One hour fire rated wooden frame members using lightweight gypsum wallboard

Patent metadata

Field	Value
Publication number	US-10066392-B2
Application number	US-201715466612-A
Country	US
Kind code	B2
Filing date	Mar 22, 2017
Priority date	Sep 29, 2016
Publication date	Sep 4, 2018
Grant date	Sep 4, 2018

Abstract

A combined wooden frame support and ceiling system is provided, each support including upper and lower wooden chords and a wooden structure connecting the lower chord to the upper chord for weight bearing purposes. A gypsum wallboard batten strip is attached to the lower chord, and defining a ledge extending from each side of the lower chord. A single thickness of gypsum wallboard panels is used to create a ceiling attached to the support, each panel used to create the ceiling is made from a slurry composition including less than 5% by weight of Grade 4 vermiculite. Upon the support being assembled in the ceiling system, with a plurality of the supports, and having lengths of insulation supported by the ledges of the adjacent supports, the ceiling system resists charring by fire for at least one hour.

First claim

What is claimed:

1. A plurality of wooden frame supports configured for use in a ceiling system having a plurality of said supports mounted in spaced parallel relation to each other, each of said supports comprising:
an upper wooden chord extending along a longitudinal axis;
a lower wooden chord disposed below the upper chord, said lower chord has two sides and an underside, and extending along an axis vertically displaced and parallel relative to said longitudinal axis, a wooden structure connecting said lower chord to said upper chord; and
at least one gypsum wallboard batten strip attached directly to said underside of said lower chord, said batten strip being dimensioned to have a width in a range of 6-8 inches to define a ledge extending from each said side of said lower chord, such that a space is defined between ledges of adjacent supports of said plurality of supports;
the ceiling system including a single thickness of gypsum wallboard panels forming a ceiling attached to said plurality of supports, said batten strip being a separate component from the single thickness of gypsum wallboard panels;
each of said gypsum wallboard panels forming said ceiling being made from a wallboard slurry composition including less than 5% by weight of vermiculite; and
wherein said plurality of supports are assembled in the ceiling system with each of said plurality of supports having lengths of insulation supported by said ledges formed by said gypsum wallboard batten strips of the adjacent supports, said ceiling system resists charring by fire for one hour per UL 263/ASTM E119.

2. The plurality of wooden frame supports of claim 1 , wherein each of said supports is an open web wooden truss having a plurality of wooden chord supports attached between said upper and lower chords, and a plurality of metal gusset plates securing said chord supports to said upper and lower chords.

3. The plurality of wooden frame supports of claim 1 , wherein each of said plurality of supports is a wooden “I”-beam.

4. The plurality of wooden frame supports of claim 1 , wherein said vermiculite is Grade 4 vermiculite and is provided in a weight percent of less than 5% of the wallboard slurry composition.

5. The plurality of wooden frame supports of claim 1 , wherein said wallboard panel has a weight of approximately 1,800 pounds per thousand square feet.

6. The plurality of wooden frame supports of claim 1 wherein said ledge extends at least one inch from each said side of said lower chord.

7. The plurality of wooden frame supports of claim 1 , wherein said batten strips extend along a length of said lower chord, and are coextensive with said lower chord.

8. The plurality of wooden frame supports of claim 1 , wherein said batten strips are secured to said lower chord so that said lower chord is generally centered relative to said batten strips, such that said batten strips extend laterally generally equally from each said side of said lower chord.

9. A ceiling system, comprising:
a plurality of wooden frame trusses, each of said trusses including:
an upper wooden chord extending along a longitudinal axis;
a lower wooden chord disposed below the upper chord, said lower chord having two sides and an underside, and extending along an axis vertically displaced and parallel relative to said longitudinal axis, a plurality of wooden supports attached between said upper and lower chords;
a plurality of metal gusset plates securing said supports to said upper and lower chords;
at least one gypsum wallboard batten strip attached directly to said underside of said lower chord, each said gypsum wallboard batten strip being constructed and arranged so that said gypsum wallboard batten strip defines a ledge extending from each said side of said lower chord;
at least one length of insulation inserted between adjacent trusses of said plurality of trusses, being placed upon and supported by said ledges such that said length of insulation extends between said adjacent trusses;
at least one resilient strip secured to an underside of each said wallboard batten strip; and
a single layer of gypsum wallboard panels secured to said at least one resilient strip and forming a ceiling, each said gypsum wallboard panel forming said ceiling having a weight of 1,800 pounds per thousand square feet, and being made from a wallboard slurry composition including less than 5% by weight of vermiculite; and
said ceiling system resists charring by fire for one hour per UL263/ASTM E119.

10. The ceiling system of claim 9 , wherein said ledges extend generally equally from each said side of said lower chord.

11. The ceiling system of claim 9 , wherein said ledges extend approximately one inch from each said side of said lower chord.

12. The ceiling system of claim 9 , wherein each said batten strip has a width in −a range of 6-8 inches.

Assignees

• United States Gypsum Co

Inventors

• Miller Gary Franklin
• SWINEA Joseph Edward
• Punati Naveen

Classifications

• E04B9/001

  characterised by provisions for heat or sound insulation · CPC title

• E04C3/16

  with apertured web, e.g. trusses (E04C3/17, E04C3/18 take precedence) · CPC title

• E04B1/7654

  comprising an insulating layer, disposed between two longitudinal supporting elements, e.g. to insulate ceilings · CPC title

• E04B1/945 Primary

  Load-supporting structures specially adapted therefor · CPC title

• E04B9/04 Primary

  comprising slabs, {panels,} sheets or the like · CPC title