WO2008124430A1 - Agencement des panneaux isolés structurels en plâtre avec fibres de bois - Google Patents

Agencement des panneaux isolés structurels en plâtre avec fibres de bois Download PDF

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Publication number
WO2008124430A1
WO2008124430A1 PCT/US2008/059124 US2008059124W WO2008124430A1 WO 2008124430 A1 WO2008124430 A1 WO 2008124430A1 US 2008059124 W US2008059124 W US 2008059124W WO 2008124430 A1 WO2008124430 A1 WO 2008124430A1
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WO
WIPO (PCT)
Prior art keywords
panel
gypsum
wood fiber
exterior
fiber board
Prior art date
Application number
PCT/US2008/059124
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English (en)
Inventor
David B. Mcdonald
Original Assignee
United States Gypsum Company
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Filing date
Publication date
Application filed by United States Gypsum Company filed Critical United States Gypsum Company
Publication of WO2008124430A1 publication Critical patent/WO2008124430A1/fr

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/10—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products
    • E04C2/24—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20
    • E04C2/246—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the like; of plastics; of foamed products laminated and composed of materials covered by two or more of groups E04C2/12, E04C2/16, E04C2/20 combinations of materials fully covered by E04C2/16 and E04C2/20

Definitions

  • This invention relates generally to structural insulated panel arrangements used in a building construction system and is particularly directed to a structural insulated panel having a plastic foam core and a pair of opposed outer facings made from gypsum wood fiber board, and a panel system for providing protection of the exterior gypsum wood fiber facing from moisture damage.
  • Structural Insulated Panels are gaining increasing acceptance in the building construction industry as an alternative to the stick built approach.
  • SIP construction employs two rigid faces on either side of a light insulating foam core.
  • High strength bonding of the outer facings to the inner core forms a structural I-beam in the form of flat panels which are typically joined together by lumber and nails.
  • the outer, opposed panel faces are typically formed from conventional building materials such as gypsum or cementitious composites, plywood, oriented strand board (OSB), drywall, or other rigid construction boards from 0.635 cm. to 1.905 cm. (1/4" to 3/4") thick.
  • U.S. Pat. No. 5,628,158 increases the strength of joined panels by inserting a spline in facing grooved edges of connected panels.
  • the spline includes an insulating core and a pair of outer facing metal strips extending the length of the spline.
  • the metal-faced spline is affixed to the panel edges by means of a structural adhesive for securely connecting the two insulated panels.
  • Still another approach is to strengthen structural insulated panels using metal strips that are incorporated in the panel and bonded to the insulating core and an outer facing.
  • Another approach employs a metal facing on one or both surfaces of the structural insulated panel to increase panel strength and environmentally isolate one side of the panel from the other, but this substantially increases the cost of the panel and precludes use of the panel in many types of common structures.
  • U.S. Pat. No.6,588,172 to Porter discloses structural insulated building panels (SIP) with plastic impregnated paper which have a first outer facing selected from the group comprising gypsum or cementitious composite material and a second outer facing which is preferably comprised of gypsum or cementitious composite.
  • SIP structural insulated building panels
  • Porter does not suggest the use of a panel assembly having gypsum wood fiberboard panels on each surface and a weather resistant barrier and another insulation panel fastened to the outer surface of the exterior facing.
  • US2005/0193676 to Palmerstein discloses structural panel for use in buildings having a first foam layer as a core and skins made from higher density, higher strength material including metals, wood products or polymers.
  • US2005/0064145 to Hoie et al. discloses a composite building panel having a foam core sandwiched between two facings.
  • the reinforcing facings can be cementitious board, plywood, gypsum/textile composite board or OSB.
  • the fire-retardant wall includes a first layer comprising an inner core, typically made of an insulated panel used in construction of buildings, and at least one second layer on each side of first layer, the at least one second layer further comprising at least one fire-resistant board of pressed milled straw.
  • the second layer may also include a structural board used as a building panel in construction of buildings and/or an interior wall board used for internal and external walls and ceilings of buildings, wherein such boards are positioned on the exterior side of at least one board of pressed milled straw.
