WO2023200649A1 - Building with noncombustible exterior structural wall - Google Patents
Building with noncombustible exterior structural wall Download PDFInfo
- Publication number
- WO2023200649A1 WO2023200649A1 PCT/US2023/017570 US2023017570W WO2023200649A1 WO 2023200649 A1 WO2023200649 A1 WO 2023200649A1 US 2023017570 W US2023017570 W US 2023017570W WO 2023200649 A1 WO2023200649 A1 WO 2023200649A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- noncombustible
- panels
- exterior
- building
- cement
- Prior art date
Links
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 17
- 239000010959 steel Substances 0.000 claims abstract description 17
- 239000012528 membrane Substances 0.000 claims abstract description 13
- 239000004568 cement Substances 0.000 claims description 14
- 239000011810 insulating material Substances 0.000 claims description 7
- 239000011398 Portland cement Substances 0.000 claims description 4
- 239000000395 magnesium oxide Substances 0.000 claims description 4
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 4
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 4
- 230000003014 reinforcing effect Effects 0.000 claims description 4
- 239000003365 glass fiber Substances 0.000 claims description 3
- 229920005989 resin Polymers 0.000 claims description 3
- 239000011347 resin Substances 0.000 claims description 3
- 229920000642 polymer Polymers 0.000 claims 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 11
- 239000000835 fiber Substances 0.000 description 7
- 230000004888 barrier function Effects 0.000 description 6
- 239000002002 slurry Substances 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 238000000034 method Methods 0.000 description 5
- 230000035699 permeability Effects 0.000 description 5
- 238000000151 deposition Methods 0.000 description 3
- 238000009432 framing Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000004775 Tyvek Substances 0.000 description 2
- 229920000690 Tyvek Polymers 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000004005 microsphere Substances 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000011396 hydraulic cement Substances 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000011490 mineral wool Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000010451 perlite Substances 0.000 description 1
- 235000019362 perlite Nutrition 0.000 description 1
- 239000011120 plywood Substances 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 239000011495 polyisocyanurate Substances 0.000 description 1
- 229920000582 polyisocyanurate Polymers 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000011493 spray foam Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 125000001273 sulfonato group Chemical group [O-]S(*)(=O)=O 0.000 description 1
- 239000008030 superplasticizer Substances 0.000 description 1
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
- E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
- E04C2/38—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels
- E04C2/384—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure with attached ribs, flanges, or the like, e.g. framed panels with a metal frame
-
- 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
- E04B2/56—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members
- E04B2/58—Load-bearing walls of framework or pillarwork; Walls incorporating load-bearing elongated members with elongated members of metal
-
- 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
- E04C2/04—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 concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/06—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 concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres reinforced
Definitions
- the present disclosure relates generally to noncombustible exterior structural walls, and more specifically to buildings with noncombustible exterior structural walls that include lightweight structural cementitious panels.
- Exterior walls of buildings serve a number of different functions. Specifically, exterior walls provide structural support and resist uniform, lateral, axial and concentrated loads applied to the building. Additionally, exterior walls act as a water, vapor and air barrier for the building. Further, exterior walls provide protection from flying debris during storms and are noncombustible. Beyond providing these functions, it is desired to reduce the overall thickness of the exterior walls.
- noncombustible paneling is attached to the steel frame members.
- This noncombustible paneling sometimes includes cement panels.
- U.S. Pat. No. 8,079,198 to Tonyan et al. discloses a residential and commercial construction including a metal frame and lightweight cement panel shear wall.
- the shear wall is made from a mixture of inorganic binder and lightweight fillers.
- the combination of a metal frame with cement panels results in the noncombustible shear wall system.
- conventional buildings which utilize a steel frame with noncombustible panels also include sheet steel cross-strapping or complete sheets of steel, referred to as shear walls, to resist lateral loading.
- the steel frame typically includes high gauge studs for accommodating axial loading.
- special multi-layered, built-up facades are commonly used for providing protection from flying debris during storms.
- these exterior wall structures require separate water, vapor and air barriers in order to achieve proper building seals.
