US20230407626A1 - Fire-rated wall joint component and related assemblies - Google Patents
Fire-rated wall joint component and related assemblies Download PDFInfo
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- US20230407626A1 US20230407626A1 US18/241,115 US202318241115A US2023407626A1 US 20230407626 A1 US20230407626 A1 US 20230407626A1 US 202318241115 A US202318241115 A US 202318241115A US 2023407626 A1 US2023407626 A1 US 2023407626A1
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Images
Classifications
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
- E04B2/7407—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
- E04B2/7409—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts special measures for sound or thermal insulation, including fire protection
- E04B2/7411—Details for fire protection
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
- E04B1/948—Fire-proof sealings or joints
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
- E04B1/941—Building elements specially adapted therefor
- E04B1/943—Building elements specially adapted therefor elongated
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
- E04B1/947—Protection against other undesired influences or dangers against fire by closing openings in walls or the like in the case of fire
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls
- E04B2/74—Removable non-load-bearing partitions; Partitions with a free upper edge
- E04B2/7407—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts
- E04B2/7453—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with panels and support posts, extending from floor to ceiling
- E04B2/7457—Removable non-load-bearing partitions; Partitions with a free upper edge assembled using frames with infill panels or coverings only; made-up of panels and a support structure incorporating posts with panels and support posts, extending from floor to ceiling with wallboards attached to the outer faces of the posts, parallel to the partition
Definitions
- This application is directed to fire-rated wall construction components for use in building construction joints.
- Fire-rated wall construction components and assemblies are commonly used in the building construction industry. These components and assemblies are aimed at preventing fire, heat, and smoke from leaving one portion of a building or room and entering another, usually through vents, joints in walls, or other openings.
- the components can incorporate fire-retardant materials which substantially block the path of the fire, heat, and/or smoke for at least some period of time in accordance with certain standards, such as UL-2079 “Test For Fire-rated Building Joints”.
- a conventional fire block arrangement includes using a fire-resistant material such as mineral wool stuffed in the gaps within a head-of-wall assembly including deflection gaps between the top of the wall boards and the ceiling.
- a flexible coating such as a spray-on elastomeric coating can cover the entire head-of-wall to secure the fire block material in place. Over time and cycles of movement the flexible coating may degrade and cause cracks or flaking. As a result, it is possible that the fire-resistant material may become dislodged and thereby reduce the effectiveness of the fire block.
- the component includes an elongate metal profile and a fire-rated board member.
- the elongate metal profile includes a vertical leg, an upper leg and a lower leg.
- the upper leg extends in a first direction from an upper edge of the vertical leg.
- the lower leg extends in the first direction from a lower edge of the vertical leg.
- the fire-rated board member is positioned within a space defined by the vertical leg, the upper leg and the lower leg to form a composite component.
- the upper leg includes a downward facing v-groove.
- the upper leg includes an extended free end attachment leg.
- an outward facing protrusion on the vertical leg rests against the drywall board of the framed wall assembly with the outward facing protrusion extending in a second direction, opposite the first direction.
- the gypsum board member is adhesively attached with the vertical leg.
- the lower leg includes a kick-out configured to retain a gypsum board member within the space.
- the upper leg, the lower leg, the v-groove, and the kick-out are configured to exert a force against the gypsum board member to retain the gypsum board in the space.
- the lower leg determines the thickness of the layer or layers of the gypsum board member.
- the metal profile is formed from a unitary piece of sheet steel and bent to form the vertical leg.
- the board member comprises a gypsum material.
- a building construction joint in another aspect of the present disclosure, includes a wall assembly and an adjacent structure formed along a linear gap.
- a fire-rated component including an elongate metal profile and a fire-rated board member is positioned at a joint between the wall assembly and the adjacent structure to provide fire-blocking across the linear gap.
- the adjacent structure is a ceiling and the wall assembly is a vertical wall.
- a fire-rated component for a linear gap between a wall assembly and an adjacent structure can comprise an elongate metal profile.
- the elongate metal profile can comprise a vertical leg, an upper leg, and a lower leg.
- the upper leg can extend in a first direction from an upper edge of the vertical leg.
- the lower leg can extend in the first direction from a lower edge of the vertical leg.
- the fire-rated board member can be positioned within a space defined by the vertical leg, the upper leg, and the lower leg.
- a gasket can be positioned between a wallboard of the wall assembly and the vertical leg.
- the gasket can be a fire blocking gasket.
- the gasket can comprise vinyl.
- a length of the gasket can be 8 feet.
- the length of the gasket can be between about 4 feet to about 10 feet. Other suitable values smaller than about 4 feet or larger than about 10 can also be utilized depending on a user's need.
- the gasket can comprise flexible material.
- FIG. 1 illustrates a cross section of a head-of-wall assembly including a composite fire-blocking component.
- FIG. 2 A shows a cross-section of the head-of-wall assembly in a fully closed configuration.
- FIG. 2 B shows a cross-section of the head-of-wall assembly in a fully opened configuration.
- FIG. 3 shows a cross-section of the composite fire-blocking component including a metal profile and board member.
- FIG. 4 shows a cross-section of an elongate metal profile.
- FIG. 5 shows a cross-section of the composite fire-blocking component including a gasket.
- FIG. 6 illustrates a cross section of a head-of-wall assembly including a composite fire-blocking component including a gasket.
- FIG. 7 is a sectional view of a fire block component.
- FIG. 8 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component of FIG. 7 .
- FIG. 9 is a sectional view of an alternative fire block component.
- FIG. 10 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component of FIG. 9 .
- FIG. 11 is a sectional view of another alternative fire block component.
- FIG. 12 is a sectional view of another alternative fire block component.
- FIG. 13 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component of FIG. 12 .
- FIG. 14 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component of FIG. 12 in action.
- FIG. 15 is a sectional view of a head-of-wall portion of a wall assembly including a prior art fire proofing arrangement.
- FIGS. 1 - 2 B illustrate a building construction joint between a wall assembly and an adjacent structure having a linear gap in the form of a head-of-wall assembly 100 .
- the embodiments disclosed herein often are described in the context of an interior of a building and configured for preventing passage of smoke and/or fire between adjacent rooms in an elevated-temperature environment. However, the embodiments herein can be applied to wall systems configured for other types of environments as well, such as for exterior wall applications, and can include different and/or additional components and types of materials other than those described herein.
- the head-of-wall assembly 100 can generally include an overhead structure or ceiling 105 .
- the ceiling 105 can be generally formed in a horizontal plane and/or include one or more flutes or grooves therein.
- the ceiling 105 can be a floor of a higher level of a building.
- the head-of-wall assembly 100 can include a header track or channel 107 .
- the channel 107 can include a web 107 a to which are attached one or more flanges 107 b, 107 c .
- the first and second flanges 107 b, 107 c can extend from opposite ends of the web 107 a in the same direction to form a generally u-shaped cross section.
- the channel 107 can be a deep leg header track.
- One or more studs 109 forming the wall can be received within the channel 107 between the first and second flanges 107 b, 107 c.
- the first and second flanges 107 b, 107 c can include slots to which fasteners can be received to attach the channel 107 with the studs 109 .
- the slots can be oriented generally orthogonal to a length of the channel 107 .
- the studs 109 can be attached with the channel 107 via fasteners through the slots of the flanges 107 b , 107 c.
- One or more wall board members (e.g., gypsum drywall) 111 , 113 can be attached with the studs 109 to form the wall. Assembly of the wall boards 111 , 113 with the studs 109 can define a deflection gap 101 between the ceiling 105 and upper ends of the wall boards 111 , 113 .
- the deflection gap 101 can vary in width depending on the relative position of the wall (e.g., wall boards 111 , 113 and the studs 109 ) and the ceiling 105 .
- the head-of-wall assembly 100 can cycle between a more closed position (such as the fully closed position in FIG. 2 A ) and a more open position (such as the fully open position in FIG. 2 B ).
- the dynamic nature of the head-of-wall assembly 100 can accommodate seismic or thermal forces or other movements of the building within which the head-of-wall assembly 100 is included.
- the head-of-wall assembly 100 can include a fire-rated composite component 10 .
- the composite component 10 can generally be configured to cover the deflection gap 101 to provide fire, smoke, heat and/or sound insulation and facilitate unencumbered movement of the joint.
- the component 10 can include an elongate metal profile 12 and a board member 14 .
- the board member 14 can comprise a fire-rated material, such as a gypsum drywall material.
- the board member 14 can adhesively attached or otherwise mechanically secured with the metal profile 12 to form the composite component 10 .
- the composite component 10 can be installed over the outer surface of the wall boards 111 , 113 and/or the flanges 107 b, 107 c on the framed wall assembly once the drywall assembly is completed.
