WO1996024486A1 - Structures ignifuges comportant des elements en gypse renforce avec des fibres - Google Patents

Structures ignifuges comportant des elements en gypse renforce avec des fibres Download PDF

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Publication number
WO1996024486A1
WO1996024486A1 PCT/US1995/015069 US9515069W WO9624486A1 WO 1996024486 A1 WO1996024486 A1 WO 1996024486A1 US 9515069 W US9515069 W US 9515069W WO 9624486 A1 WO9624486 A1 WO 9624486A1
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WO
WIPO (PCT)
Prior art keywords
lbs
partition wall
gypsum
glass
fiber
Prior art date
Application number
PCT/US1995/015069
Other languages
English (en)
Inventor
George F. Fowler, Jr.
Peter Edward Jackman
Kevin D. S. Towler
Original Assignee
Georgia-Pacific Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Georgia-Pacific Corporation filed Critical Georgia-Pacific Corporation
Priority to GB9716741A priority Critical patent/GB2312453B/en
Priority to AU41660/96A priority patent/AU4166096A/en
Publication of WO1996024486A1 publication Critical patent/WO1996024486A1/fr
Priority to US08/706,481 priority patent/US5945182A/en

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/14—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing calcium sulfate cements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/04—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material comprising such water setting substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • 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
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B5/00—Doors, windows, or like closures for special purposes; Border constructions therefor
    • E06B5/10—Doors, windows, or like closures for special purposes; Border constructions therefor for protection against air-raid or other war-like action; for other protective purposes
    • E06B5/16—Fireproof doors or similar closures; Adaptations of fixed constructions therefor
    • E06B5/165—Fireproof windows
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00655—Profiles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/30—Nailable or sawable materials
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • This invention relates generally to fire-resistant framing members suitable for use in a variety of applications, including framing for windows, doors, partition walls and the like. More particularly, the present invention relates to mineral-containing compositions for providing structures with superior fire resistance and economical construction characteristics.
  • wood is susceptible to damage by fire. This is especially disadvantageous as a result of the recently increased emphasis on fire retarding properties of building materials, particularly commercial structures, as evidenced by modern building codes.
  • wood framing members for interior glass partitions also sometimes referred to as "wall screens” or “glazing wall screens”
  • wall screens also sometimes referred to as "wall screens” or "glazing wall screens”
  • wood not only degrades relatively rapidly in fire, but it also tends to warp from the heat when exposed to fire, possibly resulting in mechanical failure of the partition wall.
  • radiant heat from the fire passes through the glass and causes combustion of the wood framing members on the unexposed side of the wall.
  • other disadvantages are associated with the use of wood as framing material. For example, the supply of clear wood stock is limited and costs have risen as a result.
  • steel has become the material of choice for many framing applications. Nevertheless, steel members also suffer from shortcomings. For example, steel members expand and distort with great force as temperatures rise in a fire. This causes great difficulty in the use of steel_ framing as mullions and transoms in glass partition walls because the distortion force exerted by the steel member could shatter the glass during a fire.
  • Steel members also possess the disadvantage that they cannot be readily worked at the building site and hence even minor adjustments such as to frame height, for example, cannot be readily accomplished in the field.
  • steel frames are typically prefabricated by welding, making handling difficult and taking up more shipping space than would be required if the frame members could be shipped in a knocked-down condition.
  • steel frames cannot be stained to match the remaining woodwork in a room and accordingly must either be painted or treated with applications which simulate a wood finish.
  • a framing member which provides adequate fire resistance at a relatively low cost, which can be easily modified at the construction site and which has good screw- and nail-holding properties, as well as an attractive finished appearance.
  • This invention provides fire-resistant structures suitable for use in numerous applications, including glass partition walls comprising panels of glass or glass-like material supported by framing members.
  • the structures preferably have at least a 20 minute ASTME-152 fire test rating and include a member comprising a gypsum-based fiberboard composition having a density of at least about 60 lbs/ft 3 , a flexural strength of at least 30 lbs (1/2 inch thick material) , and a screw-holding capacity of at least about 400 lbs.
  • the composition of the framing members preferably comprises a substantially uniform distribution of solids including about 40 wt.% to about 97 wt.% set gypsum dihydrate, about 1.5 wt.% to about 30 wt.% paper fiber, and optionally about 1.5 wt.% to about 35 wt.% of one or more performance boosters selected from inorganic fiber, clay, vermiculite, and binder polymer.
  • the gypsum fiberboard members of this invention are both safe and effective for use in structural elements subject to high temperatures.
  • the present members can be produced relatively inexpensively and can be incorporated into glass partition walls, window framing and the like without rendering them excessively heavy.
