Projectile Resistant Wall Assembly

Abstract

The present invention relates to a wall assembly that is resistant to ballistic projectiles. The assembly is useful for partitions and exterior walls. The wall assembly comprises a sub-structure made of framing members with building boards attached to two opposite sides of the sub-substructure to form a first side of the wall and a second side of the wall, the first side of the wall comprising at least one layer S1LF of at least one gypsum fiberboard, the at least one layer S1LF having a total thickness of at least 25 mm, the first side of the wall further comprising at least one layer S1LG of at least one gypsum board, any one of the gypsum boards of the layer S1LG comprising 1% to 5% by weight of polyvinyl acetate based on its solids content relative to the weight of the gypsum, the second side of the wall comprising at least one layer S2LF of at least one gypsum fiberboard, the at least one layer S2LF having a thickness of at least 25 mm, a cavity being present between the first side and the second side, the cavity having a thickness of at least 40 mm and filled with air or a thermal insulating material.

Description

[Technical field]

[0001] The present invention relates to a wall assembly resistant to bullet projectiles. In particular, the wall assembly is designed to resist perforation by ammunition FB4 to FB7 classified according to EN 1522:1998. The assembly is useful for partitions and exterior walls. [Background technology]

[0002] Bullet projectile resistant structures are made of many materials. For example, a 24 cm thick brick wall is projectile resistant. However, brick walls have many disadvantages compared to drywall structures. In this specification, the term dry lining or drywall structure or dry lining or drywall construction refers to any structure or building construction having a frame substructure and building panels or boards assembled thereto. Dry lining walls have the advantage of being faster to build and lighter compared to brick walls. In particular, non-load bearing walls can be built as dry lining structures. Load bearing walls typically require special framing members. A typical dry lining structure includes wood or metal framing with building boards such as plasterboard, gypsum fiberboard, oriented strand board, etc. attached to two opposite sides of the framing members.

[0003] Handgun projectile resistant dry lining (drywall) constructions are known in the state of the art. A conventional handgun projectile resistant wall construction includes a substructure of dry lining studs (metal studs). The upright studs are fixed to metal rails assembled horizontally to the floor and ceiling. The upright studs include parallel extending flange portions having an outer surface to which a board (building panel) can be attached. Both parallel extending flanges are connected via a web portion. The parallel extending flanges and base portion can be configured, for example, in a C-shape or a U-shape.

[0004] To achieve pistol or rifle projectile resistance of partition walls, EP 1807583 and EP 3283714 disclose constructing gypsum fiberboards inside the substructure, i.e. in the spaces between adjacent studs. This means that the gypsum fiberboards are placed with their edges in contact with the web areas of the metal studs, the web areas typically corresponding to the wide faces of non-square studs. Due to their high weight compared to normal gypsum boards, also known as plasterboards, it is not common to fasten gypsum fiberboards to the flange parts of metal studs. In previous structures, the gypsum fiberboards were attached to the flanges of the studs by glue or screws. Screwing was only possible if the gypsum fiberboards were pre-drilled. Constructing gypsum fiberboards inside the substructure is a cumbersome and time-consuming process, since it is very difficult to place the heavy boards accurately between the studs.

[0005] In addition, known dry lining constructions that are resistant to rifle bullets typically rely on metal sheets constructed between gypsum-based building boards on either side of the substructure, which are not only more expensive than gypsum board or gypsum fiberboard, but are also difficult to handle and integrate into the dry lining assembly.

[0006] The ballistic resistance of the structure is evaluated according to EN 1522. Known structures provide projectile resistance performance of classes FB4 and FB5 according to DIN EN 1522:1998. FB4 is the highest class of protection against handguns and FB5 is the lowest class of protection against large calibre rifles. FB4 (BR4) withstands three shots of a handgun with .44 Magnum FJ (full metal jacket) / FN (flat nose) / SC (soft core), weight 15.6 ± 0.1 g, range 5.00 ± 0.5 m, velocity 440 ± 10 m / s and impact energy 1510 J. FB5 is the first class for resistance against rifle bullets. The FB5 construction withstands three shots from a rifle of caliber 5.56x45mm NATO FJ (Full Metal Jacket - Copper Alloy Jacket) / PB (Pointed Bullet) / SCP (Soft Core (Lead) and Steel Penetrator), weight 4.0 ± 0.1g, range 10.00 ± 0.5m, speed 950 ± 10m / s.