- the component 10 can be attached with the ceiling 105 by one or more fasteners 103 , such as metal screws, adhesives, staples or other fasteners.
- the fasteners 103 can extend through the metal profile 12 .
- the fire board member 14 can insulate the metal profile 12 , while the metal profile 12 provides a constant fire block as it will not melt during the fire test of UL 2079. The combination of these two materials provides long lasting fire protection.
- drywall used in the board member 14 is less expensive than other fire-resistant materials, such as intumescent materials, that are often used in head-of-wall assemblies or other gaps of a building construction joint.
- the metal profile 12 can come in standard lengths (e.g., 10 ′, 12 ′, etc.). As shown further in the cross-section of FIG. 3 , the metal profile 12 can include a single sheet of metal, such as steel. The metal profile 12 can include a plurality of bends to form the metal profile shape.
- the metal profile 12 can include a vertical leg 16 , an upper leg 24 , and/or a lower leg 20 .
- the vertical leg 16 can have a length L extending from the upper leg 24 to the lower leg 20 .
- the length L can vary depending on the size of the head-of-wall deflection gap 101 and the overall dynamic movement needed.
- the length L can generally be between about 1′′ and 6′′.
- the vertical leg 16 can comprise a flattened portion of the metal profile 12 . Alternatively, the vertical leg 16 can comprise one or more strengthening features such as grooves or ribs.
- the upper leg 24 can couple with the vertical leg 16 at a corner 34 .
- the upper leg 24 can generally form perpendicular angle with the vertical leg 16 .
- the upper leg 24 can extend from the corner 34 in a first (e.g., rightward) direction.
- the upper leg 24 can be a horizontal leg.
- the upper leg 24 can be approximately 1.5′′-3.5′′ in length.
- the upper leg 24 can include a groove 22 .
- the groove 22 can be shaped as a v-groove, u-groove, or other form factor.
- the groove 22 can include an open end facing upwards and outwards.
- the groove 22 can provide structural strength to the metal profile 12 and to the upper leg 24 .
- Other retention features and/or strengthening features could also be used.
- the groove 22 can extend downwardly towards the lower leg 20 .
- the groove 22 can divide the upper leg into an inner portion 25 and an outer portion 26 .
- the inner portion 25 can be in-line with the outer portion 26 .
- the inner portion 25 can have a width W 1 from the corner to the groove 22 (e.g., approximately 0.625′′).
- the outer portion 26 can include an attachment portion of the metal profile 12 .
- the outer portion 26 can have a width of approximately 1.25′′.
- the attachment can include one or more holes or other mechanism to allow an installer to attach the metal profile 12 to the ceiling 105 (or other adjoining
- the lower leg 20 can couple with the vertical leg 16 at a corner 30 .
- the lower leg 20 can generally form perpendicular angle with the vertical leg 16 .
- the lower leg 20 can extend from the corner 30 in the first (e.g., rightward) direction.
- the lower leg 20 can extend in the same direction as the upper leg 24 .
- the lower leg 20 can be a horizontal leg.
- the lower leg 20 can include a kick-out 32 .
- the kickout 32 can be on a free end of the lower leg 20 .
- the kickout 32 can include an upturned retention lip or portion of the lower leg 20 (e.g., towards the upper leg 24 ).
- the kick-out 32 can be angled upwardly towards the upper leg 24 .
- the lower leg 20 can include a width W 2 from the corner 30 to the free end or the kickout 32 .
- the width W 2 can optionally be the same as the width W 1 .
- the lower leg 20 , the vertical leg 16 , and the upper leg 24 can form an inner, partially enclosed space.
- the inner space can receive and secure the board member 14 .
- the board member 14 can comprise a fire-rated drywall member.
- the board member 14 can comprise one or more layers of material.
- the board member 14 can be a rip of drywall comprising a gypsum material.
- the board member 14 can include a generally rectangular-shaped profile.
- the board member 14 can nest within the inner space between the upper leg 24 , the vertical leg 16 , and the lower leg 20 .
- the width W 1 of the upper leg 24 and the width W 2 of the lower leg 20 can be sized to accommodate a width W 3 of the board member 14 .
- the kickout 32 and/or the groove 22 can exert an inward force on the board member 14 to help retain the board member 14 within the inner space and/or against the vertical leg 16 .
- the width W 1 can be the same as width W 2 and correspond to the width W 3 of the board member 14 .
- the widths W 1 , W 2 can limit the W 3 of the board member 14 that can be used in the composite component 10 .
- An interior side of the board member 14 can be glued to the vertical leg 16 with an adhesive or secured with a mechanical fastener.
- the adhesive can secure the board member 14 within the inner space of the metal profile 12 .
- the kickout 32 and/or groove 22 can also retain the board member in place within the metal profile and ensure it will not fall out during a fire that may compromise the adhesive.
- the groove 22 and/or kickout 32 can be shaped in any suitable shape for retention of the board member 14 and/or strengthening of the composite 10 .
- the corner 30 can include an inward facing protrusion (e.g., towards the wall boards 111 , 113 ) that sticks out further than the interior surface of the vertical leg 16 (e.g., approximately 0.125′′).
- the inward facing protrusion can be formed of a bend in the metal of the metal profile 12 .
- the protrusion In the installed position with the head-of-wall assembly 100 , the protrusion can provide a sealing point against one of the board members 111 , 113 of the framed wall assembly.
- This protrusion can also allow the wall to cycle up and down, as is needed in order to pass the UL-2079 “Test For Fire-rated Building Joints” without causing any damage to the drywall on the framed wall assembly.
- one or both of the protrusion of the corner 30 and kickout 32 can be omitted.
- the board member 14 can be nested within the inner space of the metal profile 12 .
- the upper leg 24 can abut against and attached with the ceiling 105 (e.g., by fastener 103 ).
- the vertical leg 16 can abut an upper end of the wall board 113 and cover the deflection gap 101 .
- the protrusion of the corner 30 can abut the outer face of the wall board 113 to provide a seal therewith.
- the wall board 113 can cycle behind the installed composite component 10 between open and closed configurations.
- FIG. 4 illustrates an alternative metal profile 12 .
- the metal profile 12 can include a vertical leg 16 , an upper leg 24 , and a lower leg 20 , like the metal profile 12 previously described.
- An upward facing protrusion can be formed of a bent portion of the material of the metal profile 12 on the upper leg 24 (e.g., approximately 0.125′′).
- the upward facing protrusion can be directed or extend generally upwardly.
- the protrusion can contact and provide a sealing point against the ceiling 105 of the assembly 100 .
- the upper leg 24 can abut against and attached with the ceiling 105 .
- the upward facing protrusion of the corner 30 can abut the ceiling 105 to provide a seal therewith.
- the wall board 113 can cycle behind the installed composite component 10 between open and closed configurations.
- FIG. 5 shows a cross-section of a composite fire-blocking component including a gasket.
- the inner portion 25 can define a plane and the outer portion 26 can extend from the said plane.
- the outer portion 26 can extend from the said plane at an offset angle 29 .
- the offset angle 29 can comprise different values.
- the offset angle 29 can be about 2 degrees or about 5 degrees or any value between about 2 degrees and about 5 degrees.
- the offset angle 29 can be less than 2 degrees or greater than 5 degrees or can be any other value or incremental value to accommodate a user's need.
- the inner portion 25 and the outer portion 26 can lie in a single plane or substantially lie within a single plane.
- the outer portion 26 can be positioned on one side of the groove 22 and the inner portion 25 can be positioned on an opposite side.
- the outer portion 26 can have an extended free end.
- the extended free end of the outer portion 26 can be flexible and/or movable.
- the outer portion 26 can extend upwardly or downwardly with respect to the plane that defines the inner portion 25 .
- FIG. 6 illustrates a cross section of a head-of-wall assembly including a composite fire-blocking component 10 , which includes a gasket 18 .
- the gasket 18 can be positioned between the vertical leg 16 and the wallboard 111 (or 113 ).
- the gasket 18 can be attached to the vertical leg 16 .
- the gasket 18 can be attached to the vertical leg 16 during the manufacturing process.
- the gasket 18 can be attached to the vertical leg 16 through a variety of means.
- the gasket 18 can be adhesively attached to the vertical leg 16 , or it can be mechanically fastened to the vertical leg 16 or it can be coupled with the vertical leg 16 using a double-sided tape.
- the gasket 18 can be manufactured as a separate piece and installed in the field between the vertical leg 16 and the wallboard 111 or 113 .
- the gasket 18 can be attached separately to the wallboard 111 (or 113 ).