- the noncombustible panels are unable to adequately repel water and vapor.
- the present noncombustible structural exterior wall includes a plurality of noncombustible panels which resist uniform, lateral, axial and concentrated loads, while acting as a water, vapor and air barrier for the building.
- the presently disclosed noncombustible structural exterior wall does not include a separate water and vapor barrier such as TYVEK® (sheet membrane product), other membrane coverings, or a spray coating, as is used in conventional exterior wall structures.
- TYVEK® sheet membrane product
- a spray coating such coatings and membranes will be collectively referred to as an air/weather membrane.
- the noncombustible panels are inherently water resistant and noncombustible. Therefore, application of either caulk or tape to the joints of the noncombustible panels is sufficient to seal the building as required by building codes.
- the present noncombustible structural exterior walls are noncombustible according to the International Building Code (IBC) based on tests performed according to ASTM E136.
- IBC International Building Code
- the present noncombustible structural exterior wall includes relatively thin support studs due to the load carrying capacity and lateral resistance of the noncombustible panels. Further, the noncombustible panels protect the building from windblown debris.
- the noncombustible exterior structural walls also include an insulating material located between the support studs.
- an exterior ornamental covering is preferably applied directly to the noncombustible panels.
- the present disclosure includes a noncombustible exterior structural wall of a building, where the noncombustible wall includes a steel frame with a plurality of vertically oriented support studs, a plurality of noncombustible panels attached directly to the steel frame, and an exterior ornamental covering attached directly to the plurality of noncombustible panels with an absence of an air/weather membrane.
- the noncombustible panels are noncombustible fiber-cement-panels which include at least one of Portland cement and Magnesium Oxide cement with reinforcing.
- the noncombustible panels are resin or polymer- based reinforced panels.
- the noncombustible exterior structural wall also includes an insulating material between the vertically oriented support studs.
- the noncombustible panels resist lateral loads applied to the noncombustible exterior structural wall, and the noncombustible panels have a thickness of approximately 1 /2 inch (1 .25 cm).
- a second embodiment of the present disclosure includes a building with a plurality of noncombustible exterior structural walls.
- the noncombustible exterior structural walls include a steel frame with a plurality of vertically oriented support studs, a plurality of noncombustible panels attached directly to the steel frame, and an exterior ornamental covering attached directly to the plurality of noncombustible panels.
- FIG. 1 is a top fragmentary perspective view of the present building with noncombustible exterior structural walls
- FIG. 2 is an enlarged fragmentary perspective view of the present building with noncombustible exterior structural walls.
- the present building with noncombustible exterior structural walls is generally designated 10 and includes a plurality of noncombustible exterior structural walls 12.
- Each of the noncombustible exterior structural walls 12 includes a steel frame 14, with a plurality of vertically oriented support studs 16.
- the support studs 16 are secured to upper and lower horizontal frame members using fasteners as is known in the art.
- the vertically oriented support studs 16 are spaced an equal distance apart.
- an insulating material 18 is provided between the vertically oriented support studs 16 or continuously around the exterior of the building.
- One example of the latter is an incorporation of the insulating material 18 into an external ornamental covering (described below).
- Example insulating materials 18 include, but are not limited to, fiberglass, cellulose, foam, mineral wool, polystyrene, polyisocyanurate, polyurethane, and natural fibers as is known in the art. Moreover, the insulating material 18 is optionally provided in the form of loose-fill, batts, rolls, foam board, and spray foam.
- noncombustible panels 20 are attached to the vertically oriented studs 16 by way of mechanical fasteners, adhesive, or other attachment method as is known in the art.
- the noncombustible panels 20 are attached directly to the vertically oriented studs 16.
- the noncombustible panels 20 are fiberglass- impregnated cement board panels.
- Various types of cement panels are optionally used as the noncombustible panels 20.
- U.S. Pat. No. 8,038,790 to Dubey et al. discloses cement panels able to resist lateral forces imposed by high wind and earthquake.
