 is affixed to the wallboard-supporting panels 21 of each stud by means of screws 47. A second layer of outer wallboard panels 48 is affixed to the first layer of panels 46 and the studs 10 by means of screws 49.
In erecting the wall, because of the structure of the J-runners and studs, the entire wall may be assembled from the outside or corridor sid of the shaft without the need for placing workmen on scaffolding within the shaft to assemble,any portion of the wall from the shaft side. In assembling the wall the runners 36 and 40 are first affixed to the ceiling and floor structures. A stud 10 is then inserted between the flanges of the runners and maintained in place by the flanges. The flanges may be screwed to the stud if desired. A wallboard panel 44 is then set into place with its bottom edge within the lower runner, and the upper edge is swung into place into the upper runner. The minor flange 39 is sufficiently narrow so that the upper ~ 3~ 7~i edge of the wallboard panel 44 clears the ~lange and comes to rest against the major flange 38. It can then be moved laterally to become engaged within the channels 33 and 34.
A second stud is then mounted between the runners and moved laterally until the opposite vertical edge of the panel 44 is engaged within one of the channels 33 or 34. Then another stud is inserted. This process continues until the entire inner wall is erected. The first outer wallboard panels 48 are then placed against the wallboard-supporting panel 21 of the studs and affixed in place by means of screws 47.
The second layer of outer wallboard panels 48 is then placed against the flrst layer and affixed thereto and to the stud by means of screws 49.
The results of fire tests indicate that the wall made according to the invention and as described above equal those obtained with the structure disclosed and claimed in U.S. Patent No. 4,152,878. While performing excellently in the fire tests, the present studs are considerably lighter and less expensive than those disclosed in the afore-named patent.
Referring to FIGS. 6 and 7, a modified embodiment of the structure shown in FIGS. 4 and 5 is illustrated. This structure is in most respects identical to that shown in FIGS. 4 and 5 and identical numeral designations have been utilized to refer to identical structure. However; the structure of FIGS. 6 and 7 differs in that only a single wallboard panel 46' is provided at the corridor side, and a similar wallboard panel 4B', instead of being placed over ~3~3~7~
the panel 46', is affixed to the flanges 16 and 17 by means of screws 49'. This structure provides a finished wall on both sides and is useful for such applications as for stair cases where there is no shaft on the inner side.
The studs of the present invention have many advan-tages over those of the prior art. First~ they are as strong as and provide comparable fire resistance as the prior art studs such as those disclosed in U.S. Patent No. 4,152,878. They also permit complete assembly of a shaft wall from the corridor side. Additionally, because of the geometic configuration, less material is required ~or their construction.
It is to be understood that the invention is not to be limited to the exact details of operation or structure shown and described in the specification and drawinys, since obvious modification and equivalents will be readily apparent to one skilled in the art.
First, they break up the heat conduction path transversely through the web. Second, they facilitate heat dissipation into the wallboards, and enhance the fire-rating properties of a wall formed from a plurality of the studs and wallboards.
Although only a single row of apertures has been shown in the structure of FIGS. 1 and 2, if desired two or more rows may be utilized with the apertures preferably in staggexed relationship. Additionally, if desired, apertures may be placed in the outer panel member 12.
A pair of discontinuous flanges 28 and 29 are formed, one on each side of the web 18, by striking tabs 31 and 32 from the web 18. The tabs alternate from one side to the other of the web and are oriented substantially parallel to the flange-forming panel 11. The discontinuous flanges ~3~ 75 28 and 29 comprised of the tabs 31 ana 32 ~ooperate with the web 18 to define a pair of oppositely directea channels 33 and 34 in which the edges of adjacent wallboard liner panels are inserted and retained.
In the studs shown in FIGS. 1 and 2 the folded-over flange 17 is on the same side of the web 18 as the turned-over flange 22 of the wallboard-supporting panel 21.
Alternatively~ the stud 30 shown in ~IG. 3 may be utilized in which the folded-over flange 17' is on an opposite side of the web 18 as the turned-over flange 22 of the wallboard-supporting panel 21. In FIG. 3 the same numerals have been utilized to show the structures which are the same as those of FIG. 2, while prime numerals are utilized to show the structures which are reversed. As can be seen, in addition to the identical structures, the stud 30 comprises an outer panel member 12' extending to a fold 13l, and an inner panel member 14' extending to a second fold 15l and web 18.