- the gasket 18 can be manufactured to have a variety of different widths, lengths, and depths to accommodate a user's need.
- the gasket 18 can have a width of about 1/16 inch or about 1 ⁇ 8 inch or about 3 ⁇ 8 inch or about 1 ⁇ 2 inch or about 3 ⁇ 4 inch or about 1 inch or any other widths smaller than 1/16 inch or larger than 1 inch or any increment in between 1/16 inch and 1 inch.
- the gasket 18 can have a length of about 4 feet or about 6 feet or about 8 feet or about 10 feet or any other lengths smaller than about 4 feet or larger than about 10 feet or any increment between about 4 feet and 10 feet.
- the gasket 18 can have a thickness of about 1/16 inch or about 1 ⁇ 8 inch or about 3/16 inch or about 1 ⁇ 2 inch or any other widths smaller than 1/16 inch or larger than 1 ⁇ 2 inch or any increment in between 1/16 inch and 1 ⁇ 2 inch.
- the gasket 18 has a length that corresponds to a length of the composite component 10 .
- the gasket 18 can be a continuous gasket that is attached to the metal profile 10 of the composite component 10 and runs along the wallboard 111 (or 113 ) between the composite component 10 and the wallboard 111 (or 113 ).
- the gasket 18 can be manufactured as separate individual pieces of different or equal length that are coupled to the metal profile 10 of the composite component 10 .
- the gasket 18 can comprise one or more of a variety of different materials.
- the gasket 18 can comprise rubber, vinyl, silicone, foam, or other similar materials.
- the gasket 18 can comprise from materials that are generally flexible or have reduced stiffness so that the gasket 18 can flex in response to a pressure.
- the gasket 18 is a closed cell foam material.
- other suitable materials such as open cell foam, flexible vinyl, intumescent material or the like can also be used.
- the gasket 18 can have a solid cross section or a hollow cross section.
- FIG. 15 illustrates a head-of-wall portion of a shaft wall assembly 50 including a prior art fire proofing arrangement 52 .
- the wall assembly 50 extends in a vertical direction between a lower horizontal structure (e.g., a floor) and an upper horizontal structure 54 (e.g., a ceiling or floor of an upper level).
- the wall assembly 50 includes a lower or footer track (the floor and footer track are not shown) connected to the lower horizontal structure, a header track 56 connected to the upper horizontal structure 54 , and a plurality of studs 58 that extend between the header track 56 and the footer track.
- the wall assembly 50 also includes a shaft liner 60 connected to the plurality of studs 58 and positioned on the shaft side of the wall assembly 50 adjacent the shaft.
- the shaft liner 60 can be comprised of a plurality of (e.g., one inch thick) gypsum or drywall panels.
- the shaft liner 60 is located with the studs 58 within the header track 56 (and footer track).
- Wallboard panels 62 e.g., gypsum or drywall panels
- the wallboard panels 62 are located outside the header track 56 (and footer track).
- the illustrated upper horizontal structure 54 has a lower surface defined by a fluted deck pan, which results in a plurality of linear spaces or flutes extending along the lower surface above the wall assembly 50 .
- a mineral wool plug 64 is positioned in the flute above the wall assembly 50 .
- An elongate mineral wool plug 66 is positioned above the wallboard panels 62 .
- Flexible fire sealant caulk 68 is applied in the gap above the shaft liner 60 . The fire sealant caulk 68 is applied after assembly of the shaft liner 60 and the plurality of studs 58 and before assembly of the wallboard panels 62 .
- a flexible fire spray layer 70 is provided to each side of the wall assembly 50 extending from the upper horizontal structure 54 to the wallboard panels 62 on the non-shaft side and from the upper horizontal structure 54 to the header track 56 on the shaft side of the wall assembly 50 .
- FIG. 7 illustrates a fire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components.
- the fire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall.
- the fire block component 100 includes a header track 102 having a web 104 , a first downwardly extending leg 106 , and a second downwardly-extending leg 108 that cooperate to form a downward-facing generally C-shaped channel in a section view.
- the header track 102 has two additional retention legs 110 , 112 on one side to receive a rip of a fire-resistant material 120 , such as gypsum or drywall wallboard or an insulating fire blocking material (hereinafter “drywall”).
- a fire-resistant material 120 such as gypsum or drywall wallboard or an insulating fire blocking material (hereinafter “drywall”).
- the drywall 120 When the drywall 120 is laminated or adhered to the steel profile, it insulates the steel and creates a superior fire block that inhibits heat transfer from one side to the other side of the wall assembly 50 (See e.g., FIG. 8 for wall assembly 50 ).
- the fire block component 100 is constructed (e.g., bent) from a single piece of steel.
- the portion of the fire block component 100 forming the upper retention leg 110 is a double-wall portion having the piece of steel doubled over on itself.
- the fire block component 100 could be formed from multiple pieced connected to one another to form the final shape.
- the web 104 can define an uppermost surface of the component 100 .
- the lower retention leg 112 can be aligned with a bottom terminal edge of the first downwardly-extending leg 106 .
- the legs 110 , 112 can be parallel or substantially parallel with one another.
- first leg 106 and the second leg 108 can be parallel or substantially parallel with one another and perpendicular or substantially perpendicular with the web 104 .
- Substantially in this context can mean within normal manufacturing variations for the process used to form the component 100 , such as roll-forming, for example.
- the drywall 120 preferably is coupled to the header track 102 such that the drywall 120 is securely held in place during transportation, assembly and during the life of the associated wall assembly 50 .
- the drywall 120 preferably is installed during the manufacturing process. However, in some embodiments, the drywall 120 could be installed in the field during or after the construction of the wall assembly 50 .
- the drywall 120 can be secured to the header track 102 by any suitable arrangement, including mechanical connection (e.g., snap-fit retention or interference fit with the retention legs 110 , 112 or other portion of the header track 102 ). In the illustrated arrangement, the drywall 120 is adhered to the header track 102 , such as with double-sided tape 122 . However, other suitable adhesives could also be used.
- the upper retention leg 110 and/or the lower retention leg 112 can have inwardly extending returns that extend towards one another and the space that receives the drywall 120 to retain or assist in retaining the drywall 120 in place.
- the fire block component 100 can have any suitable dimensions.
- the legs 106 , 108 can have a length from the web 104 to the free ends of between about 2 inches and 4 inches, including any particular dimension or range of dimensions therebetween.
- the web 104 can have a width between the legs 106 , 108 of between about 2.5 inches to about 6 inches, including any particular dimension or range of dimensions therebetween, such as about 4 inches.
- the overall length of the fire block component 100 can be any suitable length to allow for convenient transportation and handling in the field, such as between about 8 feet and 16 feet, for example and without limitation.
- FIG. 8 illustrates a shaft wall assembly 50 that incorporates the fire block component 100 of FIG. 7 .
- the drywall rip 120 is located on the shaft side of the wall assembly 50 , which obviates the need for fire sealant caulk above the shaft liner 60 thereby making the fire blocking of the head-of-wall faster and more convenient in comparison to the prior art arrangement of FIG. 15 .
- a fire blocking element or material such as a mineral wool plug 64 is positioned within the flute.
- a fire blocking element or material is positioned above the drywall boards 62 . Any suitable fire blocking arrangements can be used, such as mineral wool (e.g., a mineral wool plug 66 ), or other fire blocking products, such as the Hot Rod, Fire Gasket, or Fire Bead fire block components sold by CEMCO.
- FIG. 9 illustrates an alternative fire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components.
- the fire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall.
- the fire block component 100 can be similar to the other components 100 described herein. Accordingly, features or details that are not discussed can be the same as or similar to the corresponding features or details of other components 100 described herein, or can be of another suitable arrangement.
- the fire block component 100 includes an angle member 102 having a web 104 and a downwardly-extending leg 108 that cooperate to form a generally L-shaped channel in a section view.
- the L-shaped channel can be the same as or substantially similar to the portion of the component 100 of FIG.
- the angle member 102 includes a pair of retention legs 110 , 112 at upper and lower ends of the downwardly-extending leg 108 .
- a space between the retention legs 110 , 112 is configured to receive a rip of a fire-resistant material 120 , such as gypsum or drywall board.
- a fire-resistant material 120 such as gypsum or drywall board.
- FIG. 10 illustrates a shaft wall assembly 50 that incorporates the fire block component 100 of FIG. 9 .
- the angle member 102 allows the fire block component 100 to be secured to a standard shaft wall header track 80 .
- the fire block component 100 is secured to the header track 80 prior to assembly of the header track 80 to the upper horizontal structure 54 .
- the fire block component 100 can be secured with a mechanical fastener, for example, a framing screw.