  • the wall may include gypsum board as the interior wall board
  • US2002/0136888 to Porter discloses high strength structural insulated panel including an inner insulating core of material such as of plastic foam and at least one outer facing comprised of a rigid material such as gypsum or cementitious composite, oriented strand board (OSB), or an agricultural product such as strawboard.
  • a rigid material such as gypsum or cementitious composite, oriented strand board (OSB), or an agricultural product such as strawboard.
  • OSB oriented strand board
  • United States Gypsum Company has previously developed an INSULSCREEN TM2000 exterior insulation and finish system (EIFS) insulated panel assembly system first marketed in 1992.
  • EIFS exterior insulation and finish system
  • This system used a gypsum board interior panel facing and an outer sheathing panel of OSB or cementitious composite board that was attached to wood studs, rather than a reinforced gypsum wood fiber board used in the current invention, in an assembly that included a weather resistant barrier and an exterior insulation panel of polystyrene that was fastened through the insulation panel outer panels.
  • This earlier developed panel assembly was not a structural insulation panel system and required the use of framing e.g.
  • thermal barriers When foams are used in buildings, they require a 15 minute fire barrier, designed to slow the temperature increase of the foam during a fire, and to delay the foam's involvement in a fire.
  • the building code definition of an approved thermal barrier is one which is equal in fire resistance to 12.7 mm (1/2 inch) gypsum board.
  • thermal barriers limit the temperature rise of the underlying polyurethane foam to not more than 250° F after 15 minutes of fire exposure complying with the standard time temperature curve of ASTM E 119. Thermal barriers meeting this criterion are called “15-minute thermal barriers" or classified as having as "index of 15.”
  • SIP panels manufactured using OSB and Foam do not meet this requirement and require an additional interior layer of gypsum board since the OSB layer is not suitable for interior decoration.
  • SIP panels manufactured using gypsum boards do not have the structural capacity to be used for load- bearing walls.
  • the present invention represents an improvement over the prior art by providing a low cost structural insulated panel having a plastic foam inner core and opposed outer facings comprised of gypsum wood fiberboard without the need for OSB or plywood or other structural wood sheathing which has previously been used on the exterior surface of panels for structural strength when gypsum or cementitious panels were used on the interior facing.
  • the present invention overcomes a panel bowing issue by providing two panels with equal strength and modulus values that will perform the same under the same axial load.
  • the present invention increase the tensile strength of a gypsum or cementitious sheet in a multi-layered structural insulated panel arrangement that renders the panel resistant to moisture and which overcomes the warping of multilayer panels that use gypsum or cement panels on one surface and OSB panels on the other surface.
  • Another aspect of the present invention is to provide a high strength structural panel system for building construction which is fire and moisture resistant and is thus capable of serving as a vapor barrier.
  • the gypsum wood fiber panels provide a ready to finish surface.
  • a further aspect of the present invention is that the panel arrangement which uses gypsum wood fiber panels provides a load-bearing structural panel system that is already clad with a thermal barrier that meets the building code requirement for a 15 minute thermal barrier that is required with the foam insulation used in prior art SIP panels.
  • This invention contemplates a reinforced structural insulated panel arrangement comprising: a generally flat insulating core; first and second gypsum wood fiber board outer facings attached to opposed lateral surfaces of the insulation, a first sheet of a weather resistant barrier layer such as TYVEK ® Stuccowrap Weather Resistant Barrier attached to the gypsum wood fiber panel facing that is intended to be used on the exterior side of the panel arrangement by staples or adhesive, a layer of expanded polystyrene foam insulation panel over said barrier layer which is attached to the gypsum wood fiber panel by corrosion resistant mechanical fasteners and plastic washers through the barrier to the gypsum wood fiber board facing.