Referring to FIGS. 4 and 5, a wall structure suitable for use as a cavity shaft wall is shown utilizing stud 10 as shown in FIGS. 1 and 2. The structure is in the form of a cavity shaft wall structure 35 suitable for assembly from the outer or corridor side with respect to the cavity around which the wall is assembled, and comprises an upper 3-runner 36 having a web 37, a major or lar~e flange 38 on the shaft side, and a minor or smaller flange 39 on the outer wall side. The runner 36 may be affixed to a ceiling structure.
s On the floor structure is mounted a lower J-runner 40ihaving a web 41, a major flange 42 on the shat side, an~ a minor flange 43 on the outer or corridor side. A plurality of studs 10 are mounted inside the runners 36 and 40. As shown in FIGS. 4 and 5, a layer or row of gypsum wallboard or liner panels 44 is retained within the channels 33 and,34 of each stud and restrained by the web 18, the flanges 16 and 17 and the tabs 31 and 32. The liner panels are provided with beveled panel corners 45 to facilitate insertion into the channels 33 and 34, and additionally, to clear the grooves 24 of the studs.
A first outer layer of wallboard panels 46 is affixed to the wallboard-supporting panels 21 of each stud by means of screws 47. A second layer of outer wallboard panels 48 is affixed to the first layer of panels 46 and the studs 10 by means of screws 49.
In erecting the wall, because of the structure of the J-runners and studs, the entire wall may be assembled from the outside or corridor sid of the shaft without the need for placing workmen on scaffolding within the shaft to assemble,any portion of the wall from the shaft side. In assembling the wall the runners 36 and 40 are first affixed to the ceiling and floor structures. A stud 10 is then inserted between the flanges of the runners and maintained in place by the flanges. The flanges may be screwed to the stud if desired. A wallboard panel 44 is then set into place with its bottom edge within the lower runner, and the upper edge is swung into place into the upper runner. The minor flange 39 is sufficiently narrow so that the upper ~ 3~ 7~i edge of the wallboard panel 44 clears the ~lange and comes to rest against the major flange 38. It can then be moved laterally to become engaged within the channels 33 and 34.
A second stud is then mounted between the runners and moved laterally until the opposite vertical edge of the panel 44 is engaged within one of the channels 33 or 34. Then another stud is inserted. This process continues until the entire inner wall is erected. The first outer wallboard panels 48 are then placed against the wallboard-supporting panel 21 of the studs and affixed in place by means of screws 47.
The second layer of outer wallboard panels 48 is then placed against the flrst layer and affixed thereto and to the stud by means of screws 49.
The results of fire tests indicate that the wall made according to the invention and as described above equal those obtained with the structure disclosed and claimed in U.S. Patent No. 4,152,878. While performing excellently in the fire tests, the present studs are considerably lighter and less expensive than those disclosed in the afore-named patent.
Referring to FIGS. 6 and 7, a modified embodiment of the structure shown in FIGS. 4 and 5 is illustrated. This structure is in most respects identical to that shown in FIGS. 4 and 5 and identical numeral designations have been utilized to refer to identical structure. However; the structure of FIGS. 6 and 7 differs in that only a single wallboard panel 46' is provided at the corridor side, and a similar wallboard panel 4B', instead of being placed over ~3~3~7~
the panel 46', is affixed to the flanges 16 and 17 by means of screws 49'. This structure provides a finished wall on both sides and is useful for such applications as for stair cases where there is no shaft on the inner side.
The studs of the present invention have many advan-tages over those of the prior art. First~ they are as strong as and provide comparable fire resistance as the prior art studs such as those disclosed in U.S. Patent No. 4,152,878. They also permit complete assembly of a shaft wall from the corridor side. Additionally, because of the geometic configuration, less material is required ~or their construction.
It is to be understood that the invention is not to be limited to the exact details of operation or structure shown and described in the specification and drawinys, since obvious modification and equivalents will be readily apparent to one skilled in the art.