  • FIG. 1 is a flow diagram which illustrates the process of this invention by which gypsum-containing framing members are made;
  • FIG. 2 is a graphical illustration of the effect of one of the components in a preferred fiberboard composition of this invention on one of the processing steps;
  • FIG. 3 is a graphical illustration of the flexural strength of fiberboards of this invention as a function of the density of the material;
  • FIG. 4 is a graphical depiction of numerous data points illustrating the screw-holding capacity of fiberboards of this invention as a function of the density of the material;
  • FIG. 5 is an elevation of a glass partition wall in accordance with one embodiment of this invention.
  • FIG. 6 is cross-sectional view taken along line 6-6 of FIG. 5;
  • FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 5;
  • FIG. 8 is a cross-sectional view of an alternative construction for a horizontal framing member and bead in accordance with the present invention.
  • FIG. 9 is a cross-sectional view of an alternative construction for a horizontal framing member and bead in accordance with the present invention
  • FIG. 10 is a cross-sectional view taken along lines 10-10 in FIG 9.
  • FIG. 11 is a schematic/elevational view of a glass partition wall in accordance with an embodiment of this invention as described in Example 4.
  • FIG. 12 is a schematic/cross sectional view showing the beading configuration used in accordance with the embodiment of the invention illustrated in FIG. 11 and described in Example 4.
  • FIG. 13 is a schematic view of the intumescent gasket material used according to the embodiment illustrated in Figs. 11 and 12 and described in Example 4.
  • the structural members of this invention are comprised of a gypsum-based article derived from fiberboard having a density of at least about 50 lbs/ft 3 and even more preferably at least about 60 lbs/ft 3 and a screw-holding capacity, defined below, of at least about 400 lbs.
  • the present members also preferably have a flexural strength of at least about 30 lbs (1/2 inch thick material) and a tensile strength of at least about 120 lbs.
  • These framing members are preferably comprised of a composition containing from about 50 wt.% to about 97 wt.% set gypsum dihydrate, about 1.5 wt.% to about 30 wt.% paper fiber and optionally about 1.5 wt.% to about 35 wt.% performance booster.
  • a more specific embodiment of this invention includes a structure comprising glass panels at least partially supported by a framing member comprised of gypsum-based composition as described above.
  • glass panel is used herein to encompass any transparent, translucent or similar fire resistant glass-like material.
  • this term is intended to include materials which include glass and glass-like panels which have supporting and/or enhancing components embedded therein or coated thereon.
  • the materials available under the following tradenames are adaptable for use as glass panels in accordance with the present invention: FIRELITE, PYROSWISS, PYROBEL, PYROBELITE, FYRESPAN, PYRAN, PYROSTOP, and PYRODDUR.
  • Glass panels are available in a wide variety of dimensions, and it is contemplated that all such dimensions are within the scope of the present invention. Nevertheless, the thickness of the glass panel will frequently depend on the particular material of construction and on the degree of fire protection desired for any particular application. In general, the glass thickness is preferably from about 1/4 inch to about 2 inch.
  • the framing member may be provided in a large variety of dimensions, depending at least to some extent on the thickness of the glass panel being used and on whether or not insulation is required. It is generally preferred that the member have a width and/or thickness dimension slightly larger than the thickness of the glass panel. Accordingly, dimensions ranging from 2 inch X 2 inch to about 2 inch X 3 inch are contemplated. In such embodiments, it is also preferred that the framing members are formed from a gypsum-based composition comprising about
  • the gypsum fiberboard members of this embodiment preferably have a flexural strength of at least about 40 lbs (1/2 inch thick material) , a screw-holding capacity of at least 500 lbs, and are covered with a thin, wood or wood-like veneer.
  • this composition When used as a framing member in glass partition walls and like applications, this composition preferably has at least a 20 minute ASTME-152 fire test rating, and even more preferably a 90 minute ASTME-152 fire test rating. According to other embodiments, the present invention provides a glass-panel containing partition wall capable of achieving a 90 minute rating under British standard BS476: part 2: 1987.
  • the gypsum fiberboard products of the present invention are capable of exhibiting hose stream resistance values of at least about 20 seconds, more preferably at least about 30 seconds, and even more preferably at least about 50 seconds.
  • the present invention provides fire-resistant structures, including fire-resistant structures comprised in major proportion of glass panels, capable of exhibiting hose stream endurance values of at least about 20 seconds, more preferably at least about 30 seconds and even more preferably 50 seconds.
  • gypsum fiberboard is used in a broad sense to refer to any article of manufacture comprised of set gypsum in substantial proportion (e.g. greater than about 30% by weight) and preferably in major proportion, and cellulosic and/or other fibrous materials in minor proportion. Furthermore, this term is not used herein to designate or otherwise limit any of the dimensional configurations of the article of manufacture.
  • the preferred fiberboard members of this invention at once posses a high degree of both fire resistance and structural integrity.