  • a weather resistant barrier layer such as TYVEK ® Stuccowrap Weather Resistant Barrier
  • Siding such as aluminum or vinyl siding can be attached to the exterior surface of the panel assembly with "G” (gypsum) fasteners or other fasteners meeting ASTM C1002-04 "Standard Specification for Steel Self-Piercing Tapping Screws for the Application of Gypsum Panel Products or Metal Plaster Bases to Wood Studs or Steel Studs” or other fasteners with appropriate washers.
  • G gypsum
  • FIG. 1 is a perspective view of the structural insulating panel of the invention showing its installation with mechanical fastening to exterior gypsum wood fiber panel arrangement.
  • FIG. 1A is a top view of the mechanical fastener in FIG. 1 which typically is made from a screw within a plastic washer.
  • FIG. 2 is a cross sectional view of a wall building structure of this invention incorporating the structural insulated panel assembly with moisture barrier and insulating layer over the exterior surface of the SIP panel and exterior water resistant barrier, base coat with reinforcing mesh and finish coat and which is attached to the gypsum wood fiber panel by mechanical fasteners.
  • FIG. 3 is a cut-away view of the structural insulating panel system of the invention as it is installed as a wall with a roof and soffit.
  • FIG. 4 is a cut-away view of the structural insulating panel system as it would be installed at the intersection of the wall and roof.
  • FIG. 5 is a cut-away view of the structural insulation panel as a decorative reveal having an exterior groove or notch on the exterior surface of a wall.
  • FIG. 6 is a cut-away view of the structural insulating panel system used in the construction of a flanged window head.
  • FIG. 7 is a cut-away view of the structural insulating panel system used in making a flanged window jam.
  • FIG. 8 is a cut-away view of the structural insulating panel system used in construction of a flanged window sill.
  • FIG. 9 is a cut-away view of the structural insulating panel system of this invention used in the construction of an intermediate floor.
  • FIG. 10 is a graph of shear strength to failure for various fasteners used for joining FIBEROCK ® brand gypsum wood fiber board sheathing to plywood.
  • building structure panel 1 includes first and second wall panels 40 and 10.
  • Two-part waterborne thermosetting structural adhesive may be used to join the two outer panels 40 and 10 to the plastic foam core 110.
  • Conventional adhesive in the form of mastic or epoxy cement may be used to join the two outer panels 40 and 10 to the plastic foam core 110.
  • Weather resistant barrier 80 is attached to the outer facing surface of the gypsum cellulose fiberboard panel 40 and then an exterior insulation board of 2.54 cm. to 3.81 cm.(1.0 to 1.5 in.) expanded polystyrene 90 is attached to the panel 40 and weather resistant barrier 80 with corrosion resistant fasteners meeting ASTM C1002 - 04 and plastic washers 120.
  • the exterior insulation panels are typically 1.27 to 10.16 cm. (0.5 to 4.0 inches) thick by 1.219 m. by 2.438. m (4 feet, by 8 feet) and are attached at 20.3 cm. (8 inches) off center vertical and 40.6 cm. (16 inches) off center horizontally.
  • the mechanical fastener 120 as shown in more detail in FIG.
  • FIG. 2 there is shown a cross-sectional view of a structural insulated panel generally designated as 1 in accordance with one embodiment of the present invention, installed as a wall panel structure.
  • the structural insulated panel 1 includes a first facing 40, a plastic foam core 110 and a second opposed facing 10.
  • Structural insulated panel 1 is preferably positioned in a building structure with its first outer facing 40 facing outwardly and its second outer facing 10 facing inwardly relative to the building structure. In this orientation, the panel's first outer facing 40 is comprised of gypsum cellulose fiber board.
  • the panel's second outer facing 10 is also preferably comprised of gypsum cellulose fiber board although the interior side could also be a gypsum or cementitious composite.
  • the interior wall and ceiling comprise a gypsum cellulose fiber panel 10 over an expanded insulation core 110, such as polystyrene foam.
  • An exterior gypsum cellulose fiber board panel 40, weather resistant barrier 60 and an exterior insulation board, usually 2.54 cm. to 3.81 cm. (1.0 to 1.5 in.) min thickness are attached to the exterior wood or steel framing with corrosion resistant fasteners (not shown) typically having 4.45 cm. (1.75 in.) diameter plastic washers.