[0007] So far, no dry-lining construction has been able to achieve FB6 or FB7. The FB6 construction will withstand three shots from a rifle with a caliber of 5.56x45mm NATO FJ (full metal jacket - copper alloy jacket) / PB (pointed bullet) / SCP (soft core (lead) and steel penetrator), weight of 4.0 ± 0.1g, range of 10.00 ± 0.5m, velocity of 950 ± 10m / s. It will also withstand three shots from a rifle with a caliber of 7.62x51mm NATO FJ (full metal jacket - full steel jacket, plated) / PB (pointed bullet) / SCP (soft core (lead)), weight of 9.5 ± 0.1g, range of 10.00 ± 0.5m, velocity of 830 ± 10m / s. The FB7 construction withstands three shots from a rifle of caliber 7.62x51mm NATO FJ (Full Metal Jacket - Copper Alloy Jacket) / PB (Pointed Bullet) / Steel Hard Core (mass 3.7±0.1g, hardness 63HRC or higher), weight 9.8±0.1g, range 10.00±0.5m, speed 820±10m / s.

[0008] There is a need to simplify ballistic dry lining structures to make them more economical. There is also a strong demand for dry lining structures with improved ballistic resistance compared to the current state of the art. Rifles of various calibers play an important role in serial killings and terrorist attacks. Therefore, improved projectile resistance for load-bearing and non-load-bearing interior and exterior walls is desirable, especially for public buildings (schools, police stations, court buildings, prisons, embassies, shops, etc.) and private residential buildings that often have high security requirements to protect individuals and / or property. Summary of the Invention [Problem to be solved by the invention]

[0009] It is therefore an object of the present invention to provide a wall assembly that is resistant to handgun and / or rifle bullets and is more economical compared to the structures mentioned in the prior art. A further object of the present invention is to provide a wall assembly that is easier to assemble than the wall assemblies mentioned in the prior art. In addition, cheaper materials are desirable. A further object of the present invention is to provide a projectile-resistant wall assembly that lends itself to a decorative coating such as a layer of plaster, primer, or wallpaper. Most importantly, it is an object of the present invention to provide a wall assembly that is bulletproof against rifle bullets (of a higher class and caliber than those disclosed in the prior art) and has all the advantages of a dry-lining structure. [Means for solving the problem]

[0010] This problem is solved by a wall structure having the features of claim 1. These features provide a projectile resistance which is able to meet the requirements of EN 1522: 1998. Preferred embodiments form the subject matter of the dependent claims.

[0011] Specifically, the problem concerns a wall assembly that includes a substructure made of framing members with building boards attached to two opposite sides of the substructure to form a first side of a wall and a second side of the wall, - the first side of the wall comprises at least one layer S1LF of at least one gypsum fiberboard, the at least one layer S1LF having a total thickness of at least 25 mm, the first side of the wall further comprises at least one layer S1LG of at least one gypsum board, each of the gypsum boards of the layer S1LG comprising 1% to 5% by weight of polyvinyl acetate based on its solids content relative to the weight of the gypsum; - the second side of the wall comprises at least one layer S2LF of at least one gypsum fiberboard, the at least one layer S2LF having a total thickness of at least 25 mm; - the problem is solved by a wall assembly, in which a cavity exists between a first side and a second side, the cavity having a thickness of at least 40 mm and being filled with air or a thermal insulating material.

[0012] In the context of the present invention, "at least one" can mean one, two, three, four, or more than four.

[0013] Optionally, the second side may further comprise at least one layer S2LG of at least one gypsum board.

[0014] A wall typically has two major surfaces or two major sides. The wall assembly of the present invention also comprises two sides, a first side and a second side. The first side and the second side may be essentially parallel to each other.

[0015] The substructure or support frame is made of framing members. These framing members may be made of metal or wood. The vertical framing members are typically called studs and the horizontal framing members are typically called rails, tracks, or beams. Metal framing members typically have two parallel flanges connected by a web with approximately a 90° angle between each flange and the web. Building boards are attached to the flanges of the framing members. U-shaped studs can be used as the vertical framing members, but C-shaped studs are preferred as they provide more stability. The vertical (metal) framing members are typically placed within horizontal framing members such as U-shaped tracks or rails.

[0016] A timber framing member typically has four sides that are all at right angles to one another. Building boards are attached to two opposing sides of the framing member. Typically, the two adjacent sides of the framing member have different widths. The building board is generally attached to the narrower side.

[0017] The vertical framing members (metal or wood) are often spaced 450mm or 600mm or 625mm apart, however other distances between the vertical framing members are possible.

