IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0946647
(2010-11-15)
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등록번호 |
US-8122679
(2012-02-28)
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발명자
/ 주소 |
- Tonyan, Timothy D.
- Ullett, James M.
- Reicherts, James E.
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출원인 / 주소 |
- United States Gypsum Company
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대리인 / 주소 |
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인용정보 |
피인용 횟수 :
7 인용 특허 :
62 |
초록
▼
A fire resistive assembly including metal framing members, for example, C-joists, U-joists, open web joists, HAMBRO or other metal frame systems that support a reinforced, lightweight, dimensionally stable SCP panel. The assembly is non-combustible, water durable, mold and rot resistant, termite res
A fire resistive assembly including metal framing members, for example, C-joists, U-joists, open web joists, HAMBRO or other metal frame systems that support a reinforced, lightweight, dimensionally stable SCP panel. The assembly is non-combustible, water durable, mold and rot resistant, termite resistant and is capable of resisting shear loads equal to or exceeding shear loads provided by plywood or oriented strand board panels. The panels employ one or more layers of a continuous phase resulting from the curing of an aqueous mixture of inorganic binder, for example, calcium sulfate alpha hemihydrate, hydraulic cement, an active pozzolan and lime. The continuous phase is reinforced with glass fibers and contains lightweight filler particles, for example, ceramic microspheres.
대표청구항
▼
1. A method of providing fire resistance to a building structure comprising: making an area separation wall comprising assembling a system as a firewall for the building structure by forming a shear diaphragm supported on light gauge cold formed metal framing,the system comprising:a first shear diap
1. A method of providing fire resistance to a building structure comprising: making an area separation wall comprising assembling a system as a firewall for the building structure by forming a shear diaphragm supported on light gauge cold formed metal framing,the system comprising:a first shear diaphragm comprising a first plurality of reinforced, lightweight, dimensionally stable cementitious panels, each of the panels of the first plurality having an opposed first side and second side; anda first metal framing comprising the metal cold formed metal framing elements,a second diaphragm comprising a second plurality of panels selected from the group consisting of Type X fire rated gypsum wallboard panels and reinforced, lightweight, dimensionally stable cementitious panels, each of the panels of the second plurality having an opposed first side and second side;a second framing, the second framing comprising studs between the first diaphragm and the second diaphragm; andbreak away fasteners;by the steps of:placing the first side of the structural cementitious panels of the first shear diaphragm on the metal framing elements of the first metal framing; andattaching the structural cementitious panels of the first shear diaphragm on the first metal framing, the first side of the cementitious panels of the first diaphragm supported on the first framing, wherein the cementitious panels of the first shear diaphragm are attached on the first metal framing by metal screws with winged drillers, the winged drillers located above the point and below the threads of the screw and protruding laterally from the shaft of the screw;attaching each of a plurality of the break away fasteners to both the second side of the cementitious panels of the first diaphragm and to a said stud of the second frame;wherein the plurality of second panels of the second diaphragm each have the opposed first wall and second wall, the first wall of the panels of the second diaphragm being opposed to the second wall of panels of the first diaphragm, andattaching the panels of the second diaphragm to the studs of the second framing such that the first wall of the panels of the second diaphragm opposes the studs;the first diaphragm being between the first metal framing and the second diaphragm,the breakaway fasteners being between the first diaphragm and the second diaphragm,wherein the cementitious panel of the first and second diaphragm have a thickness of about ⅜ to 1½ inches;the cementitious panels of the first and second diaphragms having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to the framing and comprising