  • An exterior basecoat 70 with reinforcing mesh and finish coat is applied over the exterior surface of the exterior insulation board 50.
  • a casing bead 200 and backer rod and sealant 190 are fitted between the exterior structural insulation panel system and the soffit 300.
  • FIG. 4 shows, the intersection of a roof and wall in which structural insulation panels with gypsum cellulose fiber board panel 40 and a weather resistant barrier 60, an exterior insulation board 50 and an exterior basecoat 70 with reinforcing mesh and finish coat over the exterior insulation board 50, are attached using corrosion-resistant fasteners 120 which, as previously described in FIG. 1A, comprise a screw 120B inside a plastic washer 120A.
  • corrosion-resistant fasteners 120 which, as previously described in FIG. 1A, comprise a screw 120B inside a plastic washer 120A.
  • a starter track 210 with weeps is installed over the structural insulation panel at a point of about 3.81 cm (1.5 in.) above the roof.
  • a step flashing 220 and kick out flashing 230 are installed by the contractor and a water barrier tape 240 applied over the point were the kick-out flashing 230 is joined to the exterior surface of the wall panel.
  • FIG. 5 a typical decorative reveal is illustrated with an interior gypsum cellulose fiber panel 10 over a moisture barrier 20 on the interior surface of the insulation foam core 110 and a gypsum cellulose fiber board sheathing 40 with a weather resistant barrier 60 and an exterior insulation board 50 attached to the gypsum wood fiberboard panel 40 by corrosion resistant fasteners and plastic washers.
  • a basecoat 70 with reinforcing mesh and finish coat are applied over the exterior surface of the insulation board.
  • An adhesive layer 30 is also provided.
  • a decorative "V" groove 250 or angle groove 260 can be routed in the insulation board 50 provided that a 1.91 cm. ( 3 A in) minimum board thickness is maintained at the location of the groove.
  • FIG. 6 a cut-away of a typical flanged window head is shown with the flange 270 being maintained at a spacing of 0.32 cm. (1/8 in.) minimum between the structural insulation panel system and the starter track 210.
  • the panel system of the invention has an interior gypsum cellulose fiber panel 10 sheathing an exterior gypsum cellulose fiber panel 40 over the foam insulation core 110 and having a weather barrier 60 and exterior insulation board panel 50 which is mechanically fastened to panel 40.
  • An exterior base coat reinforcing mesh and finish coat 70 is applied to the surface of insulation board panel 50 that is not in contact with the gypsum cellulose fiberboard panel 40.
  • FIG. 7 a cut-away of a typical flanged window jamb is shown with the flanged window 270 backer rod and sealant 190 and casing bead 200 fitted to the edge of the structural insulation panel of the invention.
  • FIG. 8 a cut-away is shown of a typical flanged window sill with the flanged window 270 backer rod and sealant 190 and casing bead 200 fitted over the slope sill or sill wedge 280 fitted over the structural insulation panel of this invention.
  • a water barrier tape 240 is applied to the sill and extends up to 5.08 cm. (2 in.) at each joint.
  • FIG. 9 a cut-away is shown of an intermediate floor made from a structural insulation panel of the invention fitted into a wall panel of the invention.
  • like reference numbers indicate like elements unless otherwise indicated or apparent from the drawings or text.
  • FIG. 2 is a cross sectional view of the structural insulated panel 1 shown in FIG. 1.
  • Structural insulated panel 1 includes first and second outer facings 10 and 40 and an insulating foam core 110 disposed between the two outer facings.
  • the inner surface of the first outer facing 10 is affixed to the panel's insulating foam core 110 by means of a conventional adhesive as previously described. This adhesive layer is not shown in the figures for simplicity.
  • a sealant 55 is used to fill the spacing between the exterior panels 40 and the foundation or footing 290 upon which were the panel arrangement is installed.
  • the structural insulated panel assembly 1 can further include a plastic impregnated paper sheet 20.
  • the plastic impregnated paper sheet 20 is bonded to the inner surface of the panel's facing 10.