- a mechanical fastener for example, a framing screw.
- other suitable arrangements can also be used, such as adhesives (e.g., double sided tape).
- the fire block component 100 could also be secured between the header track 80 and the upper horizontal structure 54 after the header track 80 is secured to the upper horizontal structure 54 .
- the fire block component 100 could be held in place by frictional forces.
- FIG. 11 illustrates an alternative fire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components.
- the fire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall.
- the fire block component 100 can be similar to the other components 100 described herein. Accordingly, features or details that are not discussed can be the same as or similar to the corresponding features or details of other components 100 described herein, or can be of another suitable arrangement.
- the fire block component 100 includes a header track 102 having a web 104 , a first downwardly extending leg 106 , and a second downwardly-extending leg 108 that cooperate to form a downward-facing generally C-shaped channel in a section view.
- the header track 102 has a pair of spaced-apart retention legs 110 , 112 on one side to receive a rip of a fire-resistant material 120 , such as gypsum or drywall board.
- the fire block component 100 also includes an additional C-shaped channel member 130 that is received between the retention legs 110 , 112 and to which the drywall 120 is attached (such as by double sided tape).
- the channel member 130 can be coupled to the header track 102 by any suitable arrangement, such as mechanical connection or an adhesive connection.
- the upper retention leg 110 and/or the lower retention leg 112 can have inwardly extending returns that extend towards one another and the space that receives the channel member 130 and the drywall 120 to retain or assist in retaining the channel member 130 and the drywall 120 in place.
- the upper and/or lower legs of the channel member 130 can have inwardly extending returns that extend towards one another and the space that receives the drywall 120 to retain or assist in retaining the drywall 120 in place.
- the downwardly-extending leg 108 can include a protrusion 132 or other set-off element that spaces the channel member 130 from the downwardly-extending leg 108 to create an air space therebetween.
- the presence of an air space may slow the transfer of heat from the non-shaft side of the fire block component 100 to the drywall 120 on the shaft side of the fire block component 100 .
- the fire block component 100 of FIG. 11 can be assembled into a wall assembly in a manner similar to the wall assembly 50 of FIG. 8 .
- FIG. 12 illustrates an alternative fire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components.
- the fire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall.
- the fire block component 100 can be similar to the other components 100 described herein. Accordingly, features or details that are not discussed can be the same as or similar to the corresponding features or details of other components 100 described herein, or can be of another suitable arrangement.
- the fire block component 100 includes a header track 102 having a web 104 , a first downwardly extending leg 106 , and a second downwardly-extending leg 108 that cooperate to form a downward-facing generally C-shaped channel in a section view.
- the header track 102 can comprise a 20-gauge steel profile.
- the header track 102 has a pair of spaced-apart retention legs 110 , 112 on one side to receive a rip of a fire-resistant material, such as gypsum or drywall board, in a space 120 A.
- the first downwardly extending leg 106 , the second downwardly extending leg 108 , and/or the retention legs 110 , 112 can be manufactured to any desirable dimension to accommodate a user's need.
- the first downwardly extending leg 106 can be about 1.5 inch
- the second downwardly extending leg 108 can be about 3′′
- the retention legs 110 and/or 112 can be between about 1 ⁇ 4 inch to about 5 ⁇ 8 inch.
- the downwardly-extending leg 108 can include a strip 151 .
- the strip 151 can be an intumescent strip or an intumescent tape.
- the strip 151 can comprise intumescent material and expand in response to heat.
- the strip 151 can comprise a variety of different widths, lengths, and thicknesses to accommodate a user's need.
- the strip 151 can be about 1 ⁇ 2 inch wide and about 1.5 millimeter ( ⁇ 0.059 inch) thick.
- the strip 151 can be coupled to the second downwardly-extending leg 108 through any appropriate means.
- the strip 151 can be coupled to the second downwardly-extending leg 108 adhesively or with a double-sided tape.
- the strip 151 can be applied to the header track 102 in the factory during the manufacturing process or in the field.
- the fire block component 100 of FIG. 12 can be assembled into a wall assembly in a manner similar to the wall assembly 50 of FIG. 8 .
- FIG. 13 illustrates a shaft wall assembly 50 that incorporates the fire block component 100 of FIG. 12 , including the strip 151 , before the shaft wall assembly 50 is exposed to heat or fire.
- the drywall rip 120 is located on the shaft side of the wall assembly 50 . which obviates the need for fire sealant caulk above the shaft liner 60 thereby making the fire blocking of the head-of-wall faster and more convenient in comparison to the prior art arrangement of FIG. 15 .
- a strip 151 can be positioned in a first gap 141 between the shaft liner 60 and the second downwardly-extending leg 108 .
- a second gap 142 can be positioned above the shaft liner 60 .
- FIG. 14 illustrates a shaft wall assembly 50 that incorporates the fire block component 100 of FIG. 12 , including the strip 151 , after the shaft wall assembly 50 is exposed to heat or fire.
- the strip 151 can comprise an intumescent material and can expand in response to heat.
- the intumescent material can expand in an upward direction (for example towards the second gap 142 ) and/or in a downward direction (for example away from the second gap 142 ) and at least partially seal the space of the first gap 141 between the second downwardly extending leg 108 and the shaft liner 60 .
- the terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result.
- the terms “approximately,” “about,” and “substantially” may refer to an amount that is within less than or equal to 10% of the stated amount.
- the term “generally” as used herein represents a value, amount, or characteristic that predominantly includes or tends toward a particular value, amount, or characteristic.
- the term “generally parallel” can refer to something that departs from exactly parallel by less than or equal to 20 degrees. All ranges are inclusive of endpoints.
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Abstract
A fire-rated component for a linear gap between a wall assembly and an adjacent structure. The component includes an elongate metal profile and a fire-rated board member. The elongate metal profile has a vertical leg, an upper leg and a lower leg. The upper leg extends in a first direction from an upper edge of the vertical leg. The lower leg extends in the first direction from a lower edge of the vertical leg. The fire-rated board member is positioned within a space defined by the vertical leg, the upper leg and the lower leg.
Description
- This application claims the benefit of U.S. Application No.: 63/374,128, filed on Aug. 31, 2022, and is a continuation-in-part of U.S. application Ser. No.: 17/108,966, filed on Dec. 1, 2020, pending, which claims the benefit of U.S. Application No.: 62/942,423 filed on Dec. 2, 2019, the entireties of which are hereby incorporated by reference.
- This application is directed to fire-rated wall construction components for use in building construction joints.
- Fire-rated wall construction components and assemblies are commonly used in the building construction industry. These components and assemblies are aimed at preventing fire, heat, and smoke from leaving one portion of a building or room and entering another, usually through vents, joints in walls, or other openings. The components can incorporate fire-retardant materials which substantially block the path of the fire, heat, and/or smoke for at least some period of time in accordance with certain standards, such as UL-2079 “Test For Fire-rated Building Joints”.
- Conventional fire-rated wall construction components are typically labor intensive and expensive to install. One example of a conventional fire block arrangement includes using a fire-resistant material such as mineral wool stuffed in the gaps within a head-of-wall assembly including deflection gaps between the top of the wall boards and the ceiling. Once the gaps are filled with the fire block material, a flexible coating such as a spray-on elastomeric coating can cover the entire head-of-wall to secure the fire block material in place. Over time and cycles of movement the flexible coating may degrade and cause cracks or flaking. As a result, it is possible that the fire-resistant material may become dislodged and thereby reduce the effectiveness of the fire block.
- One aspect of the present disclosure is a fire-rated component for a linear gap between a wall assembly and an adjacent structure. The component includes an elongate metal profile and a fire-rated board member. The elongate metal profile includes a vertical leg, an upper leg and a lower leg. The upper leg extends in a first direction from an upper edge of the vertical leg. The lower leg extends in the first direction from a lower edge of the vertical leg. The fire-rated board member is positioned within a space defined by the vertical leg, the upper leg and the lower leg to form a composite component.
- According to another aspect, the upper leg includes a downward facing v-groove. According to another aspect, the upper leg includes an extended free end attachment leg. According to another aspect, an outward facing protrusion on the vertical leg rests against the drywall board of the framed wall assembly with the outward facing protrusion extending in a second direction, opposite the first direction. According to another aspect, the gypsum board member is adhesively attached with the vertical leg. According to another aspect, the lower leg includes a kick-out configured to retain a gypsum board member within the space. According to another aspect, the upper leg, the lower leg, the v-groove, and the kick-out are configured to exert a force against the gypsum board member to retain the gypsum board in the space. According to another aspect, the lower leg determines the thickness of the layer or layers of the gypsum board member. According to another aspect, the metal profile is formed from a unitary piece of sheet steel and bent to form the vertical leg. According to another aspect, the board member comprises a gypsum material.