  • the bondability of the fiberboard members of the present invention allows the economical application of thin veneers and other surface decorations to the exposed surfaces of the structural member. This greatly and advantageously expands the number of environments and decorative motifs to which the present invention is adaptable.
  • the fiberboard members of this invention do not require a facing material, such as paper or glass mat, for flexural strength. It will be appreciated that since paper products generally have very poor fire resistance, the absence of such materials from the members of the present invention contribute to the fire and water resistant properties of the present invention. Thus, while paper facings are not preferred in accordance with the present invention, such facings can be optionally employed if the particular application so dictates. On the other hand, glass mat facings are generally very resistant to fire and therefore do not present the disadvantage of paper facing. In certain applications, therefore, the use of glass mat facings may be advantageously used.
  • a facing material such as paper or glass mat
  • the composition of the preferred fiberboard members is preferably a uniform distribution of solids, which includes by weight, about 65% to about 95% set gypsum dihydrate, about 5% to about 30% cellulosic fiber, and optionally but preferably about 1.5% to about 35% of one or more performance boosters selected from inorganic fiber, clay, vermiculite, and binder polymer and combinations of those.
  • One of the essential constituents of the gypsum- containing fiberboard members of the present invention is calcium sulfate dihydrate. This constituent is derived from the hydration of any form of calcium sulfate which is preferably in non-fibrous form and which is capable of reacting with water to form set gypsum, that is, calcium sulfate dihydrate.
  • the calcium sulfate can be in anhydrous form or in the hemihydrate form. It is believed that the hemihydrate form of calcium sulfate will be used most widely.
  • the hemihydrate can be produced from the naturally-occurring gypsum mineral by heating, or calcining, the dihydrate.
  • the gypsum-based composition preferably comprises a non-fibrous form of calcium sulfate capable of reacting with water to form set gypsum.
  • waste-type materials can be used in fabricating the fiberboard members.
  • Another example of a waste- or scrap-type material that can be used in the practice of the present invention is scrap gypsum wallboard, which can be used as a source of both calcium sulfate and the paper constituent of the fiberboard.
  • scrap paper-faced gypsum wallboard can be ground into suitably small particles which are processed in water under pressure and in the presence of a crystal modifier to form non-fibrous calcium sulfate hemihydrate.
  • Scrap gypsum wallboard can also be transformed into a suitable material for use in the practice of the present invention by grinding and calcining it at atmospheric pressure.
  • Sufficient water can be used to form the desired pulp-type material from which the product is conveniently made.
  • This invention can employ any of the above-disclosed individual sources of calcium sulfate, but a mixture of the different sources of calcium sulfate can also be used.
  • the non-fibrous calcium sulfate preferably will comprise a substantial proportion of the total solids, and more preferably from about 35% to about 97% by weight of the total solids in the dispersion, and even more preferably from about 55% to about 92% by weight, depending upon the specific application for the resultant building material.
  • the non-fibrous calcium sulfate content of the dispersion may be in the range of about 45% to about 75% by weight of the solids, and even more preferably of about 45% to about 75% by weight of the solids.
  • the calcium sulfate content of the dispersion may lie from about 65% to about 95% by weight of the solids and even more preferably from about 85 to about 90% by weight of the solids.
  • the gypsum dihydrate content of the preferred fiberboard members of this invention will be approximately 18.5% greater than the non-fibrous calcium sulfate content of the compositions from which they are made, the difference representing the added water of hydration in the set gypsum dihydrate. That is, by weight, the set gypsum preferably comprises from about 42% to about 97.5% by weight, and even more preferably between about 60% and about 94% by weight of the overall set composition.
  • a preferred member for use as edge banding in a fire door preferably comprises from about 40% to about 78% by weight of set gypsum.
  • a preferred framing member to be used as the support for glass panels in an interior partition wall comprises set gypsum in an amount of about 85% to about 95% by weight of the set composition.
  • the compositions of the preferred fiberboard members of this invention also employ a substantial amount of cellulosic fiber.
  • Cellulosic fiber includes the fibrous component of plants, such as cotton, linen, and flax, for example.
  • paper stock is conveniently employed. That is, the solid component involved in each of the aforesaid aspects of the invention preferably includes by weight about 1.5% to about 30% paper fiber, more preferably between about 5% and about 17%. Building materials intended for use in various specific products may contain somewhat different amounts of paper fiber.
  • a member intended for use as edge banding in a fire door may contain about 15% paper fiber by weight, while a member intended to be used as a support in a glass partition wall preferably contains from about 5% to about 10% by weight of paper fiber.
  • the presence of the paper fiber makes it possible to produce building materials having good physical characteristics such as flexural strength, screw- and nail-holding capacity, and surface hardness without the need for a separate surfacing membrane such as the paper facing on conventional gypsum wallboard.