- the principal starting materials used to make the cement panels are inorganic binder, e.g., calcium sulfate alpha hemihydrate, hydraulic cement, and pozzolanic materials, lightweight filler coated expanded perlite and optional additional, ceramic microspheres or glass microspheres, as well as superplasticizer, e.g., polynapthalene sulphonates and/or polyacrylates, water, and optional additives.
- U.S. Pat. No. 8,030,377 to Dubey et al. discloses a self-leveling cementitious mixture with excellent flow properties and which hardens with a controlled rate of strength development to an ultra-high compressive strength composite composition for use in making articles such as cementitious armor panel with ballistic and blast resistant properties. Such panels are also considered suitable for the noncombustible panels 20.
- U.S. Pat. No. 6,620,487 to Tonyan et al. discloses a reinforced, lightweight, dimensionally stable panel capable of resisting shear loads when fastened to framing equal to or exceeding shear loads provided by plywood or oriented strand board panels. It is contemplated that the noncombustible panels 20 optionally include cement panels made according to each of the preceding patents incorporated by reference.
- noncombustible panels 20 are fiber-cement- panels which include at least one of Portland cement and Magnesium Oxide cement with glass-fiber reinforcing.
- the noncombustible panels 20 are resin or polymer- based reinforced panels.
- U.S. Patent No. 7,670,520 to Dubey et al. discloses a process for producing fiber-reinforced structural cementitious panels made of at least one layer of fiber reinforced cementitious slurry, the process for each such layer of slurry including providing a moving web; depositing a first layer of individual, loose fibers upon the web; depositing a layer of settable slurry upon the deposited first layer of individual, loose fibers; depositing a second layer of individual, loose fibers upon the deposited layer of settable slurry; and actively embedding both layers of individual, loose fibers into the layer of slurry to distribute the fibers throughout the slurry.
- the noncombustible panels 20 resist lateral loads applied to the noncombustible exterior structural wall 12, and function as shear walls. In this way, the noncombustible exterior structural walls 12 do not require an additional shear wall.
- the noncombustible panels 20 preferably have a thickness of approximately 1 Z> inches or less.
- An exemplary structural panel 20 at 1 /2 inch thick has a shear wall capacity in excess of 1900 PLF (pounds per linear foot).
- Slightly thinner 7/16 inch panels 20 made of Oriented Strandboard (OSB) have shear wall capacity of between 458 and 1017 PLF depending on screw spacing.
- Vapor permeability of such panels 20 is approximately 2.84 permeability for 1/2 inch thick panel and 1.4 permeability for % inch panels.
- Permeability is classified as: ⁇ 0.1 is impermeable; 0.1 ⁇ x ⁇ 1 is Class II semi- impermeable; and 1 ⁇ x ⁇ 10 is Class III permeable, which is still considered semi-permeable.
- the panels 20 are Class III are a suitable air and water barrier. Joints/seams and screw heads are taped or caulked. Nominal uniform load capacity on a face of the panel 20, representing wind resistance with a stud spacing of 24 inches is 270 lb.
- Concentrated load capacity of the panel 20 is 764 lb. when the panel is dry.
- an important feature of the noncombustible panels 20 is their low water and vapor permeability.
- the noncombustible panels 20 act as a water, water-vapor and air barrier for the building 10.
- a feature of the building 10 is that it does not require application of a liquid applied exterior membrane (sprayed or rolled on over the entire exterior surface of the building) or a sheet membrane product (such as TYVEK®).
- the building 10 does not require an air/weather membrane. Rather, use of either caulk or tape on the joints or seams 22 as well as screw heads of the noncombustible panels 20 is sufficient to seal the building 10 as required by local building ordinances.
- an ornamental covering 24 of the building 10 is preferably applied directly to the noncombustible panels 20.
- Suitable attachment methods such as with adhesive or mechanical fasteners, are appropriate for directly attaching the ornamental covering 24 to the noncombustible panels 20 as is known in the art.
- the noncombustible panels 20 are noncombustible according to International Building Code (IBC) as the noncombustible panels 20 pass an un-modified ASTM E136 test for noncombustibility (per the IBC). Additionally, the noncombustible panels 20 resist lateral forces applied to the building 10, such that the noncombustible panels 20 act as an exterior shear wall for the building 10.