Claims (16)
1. A stud adapted for use in constructing a wall com-prised of a pair of spaced-apart coplanar layers of gypsum wallboard panels, the panels of each layer being in abutting relationship, said wall having a plurality of said studs interposed between said layers of wallboard panels and affixed thereto, said stud being formed of a unitary integral sheet metal structure and comprising:
(A) a wallboard panel layer-engaging structure comprising;
(1) a continuous flange-forming panel comprising (a) an outer panel member extending to a first fold, and (b) an inner panel member connected at said first fold and folded over a surface of said outer panel member and extending to a second fold intermediate the edges of said outer panel member, thereby forming a pair of flanges one on each side of said second fold, (2) a web connected at said second fold and ex-tending away from said continuous flange-forming panel disposed substantially perpendicular thereto and terminating at a third fold, said web being provided with a plurality of elongate apertures arranged in a row, the length of said apertures being substantially greater than the portion of said web connecting the ends of said apertures, (3) an oblique panel extending from the third fold of said web and disposed at an acute angle with respect to the plane of said web, (4) a discontinuous flange-forming structure comprising a plurality of spaced-apart tabs struck from said oblique panel on both sides thereof and oriented substantially parallel with respect to said continuous flange-forming panel and cooperating therewith and with said web to define a pair of oppositely oriented channels, (B) a wallboard-supporting panel operatively con-nected to said oblique panel in a direction substantially parallel to and spaced-apart from said first flange-forming panels and being adapted for having a second layer of panels affixed to the outer surface of said wallboard-supporting panel.
(A) a wallboard panel layer-engaging structure comprising;
(1) a continuous flange-forming panel comprising (a) an outer panel member extending to a first fold, and (b) an inner panel member connected at said first fold and folded over a surface of said outer panel member and extending to a second fold intermediate the edges of said outer panel member, thereby forming a pair of flanges one on each side of said second fold, (2) a web connected at said second fold and ex-tending away from said continuous flange-forming panel disposed substantially perpendicular thereto and terminating at a third fold, said web being provided with a plurality of elongate apertures arranged in a row, the length of said apertures being substantially greater than the portion of said web connecting the ends of said apertures, (3) an oblique panel extending from the third fold of said web and disposed at an acute angle with respect to the plane of said web, (4) a discontinuous flange-forming structure comprising a plurality of spaced-apart tabs struck from said oblique panel on both sides thereof and oriented substantially parallel with respect to said continuous flange-forming panel and cooperating therewith and with said web to define a pair of oppositely oriented channels, (B) a wallboard-supporting panel operatively con-nected to said oblique panel in a direction substantially parallel to and spaced-apart from said first flange-forming panels and being adapted for having a second layer of panels affixed to the outer surface of said wallboard-supporting panel.
2. A stud according to Claim 1, wherein said oblique panel terminates in a small panel portion substantially perpendicular to said wallboard-supporting panel, thereby permitting fasteners to be engaged in and penetrating said wallboard-supporting panel without striking said oblique panel.
3. A stud according to Claim 2, wherein said first fold and the end of said wallboard-supporting panel are on the same sides of said web.
4. A stud according to Claim 2, wherein said first fold and the end of said wallboard-supporting panel are on opposite sides of said web.
5. A stud according to Claim 2, wherein a longitudinal groove is provided in a median portion of the outer panel member of said first flange-forming panel for providing structural rigidity.
6. A stud according to Claim 2, wherein a flange is provided on said wallboard-supporting panel to increase structural rigidity.
7. A stud according to Claim 2, having apertures provided in said oblique panel to permit passage of conduits, wires and pipes.
8. A fire-retardant wall structure comprising in combination:
(I) upper and lower runners, (II) a plurality of studs mounted in said runners, each of said studs comprising:
(A) a wallboard panel layer-engaging structure comprising;
(1) a continuous flange-forming panel comprising:
(a) an outer panel member extending to a first fold, and (b) an inner panel member connected at said first fold and folded over a surface of said outer panel member and extending to a second fold intermediate the edges of said outer panel member, thereby forming a pair of flanges one on each side of said second fold, (2) a web connected at said second fold and extending away from said continuous flange-forming panel disposed substantially perpendicular thereto and terminating at a third fold, said web being provided with a plurality of elongate apertures arranged in a row, the length of said apertures being substantially greater than the portion of said web connecting the ends of said apertures, (3) an oblique panel extending from the third fold of said web and disposed at an acute angle with respect to the plane of said web, (4) a discontinuous flange-forming structure comprising a plurality of spaced-part tabs struck from said oblique panel on both sides thereof and oriented substan-tially parallel with respect to said con-tinuous flange-forming panel and coopera-ting therewith and with said web to define a pair of oppositely oriented channels, and (B) a wallboard-supporting panel operatively con-nected to said oblique panel in a direction substantially parallel to and spaced-apart from said first flange-forming panels and being adapted for having a second layer of panels affixed to the outer surface of said wallboard-supporting panel, (III)a first row of gypsum wallboard panels, the edges of adjacent panels being engaged and retained within the oppositely directed channels of said studs, and (IV) a second row of gypsum wallboard panels engaged by and affixed to said wallboard-supporting panels in substantially parallel spaced-apart relationship with respect to said first row of panels.