[0018] Gypsum fiberboard is a type of building board with a gypsum core, and typically contains >70% by weight, preferably 75% to 98% by weight, calcium sulfate dihydrate, based on the weight of the board. In contrast to gypsum board, gypsum fiberboard has a higher fiber content, mainly cellulose fiber. Generally, gypsum fiberboard contains 6% to 25% by weight fiber, preferably 8% to 16% by weight fiber, based on the gypsum in the board. Standard production lines for gypsum board cannot handle this high fiber content, which is one of the reasons why gypsum fiberboard is manufactured by a different process. The cellulose fiber in gypsum fiberboard is usually derived from recycled paper, which is mixed with water and added to the gypsum slurry as paper pulp. In addition to calcium sulfate dihydrate and cellulose fiber, it can contain other additives such as glass fiber, setting additives, or rheology modifiers. The additives are generally added to the stucco (calcium sulfate hemihydrate) and are given as a weight percentage based on the weight of the stucco. In the finished board, the relative amount of additive(s) is based on the weight of gypsum (calcium sulfate dihydrate). Since calcium dihydrate contains more water of crystallization, its molecular weight differs by about 1.2 times. As a result, the relative amount of additive is slightly shifted, i.e. slightly decreased, compared to the original relative amount based on stucco. Gypsum fiberboards do not require a liner. They are generally produced without a liner. Typical dimensions of gypsum fiberboards are 600mm x 1200mm or 600mm x 600mm for boards with a thickness of 25mm to 30mm. Thinner gypsum fiberboards (e.g. 10mm to 15mm thick) can be sized to 1200mm x 2400mm.

[0019] Gypsum board (often also called plasterboard) is another type of building board. Gypsum board contains a gypsum core and typically contains >70% by weight, preferably 75% to 98% by weight, of calcium sulfate dihydrate, based on the weight of the board. In addition to calcium sulfate dihydrate, it can contain other additives such as glass or cellulose fibers, setting additives or rheology modifiers. When fibers are present, they are typically present at up to 3% by weight, preferably up to 1.5% by weight, based on the weight of the gypsum in the gypsum board. Preferably, more glass fibers than cellulose fibers are incorporated. The gypsum board of the present invention contains at least polyvinyl acetate as an additive. As with gypsum fiberboard, additives for gypsum board are generally added in conjunction with the plaster. Their relative amounts need to be adjusted as described above, based on the gypsum present in the finished board. As with most gypsum boards, gypsum boards containing polyvinyl acetate also contain liners on both major or major surfaces. These liners increase the overall strength of the board. These can be paper liners or woven or nonwoven mats. Most preferably, the gypsum boards containing polyvinyl acetate have paper liners. The liners can have a basis weight of 160 g / m2 to 250 g / m2, and often one side has a liner with a higher basis weight than the other side. Paper liners are advantageous because they are easier to handle, cheaper, and can be recycled more easily. On the other hand, woven or nonwoven mats can be chosen, for example, when hydrophobization or mold resistance is important.

[0020] As an exterior wall, the wall assembly of the present invention can receive additional cladding (with or without insulating material) as a facade. Alternatively, the wall assembly of the present invention can be built inside an existing exterior wall or facade. In addition, the wall assembly of the present invention may be used as a ceiling or floor element, for example for a projectile-resistant box or projectile-resistant shelter.

[0021] Although not an essential part of the present invention, cement board and / or cement fiberboard containing polyvinyl acetate may be used in place of or in addition to gypsum board and / or gypsum fiberboard, respectively.

[0022] In a wall assembly, the various building boards are arranged in layers, for example, one, two or more layers of gypsum board and / or one, two or more layers of gypsum fiberboard. Typically, the first layer of building board is attached directly to the substructure and subsequent layers of building board are attached to the underlying layer of building board. However, it is contemplated that all layers are attached to the substructure.

[0023] At least two layers of building boards S1LF and S1LG are attached to one side of the substructure to form a first side of the wall, and at least one layer of building boards S2LF is attached to an opposing side of the substructure to form a second side of the wall. In its minimal form, a layer may consist of only one building board. In many cases, the opposing sides (of the wall assembly), i.e. the first side and the second side, are essentially parallel to each other.

[0024] According to the invention, the layers S1LF and / or S2LF may consist of one, two or more sub-layers of the same material. To be considered as part of the same layer, the sub-layers, i.e. gypsum fiberboards, are in direct contact with each other without being separated by another material. For example, S1LF may consist of one sub-layer of gypsum fiberboard with a thickness of 28 mm. It may also consist of two sub-layers of gypsum fiberboard with a thickness of 12.5 mm, stacked on top of each other for a total thickness of at least 25 mm, as a further example.

[0025] The total thickness of the S1LF and / or S2LF may vary in other embodiments. A maximum thickness of 80 mm for the S1LF and / or S2LF is preferred for most applications. More preferably, the S1LF and / or S2LF are between 25 mm and 70 mm thick.