a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis,49 to 68 weight % reactive powder,23 to 36.1 weight % lightweight filler, comprising ceramic microspheres, and5 to 20 weight % alkali-resistant glass fibers, the continuous phase being uniformly reinforced with the glass fibers, wherein the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers) and a length of about 0.25 to 3 inches (6.3 to 76 mm),the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers),wherein the reactive powders comprise water and optional superplasticizer and, on a dry basis,45 to 75 wt. % calcium sulfate alpha hemihydrate,20 to 40 wt. % Portland cement,0.2 to 3.5 wt. % lime, and5 to 25 wt. % of an active pozzolan comprising silica fume,wherein, the system is the fire wall and a shear wall for carrying shear load and axial load when exposed to fire. 2. An apparatus selected from the group consisting of a solid area separation wall, a cavity area separation wall, a shaft wall, and a garage ceiling wall, comprising a non-combustible wall system for a construction located in a building structure as a fire resistive building assembly comprising: a shear diaphragm,a light gauge cold formed metal framing having an opposed first side and second side, said metal framing comprising cold formed metal framing elements,the shear diaphragm supported on the first side of the metal framing, the first shear diaphragm comprising a reinforced, lightweight, dimensionally stable cementitious panel; anda second cementitious panel attached to the second side of the metal framing, wherein the cementitious panel is only on the one side of the metal framing opposed to the shear diaphragm, andthe shear diaphragm cementitious panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to the framing and comprising a continuous phase resulting from the curing of an aqueous mixture comprising water and optional superplasticizer, and on a dry basis,49 to 68 weight % reactive powder,23 to 36.1 weight % lightweight filler particles comprising uniformly distributed ceramic microspheres, and5 to 20 weight % alkali-resistant glass fibers, the continuous phase being uniformly reinforced with the alkali-resistant glass fibers, wherein the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers) and a length of about 0.25 to 3 inches (6.3 to 76 mm),the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers),wherein the reactive powders comprise45 to 75 wt. % calcium sulfate alpha hemihydrate,20 to 40 wt % Portland cement,0.2 to 3.5 wt. % lime, and5 to 25 wt. % of an active pozzolan comprising silica fume;wherein, the system is a shear wall capable of carrying shear load and axial load when exposed to fire, andwherein the shear diaphragm cementitious panel is attached on the metal framing by metal screws with winged drillers, the winged drillers located above the point and below the threads of the screw and protruding laterally from the shaft of the screw. 3. A non-combustible fire-wall system for construction located in a building structure as a fire resistive building assembly comprising: a first shear diaphragm comprising a first plurality of reinforced, lightweight, dimensionally stable cementitious panels;a first light gauge cold formed metal framing comprising cold formed metal framing elements; anda second diaphragm comprising a second plurality of panels selected from the group consisting of Type X fire rated gypsum wallboard panels and reinforced, lightweight, dimensionally stable cementitious panels, each of the panels of the second plurality having an opposed first side and second side;a second framing, the second framing comprising studs between the first diaphragm and the second diaphragm; andbreak away fasteners;the cementitious panels of the first and second diaphragm having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to the first framing and comprising a continuous phase resulting from the curing of an aqueous mixture comprising water and optional superplasticizer and, on a dry basis,49 to 68 weight % a blend of reactive powder,23 to 36.1 weight % lightweight filler particles comprising uniformly distributed ceramic microspheres, and5 to 20 weight % alkali-resistant glass fibers, the continuous phase being uniformly reinforced with the alkali-resistant glass fibers, wherein the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers) and a length of about 0.25 to 3 inches (6.3 to 76 mm),the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers),wherein the reactive powders comprise:45 to 75 wt. % calcium sulfate alpha hemihydrate,20 to 40 wt % Portland