- In another aspect of the present disclosure, a building construction joint includes a wall assembly and an adjacent structure formed along a linear gap. A fire-rated component including an elongate metal profile and a fire-rated board member is positioned at a joint between the wall assembly and the adjacent structure to provide fire-blocking across the linear gap. According to another aspect, the adjacent structure is a ceiling and the wall assembly is a vertical wall.
- According to another aspect, a fire-rated component for a linear gap between a wall assembly and an adjacent structure can comprise an elongate metal profile. The elongate metal profile can comprise a vertical leg, an upper leg, and a lower leg. The upper leg can extend in a first direction from an upper edge of the vertical leg. The lower leg can extend in the first direction from a lower edge of the vertical leg. The fire-rated board member can be positioned within a space defined by the vertical leg, the upper leg, and the lower leg. A gasket can be positioned between a wallboard of the wall assembly and the vertical leg. The gasket can be a fire blocking gasket. In some embodiments, the gasket can comprise vinyl. In some embodiments, a length of the gasket can be 8 feet. In some other embodiments, the length of the gasket can be between about 4 feet to about 10 feet. Other suitable values smaller than about 4 feet or larger than about 10 can also be utilized depending on a user's need. In some embodiments, the gasket can comprise flexible material.
- The foregoing summaries are illustrative only and are not intended to be limiting. Other aspects, features, and advantages of the systems' devices and methods and/or other subject matter described in this application will become apparent in the teaching set forth below. The summaries provided introduce a selection of some of the concepts of this disclosure. The summary is not intended to identify key or essential features of any subject matter described herein.
- Various examples are depicted in the accompanying drawings for illustrative purposes and should in no way be interpreted as limiting the scope of the examples. Various features of different disclosed examples can be combined to form additional examples which are part of this disclosure.
-
FIG. 1 illustrates a cross section of a head-of-wall assembly including a composite fire-blocking component. -
FIG. 2A shows a cross-section of the head-of-wall assembly in a fully closed configuration. -
FIG. 2B shows a cross-section of the head-of-wall assembly in a fully opened configuration. -
FIG. 3 shows a cross-section of the composite fire-blocking component including a metal profile and board member. -
FIG. 4 shows a cross-section of an elongate metal profile. -
FIG. 5 shows a cross-section of the composite fire-blocking component including a gasket. -
FIG. 6 illustrates a cross section of a head-of-wall assembly including a composite fire-blocking component including a gasket. -
FIG. 7 is a sectional view of a fire block component. -
FIG. 8 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component ofFIG. 7 . -
FIG. 9 is a sectional view of an alternative fire block component. -
FIG. 10 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component ofFIG. 9 . -
FIG. 11 is a sectional view of another alternative fire block component. -
FIG. 12 is a sectional view of another alternative fire block component. -
FIG. 13 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component ofFIG. 12 . -
FIG. 14 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component ofFIG. 12 in action. -
FIG. 15 is a sectional view of a head-of-wall portion of a wall assembly including a prior art fire proofing arrangement. -
FIGS. 1-2B illustrate a building construction joint between a wall assembly and an adjacent structure having a linear gap in the form of a head-of-wall assembly 100. The embodiments disclosed herein often are described in the context of an interior of a building and configured for preventing passage of smoke and/or fire between adjacent rooms in an elevated-temperature environment. However, the embodiments herein can be applied to wall systems configured for other types of environments as well, such as for exterior wall applications, and can include different and/or additional components and types of materials other than those described herein. - The head-of-
wall assembly 100 can generally include an overhead structure orceiling 105. Theceiling 105 can be generally formed in a horizontal plane and/or include one or more flutes or grooves therein. Theceiling 105 can be a floor of a higher level of a building. The head-of-wall assembly 100 can include a header track orchannel 107. Thechannel 107 can include aweb 107 a to which are attached one ormore flanges second flanges web 107 a in the same direction to form a generally u-shaped cross section. Optionally, thechannel 107 can be a deep leg header track. - One or
more studs 109 forming the wall can be received within thechannel 107 between the first andsecond flanges second flanges channel 107 with thestuds 109. The slots can be oriented generally orthogonal to a length of thechannel 107. Thestuds 109 can be attached with thechannel 107 via fasteners through the slots of theflanges - One or more wall board members (e.g., gypsum drywall) 111, 113 can be attached with the
studs 109 to form the wall. Assembly of thewall boards studs 109 can define adeflection gap 101 between theceiling 105 and upper ends of thewall boards deflection gap 101 can vary in width depending on the relative position of the wall (e.g.,wall boards ceiling 105. The head-of-wall assembly 100 can cycle between a more closed position (such as the fully closed position inFIG. 2A ) and a more open position (such as the fully open position inFIG. 2B ). The dynamic nature of the head-of-wall assembly 100 can accommodate seismic or thermal forces or other movements of the building within which the head-of-wall assembly 100 is included. - The head-of-
wall assembly 100 can include a fire-ratedcomposite component 10. Thecomposite component 10 can generally be configured to cover thedeflection gap 101 to provide fire, smoke, heat and/or sound insulation and facilitate unencumbered movement of the joint. Thecomponent 10 can include anelongate metal profile 12 and aboard member 14. Theboard member 14 can comprise a fire-rated material, such as a gypsum drywall material. In certain implementations, theboard member 14 can adhesively attached or otherwise mechanically secured with themetal profile 12 to form thecomposite component 10. - The
composite component 10 can be installed over the outer surface of thewall boards flanges component 10 can be attached with theceiling 105 by one ormore fasteners 103, such as metal screws, adhesives, staples or other fasteners. Thefasteners 103 can extend through themetal profile 12. Thefire board member 14 can insulate themetal profile 12, while themetal profile 12 provides a constant fire block as it will not melt during the fire test of UL 2079. The combination of these two materials provides long lasting fire protection. In addition, drywall used in theboard member 14 is less expensive than other fire-resistant materials, such as intumescent materials, that are often used in head-of-wall assemblies or other gaps of a building construction joint. - The
metal profile 12 can come in standard lengths (e.g., 10′, 12′, etc.). As shown further in the cross-section ofFIG. 3 , themetal profile 12 can include a single sheet of metal, such as steel. Themetal profile 12 can include a plurality of bends to form the metal profile shape. Themetal profile 12 can include avertical leg 16, anupper leg 24, and/or alower leg 20. Thevertical leg 16 can have a length L extending from theupper leg 24 to thelower leg 20. The length L can vary depending on the size of the head-of-wall deflection gap 101 and the overall dynamic movement needed. The length L can generally be between about 1″ and 6″. Thevertical leg 16 can comprise a flattened portion of themetal profile 12. Alternatively, thevertical leg 16 can comprise one or more strengthening features such as grooves or ribs. - The
upper leg 24 can couple with thevertical leg 16 at acorner 34. Theupper leg 24 can generally form perpendicular angle with thevertical leg 16. Theupper leg 24 can extend from thecorner 34 in a first (e.g., rightward) direction. Theupper leg 24 can be a horizontal leg. Theupper leg 24 can be approximately 1.5″-3.5″ in length. - The
upper leg 24 can include agroove 22. Thegroove 22 can be shaped as a v-groove, u-groove, or other form factor. Thegroove 22 can include an open end facing upwards and outwards. Thegroove 22 can provide structural strength to themetal profile 12 and to theupper leg 24. Other retention features and/or strengthening features could also be used. Thegroove 22 can extend downwardly towards thelower leg 20. Thegroove 22 can divide the upper leg into aninner portion 25 and anouter portion 26. Theinner portion 25 can be in-line with theouter portion 26. Theinner portion 25 can have a width W1 from the corner to the groove 22 (e.g., approximately 0.625″). Theouter portion 26 can include an attachment portion of themetal profile 12. Theouter portion 26 can have a width of approximately 1.25″. The attachment can include one or more holes or other mechanism to allow an installer to attach themetal profile 12 to the ceiling 105 (or other adjoining structure). - The
lower leg 20 can couple with thevertical leg 16 at acorner 30. Thelower leg 20 can generally form perpendicular angle with thevertical leg 16. Thelower leg 20 can extend from thecorner 30 in the first (e.g., rightward) direction. Thelower leg 20 can extend in the same direction as theupper leg 24. Thelower leg 20 can be a horizontal leg. - The
lower leg 20 can include a kick-out 32. Thekickout 32 can be on a free end of thelower leg 20. Thekickout 32 can include an upturned retention lip or portion of the lower leg 20 (e.g., towards the upper leg 24). The kick-out 32 can be angled upwardly towards theupper leg 24. Thelower leg 20 can include a width W2 from thecorner 30 to the free end or thekickout 32. The width W2 can optionally be the same as the width W1. - The
lower leg 20, thevertical leg 16, and theupper leg 24 can form an inner, partially enclosed space. The inner space can receive and secure theboard member 14. Theboard member 14 can comprise a fire-rated drywall member. Theboard member 14 can comprise one or more layers of material. Theboard member 14 can be a rip of drywall comprising a gypsum material. Theboard member 14 can include a generally rectangular-shaped profile. Theboard member 14 can nest within the inner space between theupper leg 24, thevertical leg 16, and thelower leg 20. Preferably, the width W1 of theupper leg 24 and the width W2 of thelower leg 20 can be sized to accommodate a width W3 of theboard member 14. Thekickout 32 and/or thegroove 22 can exert an inward force on theboard member 14 to help retain theboard member 14 within the inner space and/or against thevertical leg 16. In certain implementations, the width W1 can be the same as width W2 and correspond to the width W3 of theboard member 14. The widths W1, W2 can limit the W3 of theboard member 14 that can be used in thecomposite component 10. - An interior side of the