[0026] Similarly, layers S1LG and / or S2LG, if present, may consist of one, two or more sub-layers of board of the same material. To be considered part of the same layer, the sub-layers (in this case gypsum board) are in direct contact with each other without being separated by a different material. The liner is considered to be part of the gypsum board and therefore is not considered to be of a different material. For example, S1LG and / or S2LG may each consist of two sub-layers. If each sub-layer is 9 mm thick, the total thickness of this layer is 18 mm. Other typical thicknesses of the sub-layers are 12.5 mm or 15 mm. Preferably, layers S1LG and / or S2LG, if present, have a total thickness of at least 12 mm. A maximum thickness of 60 mm for S1LG and / or S2LG is preferred for most applications. If necessary, the above-mentioned layers may be up to 60 mm thick. More preferably, S1LG and / or S2LG are 12 mm to 50 mm thick.

[0027] Thus, the total thickness is meant to indicate the thickness of one, two or more sub-layers of a building board of the same material that are in direct contact with each other, where direct contact in the context of the present invention means that these layers are attached to each other by an attachment means and are not separated by another material along the contact surface. The only material present along the contact surface may be the attachment means, which may be associated with the structure, or a thin layer of air. Preferably, the thin layer of air is <2 mm thick, more preferably <1 mm thick. If present, the thin layer of air is generally unintentional. In general, the thicknesses of the sub-layers are summed to obtain the total thickness.

[0028] The cavity is disposed between a layer of building board(s) on a first side of the wall assembly and a layer of building board(s) on a second side. More specifically, it is disposed between the innermost layer of building board(s) on the first side and the innermost layer of building board(s) on the second side, the term "innermost" indicating the building board on the side closest to the substructure or framing member. Preferably, the cavity corresponds to the space of the adjacent framing members. Since the thickness of the cavity corresponds to the distance between the layer of building board(s) on the first side and the layer of building board(s) on the second side, the thickness of the cavity preferably corresponds to the width of the web of the framing members if metal framing members are used. If wood framing members are used, the cavity preferably corresponds to the width of the framing members. It is essential that the cavity is not filled or is filled with a low density material. Low density means that the cavity is filled with material at a density of up to 150 kg / m3, preferably at a density of up to 50 kg / m3, most preferably between 0.8 kg / m3 and 50 kg / m3. Aerographene has a density of 0.2 kg / m3, air has a density of 1.2 kg / m3, and insulating materials such as glass wool have a density of 30 kg / m3. Other suitable insulating materials can be, for example, glass wool, rock wool, wood wool, polystyrene. The thickness of the cavity can be up to 200 mm. Preferably, the thickness of the cavity is between 60 mm and 150 mm.

[0029] The disclosed assembly provides the following advantages: -Easy to assemble. - Economical in that assembly time is reduced, e.g. no adhesives are required, no heavy fiberboard layers need to be placed between the studs, no steel plates are required When gypsum board is used as the outermost layer, it provides a better base for a layer of plaster or a decorative coat such as wallpaper compared to the prior art.

[0030] It is noted that any aspect and / or feature of the present invention disclosed individually in this specification and / or claims may be realized in common with one, two, more or all of the other aspects and / or features in each embodiment of the present invention, unless there is a technical reason for their combination.

[0031] In a preferred embodiment of the invention, the second side further comprises at least one layer S2LG of at least one gypsum board, all of the gypsum boards of the layer S2LG containing 1% to 5% by weight of polyvinyl acetate based on its solid content relative to the weight of the gypsum in the board. The layer S2LG has the advantage that both sides of the wall assembly can achieve the same protection against projectiles. Also, the S2LG provides a better base for a layer of plaster or a decorative coat such as wallpaper.

[0032] Advantageously, any, some or all of the gypsum boards of layers S1LG and / or S2LG further comprise glass fibres, preferably 0.5% to 2% by weight glass fibres, more preferably 0.6% to 1% by weight glass fibres, based on the weight of the gypsum in the board. The glass fibres give the board greater overall strength.

[0033] Any, some, or all of the gypsum boards of layers S1LG and / or S2LG may further comprise 0.1% to 3% by weight starch, preferably 0.1% to 1% by weight starch, based on the weight of gypsum present in the board. The starch may be, for example, native starch, modified starch, pregelatinized starch, cold water soluble starch, migratory starch, non-migratory starch. In many cases, the starch improves bonding of the liner to the gypsum core and / or improves the overall strength of the board.

[0034] Preferably, any, some, or all of the gypsum boards of layers S1LG and / or S2LG contain 2-4% polyvinyl acetate by weight based on the solids of the gypsum present in the board. The disclosed amounts of polyvinyl acetate provide toughness and / or greater strength.

[0035] Gypsum boards containing combinations of polyvinyl acetate, fiberglass, and starch in the disclosed amounts are believed to be particularly advantageous.