cement,0.2 to 3.5 wt. % lime, and5 to 25 wt. % of an active pozzolan comprising silica fume,wherein, the system is a fire wall and a load bearing shear wall for carrying shear load and axial load when exposed to fire, andwherein, the cementitious panels of the first diaphragm have opposed first and second sides, and are fastened with metal screws with winged drillers, the winged drillers located above the point and below the threads of the screw and protruding laterally from the shaft of the screw, on the first metal framing the first side of the cementitious panels of the first diaphragm supported on the first metal framing;wherein each of a plurality of the break away fasteners are attached to both the second side of the cementitious panels of the first diaphragm and to a said stud of the second frame;wherein each panel of the second plurality of panels of the second diaphragm has an opposed first wall and a second wall, the first wall of the panels of the second diaphragm being opposed to the second wall of panels of the first diaphragm,wherein the panels of the second diaphragm are attached to the studs of the second framing such that the first wall of the panels of the second diaphragm opposes the studs;the first diaphragm being between the first metal framing and the second diaphragm, andthe break away fasteners being between the first diaphragm and the second diaphragm;wherein the cementitious panels of the first and second diaphragm have a thickness of about ⅜ to 1½ inches. 4. The system of claim 3, wherein the aqueous mixture consists of water and optional superplasticizer and, further consists of on a dry basis: 58 to 68 wt. % of the reactive powders,6 to 17 wt. % of the alkali-resistant glass fibers, and23 to 35 wt. % of said lightweight filler particles consisting of ceramic microspheres and optionally up to 1.0% at least one member selected from the group consisting of glass microspheres, fly ash cenospheres or perlite, each on a dry basis, andwherein the reactive powders consisting of, on a dry basis,65 to 75 wt. % calcium sulfate alpha hemihydrate,20 to 25 wt. % Portland cement,0.75 to 1.25 wt. % lime, and10 to 15 wt. % of silica fume active pozzolan. 5. The system of claim 3, wherein the reactive powders contain, on a dry basis, 7 to 12 wt. % of the glass fibers, and the ceramic microspheres have a particle density of 0.50 to 0.80 g/mL. 6. The system of claim 3, wherein the ceramic microspheres have a mean particle size from 50 to 250 microns and/or fall within a particle size range of 10 to 500 microns and wherein the filler also comprises uniformly distributed glass microspheres and/or fly ash cenospheres having an average diameter of about 10 to 350 microns (micrometers). 7. The system of claim 3, wherein the aqueous mixture comprises water and optional superplasticizer and, on a dry basis: 54 to 58 wt. % said reactive powders,5 to 15 wt. % said glass fibers,33.8 to 36.1 wt. % of said ceramic microspheres, andup to 1.0 wt. % of said glass microspheres. 8. The system of claim 3, wherein the cementitious panel comprises a core comprising the continuous phase resulting from the curing of the aqueous mixture, and at least one outer layer, each said outer layer comprising a second continuous phase resulting from the curing of a second aqueous mixture comprising water and optional superplasticizer and, on a dry basis:49 to 68 weight % a second blend of reactive powders,23 to 36.1 weight % uniformly distributed lightweight filler particles comprising uniformly distributed ceramic microspheres, and5 to 20 weight % uniformly distributed alkali-resistant glass fibers,the second blend of reactive powders comprising, on a dry basis,45 to 75 wt. % calcium sulfate alpha hemihydrate,20 to 40 wt. % Portland cement,0.2 to 3.5 wt. % lime, and5 to 25 wt. % of active pozzolan,the second continuous phase being uniformly reinforced with the alkali-resistant glass fibers, and the lightweight filler particles comprising ceramic microspheres having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers),at least one outer layer having reduced phase density relative to the core, wherein each outer layer has a thickness of about 1/32 to 4/32 inches (0.8 to 3.2 mm). 9. The system of claim 8, wherein the outer layer(s) has been formed from 54 to 68 wt. % of the reactive powders,5 to 15 wt. % of the glass fibers,up to 1.0 wt. % of glass microspheres having an average diameter of about 10 to 350 microns (micrometers), and23 to 35 wt. % of the lightweight filler particles comprising ceramic spheres, each on a dry basis. 