  • the paper fiber can be derived from either virgin paper stock, or previously used, waste paper stock can be employed.
  • the source of the cellulosic fiber can be wood, cotton or linen rags, straw, etc.; however, paper fibers are preferred.
  • the paper may be a product of the sulfite process, the sulfate (Kraft paper) process, or other processes.
  • the types of paper stock that have been successfully employed are virgin and brown Kraft papers, and especially, newsprint. Waste newspaper provides very satisfactory results, is inexpensive, and its use helps to overcome an environmental pollution problem.
  • the source of the paper stock can include the paper of ground paper- faced gypsum wallboard.
  • Fiberboard members within the scope of this invention desirably and preferably include one or more performance boosting additives, their specific nature depending to some extent on the intended utility of the final product.
  • the performance booster generally will comprise about 1.5% to about 35% by weight of the solids and will preferably be selected from inorganic fiber, clay, vermiculite, and binder polymer.
  • Inorganic fiber includes glass textile fiber and mineral wool. These latter terms are defined in U.S. Patent No. 4,557,973, and those definitions are incorporated herein by reference.
  • the term “mineral wool” means glass or other mineral fibers prepared by attenuating a melt of glass, basalt, blast furnace slag or other vitreous mineral composition from the face of a heated centrifugal rotor or the like. This process is in contrast to that used to produce textile fibers, where the melt is drawn through an orifice.
  • An especially useful and readily available type of mineral wool is glass wool as found in glass wool insulation material. Glass textile fiber and glass wool, jointly or severally, are referred to herein as "siliceous fiber.” As employed in this invention, the glass textile fiber generally will be chopped, e.g., the fibers may be about 1/2 inch long.
  • the fiberboards of this invention preferably include siliceous fiber.
  • Siliceous fiber improves the fire resistance of the building materials and other products of this invention, apparently by decreasing the tendency of the gypsum construction to crack under thermal stress.
  • the siliceous fiber preferably comprises up to about 7% by weight and may include glass textile fiber and, in addition, glass wool, depending upon the specific product.
  • a building board intended for use as edge banding in a fire door preferably includes up to about 7% by weight glass textile fiber, whereas a framing member for use in glass partition walls most preferably from about 1% to about 2% by weight of glass fiber.
  • the performance booster preferably includes clay and/or vermiculite, and even more preferably both.
  • the use of such additives are especially desirable for members requiring excellent fire resistance.
  • Both of these materials may be present in amounts up to about 15.0% by weight or greater, preferably up to about 6%, and more preferably from about 0.5% to about 2% by weight of the solids.
  • the clay to be employed will generally be kaolin clay, which is effective to control the shrinkage of the gypsum-containing construction under extreme heat, for example, ASP 70 Kaolin clay sold by Minerals and Chemicals Philip Corporation.
  • the vermiculite should be raw, or unexpended vermiculite, which swells when heated, helping to control shrinkage of the construction and possible cracking. The requirement for the presence of these materials depends somewhat on the intended use for the final product.
  • composition of the preferred fiberboard members of this invention may also employ binder polymer.
  • the binder polymer affects the physical properties of the fiberboard members, especially their flexural strength, and also permits good fastener retention at lower density. Furthermore, the binder polymer improves the surface characteristics and flexural strength of the member, especially when applied as a coating on the surface thereof.
  • the binder polymer when present, may comprise up to about 15% by weight of the solids or greater, but preferably about 1% to about 3% by weight.
  • binder polymer A number of different polymeric materials may be employed as binder polymer, including homopolymers, such as poly(vinyl acetate) and polyacrylate, as well as copolymers, such as poly(ethylene)- co-(vinyl chloride), poly(styrene)-co-(butadiene) , and poly(vinyl acetate)-co-(methyl acrylate) .
  • homopolymers such as poly(vinyl acetate) and polyacrylate
  • copolymers such as poly(ethylene)- co-(vinyl chloride), poly(styrene)-co-(butadiene) , and poly(vinyl acetate)-co-(methyl acrylate) .
  • esters of poly(vinyl alcohol) are especially effective, and poly(vinyl acetate) homopolymer is preferred. It is also convenient in most cases to introduce the binder polymer as an aqueous emulsion, many of which are commercially available
  • thermoplastic resins are preferred since they tend to form a tough, forgiving film, rather than a brittle film, or one which is soft and has a very low tensile strength when applied for joining the surfaces of the fiberboards, stiles, and rails.
  • Thermoplastic resins are also preferred since the heat required to set a thermosetting resin tends to calcine the gypsum in the preferred fiberboard compositions of this invention.
  • One particularly useful resin emulsion which is suitable for use as the resin polymer of the preferred fiberboard composition and as an adhesive for bonding the various fire door and fire panel elements to one another is UCAR-130 poly-(vinyl acetate) polymer by Union Carbide.