(I) upper and lower runners, (II) a plurality of studs mounted in said runners, each of said studs comprising:
(A) a wallboard panel layer-engaging structure comprising;
(1) a continuous flange-forming panel comprising:
(a) an outer panel member extending to a first fold, and (b) an inner panel member connected at said first fold and folded over a surface of said outer panel member and extending to a second fold intermediate the edges of said outer panel member, thereby forming a pair of flanges one on each side of said second fold, (2) a web connected at said second fold and extending away from said continuous flange-forming panel disposed substantially perpendicular thereto and terminating at a third fold, said web being provided with a plurality of elongate apertures arranged in a row, the length of said apertures being substantially greater than the portion of said web connecting the ends of said apertures, (3) an oblique panel extending from the third fold of said web and disposed at an acute angle with respect to the plane of said web, (4) a discontinuous flange-forming structure comprising a plurality of spaced-part tabs struck from said oblique panel on both sides thereof and oriented substan-tially parallel with respect to said con-tinuous flange-forming panel and coopera-ting therewith and with said web to define a pair of oppositely oriented channels, and (B) a wallboard-supporting panel operatively con-nected to said oblique panel in a direction substantially parallel to and spaced-apart from said first flange-forming panels and being adapted for having a second layer of panels affixed to the outer surface of said wallboard-supporting panel, (III)a first row of gypsum wallboard panels, the edges of adjacent panels being engaged and retained within the oppositely directed channels of said studs, and (IV) a second row of gypsum wallboard panels engaged by and affixed to said wallboard-supporting panels in substantially parallel spaced-apart relationship with respect to said first row of panels.
9. A fire-retardant wall structure according to Claim 8, wherein said oblique panel terminates in a small panel portion substantially perpendicular to said wallboard-support ing panel, thereby permitting fasteners lo be engaged in and penetrating said wallboard-supporting panel without striking said oblique panel.
10. A wall according to Claim 9, wherein a third layer of gypsum wallboard panels is affixed to said second layer of wallboard panels.
11. A wall according to Claim 9, wherein a third layer of gypsum wallboard panels is affixed to said first layer of wallboard panels.
12. A wall according to Claim 9, wherein said first fold and the end of said wallboard-supporting panel are on the same sides of said web.
13. A wall according to Claim 9, wherein a longitudinal groove is provided in a median portion of the outer panel member of said continuous flange-forming panel of each stud for providing structural rigidity.
14. A wall according to Claim 9, wherein a flange is provided on the wallboard-supporting panel of each stud to increase structural rigidity.
15. A wall according to Claim 9, wherein apertures are provided in said oblique panel of each stud to permit passage of conduits, wire and pipes.
16. A wall according to Claim 9, wherein the corners of the vertical edges of each panel of said first layer are bevelled to facilitate their insertion into said oppositely directed channels.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US9452379A | 1979-11-15 | 1979-11-15 | |
| US094,523 | 1979-11-15 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1139075A true CA1139075A (en) | 1983-01-11 |
Family
ID=22245682
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000363653A Expired CA1139075A (en) | 1979-11-15 | 1980-10-30 | Economy stud for forming fire-rated wall and structure formed therewith |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1139075A (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2000014354A1 (en) * | 1998-09-02 | 2000-03-16 | James Hardie Research Pty. Limited | Construction technique and structure resulting therefrom |
-
1980
- 1980-10-30 CA CA000363653A patent/CA1139075A/en not_active Expired
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2000014354A1 (en) * | 1998-09-02 | 2000-03-16 | James Hardie Research Pty. Limited | Construction technique and structure resulting therefrom |
| US6688066B1 (en) | 1998-09-02 | 2004-02-10 | James Hardie Research Pty Limited | Construction technique and structure resulting therefrom |
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