[0036] Advantageously, any, some, or all of the S1LF and / or S2LF gypsum fiberboards each have two adjacent tongue and groove edges so that adjacent gypsum fiberboards can be joined by a tongue and groove joint, and preferably all of the S1LF and / or S2LF gypsum fiberboards have two adjacent tongue and groove edges. The tongue and groove edges of a gypsum fiberboard can be joined to the groove edge of another gypsum fiberboard to form a tongue and groove joint. In embodiments where the layer S1LF or layer S2LF includes at least two fiberboards, these tongue and groove joints provide more stability to the wall assembly than standard joints or joints requiring adhesives, especially horizontal joints in the wall assembly. Tongue and groove joints provide more flexibility in the placement of vertical framing members because building boards with tongue and groove joints do not need to be attached to the substructure along the board edges. Indeed, preferably the attachment means does not attach the gypsum fiberboards with a tongue and groove edge near the edge, where "near" refers to a distance of less than 40 mm from the edge. In particular, with a tongue and groove joint, no adhesive is required to bond one layer of gypsum fiberboard to an adjacent layer.

[0037] Preferably, the layer S1LF includes at least two gypsum fiberboards, and any, some, or all of the gypsum fiberboards of the layer S1LF are bonded to adjacent gypsum fiberboards of the same layer without adhesive, and / or the layer S2LF includes at least two gypsum fiberboards, and all of the gypsum fiberboards of the layer S2LF are bonded to adjacent gypsum fiberboards of the same layer without adhesive. By eliminating adhesive at the joints, assembly steps are reduced, and therefore labor costs are reduced.

[0038] The framing members may be made of, for example, steel or wood, preferably steel, more preferably at least 0.8 mm gauge steel, and most preferably at least 1.0 mm gauge steel. Reinforced framing members, especially reinforcing studs, are made of at least 0.8 mm gauge steel. They are typically used in load-bearing walls or unusually tall non-load-bearing walls. Reinforced framing members are necessary when gypsum fiberboard or gypsum board is nailed to a substructure.

[0039] Preferably, the layers S1LF and / or S2LF each have a total thickness of at least 50 mm. A total thickness of at least 50 mm improves the ballistic resistance to at least FB6 according to EN 1522:1998. For example, two 28 mm thick sub-layers can be used to achieve a total thickness of at least 50 mm. Non-mirror symmetric wall assemblies are most effective when the first side, i.e. the side with the thicker layer, faces the impact, strike, projectile, or assault.

[0040] Preferably, layers S1LG and / or S2LG each have a total thickness of at least 24 mm. For example, two sub-layers of 12.5 mm thickness can be used to achieve a total thickness of at least 24 mm. A total thickness of at least 24 mm improves ballistic resistance to at least FB5 according to EN 1522:1998. Non-mirror symmetric wall assemblies are most effective when the first side, i.e. the side with the thicker layer, faces the impact, strike, projectile, or assault.

[0041] Advantageous embodiments embody one, more than one, or all of the following preferred aspects of the invention. Such embodiments may also embody one or more of the features disclosed elsewhere in this application.

[0042] Preferably, layers S1LF and / or S2LF each have a total thickness of at least 50 mm and layer S1LG has a total thickness of at least 24 mm. A total thickness of at least 24 mm of gypsum boards allows for an improved ballistic resistance beyond FB6 according to EN 1522:1998.

[0043] Preferably, layers S1LF and S1LG are in direct contact with each other, meaning that no other material than the attachment means or air separates layers S1LF and S1LG.

[0044] Preferably, the first side of the wall and the second side of the wall are mirror symmetric. For example, if the layer S1LF is attached directly to the substructure, the layer S2LF is attached directly to the substructure. If the layer S1LF includes two sublayers, the layer S2LF includes two sublayers. Also, to achieve the specified symmetry, there must be at least one layer S2LG of at least one gypsum board, where all of the gypsum boards of the layer S2LG include 1% to 5% by weight of polyvinyl acetate based on its solid content, relative to the weight of the gypsum. If S1LG is the outermost layer, then the layer S2LG is the outermost layer. In the context of the present invention, "outermost" refers to the layer of the building board, either gypsum board or gypsum fiberboard, that is furthest from the substructure and / or faces the interior of the room. Generally, this is the layer of the building board on one side of the gypsum board or gypsum fiberboard that was last attached. Also, S1LF and S2LF are identical in thickness and / or composition. The same is true for S1LG and S2LG. If a second layer of gypsum fiberboard S1LF2 is present on a first side, then a second layer of gypsum fiberboard S2LF2 is present on a second side. If a second layer of gypsum board S1LG2 is present on a first side, then a second layer of gypsum board S2LG2 is present on a second side. A mirror-symmetric wall assembly has the advantage of having the same projectile resistance on both sides of the wall assembly.