- IBC International Building Code
Abstract
A noncombustible exterior structural wall (12) of a building (10), where the noncombustible wall (12) includes a steel frame (14) with a plurality of vertically oriented support studs (10), a plurality of noncombustible panels (22) attached directly to the steel frame (14), and an exterior ornamental covering (24) attached directly to the plurality of noncombustible panels (22) with an absence of an air/ weather membrane.
Description
BUILDING WITH NONCOMBUSTIBLE EXTERIOR STRUCTURAL WALL
RELATED APPLICATION
[0001] The present application is a Non-Provisional of, and claims 35 U.S.C. 119 priority from, US Provisional application Serial No. 63/362,798 filed April 11 , 2022, and US application Serial No. 18/060,384 filed November 30, 2022, the contents of which are incorporated by reference.
BACKGROUND
[0002] The present disclosure relates generally to noncombustible exterior structural walls, and more specifically to buildings with noncombustible exterior structural walls that include lightweight structural cementitious panels.
[0003] Exterior walls of buildings serve a number of different functions. Specifically, exterior walls provide structural support and resist uniform, lateral, axial and concentrated loads applied to the building. Additionally, exterior walls act as a water, vapor and air barrier for the building. Further, exterior walls provide protection from flying debris during storms and are noncombustible. Beyond providing these functions, it is desired to reduce the overall thickness of the exterior walls.
[0004] Many modern buildings use a steel frame within the exterior structural walls. Typically, noncombustible paneling is attached to the steel frame members. This noncombustible paneling sometimes includes cement panels. For example, U.S. Pat. No. 8,079,198 to Tonyan et al., incorporated herein by reference, discloses a residential and commercial construction including a metal frame and lightweight cement panel shear wall. The shear wall is made from a mixture of inorganic binder and lightweight fillers. The combination of a metal frame with cement panels results in the noncombustible shear wall system.
[0005] Additionally, U.S. Pat. No. 8,122,679 to Tonyan et al., incorporated herein by reference, discloses wall systems having cement panels employed on metal frames. In particular, the disclosed wall system includes structural cement panels which are mechanically and/or adhesively fastened to a fire wall or other fire resistive assembly light gauge cold formed metal framing system, which acts as a shear resistant diaphragm. Moreover, U.S. Pat. No. 8,061 ,108 to Tonyan et al., incorporated herein by reference, discloses a foundation system which includes metal framing members that support a reinforced, lightweight, dimensionally stable cementitious panel.
[0006] However, conventional buildings which utilize a steel frame with noncombustible panels also include sheet steel cross-strapping or complete sheets of steel, referred to as shear walls, to resist lateral loading. Moreover, the steel frame typically includes high gauge studs for accommodating axial loading. Further, special multi-layered, built-up facades are commonly used for providing protection from flying debris during storms. Additionally, these exterior wall structures require separate water, vapor and air barriers in order to achieve proper building seals. In particular, the noncombustible panels are unable to adequately repel water and vapor.
[0007] Accordingly, there is the need for a building with a noncombustible exterior wall structure which addresses the above-listed drawbacks.
SUMMARY
[0008] The above-listed need is met or exceeded by the present noncombustible exterior structural wall. In particular, the present noncombustible structural exterior wall includes a plurality of noncombustible panels which resist uniform, lateral, axial and concentrated loads, while acting as a water, vapor and air barrier for the building.
Accordingly, the presently disclosed noncombustible structural exterior wall does not include a separate water and vapor barrier such as TYVEK® (sheet membrane product), other membrane coverings, or a spray coating, as is used in conventional exterior wall structures. In this application, such coatings and membranes will be collectively referred to as an
air/weather membrane. The noncombustible panels are inherently water resistant and noncombustible. Therefore, application of either caulk or tape to the joints of the noncombustible panels is sufficient to seal the building as required by building codes. [0009] Moreover, the present noncombustible structural exterior walls are noncombustible according to the International Building Code (IBC) based on tests performed according to ASTM E136. In addition, the present noncombustible structural exterior wall includes relatively thin support studs due to the load carrying capacity and lateral resistance of the noncombustible panels. Further, the noncombustible panels protect the building from windblown debris. Preferably, the noncombustible exterior structural walls also include an insulating material located between the support studs. Moreover, an exterior ornamental covering is preferably applied directly to the noncombustible panels.