  • composition for preparing the fiberboard members of this invention will also include water in an amount in excess of that required to react with and hydrate the calcined non- fibrous gypsum. That is, at least about, and preferably greater than, a 10-fold excess amount of water should be present. Contrary to the conventional wisdom, the excess water provides processing advantages and leads to products which possess superior properties.
  • the fiberboard compositions of this invention may be formulated in a variety of ways, and any number of different techniques may be employed to produce the members this invention, a process which is preferred for making these structures is illustrated diagrammatically in FIG. 1. With reference to FIG.
  • the paper fiber component e.g., newspaper
  • water at least about 20 times as much water by weight as paper
  • the mixture is reduced to pulp, producing a substantially homogeneous suspension.
  • Glass wool if it is specified in the composition, can be separately pulped in at least about 20 times its weight of water and the separately pulped wool and paper combined.
  • the paper and glass wool can be pulped together, if desired, in at least about 20 times their combined weight of water.
  • Any textile glass fiber, clay and vermiculite are then added to the pulper and thoroughly mixed and incorporated into the suspension. The suspension is then transferred to tank 21.
  • pulped suspension from tank 21 is added to mixer 24, any binder polymer from tank 22 as may be required for the composition is added to mixer 24, and sufficient non-fibrous calcium sulfate to yield the requisite amount of dihydrate when reacted with less than about 5% of the water is added from tank 23 to mixer 24, wherein all the components are mixed and incorporated into the suspension, producing a slurry.
  • the wet slurry 25, sometimes referred to herein as "gypsum stucco" is then cast into mold 26, and the slurry is pressed under hydraulic press 27 for dewatering the slurry and for producing a green casting 28.
  • the mold 26 can be adapted to form the gypsum slurry 25 into the final shape and dimension of the member to be produced. For example if an elongate member to be used as a stud is desired, a mold having the appropriate dimension to produce the finished product can be employed. Alternatively and preferably, the mold can be in the form a more conventional sheet have the appropriate thickness, which after setting and drying is cut to the desired width and/or length.
  • a density of at least about 60 lbs/ft 3 , more preferably above 65 lbs/ft 3 , and even more preferably above about 75 lbs/ft 3 is preferred.
  • the green casting is allowed to set and is then conveyed into oven 29 and the set casting is dried. If desired, dried set casting 30 may be sanded at sanding station 31 to the desired thickness and/or then cut to the desired size with saw 32. It will be evident that the aforesaid steps can be adapted to either a batch or continuous process.
  • the aforementioned aqueous dispersion of constituents is formed into a sheet of indefinite length by the use of standard paper-making techniques.
  • the aqueous dispersion of constituents can be fed from a head box of the type associated with a paper-making machine to a foraminous moving belt through which water drains as the mass of solids coagulates and sets.
  • the resulting composite sheet is consolidated by passing through press rolls. Heated rollers can also be used to dry the sheet.
  • the processes of the present invention can be used to make an unsupported (unfaced) fiberboard which has a substantially uniform and homogeneous composition throughout its thickness.
  • unfaced is used herein to mean that the fiberboard is preferably not faced with a sheet material, for example, the paper or glass fiber mat that is often used as a facing material for gypsum wallboard.
  • the fiberboard members of the present invention have a density of at least about 60 lbs/ft 3 , but it will be understood that the material can have a density of as low as 40 lbs/ft 3 for some applications.
  • the minimum flexural strength and screw-holding capacity referred to above (30 lbs and 400 lbs respectively) in building materials having densities below 60 lbs/ft 3
  • binder polymer for example, about 25 wt.% to about 35 wt.% based on solids content.
  • the use of such binder polymer can be absent or provided in smaller amounts.
  • the density of the fiberboard can be controlled by the use of pressure in forming the product and/or by the use of a low-density material, for example, expanded perlite.
  • Table I presents data obtained in producing building materials using the aforesaid batch process and various cellulosic fibers. All samples were pressed at 300 psi in a 4 inch by 4 inch mold. Samples were removed from the mold after pressing, hydrated, and then dried at 110°F. The drie samples were sanded to about 0.3 inches thick, cut to 1 inch wide by 4 inches long and tested for flexural strength on 3 inch centers.
  • the various cellulosic fibers used in forming the fiberboard panels comprise either wood chips which are pulped (comparative example) or paper stock which is pulped, the paper stock comprising either newspaper, Kraft paper, sulfite paper or paper of the type used to face wallboard. The significant improvements achieved by using the pulp of paper stock relative to the use of wood pulp are evident from the results reported in Table I.
  • Weight of fiber material (g) 20.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0
  • Weight of Gypsum (g) 113.0 113.0 113.0 113.0 113 . 00
  • Gypsum lost before press (g) 2.82 5.47 36.59 5.07 1 . 3333
  • Gypsum lost during press (g) 0.61 0.73 4.02 0.74 0 . 33
  • Weight of sample-wet (g) 180.98 179.7 126.7 177.28 183, .12
  • Fiberboard Example 1 Four casting compositions were prepared containing the following ingredients in parts by weight:
  • the newspaper was pulped in a Waring blender; the gypsum and polymer binder were added, and the blended mixture was pressed into 3/4 inch thick slabs at a rate to avoid geysering.