[0045] Preferably, any, some or all of the gypsum fiberboards and all of the gypsum boards are attached to the substructure or underlying building board (gypsum fiberboard or gypsum board) by an attachment means. The attachment means can be, for example, screws, staples, nails, or adhesives. On the other hand, gypsum boards are typically screwed to the substructure or underlying building board, whereas gypsum fiberboards typically require pre-drilled holes for screwing. In the past, adhesives have been used to attach gypsum fiberboards to either the substructure or underlying building board. This has the advantage that no joint compound is required, for example, to cover the screw heads. In the present invention, the preferred attachment means is a nail, and more preferably, the attachment means is a ballistic nail / nailable nail. Attachment via nails is quicker and equally reliable compared to screws. Ballistic nails are nails that are fired from a nailing pistol (e.g., pneumatic or powder-actuated tool). In particular, (magazine-fed) ballistic nails are a very efficient attachment means. Most preferably, the ballistic nail is made of galvanized carbon steel and / or is grooved and / or has a diamond coated tip or ballistic tip. The ballistic tip is somewhat rounded like a bullet. Headed or headless (ballistic) nails are equally effective for attaching layers of fiberboard such as S1LF or S2LF and / or for attaching layers of gypsum board such as S2LG or S2LG. Particularly preferably, headed (ballistic) nails can be used for attaching layers of fiberboard such as S1LF or S2LF and / or headless (ballistic) nails can be used for attaching layers of gypsum board such as S2LG or S2LG. The length of the nail shaft can vary from 20mm to 60mm. Typically, shorter lengths such as 25mm are used for gypsum board. Longer lengths such as 35mm to 55mm are generally used for gypsum fiberboard, whereby attachment to a substructure requires a longer nail than attachment to another board. Nail shaft diameters can vary from 1.5mm to 3.0mm. Typically smaller diameters such as 1.8mm are used for gypsum board.Larger diameters, such as 2.2mm to 2.8mm, are typically used for gypsum fiberboard. By using headless nails, less joint material is required to cover the nails. This is particularly advantageous for the outermost layers. Also, by not attaching all layers to the substructure, loads can be distributed and / or the joints between building boards of adjacent layers can be staggered, i.e., non-overlapping. Non-overlapping means that the vertical joints of one layer do not overlap the vertical joints of an adjacent layer. However, depending on the configuration, vertical joints between building boards of one layer that intersect with horizontal joints between building boards of an adjacent layer are not considered to be overlapping.

[0046] Preferably, the mounting means of the wall assembly does not include adhesive. In another preferred embodiment, any, some, or all of the S1LF and / or S2LF gypsum fiberboards are not pre-drilled.

[0047] Preferably, there are joints between building boards of one layer, and the joints do not overlap with joints of an adjacent (e.g., underlying or overlying) layer. A layer of building board can be layer S1LF, layer S2LF, layer S1LG, layer S2LG, or a further layer. The joints are formed between adjacent building boards of the same layer. The joints are generally considered to be weak points. By staggering the joints of adjacent layers, the overall strength of the wall assembly can be greater.

[0048] Preferably, the wall assembly of the present invention in all embodiments does not include metal sheets, omitting the metal sheets saves costs and simplifies assembly of the wall.

[0049] Preferably, both layers S1LF and S2LF are in direct contact with the substructure, preferably with the studs. Direct contact to the substructure means that both layers S1LF and S2LF are attached to the substructure by attachment means. More preferably, they are not separated by another material along the contact surface, whereby the only material present along the contact surface is the attachment means or a thin layer of air, which may be associated with the structure. By attaching S1LF and S2LF directly to the substructure, a more stable wall assembly is obtained.

[0050] Preferably, the layer S1LG and / or the layer S2LG are the outermost layer. The gypsum board of the layer S1LG or the layer S2LG not only provides the technical feature for improved ballistic resistance, but also provides a better base for a layer of plaster or a decorative coat such as wallpaper, for example, compared to a gypsum fiberboard. If the gypsum board is used as the outermost layer, it serves this additional advantage.

[0051] Preferably, any, some or all of the gypsum fiberboards of both layers S1LF and S2LF have a thickness of 10mm to 40mm, preferably 15mm to 35mm, most preferably 24 to 30mm, and / or a density of more than 1200kg / m3 and less than 2000kg / m3, preferably more than 1400kg / m3 and less than 1800kg / m3, even more preferably more than 1500kg / m3 and less than 1700kg / m3. Gypsum fiberboards with dimensions of 1200mm x 600mm are particularly useful. Typically, the fibers of the gypsum fiberboards are cellulosic and / or derived from paper pulp.