board member 14 can be glued to thevertical leg 16 with an adhesive or secured with a mechanical fastener. The adhesive can secure theboard member 14 within the inner space of themetal profile 12. Thekickout 32 and/or groove 22 can also retain the board member in place within the metal profile and ensure it will not fall out during a fire that may compromise the adhesive. Thegroove 22 and/orkickout 32 can be shaped in any suitable shape for retention of theboard member 14 and/or strengthening of the composite 10. - The
corner 30 can include an inward facing protrusion (e.g., towards thewall boards 111, 113) that sticks out further than the interior surface of the vertical leg 16 (e.g., approximately 0.125″). The inward facing protrusion can be formed of a bend in the metal of themetal profile 12. In the installed position with the head-of-wall assembly 100, the protrusion can provide a sealing point against one of theboard members corner 30 andkickout 32 can be omitted. - In the installed configuration within the head-of-
wall assembly 100, theboard member 14 can be nested within the inner space of themetal profile 12. Theupper leg 24 can abut against and attached with the ceiling 105 (e.g., by fastener 103). Thevertical leg 16 can abut an upper end of thewall board 113 and cover thedeflection gap 101. The protrusion of thecorner 30 can abut the outer face of thewall board 113 to provide a seal therewith. Thewall board 113 can cycle behind the installedcomposite component 10 between open and closed configurations. -
FIG. 4 illustrates analternative metal profile 12. Themetal profile 12 can include avertical leg 16, anupper leg 24, and alower leg 20, like themetal profile 12 previously described. An upward facing protrusion can be formed of a bent portion of the material of themetal profile 12 on the upper leg 24 (e.g., approximately 0.125″). The upward facing protrusion can be directed or extend generally upwardly. In the installed configuration, the protrusion can contact and provide a sealing point against theceiling 105 of theassembly 100. In the installed configuration within the head-of-wall assembly 100, theupper leg 24 can abut against and attached with theceiling 105. The upward facing protrusion of thecorner 30 can abut theceiling 105 to provide a seal therewith. Thewall board 113 can cycle behind the installedcomposite component 10 between open and closed configurations. -
FIG. 5 shows a cross-section of a composite fire-blocking component including a gasket. In some embodiments, theinner portion 25 can define a plane and theouter portion 26 can extend from the said plane. For example, theouter portion 26 can extend from the said plane at an offsetangle 29. The offsetangle 29 can comprise different values. For example, the offsetangle 29 can be about 2 degrees or about 5 degrees or any value between about 2 degrees and about 5 degrees. In some configurations, the offsetangle 29 can be less than 2 degrees or greater than 5 degrees or can be any other value or incremental value to accommodate a user's need. In some configurations, theinner portion 25 and theouter portion 26 can lie in a single plane or substantially lie within a single plane. Theouter portion 26 can be positioned on one side of thegroove 22 and theinner portion 25 can be positioned on an opposite side. Theouter portion 26 can have an extended free end. The extended free end of theouter portion 26 can be flexible and/or movable. Theouter portion 26 can extend upwardly or downwardly with respect to the plane that defines theinner portion 25. -
FIG. 6 illustrates a cross section of a head-of-wall assembly including a composite fire-blockingcomponent 10, which includes agasket 18. Thegasket 18 can be positioned between thevertical leg 16 and the wallboard 111 (or 113). Thegasket 18 can be attached to thevertical leg 16. In some embodiments, thegasket 18 can be attached to thevertical leg 16 during the manufacturing process. Thegasket 18 can be attached to thevertical leg 16 through a variety of means. For example, thegasket 18 can be adhesively attached to thevertical leg 16, or it can be mechanically fastened to thevertical leg 16 or it can be coupled with thevertical leg 16 using a double-sided tape. In some other embodiments, thegasket 18 can be manufactured as a separate piece and installed in the field between thevertical leg 16 and thewallboard gasket 18 can be attached separately to the wallboard 111 (or 113). - The
gasket 18 can be manufactured to have a variety of different widths, lengths, and depths to accommodate a user's need. For example, thegasket 18 can have a width of about 1/16 inch or about ⅛ inch or about ⅜ inch or about ½ inch or about ¾ inch or about 1 inch or any other widths smaller than 1/16 inch or larger than 1 inch or any increment in between 1/16 inch and 1 inch. Thegasket 18 can have a length of about 4 feet or about 6 feet or about 8 feet or about 10 feet or any other lengths smaller than about 4 feet or larger than about 10 feet or any increment between about 4 feet and 10 feet. Thegasket 18 can have a thickness of about 1/16 inch or about ⅛ inch or about 3/16 inch or about ½ inch or any other widths smaller than 1/16 inch or larger than ½ inch or any increment in between 1/16 inch and ½ inch. In some embodiments, thegasket 18 has a length that corresponds to a length of thecomposite component 10. For example, thegasket 18 can be a continuous gasket that is attached to themetal profile 10 of thecomposite component 10 and runs along the wallboard 111 (or 113) between thecomposite component 10 and the wallboard 111 (or 113). In some other embodiments, thegasket 18 can be manufactured as separate individual pieces of different or equal length that are coupled to themetal profile 10 of thecomposite component 10. Thegasket 18 can comprise one or more of a variety of different materials. For example, thegasket 18 can comprise rubber, vinyl, silicone, foam, or other similar materials. Thegasket 18 can comprise from materials that are generally flexible or have reduced stiffness so that thegasket 18 can flex in response to a pressure. In some configurations, thegasket 18 is a closed cell foam material. In some other configurations, other suitable materials such as open cell foam, flexible vinyl, intumescent material or the like can also be used. Thegasket 18 can have a solid cross section or a hollow cross section. -
FIG. 15 illustrates a head-of-wall portion of ashaft wall assembly 50 including a prior artfire proofing arrangement 52. Thewall assembly 50 extends in a vertical direction between a lower horizontal structure (e.g., a floor) and an upper horizontal structure 54 (e.g., a ceiling or floor of an upper level). Thewall assembly 50 includes a lower or footer track (the floor and footer track are not shown) connected to the lower horizontal structure, aheader track 56 connected to the upperhorizontal structure 54, and a plurality ofstuds 58 that extend between theheader track 56 and the footer track. Thewall assembly 50 also includes ashaft liner 60 connected to the plurality ofstuds 58 and positioned on the shaft side of thewall assembly 50 adjacent the shaft. Theshaft liner 60 can be comprised of a plurality of (e.g., one inch thick) gypsum or drywall panels. Theshaft liner 60 is located with thestuds 58 within the header track 56 (and footer track). Wallboard panels 62 (e.g., gypsum or drywall panels) are connected to the plurality ofstuds 58 on a side opposite theshaft liner 60. Thewallboard panels 62 are located outside the header track 56 (and footer track). - The illustrated upper
horizontal structure 54 has a lower surface defined by a fluted deck pan, which results in a plurality of linear spaces or flutes extending along the lower surface above thewall assembly 50. In the illustrated prior artfire proofing arrangement 52, amineral wool plug 64 is positioned in the flute above thewall assembly 50. An elongatemineral wool plug 66 is positioned above thewallboard panels 62. Flexiblefire sealant caulk 68 is applied in the gap above theshaft liner 60. Thefire sealant caulk 68 is applied after assembly of theshaft liner 60 and the plurality ofstuds 58 and before assembly of thewallboard panels 62. Nonetheless, application of thefire sealant caulk 68 is difficult due to the presence of thestuds 58 and because the gap is located on the shaft side of thewall assembly 50 opposite the accessible side of thewall assembly 50 from which thefire sealant caulk 68 is introduced. A flexiblefire spray layer 70 is provided to each side of thewall assembly 50 extending from the upperhorizontal structure 54 to thewallboard panels 62 on the non-shaft side and from the upperhorizontal structure 54 to theheader track 56 on the shaft side of thewall assembly 50. -
FIG. 7 illustrates afire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components. In particular, thefire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall. Thefire block component 100 includes aheader track 102 having aweb 104, a first downwardly extendingleg 106, and a second downwardly-extendingleg 108 that cooperate to form a downward-facing generally C-shaped channel in a section view. Theheader track 102 has twoadditional retention legs resistant material 120, such as gypsum or drywall wallboard or an insulating fire blocking material (hereinafter “drywall”). When thedrywall 120 is laminated or adhered to the steel profile, it insulates the steel and creates a superior fire block that inhibits heat transfer from one side to the other side of the wall assembly 50 (See e.g.,FIG. 8 for wall assembly 50). - In the illustrated arrangement, the
fire block component 100 is constructed (e.g., bent) from a single piece of steel. The portion of thefire block component 100 forming theupper retention leg 110 is a double-wall portion having the piece of steel doubled over on itself. However, in other embodiments, thefire block component 100 could be formed from multiple pieced connected to one another to form the final shape. Theweb 104 can define an uppermost surface of thecomponent 100. Thelower retention leg 112 can be aligned with a bottom terminal edge of the first downwardly-extendingleg 106. Thelegs first leg 106 and thesecond leg 108 can be parallel or substantially parallel with one another and perpendicular or substantially perpendicular with theweb 104. Substantially in this context can mean within normal manufacturing variations for the process used to form thecomponent 100, such as roll-forming, for example. - The