[0010] More specifically, the present disclosure includes a noncombustible exterior structural wall of a building, where the noncombustible wall includes a steel frame with a plurality of vertically oriented support studs, a plurality of noncombustible panels attached directly to the steel frame, and an exterior ornamental covering attached directly to the plurality of noncombustible panels with an absence of an air/weather membrane. In preferred embodiments, the noncombustible panels are noncombustible fiber-cement-panels which include at least one of Portland cement and Magnesium Oxide cement with reinforcing.
[0011] In another embodiment, the noncombustible panels are resin or polymer- based reinforced panels. Preferably, the noncombustible exterior structural wall also includes an insulating material between the vertically oriented support studs.
[0012] In yet another embodiment, the noncombustible panels resist lateral loads applied to the noncombustible exterior structural wall, and the noncombustible panels have a thickness of approximately 1/2 inch (1 .25 cm).
[0013] A second embodiment of the present disclosure includes a building with a plurality of noncombustible exterior structural walls. The noncombustible exterior structural walls include a steel frame with a plurality of vertically oriented support studs, a plurality of
noncombustible panels attached directly to the steel frame, and an exterior ornamental covering attached directly to the plurality of noncombustible panels.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a top fragmentary perspective view of the present building with noncombustible exterior structural walls; and
[0015] FIG. 2 is an enlarged fragmentary perspective view of the present building with noncombustible exterior structural walls.
DETAILED DESCRIPTION
[0016] Referring now to FIGs. 1 and 2, the present building with noncombustible exterior structural walls is generally designated 10 and includes a plurality of noncombustible exterior structural walls 12. Each of the noncombustible exterior structural walls 12 includes a steel frame 14, with a plurality of vertically oriented support studs 16. The support studs 16 are secured to upper and lower horizontal frame members using fasteners as is known in the art. In a preferred embodiment, the vertically oriented support studs 16 are spaced an equal distance apart. Preferably, an insulating material 18 is provided between the vertically oriented support studs 16 or continuously around the exterior of the building. One example of the latter is an incorporation of the insulating material 18 into an external ornamental covering (described below).
[0017] Example insulating materials 18 include, but are not limited to, fiberglass, cellulose, foam, mineral wool, polystyrene, polyisocyanurate, polyurethane, and natural fibers as is known in the art. Moreover, the insulating material 18 is optionally provided in the form of loose-fill, batts, rolls, foam board, and spray foam.
[0018] Additionally, noncombustible panels 20 are attached to the vertically oriented studs 16 by way of mechanical fasteners, adhesive, or other attachment method as is known in the art. In a preferred embodiment, the noncombustible panels 20 are attached directly to
the vertically oriented studs 16. Preferably, the noncombustible panels 20 are fiberglass- impregnated cement board panels.
[0019] Various types of cement panels are optionally used as the noncombustible panels 20. For example, U.S. Pat. No. 8,038,790 to Dubey et al., incorporated herein by reference, discloses cement panels able to resist lateral forces imposed by high wind and earthquake. The principal starting materials used to make the cement panels are inorganic binder, e.g., calcium sulfate alpha hemihydrate, hydraulic cement, and pozzolanic materials, lightweight filler coated expanded perlite and optional additional, ceramic microspheres or glass microspheres, as well as superplasticizer, e.g., polynapthalene sulphonates and/or polyacrylates, water, and optional additives.
[0020] Moreover, U.S. Pat. No. 8,030,377 to Dubey et al., incorporated herein by reference, discloses a self-leveling cementitious mixture with excellent flow properties and which hardens with a controlled rate of strength development to an ultra-high compressive strength composite composition for use in making articles such as cementitious armor panel with ballistic and blast resistant properties. Such panels are also considered suitable for the noncombustible panels 20.