  • the plastic impregnated paper sheet is also bonded to the panel's insulating foam core 110.
  • a conventional adhesive as previously described may be used to securely bond the plastic impregnated paper sheet to the panel's insulating foam core 110.
  • the panel's first outer facing 40 is comprised of a gypsum cellulose fiber board such as gypsum wood fiberboard (GWF) board and faces outwardly
  • the panel's second outer facing 10 is comprised of gypsum or cementitious composite but is preferably also a gypsum cellulose fiber board such as GWF, and faces inwardly.
  • GWF gypsum wood fiberboard
  • the invention provides for a structural insulated panel comprised of an insulating foam core with opposed first and second outer facings each comprised of a gypsum cellulose fiber board such as GWF.
  • a vapor retarder such as a plastic impregnated paper sheet can optionally be disposed between the interior gypsum facing layer or sheathing and the insulating core by adhering the paper sheet to the panel's insulating foam core and the outer facings.
  • the paper sheet is impregnated with urethane or polyisocyanurate plastic in a preferred embodiment which serves as a fire resistant vapor barrier near the panel's inner surface to prevent moisture from escaping from the warm interior of a building structure through the insulating foam core to the outside.
  • the high strength plastic impregnated paper sheet also substantially increases the tensile strength of the panel to withstand large transverse loads. The strength of the panel may be further increased by also impregnating the paper sheet with fiberglass.
  • a structural insulated panel in accordance with the present invention may include one or more such plastic impregnated paper sheets where panels of high strength are required.
  • the plastic impregnated paper sheets may be layered and sized in accordance with the stress profile of the structural insulated panel to further increase the panel's tensile strength while employing the minimum required amount of plastic impregnated paper.
  • the plastic impregnated paper sheet may be applied to a gypsum composite facing to substantially increase the strength of the facing and to environmentally isolate one side of the panel from the other.
  • the weather resistant barrier 80 is an air infiltration and moisture barrier.
  • a number of weather barriers are available commercially including Building Felt (typically 15 pounds); Reef Industries GRIFFOLYN ® Vapor Retarders; Kraft Grade D Kraft paper; Tenneco Building Products, AMOWRAPTM woven polypropylene with a perforated coating; Simplex Products Division BARRICADETM woven polyethylene with a perorated coating; Owens Corning PINKWRAP ® woven polypropylene with a perforated coating; Simplex Products Division R-Wrap porous polyethylene film laminated to a scrim; Reemay, Inc. TYPARTM spun-bonded polypropylene with a perforated coating; E. I. DuPont de Nemours & Co.
  • TYVEK STUCCOWRAP ® Home Wrap spun-bonded polyethylene BASF SENERWRAPTM 20-mil thick, self- sealing, self-healing rubberized asphalt coating laminated to a polyethylene film and liquid applied membranes available from BASF as SENSERSHIELDTM and Parex LIQUID MEMBRANE 395a (Key Coat) 100% acrylic based, trowel able adhesive and weather-resistive barrier membrane.
  • a typical resistance barrier found to have utility in the assembly of this invention is TYVEK STUCCOWRAP ® brand Weather Resistant Barrier sold by El DuPont de Nemours & Co. of Wilmington, Delaware.
  • the expanded foam core or layer insulation 110 and the exterior grooved insulation panels used over the weather resistant barrier 80 on the exterior surface gypsum wood fiber board sheathing 40 are made from lightweight foamed polymer such as polystyrene or polyurethane.
  • the foam core is further described in US Pat. No. 6,523,324 issued on February 25, 2003, the disclosure of which is incorporated herein by reference in its entirety.
  • Commercially available expanded polystyrene is available from Dow Chemical Company under the tradename STYROFOAM®.