[0052] Preferably, any, some, or all of the gypsum fiberboards include fibers with at least one primary orientation, more preferably at least two primary orientations that are perpendicular to each other, and most preferably the primary orientation further includes an orientation parallel to the major surface of the gypsum fiberboard. The primary orientation is a characteristic feature of a particular manufacturing process, resulting in a gypsum fiberboard with a higher bending strength compared to gypsum fiberboards that include fibers that do not have a primary orientation from a different manufacturing process. During this particular type of manufacturing, the fibers of the gypsum fiberboard are aligned in the machine direction. This alignment or primary orientation affects the bending strength and breaking load of the board. To further strengthen the boards, for example to further increase their bending strength, the gypsum fiberboards can include at least two layers that are laterally bonded (by pressure) such that the fibers of one layer are essentially perpendicular to the fibers of the adjacent fiberboard layer. These gypsum fiberboards are also more elastic compared to gypsum fiberboards that include fibers that have a random arrangement or no specific orientation. The fibers can have an average length of 1 mm to 5 mm, preferably 1 mm to 4 mm, and more preferably 1 mm to 3 mm. Preferably, the fibers have an average diameter of 15 μm to 50 μm.The building panel may have a fiber content of 5% to 25% by weight relative to the weight of the gypsum.

[0053] Preferably the assembly meets a classification according to EN1522:1998 of at least FB4, preferably at least FB5, more preferably at least FB6, most preferably at least FB7.

[0054] Preferably, the vertical framing members of a wall assembly of the invention are spaced 400-650mm apart. These measurements refer to on-centre measurements, where the midline of a stud (i.e. the flange of a metal stud) or side (timber stud) is spaced, for example, 450mm, 500mm, 600mm or 625mm from the midline of an adjacent stud. More preferably, the framing members are spaced 445mm-630mm apart.

[0055] The preferred framing member is a reinforced framing member. The reinforced framing member preferably has a steel gauge of 1.0 mm to 1.5 mm. The web may have a width of 45 mm, 70 mm, 95 mm, 120 mm, 145 mm, or 160 mm wide. Widths of 60 mm to 80 mm are particularly preferred. The two flanges may have different widths, for example 42 mm on one side and 46 mm on the other side.

[0056] The wall assembly of the present invention in all its embodiments may be a partition.

[0057] Another aspect of the invention is a method of building a wall assembly comprising a substructure made of framing members with building boards attached to two opposite sides of the substructure to form a first side of a wall and a second side of the wall, the method comprising: - positioning at least two framing members; - attaching at least one layer S1LF of gypsum fiberboard having a total thickness of 25 mm to a first side; - attaching at least one layer S1LG of gypsum board to the first side, the gypsum board comprising 1% to 5% by weight of polyvinyl acetate based on its solids content, relative to the weight of the gypsum; - attaching at least one layer of gypsum fiberboard S2LF having a total thickness of at least 25 mm to the second side; - providing a cavity between two opposing sides, the cavity having a thickness of at least 40 mm and being filled with air or a thermal insulating material.

[0058] Preferably, the wall assembly of the present invention is constructed in this manner.

[0059] This method may also be applied to any of the described embodiments of the wall assembly.

[0060] A further aspect of the invention relates to the use of a gypsum board in a wall assembly, the gypsum board comprising 1% to 5% by weight of polyvinyl acetate based on its solids content relative to the weight of gypsum in the board, to achieve ballistic resistance of the wall assembly, preferably the ballistic resistance at least meets the classification FB6 according to EN1522:1998.

[0061] Preferably, the use of gypsum board results in a wall assembly of the present invention or a wall assembly constructed by the method of the present invention.

[0062] Preferably, the use further comprises any of the advantageous embodiments disclosed for the wall assembly.

[0063] The present invention is further illustrated in the following list of preferred embodiments (FE).

[0064] Embodiment FE1: A wall assembly comprising a substructure made of framing members with building boards attached to two opposite sides of the substructure to form a first side of a wall and a second side of the wall, - the first side of the wall comprises at least one layer S1LF of at least one gypsum fiberboard, the layer S1LF having a total thickness of at least 25 mm; the first side of the wall further comprises at least one layer S1LG of at least one gypsum board, all of the gypsum boards of the layer S1LG comprising 1-5% by weight of polyvinyl acetate based on the solids content of the gypsum, relative to the weight of the gypsum; - the second side of the wall comprises at least one layer S2LF of at least one gypsum fiberboard, the at least one layer S2LF having a total thickness of at least 25 mm; A wall assembly, wherein a cavity exists between a first side and a second side, the cavity having a thickness of at least 40 mm and being filled with air or a thermal insulating material.

[0065] Embodiment FE2: The wall assembly of embodiment FE1, wherein the second side further comprises at least one layer S2LG of at least one gypsum board, any, some, or all of the gypsum boards of layer S2LG comprising 1% to 5% by weight polyvinyl acetate based on its solids content, relative to the weight of the gypsum.