  • Building materials within the scope of this invention prepared by the process described hereinabove, were tested for flexural strength, as defined by the following procedure. These tests generally employed ASTM Method C 473-86a modified in that the specimens were 1/2 inch thick, 1 inch wide, and 4 inches long, with random orientation. In each case, the specimen was supported on bearings 3 inches apart, and the specimen was broken across the 1 inch width. Evaluation of flexural strength as a function of the density of fiberboards was undertaken, and the results appear in FIG. 3.
  • the flexural strength of fiberboards within the scope of this invention generally should be at least about 30 lbs, preferably at least about 60 lbs (1/2 inch thick sample) .
  • Fiberboards within the scope of this invention were evaluated for screw-holding capacity, as defined by the following procedure.
  • a specimen of material to be tested dried to constant weight and 1/2 inch +/- 1/32 inch thick, at least 9 inches long, and nominally 1 9/16 inches wide, was employed.
  • a 5/32 inch pilot hole was drilled to receive a No. 12 sheet metal screw.
  • the screw was turned until the full shank thickness penetrated the specimen. Force was then applied vertically at the center of the screw, forcing the screw through the specimen, and the force was noted.
  • screw-holding capacity was generally about 400 lbs or greater for board densities of about 60 lbs/ft3 or greater, with screw-holding capacities o about 700 - 800 lbs being achieved with board densities as o about 70 - 75 lbs/ft3.
  • the screw-holding capacity of a building material within the scope of this invention should be at least about 400 lbs, and for a member used as a support or mullion in glass partition walls, the screw-holding capacity should preferably be at least about 500 lbs, more preferably in excess of about 600 lbs.
  • Fiberboard Example 2 A casting composition was prepared containing the following ingredients in parts by weight: TABLE III: Base Casting Composition
  • the newspaper was pulped in a Waring blender; the gypsum was added, and varying amounts of the blended mixture were added to a mold and pressed to 1/2 inch thick slabs. After curing and drying, the density and screw-holding capacity of each slab was measured.
  • the screw-holding capacity of the fiberboards of this invention is enhanced through the use of binder polymer as illustrated in Fiberboard Example 3.
  • the casting composition included 113 g calcined non-fibrous gypsum, 20 g paper, 2.2 g glass textile fiber, and 5 g binder polymer.
  • the AIRFLEX products are all ethylene/vinyl chloride b Polyvinyl acetate homopolymer c Styrene/butadiene "Vinyl/acrylic e Acrylic
  • Glass Partition Walls Applicants have surprisingly discovered that fire resistant structures comprising glass panels and gypsum-base framing members supporting the glass panels are capable of exhibiting extraordinary fire resistant properties.
  • the broad scope of the present invention is directed to any structure which incorporate glass panels, including doors with window lights, window frames and the like.
  • a specifically preferred embodiment of the present invention is directed to glass partition walls, an even more particularly interior glass partition walls.
  • An exemplary partition wall in accordance with this aspect of the present invention is illustrated in a semi-schematic, elevation view in FIG. 5 hereof.
  • a glass partition wall is indicated generally as 100.
  • the wall 100 is comprised of a plurality of glass panels 105 supported by framing members 110.
  • the partition wall 100 also includes a doorway containing doors 115 and 116.
  • the glass panels 105 are supported by a plurality of framing members 110, at least a portion of which and preferably substantially all of which, are formed from the gypsum-based fiberboard compositions described above.
  • the gypsum- based fiberboard members have decorative materials applied to the exposed surfaces thereof to enhance the ascetics of the partition wall in which they are used.
  • decorative materials for example, paints, lacquers and the like may be readily applied to the gypsum fiberboard members of the present invention to enhance the appearance thereof.
  • a thin, wood-like veneer is fastened, and preferably adhesively fastened, to the exposed surfaces of the framing member. Applicants have found that such veneer materials are easily and strongly adhered to the gypsum-based framing members of the present invention and greatly enhance the ascetic quality of partition walls formed therefrom.
  • Applicants have also surprisingly found that the incorporation of such wood or wood-like veneers does not substantially detract from the fire-resistant properties of the present structures. More particularly, the use of gypsum-based fiberboard members in accordance with the present invention substantially reduces the tendency of such veneer materials to detrimentally flame during fire tests. Instead, applicants have observed that such materials tend to char in a fashion that is not detrimental to the structural integrity of the partition wall. Although applicants do not intend to necessarily be bound by or limited to any particular theory of operation, it is believed that the relatively high heat capacity of the water of hydration bound in the set gypsum of the present framing members tends to protect such veneers from rapid and detrimental flaming.
  • highly fire-resistant structural members having many of the desirable features, qualities, and ascetics of wood can be formed from gypsum-based fiberboard compositions in accordance with the present invention.
