Fire-rated wall construction product

Patent metadata

Field	Value
Publication number	US-2016130802-A1
Application number	US-201614996502-A
Country	US
Kind code	A1
Filing date	Jan 15, 2016
Priority date	Apr 8, 2010
Publication date	May 12, 2016
Grant date	—

Abstract

Fire-rated wall construction components and wall systems for use in building construction. Embodiments can include tracks for holding studs which incorporate various geometries capable of receiving fire-retardant material, including but not limited to intumescent material. The fire-retardant material can be attached to compressible backer rods inserted within deflection gaps in the wall systems such that the fire-retardant material expands and seals gaps and/or areas between the tracks and wall components such as ceilings, floors, and drywall. Various assemblies and methods can be used to cover the deflection gap.

First claim

What is claimed is:

1 . A fire-rated assembly for a linear wall gap, comprising:
a header track; a bottom track; a plurality of vertical wall studs extending in a vertical direction between the bottom track and the header track; at least a first wall board supported by the plurality of wall studs; wherein the header track is attached to an overhead structure and the bottom track, wall studs and wall board is movable relative to the header track, wherein the wall board is spaced from the overhead structure to define a deflection gap having an opening, a compressible backer rod positioned within the deflection gap between the upper edge of the first wall board and the horizontal ceiling element, an outer surface of the compressible backer rod at least partially coated with an intumescent material; a flexible sealant material applied to the first wall board and covering the opening of the deflection gap to enclose the compressible backer rod between the header track and the flexible sealant material.

2 . The assembly of claim 1 wherein the backer rod is sized to contact the ceiling and the top surface of the wall board.

3 . The assembly of claim 2 wherein at least one-half of an outer surface of the backer rod is coated in intumescent material.

4 . The assembly of claim 3 wherein less than one-half of an outer surface of the backer rod is coated in intumescent material.

5 . The assembly of claim 4 wherein the backer rod is inserted into the deflection gap with at least part of the coated surface of the backer rod facing towards the overhead structure and at least part of the uncoated surface of the backer rod facing the opening of the deflection gap and the flexible sealant engages the uncoated surface of the backer rod.

6 . The assembly of claim 6 wherein the backer rod has a cross-sectional profile that is circular, square, rectangular, or half circular.

7 . The assembly of claim 6 wherein the flexible sealant is a combination of joint compound and joint tape applied to the first wall board and backer rod.

8 . The assembly of claim 6 wherein the flexible sealant is an elastomeric spray applied to the first wall board and the backer rod.

9 . The assembly of claim 6 wherein melt temperature of the backer rod is greater than the activation temperature of the intumescent material.

10 . A method of assembling a fire-rated wall joint, comprising:
securing a header track to a ceiling; positioning upper ends of a plurality of studs into the header track; securing at least one wall board member to the plurality of studs such that a top surface of the wall board member is spaced away from the ceiling to define a deflection gap, the deflection gap having an opening; positioning a compressible backer rod within the deflection gap, an outer surface of the backer rod at least partially coated with an intumescent material; applying a flexible sealant to the first wall board and covering the opening of the deflection gap to enclose the compressible backer rod between the header track and the flexible sealant.

11 . The method of claim 10 further comprising sizing the backer rod to contact the ceiling and the top surface of the wall board.

12 . The method of claim 11 , wherein at least one-half of an outside surface of the backer rod is coated in intumescent material.

13 . The method of claim 11 , wherein less than one-half of an outer surface of the backer rod is coated in intumescent material.

14 . The method of claim 12 further comprising inserting the backer rod into the deflection gap with at least part of the intumescent coated surface of the backer rod facing towards the overhead structure and at least part of the uncoated surface of the backer rod facing the opening of the deflection gap such that the sealant engages the uncoated surface of the backer rod.

15 . The method of claim 14 , wherein the backer rod has a cross-sectional profile that is circular, square, rectangular, or half circular.

16 . The method of claim 15 , wherein the flexible sealant is a combination of joint compound and joint tape applied to the first wall board.

17 . The method of claim 15 further comprising selecting the backer rod and the intumescent material such that the melt temperature of the backer rod is higher than the activation temperature of the intumescent material.

18 . A fire-retardant wall system, comprising:
a horizontal ceiling element; a plurality of vertical wall studs; a header track for receiving the wall studs, the track connected to the horizontal ceiling element, the track comprising a web and a pair of flanges extending in the same direction from opposite edges of the web; at least one piece of wall board supported by the wall studs, the wall board having an upper edge that is spaced from the horizontal ceiling element to define a deflection gap therebetween; a compressible backer rod positioned within the deflection gap between the upper edge of the wall board and the horizontal ceiling element, wherein at least part of an outer surface of the compressible backer rod is coated with a fire-retardant material; and a combination of joint compound and joint tap applied to the wall board and covering the deflection gap to enclose the compressible backer rod between an outwardly-facing surface of one of the pair of flanges and the combination of joint compound and joint tape.

19 . The wall system of claim 18 , wherein the compressible backer rod has a circular cross-sectional shape.

20 . The wall system of claim 18 , wherein the compressible backer rod has a square cross-sectional shape.

21 . The wall system of claim 20 , wherein a surface of the compressible backer rod facing the ceiling element is coated with a fire-retardant material.

22 . The wall system of claim 20 , wherein a surface of the compressible backer rod facing the ceiling element has a strip of intumescent material adhesively applied to the surface of the backer rod.

Assignees

• California Expanded Metal Products Co

Inventors

• Pilz Donald A

Classifications

• E04B2/58

  with elongated members of metal · CPC title

• E04B1/948 Primary

  Fire-proof sealings or joints (for doors or windows E06B5/164) · CPC title

• E04B2/7457

  with wallboards attached to the outer faces of the posts, parallel to the partition (E04B2/7459 takes precedence) · CPC title

• E04B2/825

  the connection between the floor and the ceiling being achieved without any restraining forces acting in the plane of the partition · CPC title

• E04B2/7411 Primary

  Details for fire protection · CPC title