  • the exterior base coat can be a cement and acrylic emulsion, such as the commercially available Parex Basecoat and Adhesive 12, Parflex Basecoat BASF SENERQUICKTM Adhesive water reducible, non-cementitious, translucent white adhesive, BASF NC-II Base which is a pre-mixed 100% acrylic polymer-based, non-cementitious base coat and adhesive; BASF Alpha Dry Base Coat, which is a dry-mix polymer adhesive and base coat containing Portland cement for mixing with water; BASF Alpha Genie Base Coat, which is a 100% acrylic, fiber reinforced base coat, adhesive and leveler additive that is mixed prior to use with Type I or Type Il Portland cement; or BASF SENERTHIK ® brand base liquid & FIBERLATH MESH, which is a 100% acrylic polymer resin-based liquid.
  • BASF SENERTHIK ® brand base liquid & FIBERLATH MESH which is a 100% acrylic polymer resin-based liquid.
  • the exterior base coat is used with an embedded mesh which can be a metal mesh or an open-weave glass fiber reinforcing mesh which is twisted multi-end strands treated with a polymer coating e.g. polyvinyl chloride solution, for alkali resistance for compatibility with Portland cement.
  • a polymer coating e.g. polyvinyl chloride solution
  • Commercially available mesh can be SENERGY ® brand Reinforcing Mesh from BASF WALL SYSTEMS, Jacksonville, Florida: Dryvit Standard Mesh, Intermediate Mesh, Corner Mesh, PANZER 15 Mesh, PANZER 20 Mesh, ULTRAMESH from Dryvit Systems Inc., West Warick, Rhode Island; L. S. Reinforcing Mesh; Standard Plus Mesh; 4 in.
  • a typical exterior base coat which was previously sold commercially by United States Gypsum Company, Chicago, IL, USA under the brand name USG EXTERIOR BASECOAT, consisted of: 40 to 50 percent portland cement (ASTM C150) with a minimum of 4 percent polymer and silica sand. This bagged product was mixed with water to trowelable consistency.
  • the basecoat may be an acrylic sand solution mixed with Type I Portland Cement. The acrylic mixture consisting of sand and additives shall have a minimum solids content of 67 percent.
  • a typical mesh was previously sold commercially by United States Gypsum Company, Chicago, IL, USA under the brand name USG EXTERIOR STANDARD MESH REINFORCEMENT and had a weight of no less than 4.0 oz/ft2.
  • the mesh should be alkali resistant and may be formed from either woven or non-woven glasses coated with an organic alkali resistance coating.
  • the mesh should have a tensile strength no less than 150 pounds/inch when evaluated according to ASTM D578 and D579. Heavier mesh with a weight up to 25 oz/ft2 may be used where improved impact resistance is required.
  • the Exterior Finish or finishing coat applied over the Base Coat and embedded mesh is typically an acrylic co-polymer based coating.
  • the finish coat typically comprises 55 to 65 percent silica sand or dolomite sand with a minimum of 8 percent dry acrylic solids.
  • the product should be premixed and supplied in ready-to-apply buckets. Tinting may be field or factory added.
  • the product should pass 4 in. mandrel bend determined per ASTM D522. No deleterious effects at 2000 hours caused by accelerated weathering per ASTM G53. No mildew growth at 28 days per ASTM D3273. Salt spray resistance when applied to basecoat and 1 Ib/yd3 expanded polystyrene shall be greater than 500 hours with no deleterious effects per ASTM B117.
  • a number of commercially available finish coatings including the various finish and coating options offered by Dryvit under the following categories: (i) AMERISTONETM 100% acrylic based finish with multi-colored quartz aggregates; (ii) CUSTOM BRICKTM Polymer Finish which has the architectural finish in the Look of brick, Stone, Slate and Tile for Vertical Surfaces; (iii) DEMANDIT ® brand interior/exterior Acrylic PMR Coating in Standard and custom colors; (iv) DPR FMTM Finishes of 100% acrylic, DPR finish designed for use in the Dryvit PM wall System; (v) QUARTZPUTZ E, SANDPEBBLE E and SANDPEBBLE® fine E finishes of lightweight, premixed 100% acrylic- based coatings in standard and custom colors; (vi) LYMESTONETM premixed 100% acrylic-based finish designed to replicate the appearance of limestone blocks; (vii) MEDALLION SERIESTM Finish (PMR)dirt and mildew resistant Finishes for demanding building environments; (viii) METTA
  • the gypsum wood fiber board panels that are preferably used as both surface layer panels on both surfaces of the insulation core in the building panel assembly of this invention are typically commercially available gypsum wood fiber board such as FIBEROCK® brand gypsum wood fiber board available from United States Gypsum Company, Chicago, IL , USA. Gypsum wood fiber board used in this invention may be made by the process shown in U.S. Pat. No. 5,320,677 of M. Baig which is incorporated herein by reference in its entirety.