10. The system of claim 3, wherein the panels of the second diaphragm are the Type X gypsum wallboard panels. 11. The system of claim 3, wherein the shear diaphragm is horizontally located on an upper surface of a horizontally oriented portion of the metal framing to form a floor, wherein the structural cement panels are ¾ inch (19 mm) thick structural cement panels suitable when tested according to ASTM 661-88 and APA S-1 test methods, effective as of 1988 (reapproved 1997) and Aug. 12, 1980, respectively, over a span of 16 inches (406.4 mm) on centers, to have an ultimate load capacity greater than 550 lb (250 kg), under static loading, an ultimate load capacity greater than 400 lb (182 kg) under impact loading, and a deflection of less than 0.078 inches (1.98 mm) under both static and impact loading with a 200 lb (90.9 kg) load. 12. The system of claim 3, wherein the flexural strength of a panel having a dry density of 65 lb/ft3 to 95 lb/ft3 (1041 to 1522 kg/m3) after being soaked in water for 48 hours is at least 1000 psi (7 MPa) as measured by the ASTM C 947-03 test, effective 2003. 13. The system of claim 3, wherein the flexural strength of a panel having a dry density of 65 lb/ft3 to 95 lb/ft3 (1041 to 1522 kg/m3) after being soaked in water for 48 hours is at least 1650 psi (11.4 MPa) as measured by the ASTM C 947-03 test, effective 2003. 14. The system of claim 3, wherein the reactive powders consist of: 65 to 75 wt. % calcium sulfate hemihydrate,20 to 25 wt. % Portland cement,0.75 to 1.25 wt. % lime, and10 to 15 wt. % of silica fume active pozzolan. 15. The system of claim 3, wherein the horizontal shear diaphragm load carrying capacity of the system will not be lessened by more than 20% when exposed to water in a test wherein a 2 inch head of water is maintained over ¾ inch thick structural cement panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours. 16. The system of claim 3, wherein every component meets ASTM G-21-96, effective 1996 (reapproved 2002), in which the system achieves approximately a 1 and meets ASTM D-3273-94, effective 1994, in which the system achieves approximately a 10. 17. The system of claim 3, wherein the cementitious panel comprises: a core layer comprising the continuous phase resulting from the curing of the aqueous mixture, andat least one outer layer of respectively a second continuous phase resulting from the curing of a second aqueous mixture comprising, water and optional superplasticizer and, on a dry basis,49 to 68 weight % a second blend of reactive powder,23 to 36.1 weight percent uniformly distributed lightweight filler comprising uniformly distributed ceramic microspheres, and5 to 20 weight % uniformly distributed alkali-resistant glass fibers,the second blend of reactive powders comprising, on a dry basis,45 to 75 wt. % calcium sulfate alpha hemihydrate,20 to 40 wt. % Portland cement,0.2 to 3.5 wt. % lime, and5 to 25 wt. % of active pozzolan,the second continuous phase being reinforced with the glass fibers, the lightweight filler particles comprising ceramic microspheres having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers) on each opposed side of the inner core layer,wherein the at least one outer layer has a higher percentage of glass fibers than the inner core layer, wherein each outer layer has a thickness of about 1/32 to 4/32 inches (0.8 to 3.2 mm). 18. The system of claim 3, wherein the first metal framing of the fire wall has opposed first and second sides, wherein the first shear diaphragm is attached to the first side of the first metal framing to form a shear wall, a third shear diaphragm of said structural cementitious panels is attached to the second side of the first metal framing, anda second plurality of the breakaway fasteners is attached to the third shear diaphragm and studs of a third framing; anda fourth plurality of said cementitious panels forming a shear wall of an adjoining structure is attached to the studs of the third framing,wherein the breakaway fasteners are aluminum L-shaped break away angle clips. 19. The system of claim 3, wherein the system has a horizontal design shear capacity of the diaphragm of 400 to 1000 pounds per linear foot per ASTM E-455-04, effective 2004. 20. The system of claim 3, wherein the system having ⅜-¾ inch thick cementitious panels mechanically or adhesively fastened to laterally braced metal framing when tested according to ASTM E-72-05, effective 2005, has a wall shear capacity of 800 to 1200 pounds per linear foot.
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