drywall 120 preferably is coupled to theheader track 102 such that thedrywall 120 is securely held in place during transportation, assembly and during the life of the associatedwall assembly 50. Thedrywall 120 preferably is installed during the manufacturing process. However, in some embodiments, thedrywall 120 could be installed in the field during or after the construction of thewall assembly 50. Thedrywall 120 can be secured to theheader track 102 by any suitable arrangement, including mechanical connection (e.g., snap-fit retention or interference fit with theretention legs drywall 120 is adhered to theheader track 102, such as with double-sided tape 122. However, other suitable adhesives could also be used. Theupper retention leg 110 and/or thelower retention leg 112 can have inwardly extending returns that extend towards one another and the space that receives thedrywall 120 to retain or assist in retaining thedrywall 120 in place. - The
fire block component 100 can have any suitable dimensions. For example, thelegs web 104 to the free ends of between about 2 inches and 4 inches, including any particular dimension or range of dimensions therebetween. Theweb 104 can have a width between thelegs fire block component 100 can be any suitable length to allow for convenient transportation and handling in the field, such as between about 8 feet and 16 feet, for example and without limitation. -
FIG. 8 illustrates ashaft wall assembly 50 that incorporates thefire block component 100 ofFIG. 7 . As illustrated, thedrywall rip 120 is located on the shaft side of thewall assembly 50, which obviates the need for fire sealant caulk above theshaft liner 60 thereby making the fire blocking of the head-of-wall faster and more convenient in comparison to the prior art arrangement ofFIG. 15 . A fire blocking element or material, such as amineral wool plug 64 is positioned within the flute. A fire blocking element or material is positioned above thedrywall boards 62. Any suitable fire blocking arrangements can be used, such as mineral wool (e.g., a mineral wool plug 66), or other fire blocking products, such as the Hot Rod, Fire Gasket, or Fire Bead fire block components sold by CEMCO. -
FIG. 9 illustrates an alternativefire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components. In particular, thefire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall. Thefire block component 100 can be similar to theother components 100 described herein. Accordingly, features or details that are not discussed can be the same as or similar to the corresponding features or details ofother components 100 described herein, or can be of another suitable arrangement. Thefire block component 100 includes anangle member 102 having aweb 104 and a downwardly-extendingleg 108 that cooperate to form a generally L-shaped channel in a section view. The L-shaped channel can be the same as or substantially similar to the portion of thecomponent 100 ofFIG. 7 that includes thedrywall rip 120. Theangle member 102 includes a pair ofretention legs leg 108. A space between theretention legs resistant material 120, such as gypsum or drywall board. When thedrywall 120 is laminated or adhered to the steel profile, it insulates the steel and creates a superior fire block that inhibits heat transfer from one side to the other side of thewall assembly 50. -
FIG. 10 illustrates ashaft wall assembly 50 that incorporates thefire block component 100 ofFIG. 9 . Theangle member 102 allows thefire block component 100 to be secured to a standard shaftwall header track 80. Preferably, thefire block component 100 is secured to theheader track 80 prior to assembly of theheader track 80 to the upperhorizontal structure 54. Thefire block component 100 can be secured with a mechanical fastener, for example, a framing screw. However, other suitable arrangements can also be used, such as adhesives (e.g., double sided tape). Thefire block component 100 could also be secured between theheader track 80 and the upperhorizontal structure 54 after theheader track 80 is secured to the upperhorizontal structure 54. Thefire block component 100 could be held in place by frictional forces. -
FIG. 11 illustrates an alternativefire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components. In particular, thefire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall. Thefire block component 100 can be similar to theother components 100 described herein. Accordingly, features or details that are not discussed can be the same as or similar to the corresponding features or details ofother components 100 described herein, or can be of another suitable arrangement. - The
fire block component 100 includes aheader track 102 having aweb 104, a first downwardly extendingleg 106, and a second downwardly-extendingleg 108 that cooperate to form a downward-facing generally C-shaped channel in a section view. Theheader track 102 has a pair of spaced-apartretention legs resistant material 120, such as gypsum or drywall board. Thefire block component 100 also includes an additional C-shapedchannel member 130 that is received between theretention legs drywall 120 is attached (such as by double sided tape). Thechannel member 130 can be coupled to theheader track 102 by any suitable arrangement, such as mechanical connection or an adhesive connection. Theupper retention leg 110 and/or thelower retention leg 112 can have inwardly extending returns that extend towards one another and the space that receives thechannel member 130 and thedrywall 120 to retain or assist in retaining thechannel member 130 and thedrywall 120 in place. In addition or in the alternative, the upper and/or lower legs of thechannel member 130 can have inwardly extending returns that extend towards one another and the space that receives thedrywall 120 to retain or assist in retaining thedrywall 120 in place. - Optionally, the downwardly-extending
leg 108 can include aprotrusion 132 or other set-off element that spaces thechannel member 130 from the downwardly-extendingleg 108 to create an air space therebetween. The presence of an air space may slow the transfer of heat from the non-shaft side of thefire block component 100 to thedrywall 120 on the shaft side of thefire block component 100. Thefire block component 100 ofFIG. 11 can be assembled into a wall assembly in a manner similar to thewall assembly 50 ofFIG. 8 . -
FIG. 12 illustrates an alternativefire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components. In particular, thefire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall. Thefire block component 100 can be similar to theother components 100 described herein. Accordingly, features or details that are not discussed can be the same as or similar to the corresponding features or details ofother components 100 described herein, or can be of another suitable arrangement. - The
fire block component 100 includes aheader track 102 having aweb 104, a first downwardly extendingleg 106, and a second downwardly-extendingleg 108 that cooperate to form a downward-facing generally C-shaped channel in a section view. In some embodiments, theheader track 102 can comprise a 20-gauge steel profile. Theheader track 102 has a pair of spaced-apartretention legs leg 106, the second downwardly extendingleg 108, and/or theretention legs leg 106 can be about 1.5 inch, the second downwardly extendingleg 108 can be about 3″, theretention legs 110 and/or 112 can be between about ¼ inch to about ⅝ inch. - In some embodiments, the downwardly-extending
leg 108 can include astrip 151. Thestrip 151 can be an intumescent strip or an intumescent tape. Thestrip 151 can comprise intumescent material and expand in response to heat. Thestrip 151 can comprise a variety of different widths, lengths, and thicknesses to accommodate a user's need. For example, thestrip 151 can be about ½ inch wide and about 1.5 millimeter (˜0.059 inch) thick. Thestrip 151 can be coupled to the second downwardly-extendingleg 108 through any appropriate means. For example, thestrip 151 can be coupled to the second downwardly-extendingleg 108 adhesively or with a double-sided tape. Thestrip 151 can be applied to theheader track 102 in the factory during the manufacturing process or in the field. Thefire block component 100 ofFIG. 12 can be assembled into a wall assembly in a manner similar to thewall assembly 50 ofFIG. 8 . -
FIG. 13 illustrates ashaft wall assembly 50 that incorporates thefire block component 100 ofFIG. 12 , including thestrip 151, before theshaft wall assembly 50 is exposed to heat or fire. As illustrated, thedrywall rip 120 is located on the shaft side of thewall assembly 50. which obviates the need for fire sealant caulk above theshaft liner 60 thereby making the fire blocking of the head-of-wall faster and more convenient in comparison to the prior art arrangement ofFIG. 15 . Astrip 151 can be positioned in afirst gap 141 between theshaft liner 60 and the second downwardly-extendingleg 108. Asecond gap 142 can be positioned above theshaft liner 60. -
FIG. 14 illustrates ashaft wall assembly 50 that incorporates thefire block component 100 ofFIG. 12 , including thestrip 151, after theshaft wall assembly 50 is exposed to heat or fire. As discussed earlier, thestrip 151 can comprise an intumescent material and can expand in response to heat. As it can be seen inFIG. 14 , in use, the intumescent material can expand in an upward direction (for example towards the second gap 142) and/or in a downward direction (for example away from the second gap 142) and at least partially seal the space of thefirst gap 141 between the second downwardly extendingleg 108 and theshaft liner 60. - Terms of orientation used herein, such as “top,” “bottom,” “proximal,” “distal,” “longitudinal,” “lateral,” and “end,” are used in the context of the illustrated example. However, the present disclosure should not be limited to the illustrated orientation. Indeed, other orientations are possible and are within the scope of this disclosure. Terms relating to circular shapes as used herein, such as diameter or radius, should be understood not to require perfect circular structures, but rather should be applied to any suitable structure with a cross-sectional region that can be measured from side-to-side. Terms relating to shapes generally, such as “circular,” “cylindrical,” “semi-circular,” or “semi-cylindrical” or any related or similar terms, are not required to conform strictly to the mathematical definitions of circles or cylinders or other structures, but can encompass structures that are reasonably close approximations.
- Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain examples include or do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more examples.
- Conjunctive language, such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain examples require the presence of at least one of X, at least one of Y, and at least one of Z.
- The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, in some examples, as the context may dictate, the terms “approximately,” “about,” and “substantially,” may refer to an amount that is within less than or equal to 10% of the stated amount. The term “generally” as used herein represents a value, amount, or characteristic that predominantly includes or tends toward a particular value, amount, or characteristic. As an example, in certain examples, as the context may dictate, the term “generally parallel” can refer to something that departs from exactly parallel by less than or equal to 20 degrees. All ranges are inclusive of endpoints.
- Several illustrative examples of construction joints have been disclosed. Although this disclosure has been described in terms of certain illustrative examples and uses, other examples and other uses, including examples and uses which do not provide all of the features and advantages set forth herein, are also within the scope of this disclosure. Components, elements, features, acts, or steps can be arranged or performed differently than described and components, elements, features, acts, or steps can be combined, merged, added, or left out in various examples. All possible combinations and subcombinations of elements and components described herein are intended to be included in this disclosure. No single feature or group of features is necessary or indispensable.
- Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation also can be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can in some cases be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.
- Any portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in one example in this disclosure can be combined or used with (or instead of) any other portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in a different example or flowchart. The examples described herein are not intended to be discrete and separate from each other. Combinations, variations, and some implementations of the disclosed features are within the scope of this disclosure.
- While operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Additionally, the operations may be rearranged or reordered in some implementations. Also, the separation of various components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. Additionally, some implementations are within the scope of this disclosure.
- Further, while illustrative examples have been described, any examples having equivalent elements, modifications, omissions, and/or combinations are also within the scope of this disclosure. Moreover, although certain aspects, advantages, and novel features are described herein, not necessarily all such advantages may be achieved in accordance with any particular example. For example, some examples within the scope of this disclosure achieve one advantage, or a group of advantages, as taught herein without necessarily achieving other advantages taught or suggested herein. Further, some examples may achieve different advantages than those taught or suggested herein.
- Some examples have been described in connection with the accompanying drawings. The figures are drawn and/or shown to scale, but such scale should not be limiting, since dimensions and proportions other than what are shown are contemplated and are within the scope of the disclosed invention. Distances, angles, etc. are merely illustrative and do not necessarily bear an exact relationship to actual dimensions and layout of the devices illustrated. Components can be added, removed, and/or rearranged. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with various examples can be used in all other examples set forth herein. Additionally, any methods described herein may be practiced using any device suitable for performing the recited steps.
- For purposes of summarizing the disclosure, certain aspects, advantages and features of the inventions have been described herein. Not all, or any such advantages are necessarily achieved in accordance with any particular example of the inventions disclosed herein. No aspects of this disclosure are essential or indispensable. In many examples, the devices, systems, and methods may be configured differently than illustrated in the figures or description herein. For example, various functionalities provided by the illustrated modules can be combined, rearranged, added, or deleted. In some implementations, additional or different processors or modules may perform some or all of the functionalities described with reference to the examples described and illustrated in the figures. Many implementation variations are possible. Any of the features, structures, steps, or processes disclosed in this specification can be included in any example.
- In summary, various examples of construction joints and related methods have been disclosed. This disclosure extends beyond the specifically disclosed examples to other alternative examples and/or other uses of the examples, as well as to certain modifications and equivalents thereof. Moreover, this disclosure expressly contemplates that various features and aspects of the disclosed examples can be combined with, or substituted for, one another. Accordingly, the scope of this disclosure should not be limited by the particular disclosed examples described above, but should be determined only by a fair reading of the claims.
Claims (12)
1. A fire-resistant component for providing a fire-block to a head-of-wall gap of a shaft wall, comprising:
a bent metal header component, comprising:
a web;
at least one downwardly-extending leg; and
a pair of spaced-apart retention legs extending from opposing ends of one of the at least one downwardly-extending leg; and
a drywall strip positioned in a space between the retention legs.
2. The fire-resistant component of claim 1 , wherein the at least one downwardly-extending leg comprises a pair of downwardly-extending legs spaced apart on opposite sides of the web.
3. The fire-resistant component of claim 1 , wherein the drywall strip is secured to the header component.
4. The fire-resistant component of claim 1 , further comprising a C-shaped channel that receives the drywall strip, wherein the C-shaped channel is received within the space between the retention legs.
5. The fire-resistant component of claim 4 , wherein the one downwardly-extending leg comprises an intumescent strip located on an interior side of the C-shaped channel adjacent to a shaft liner.
6. The fire-resistant component of claim 1 , wherein the header component is created from a single piece.
7. A shaft wall assembly comprising the fire-resistant component of claim 1 .
8. The shaft wall assembly of claim 7 , wherein the shaft wall assembly achieves a fire rating without fire sealant provided above the shaft liner between a shaft liner and the header component.
9. A fire-rated component for a linear gap between a wall assembly and an adjacent structure, the component comprising:
an elongate metal profile comprising a vertical leg, an upper leg and a lower leg, the upper leg extending in a first direction from an upper edge of the vertical leg, the lower leg extending in the first direction from a lower edge of the vertical leg;
a fire-rated gypsum board or an insulating fire blocking material positioned within a space defined by the vertical leg, the upper leg and the lower leg; and
a fire block gasket secured to the elongate metal profile such that in use it is positioned between a wallboard of the wall assembly and the vertical leg.
10. The fire-rated component of claim 9 , wherein the gasket comprises a composite material of either open cell foam, flexible vinyl, or intumescent.
11. The fire-rated component of claim 9 , wherein a length of the gasket is between 4 to 10 feet.
12. The fire-rated component of claim 9 , wherein the gasket comprises flexible material.
Priority Applications (1)
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US18/241,115 US20230407626A1 (en) | 2019-12-02 | 2023-08-31 | Fire-rated wall joint component and related assemblies |
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US201962942423P | 2019-12-02 | 2019-12-02 | |
US17/108,966 US11920343B2 (en) | 2019-12-02 | 2020-12-01 | Fire-rated wall joint component and related assemblies |
US202263374128P | 2022-08-31 | 2022-08-31 | |
US18/241,115 US20230407626A1 (en) | 2019-12-02 | 2023-08-31 | Fire-rated wall joint component and related assemblies |
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US17/108,966 Continuation-In-Part US11920343B2 (en) | 2019-12-02 | 2020-12-01 | Fire-rated wall joint component and related assemblies |
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US20230407626A1 true US20230407626A1 (en) | 2023-12-21 |
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US18/241,115 Pending US20230407626A1 (en) | 2019-12-02 | 2023-08-31 | Fire-rated wall joint component and related assemblies |
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US (1) | US20230407626A1 (en) |
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