[0021] Further, U.S. Pat. No. 6,620,487 to Tonyan et al., incorporated herein by reference, discloses a reinforced, lightweight, dimensionally stable panel capable of resisting shear loads when fastened to framing equal to or exceeding shear loads provided by plywood or oriented strand board panels. It is contemplated that the noncombustible panels 20 optionally include cement panels made according to each of the preceding patents incorporated by reference.
[0022] It is also contemplated that the noncombustible panels 20 are fiber-cement- panels which include at least one of Portland cement and Magnesium Oxide cement with glass-fiber reinforcing. Alternatively, the noncombustible panels 20 are resin or polymer- based reinforced panels.
[0023] Various methods are optionally employed to make the noncombustible panels 20. For example, U.S. Patent No. 7,670,520 to Dubey et al., incorporated by reference,
discloses a process for producing fiber-reinforced structural cementitious panels made of at least one layer of fiber reinforced cementitious slurry, the process for each such layer of slurry including providing a moving web; depositing a first layer of individual, loose fibers upon the web; depositing a layer of settable slurry upon the deposited first layer of individual, loose fibers; depositing a second layer of individual, loose fibers upon the deposited layer of settable slurry; and actively embedding both layers of individual, loose fibers into the layer of slurry to distribute the fibers throughout the slurry.
[0024] Preferably, the noncombustible panels 20 resist lateral loads applied to the noncombustible exterior structural wall 12, and function as shear walls. In this way, the noncombustible exterior structural walls 12 do not require an additional shear wall.
Moreover, the noncombustible panels 20 preferably have a thickness of approximately 1Z> inches or less.
[0025] An exemplary structural panel 20 at 1/2 inch thick has a shear wall capacity in excess of 1900 PLF (pounds per linear foot). Slightly thinner 7/16 inch panels 20 made of Oriented Strandboard (OSB) have shear wall capacity of between 458 and 1017 PLF depending on screw spacing. Vapor permeability of such panels 20 is approximately 2.84 permeability for 1/2 inch thick panel and 1.4 permeability for % inch panels.
[0026] Permeability is classified as: <0.1 is impermeable; 0.1 <x<1 is Class II semi- impermeable; and 1 <x<10 is Class III permeable, which is still considered semi-permeable.
Accordingly, the panels 20 are Class III are a suitable air and water barrier. Joints/seams and screw heads are taped or caulked. Nominal uniform load capacity on a face of the panel 20, representing wind resistance with a stud spacing of 24 inches is 270 lb.
Concentrated load capacity of the panel 20 is 764 lb. when the panel is dry.
[0027] In view of the above data, an important feature of the noncombustible panels 20 is their low water and vapor permeability. In particular, the noncombustible panels 20 act as a water, water-vapor and air barrier for the building 10. Accordingly, a feature of the building 10 is that it does not require application of a liquid applied exterior membrane (sprayed or rolled on over the entire exterior surface of the building) or a sheet membrane
product (such as TYVEK®). In other words, the building 10 does not require an air/weather membrane. Rather, use of either caulk or tape on the joints or seams 22 as well as screw heads of the noncombustible panels 20 is sufficient to seal the building 10 as required by local building ordinances.
[0028] As a result of not needing the liquid applied exterior membrane or sheet membrane product, an ornamental covering 24 of the building 10 is preferably applied directly to the noncombustible panels 20. Suitable attachment methods, such as with adhesive or mechanical fasteners, are appropriate for directly attaching the ornamental covering 24 to the noncombustible panels 20 as is known in the art.
[0029] Further, the noncombustible panels 20 are noncombustible according to International Building Code (IBC) as the noncombustible panels 20 pass an un-modified ASTM E136 test for noncombustibility (per the IBC). Additionally, the noncombustible panels 20 resist lateral forces applied to the building 10, such that the noncombustible panels 20 act as an exterior shear wall for the building 10.
[0030] While a particular embodiment of the present building with noncombustible exterior structural walls has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.