  • Applicants have found that this highly unexpected and surprising property of the present structures is of critical importance to the success of certain embodiments of the present invention. For example, an appealing appearance and other aesthetic qualities are essential features of many commercially successful interior partition structures. Since gypsum-based fiberboard products generally do not themselves possess attractive or aesthetic qualities, they would not be considered acceptable alternatives in the first instance. On the other hand, while wood and other materials exhibit acceptable aesthetic characteristics, they are wholly unacceptable from the perspective of fire-resistant properties.
  • the combination of a gypsum-based fiberboard member faced with an aesthetic veneer is a critical requirement according to certain embodiments of the present invention.
  • this essential feature produces highly unexpected results since the veneer materials would not under normal circumstances exhibit satisfactory fire-resistant qualities when exposed directly to the heat and flame conditions of a fire test.
  • the present invention achieves at once both fire-resistant properties and highly aesthetic appearance.
  • a horizontal gypsum-based fiberboard framing member 110A is attached to a gypsum-based vertical framing member HOB.
  • Framing members 110A and HOB can be attached by any conventional means employed for wood framing members, including adhesive bonding, nailing, screwing and the like.
  • These gypsum-based fiberboard framin members together support glass panels 105, which are preferably held in place by lengths of decorative molding 120.
  • the decorative molding 120 can be formed from any one of several well-known and conventional materials used for such functions, including wood and the like.
  • molding strips 120 may, if desired, also be formed of a gypsum-based fiberboard composition of the present invention, which in turn can then be screwed, nailed, or otherwise fastened to gypsum-based fiberboard framing members HOA.
  • FIG. 8 illustrates an alternative to the construction technique illustrated in FIG. 7. More particularly, a horizontal gypsum-based fiberboard member HOA having an I-beam type configuration is utilized. It is contemplated that such a member can be produced in any one of several ways. For example, because of its excellent machinability, it is possible to machine channels in a stud-like member using conventional techniques. Alternatively, it is contemplated that such gypsum-based fiberboard members may be produced with the appropriate configuration by use of an appropriate mold.
  • FIGS. 9 and 10 illustrate the construction of a glass panel wall which eliminates the need for intumescent gaskets and like material between the gypsum- based framing members and the glass panels of the present invention. More particularly, FIG. 9 illustrates a pair of glass panels 105 supported by horizontal, gypsum-based framing members HOA. Bead members 120, also formed of the gypsum-based composition of the present invention, are utilized to further support glass panels 105.
  • gypsum-based compositions as framing members in accordance with the present invention permits the use of nonintumescent gasket material 130 to fill the voids between the gypsum- based members HOA/120 and glass panels 105.
  • glass-containing structures in accordance with this embodiment of the present invention are capable of achieving a 20-minute ASTME-152 fire test rating, and even more preferably a 90-minute ASTME-152 fire test rating.
  • Example 4 An interior partition wall comprising at least 50% glass pursuant to British Standard BS476: part 22: 1987 was constructed from gypsum-based framing members having composition substantially as disclosed in Example 3 hereof. As illustrated in FIG. 11, the partition wall 100 had an overall horizontal dimension of 3,000 millimeters and an overall vertical dimension of about 3,000 millimeters. The partition wall consisted of a two-light glass door 115 (which is shown separated from the opening 300 in which it was installed during the test described hereinafter) door having a width of about 1,000 millimeters and a height of about
  • the door was constructed from gypsum fiberboard members 110 in which mortis and tendon joints were used at the transom/mullion intersections. Fastening of the gypsum-based fiberboard framing members was otherwise accomplished in conventional fashion with screws and/or nails.
  • Horizontally adjacent to the door was a glass pane having a height of about 2,000 millimeters and a width of about 1,000 millimeters.
  • Above the top of the glass door and the aforementioned glass pane was a glass pane, having a width of about 2,000 millimeters and a height of about 2,000 millimeters. Adjacent to the glass panes described above were a series of 3 vertically stacked glass panes having a height and a width of about 1,000 millimeters.
  • the glass panes and the window lights for the doors were glass panels sold under the trade designation "Pyran S” by Schott Glass LTD, Drummond Road, Stratford, England.
  • the glass panels were approximately 6.5 millimeters ( ⁇ 0.5mm) thick.
  • the gypsum-based framing members had a thickness of about 40 millimeters and were faced with wood veneer.
  • the beads and the framing members were attached to one another via screws and nails.
  • Mortis- tendon joints were used at the transom/mullion intersections.
  • Intumescent material having the configuration shown in FIG. 13 was used between the gypsum-based framing members and the glass panels, as shown in FIG. 12.
  • a hose stream test is performed on a partition structure comprising at least about 50% glass in accordance with BS476: part 22: 1987.
  • the partition wall is exposed to a hose stream test.
  • the hose stream test includes exposing the partition wall to a stream of water at a pressure of about 30 lbs/sq.in. (psi) .
  • the pressurized stream is traversed over the exposed face of the partition wall for a period of about 24 seconds (1.5 sec/sq.ft) in accordance with requirements for test standards for 90 minute rated openings. No through openings in the partition wall or any part thereof are observed either during or after the test.