  • a particular embodiment of the structural insulation panel assembly of this invention is made with a 31.78 Kg. /m 3 (2 Ibs./ft 3 ) expanded polystyrene foam core with 1.27 cm.
  • FIBEROCK ® brand gypsum wood fiber (GWF) panels adhesively bonded to each surface by a commercial adhesive such as MorAd ® adhesives available from Rohm and Haas Company, Philadelphia, PA.
  • the surface panel to be used on the exterior side of the SIP panel is then covered with of a very fine high density polypropylene fiber weather resistant barrier sold by E.I Du Pont under the brand name TYVEK STUCCOWRAP ® which is attached to the FIBEROCK ® panel with staples. A 3.81 cm.
  • SIP panels are manufactured by Stress Panel Manufacturing using 1.27 cm. (1/2 in.) FIBEROCK ® brand sheathing panels adhesively attached on both sides of either 8.89 or 16.51 cm. (3.5 or 6.5 in.) thick polystyrene foam.
  • the panels were created using 31.78 kg/m 3 (2 Ib/ft 3 ) expanded polyethylene foam (EPS foam).
  • EPS foam expanded polyethylene foam
  • a total of six 1.22 x 2.44 m. (4 x 8 ft) panels were tested to determine the load capacity of the system. Tests were conducted according to ASTM E-72 -05 and ASTM E-330. The axial load tests were conducted on the panels without splines.
  • a 11.43 cm. (4-1/2 in.) thick panel was cut vertically into a 61 cm. (24 in.) strip and the 2.44 m. (8 ft) tall section axially loaded to failure.
  • Loading was conducted by placing flat steel plates at the top and bottom of the specimen and placing the loading ram 1/6 of the panel thickness away from the center of the panel, as described in ASTM E-72 - 05.
  • the load at failure was approximately 8636.4 kg. (19,000 Ib), which is equivalent to an ultimate load of 14250 kg./m (9500 plf) or a design load of 4750 kg/m (3167 Ib/ft.). Failure of the panel occurred from crushing of the interior FIBEROCK ® Panel at mid- span.
  • a 16.51 cm. (6-1/2 in.) panel was cut vertically into a 30.5 cm. (12 in.) strip and the 2.438 m. (8 ft) tall section loaded to failure.
  • the load at failure was 4318.2 kg. (9500 Ib), which gives a design load of 4750 kg/linear m.(3167 Ib/ft.). Failure of the panel occurred from crushing of the base of both of the FIBEROCK ® brand panels.
  • the wind-load capacity of the panels was determined using a vacuum chamber using methods shown in ASTM E-330. Rollers were placed at a spacing of 2.286 m. (90 in.), 7.62 cm. (3 in.) from the top and the bottom of the panel.
  • the 11.43 cm. (4-1/2 in.) thick panel was sequentially loaded to 73.4, 146.8 and 220.2 kg./m 2 (15, 30 and 45 lbs/ft 2 ), prior to loading to failure.
  • the 16.51 cm. (6-1/2 in.) panel was sequentially loaded to 146.8, 293.6 and 440.4 kg/m 2 (30, 60 and 90 Ib/ft 2 ) prior to loading to failure.
  • the deflection limitations L/360, L/240 and L/180 are 0.635 cm.; 0.953 cm. and 1.27 cm. (0.25, 0.375 and 0.5 in.), respectively. Deflections measured were significantly lower than these deflection limitations.