Claims
1 . A noncombustible exterior structural wall of a building, the noncombustible wall comprising: a steel frame comprising a plurality of vertically oriented support studs; a plurality of noncombustible panels attached directly to said steel frame; and an exterior ornamental covering attached directly to said plurality of noncombustible panels with an absence of an air/weather membrane.
2. The noncombustible exterior structural wall of claim 1 , wherein said noncombustible panels are noncombustible fiber-cement-panels.
3. The noncombustible exterior structural wall of claim 2, wherein said noncombustible fiber-cement-panels comprise at least one of Portland cement and Magnesium Oxide cement with glass-fiber reinforcing.
4. The noncombustible exterior structural wall of claim 1 , wherein said noncombustible panels are resin or polymer-based reinforced panels.
5. The noncombustible exterior structural wall of claim 1 , further comprising an insulating material between said vertically oriented support studs or continuously around an exterior of the building.
6. The noncombustible exterior structural wall of claim 1 , wherein said noncombustible panels resist lateral loads applied to said noncombustible exterior structural wall.
7. The noncombustible exterior structural wall of claim 1 , wherein said noncombustible panels have a thickness of approximately 1/2 inches.
8. A building, comprising: a plurality of noncombustible exterior structural walls, comprising: a steel frame comprising a plurality of vertically oriented support studs; a plurality of noncombustible panels attached directly to said steel frame; and an exterior ornamental covering attached directly to said plurality of noncombustible panels with an absence of an air/weather membrane.
9. The building of claim 8, wherein said noncombustible panels are noncombustible fiber-cement-panels.
10. The building of claim 8, wherein said noncombustible fiber-cement- panels comprise at least one of Portland cement and Magnesium Oxide cement with glassfiber reinforcing.
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US202263362798P | 2022-04-11 | 2022-04-11 | |
US63/362,798 | 2022-04-11 | ||
US18/060,384 US20230323660A1 (en) | 2022-04-11 | 2022-11-30 | Building with noncombustible exterior structural wall |
US18/060,384 | 2022-11-30 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2023200649A1 true WO2023200649A1 (en) | 2023-10-19 |
Family
ID=86387327
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2023/017570 WO2023200649A1 (en) | 2022-04-11 | 2023-04-05 | Building with noncombustible exterior structural wall |
Country Status (1)
Country | Link |
---|---|
WO (1) | WO2023200649A1 (en) |
Citations (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6620487B1 (en) | 2000-11-21 | 2003-09-16 | United States Gypsum Company | Structural sheathing panels |
WO2009111302A2 (en) * | 2008-03-03 | 2009-09-11 | United States Gypsum Company | Cement based armor panel system |
US7670520B2 (en) | 2003-09-18 | 2010-03-02 | United States Gypsum Company | Multi-layer process for producing high strength fiber-reinforced structural cementitious panels with enhanced fiber content |
US8030377B2 (en) | 2008-03-03 | 2011-10-04 | United States Gypsum Company | Self-leveling cementitious composition with controlled rate of strength development and ultra-high compressive strength upon hardening and articles made from same |
US8038790B1 (en) | 2010-12-23 | 2011-10-18 | United States Gypsum Company | High performance non-combustible gypsum-cement compositions with enhanced water durability and thermal stability for reinforced cementitious lightweight structural cement panels |
US8061108B2 (en) | 2006-06-27 | 2011-11-22 | U.S. Gypsum Company | Non-combustible reinforced cementitious lightweight panels and metal frame system for building foundations |
US8079198B2 (en) | 2005-01-27 | 2011-12-20 | United States Gypsum Company | Non-combustible reinforced cementitious lightweight panels and metal frame system for shear walls |
US8122679B2 (en) | 2005-01-27 | 2012-02-28 | United States Gypsum Company | Non-combustible reinforced cementitious lightweight panels and metal frame system for a fire wall and other fire resistive assemblies |