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Abstract

L'invention concerne des structures ignifuges avec une résistance au feu de 20 minutes au moins selon la norme ASTM E-152. Les structures sont constituées de panneaux en verre (105) ayant des éléments de cadre (110A, 110B) formés à partir d'une composition contenant du gypse et ayant une densité d'au moins 60 livres par pied cube environ, une résistance à la flexion d'au moins 30 livres environ (plaque de 1/2 pouce d'épaisseur) et une force de retenue d'une vis d'au moins 400 livres environ. La composition contient des matières solides réparties d'une manière sensiblement uniforme et constituées par entre environ 65 % en poids et environ 90 % en poids de gypse dihydraté, entre environ 7 % en poids et 30 % en poids de fibres de papier et entre environ 1,5 % en poids et 35 % en poids d'un ou plusieurs améliorants choisis parmi les fibres minérales, l'argile, la vermiculite et les polymères agissant comme liants.
PCT/US1995/015069 1995-02-10 1995-11-17 Structures ignifuges comportant des elements en gypse renforce avec des fibres WO1996024486A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
GB9716741A GB2312453B (en) 1995-02-10 1995-11-17 Fire-resistant members containing gypsum fiberboard
AU41660/96A AU4166096A (en) 1995-02-10 1995-11-17 Fire-resistant members containing gypsum fiberboard
US08/706,481 US5945182A (en) 1995-02-14 1996-09-04 Fire-resistant members containing gypsum fiberboard

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBPCT/US95/01685 1995-02-10
PCT/US1995/001685 WO1996024562A1 (fr) 1995-02-10 1995-02-10 Elements resistants au feu contenant des panneaux de fibres renfermant du gypse

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WO1996024486A1 true WO1996024486A1 (fr) 1996-08-15

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PCT/US1995/001685 WO1996024562A1 (fr) 1995-02-10 1995-02-10 Elements resistants au feu contenant des panneaux de fibres renfermant du gypse
PCT/US1995/015069 WO1996024486A1 (fr) 1995-02-10 1995-11-17 Structures ignifuges comportant des elements en gypse renforce avec des fibres

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PCT/US1995/001685 WO1996024562A1 (fr) 1995-02-10 1995-02-10 Elements resistants au feu contenant des panneaux de fibres renfermant du gypse

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WO (2) WO1996024562A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012031345A1 (fr) 2010-09-07 2012-03-15 Flamehalt Technologies, Inc. Procédé pour former un produit en cellulose résistant au feu, et appareil associé
EP2369117A3 (fr) * 2009-12-29 2013-09-18 Jaatimet Oy Porte coupe-feu
US11505498B2 (en) 2014-11-20 2022-11-22 Saint-Gobain Placo Sas Construction panel having improved fixing strength

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2053184A (en) * 1979-05-22 1981-02-04 Stockton L W Plaster composition
US5171366A (en) * 1989-10-12 1992-12-15 Georgia-Pacific Corporation Gypsum building product

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2053184A (en) * 1979-05-22 1981-02-04 Stockton L W Plaster composition
US5171366A (en) * 1989-10-12 1992-12-15 Georgia-Pacific Corporation Gypsum building product

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2369117A3 (fr) * 2009-12-29 2013-09-18 Jaatimet Oy Porte coupe-feu
WO2012031345A1 (fr) 2010-09-07 2012-03-15 Flamehalt Technologies, Inc. Procédé pour former un produit en cellulose résistant au feu, et appareil associé
CN103392040A (zh) * 2010-09-07 2013-11-13 Blh科技股份有限公司 形成耐火纤维素产品的方法及其相关设备
US9005396B2 (en) 2010-09-07 2015-04-14 Blh Technologies Inc. Method for forming a fire resistant cellulose product, and associated apparatus
US11505498B2 (en) 2014-11-20 2022-11-22 Saint-Gobain Placo Sas Construction panel having improved fixing strength

Also Published As

Publication number Publication date
GB2312453B (en) 1998-11-11
WO1996024562A1 (fr) 1996-08-15
GB9716741D0 (en) 1997-10-15
GB2312453A (en) 1997-10-29
AU4166096A (en) 1996-08-27

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