  • the tests indicate wind load capacities of 146.8 and 220.2 kg./m 2 (30 and 45 lbs/ft 2 ) for the 11.43 cm. (4-1/2 in.) and 16.51 cm. (6-1/2 in.) panels, respectively, and an axial capacity of approximately 4650 kg./linear m. (3100 lbs/ft).
  • Tests were conducted according to ASTM C514 -04 to determine the amount of force required to remove various fasteners from 1.27 cm. (V 2 in.) FIBEROCK ® brand gypsum wood fiber panels available commercially from United States Gypsum Company, Chicago, IL, USA. Results were also obtained for 1.48 cm. (7/16 in.) panels of oriented strand board (OSB) and plywood, meeting ASTM commercially available from a number of suppliers such as Louisiana Pacific and Weyerhaeuser. Results are shown in TABLE 1 , below.
  • Tests were conducted to determine the shear strength of various fasteners in FIBEROCK ® brand sheathing. This data may be used to determine the number of fasteners required to attach SIPS panels to footers and headers.
  • Tests were conducted by attaching 5.08 x 15.24 x 1.91 cm. (2 x 6 x 3/4 in.) plywood to 15.24 cm. x 15.24 cm. x 1.27cm. (6 in. x 6 in. x 0.5 in.) FIBEROCK ® brand sheathing and to 15.24 cm. x 15.24 cm. x 1.525 cm. (6 in. x 6 in. x 5/8 in.) FIBEROCK ® brand sheathing using single fasteners. These fasteners are either USG Exterior Sheathing Screws, standard drywall nails or 3.81 cm. (1 -1/2 in.) long staples with 0.635 cm. (1/4 in.) crowns. In each case, the fastener was 1.91 cm. (3/4 in.) from the edge of the panel.
  • Shear strength to failure values for various fasteners used for joining FIBEROCK® brand gypsum wood fiber board sheathing to plywood obtained from the testing are shown in the bar graph in FIG. 10. For each configuration, five samples were evaluated. For screws in 1.27cm. and 1.59 cm. (1/2 and 5/8 in.) board, and for nails in the 1.27 cm. (1/2 in.) board all failures were from shear failure of the FIBEROCK ® brand gypsum wood fiberboard (GWF) sheathing. For nails in the 1.59 cm. (5/8 in.) board all failures were from the nails pulling out of the board. For staples in 1.27 cm.
  • Results were also obtained from the specimens using OSB instead of FIBEROCK ® brand sheathing.
  • the value obtained for the OSB was approximately 40 percent greater than that obtained for the FIBEROCK ® brand sheathing. Failure occurred by the fastener pulling out of the plywood.

Abstract

L'invention concerne un panneau isolé structurel, généralement plan, destiné à bâtir une construction, lequel inclut une paire de parements extérieurs disposés sur des surfaces opposées d'un noyau de mousse de plastique. Les deux parements extérieurs sont des panneaux de plâtre avec fibres de cellulose tels que des panneaux de plâtre avec fibres de bois. Une barrière résistant au temps est disposée sur la surface extérieure du panneau de plâtre avec fibres de bois, sur la surface extérieure et entre un autre panneau d'isolation en polystyrène expansé, laquelle est fixée au panneau de plâtre avec fibres de bois. La surface extérieure du second panneau d'isolation est fixée au panneau de plâtre avec fibres de bois grâce à des attaches mécaniques. Les panneaux d'isolation sont ensuite revêtus d'un enduit de fond qui possède un renforcement intégré en treillis, puis un revêtement de finition est appliqué sur l'enduit de fond. Un bardage de vinyle ou d'aluminium peut être fixé à l'assemblage structurel grâce à des vis de type G ou d'autres attaches mécaniques.
PCT/US2008/059124 2007-04-04 2008-04-02 Agencement des panneaux isolés structurels en plâtre avec fibres de bois WO2008124430A1 (fr)

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US11/696,567 2007-04-04
US11/696,567 US20080245007A1 (en) 2007-04-04 2007-04-04 Gypsum wood fiber structural insulated panel arrangement

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