WO2014106367A1 (en) * | 2013-01-07 | 2014-07-10 | Zhang Jianzhong | Precast slab and fixed mounting structure thereof |
WO2016118493A1 (en) * | 2015-01-19 | 2016-07-28 | Basf Se | Wall assembly |
US20200139674A1 (en) * | 2018-11-01 | 2020-05-07 | United States Gypsum Company | Water barrier exterior sheathing panel |
WO2020120382A1 (en) * | 2018-12-14 | 2020-06-18 | Basf Se | Wall assembly |
-
2023
- 2023-04-05 WO PCT/US2023/017570 patent/WO2023200649A1/en unknown
Patent Citations (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6620487B1 (en) | 2000-11-21 | 2003-09-16 | United States Gypsum Company | Structural sheathing panels |
US7670520B2 (en) | 2003-09-18 | 2010-03-02 | United States Gypsum Company | Multi-layer process for producing high strength fiber-reinforced structural cementitious panels with enhanced fiber content |
US8079198B2 (en) | 2005-01-27 | 2011-12-20 | United States Gypsum Company | Non-combustible reinforced cementitious lightweight panels and metal frame system for shear walls |
US8122679B2 (en) | 2005-01-27 | 2012-02-28 | United States Gypsum Company | Non-combustible reinforced cementitious lightweight panels and metal frame system for a fire wall and other fire resistive assemblies |
US8061108B2 (en) | 2006-06-27 | 2011-11-22 | U.S. Gypsum Company | Non-combustible reinforced cementitious lightweight panels and metal frame system for building foundations |
WO2009111302A2 (en) * | 2008-03-03 | 2009-09-11 | United States Gypsum Company | Cement based armor panel system |
US8030377B2 (en) | 2008-03-03 | 2011-10-04 | United States Gypsum Company | Self-leveling cementitious composition with controlled rate of strength development and ultra-high compressive strength upon hardening and articles made from same |
US8038790B1 (en) | 2010-12-23 | 2011-10-18 | United States Gypsum Company | High performance non-combustible gypsum-cement compositions with enhanced water durability and thermal stability for reinforced cementitious lightweight structural cement panels |
WO2014106367A1 (en) * | 2013-01-07 | 2014-07-10 | Zhang Jianzhong | Precast slab and fixed mounting structure thereof |
WO2016118493A1 (en) * | 2015-01-19 | 2016-07-28 | Basf Se | Wall assembly |
US20200139674A1 (en) * | 2018-11-01 | 2020-05-07 | United States Gypsum Company | Water barrier exterior sheathing panel |
WO2020120382A1 (en) * | 2018-12-14 | 2020-06-18 | Basf Se | Wall assembly |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
CA2593435C (en) | Non-combustible reinforced cementitious lightweight panels and metal frame system for a fire wall and other fire resistive assemblies | |
US5371989A (en) | Use of fibrous mat-faced gypsum board in exterior finishing systems for buildings and shaft wall assemblies | |
US4647496A (en) | Use of fibrous mat-faced gypsum board in exterior finishing systems for buildings | |
US4852316A (en) | Exterior wall panel | |
EP1809830B1 (en) | New gypsum board and systems comprising it | |
CA2788910C (en) | Exterior finish system | |
US5644880A (en) | Gypsum board and systems containing same | |
US5704179A (en) | Finishing and roof deck systems containing fibrous mat-faced gypsum boards | |
US20110036035A1 (en) | Compositions and methods for coating surfaces | |
US5280689A (en) | Composite cladding panel | |
MX2007009055A (en) | Non-combustible reinforced cementitious lightweight panels and metal frame system for roofing. | |
WO2008124430A1 (en) | Gypsum wood fiber structural insulated panel arrangement | |
MX2007009053A (en) | Non-combustible reinforced cementitious lightweight panels and metal frame system for shear walls. | |
US20100064613A1 (en) | Steamproof wallboards for damp room | |
US20230323660A1 (en) | Building with noncombustible exterior structural wall | |
WO2023200649A1 (en) | Building with noncombustible exterior structural wall | |
AU2011202916A1 (en) | Non-combustible reinforced cementitious lightweight panels and metal frame system for a fire wall and other fire resistive assemblies |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 23724445 Country of ref document: EP Kind code of ref document: A1 |