[0066] Embodiment FE3: A wall assembly as described in embodiment FE1 or FE2, wherein any, some, or all of the gypsum boards of layer S1LG and / or all of the gypsum boards of layer S2LG further comprise glass fibers, preferably 0.5% to 2% by weight glass fibers, more preferably 0.6% to 1% by weight glass fibers based on the weight of the gypsum in the board.

[0067] Embodiment FE4: A wall assembly according to any of embodiments FE1, FE2, or FE3, wherein any, some, or all of the gypsum boards of layer S1LG and / or all of the gypsum boards of layer S2LG further comprise 0.1% to 3% by weight starch, preferably 0.1% to 1% by weight starch, based on the weight of gypsum present in the board.

[0068] Embodiment FE5: A wall assembly according to any of embodiments FE1, FE2, FE3, or FE4, wherein any, some, or all of the gypsum boards of layer S1LG and / or all of the gypsum boards of layer S2LG contain 2% to 4% polyvinyl acetate by weight based on the solids content of the gypsum.

[0069] Embodiment FE6: A wall assembly of any of embodiments FE1, FE2, FE3, FE4, or FE5, wherein any, some, or all of the gypsum fiberboards of both layers S1LF and S2LF have two adjacent tongue and two groove edges such that adjacent gypsum fiberboards may be joined by a tongue and groove joint, preferably all of the gypsum fiberboards of layers S1LF and S2LF have two adjacent tongue and two adjacent groove edges.

[0070] Embodiment FE7: A layer S1LF includes at least two gypsum fiberboards, and all of the gypsum fiberboards of the layer S1LF are bonded to adjacent gypsum fiberboards of the same layer without adhesive; And / or the wall assembly of any of embodiments FE1, FE2, FE3, FE4, FE5, or FE6, wherein layer S2LF comprises at least two gypsum fiberboards, any of the gypsum fiberboards of layer S2LF being joined without adhesive to an adjacent gypsum fiberboard of the same layer.

[0071] Embodiment FE8: A wall assembly of any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, or FE7, wherein the framing members are made of steel or wood, preferably steel, more preferably steel of at least 0.8 mm gauge, and most preferably steel of at least 1.0 mm gauge.

[0072] Embodiment FE9: A wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, or FE8, wherein layer S1LF and / or layer S2LF have a total thickness of at least 50 mm.

[0073] Embodiment FE10: A wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, or FE9, wherein layer S1LG and / or layer S2LG have a total thickness of at least 24 mm.

[0074] Embodiment FE11: A wall assembly according to any of embodiments FE9 or FE10, wherein both layers S1LF and S2LF have a total thickness of at least 50 mm, and layer S1LG has a total thickness of at least 24 mm.

[0075] Embodiment FE12: A wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, or FE11, wherein layer S1LF and layer S1LG are in direct contact with each other.

[0076] Embodiment FE13: A wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, or FE12, wherein the first side and the second side of the wall structure are mirror symmetrical.

[0077] Embodiment FE14: A wall assembly of any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, or FE13, wherein any, some, or all of the gypsum fiberboards and all of the gypsum boards are attached to the substructure or underlying building board by attachment means, preferably the attachment means are nails, more preferably the attachment means are ballistic nails, and most preferably the ballistic nails are made of galvanized carbon steel and / or are grooved and / or have a ballistic tip.

[0078] Embodiment FE15: A wall assembly as described in embodiment FE14, wherein the attachment means does not include an adhesive.

[0079] Embodiment FE16: The wall assembly of any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, FE13, FE14, or FE15, wherein all of the gypsum fiberboards of S1LF and / or S2LF are not pre-drilled.

[0080] Embodiment FE17: A wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, FE13, FE14, FE15, or FE16, wherein there are joints between the building boards of one layer, and the joints do not overlap with the joints of an adjacent layer.

[0081] Embodiment FE18: A wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, FE13, FE14, FE15, FE16, or FE17, wherein the wall assembly does not include a metal sheet.

[0082] Embodiment FE19: A wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, FE13, FE14, FE15, FE16, FE17, or FE18, wherein both layers S1LF and S2LF are in direct contact with the substructure, preferably with the studs.

[0083] Embodiment FE20: A wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, FE13, FE14, FE15, FE16, FE17, FE18, or FE19, wherein layer S1LG and / or layer S2LG are the outermost layers.

[0084] Embodiment FE21: A wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, FE13, FE14, FE15, FE16, FE17, FE18, FE19, or FE20, wherein any of the gypsum fiberboards of both layers S1LF and S2LF have a thickness of from 10mm to 40mm, preferably from 15mm to 35mm, most preferably from 24 to 30mm, and / or a density of from more than 120kg / m3 and less than 2000kg / m3, preferably from more than 1400kg / m3 and less than 1800kg / m3, even more preferably from more than 1500kg / m3 and less than 1700kg / m3.

[0085] Embodiment FE22: The wall assembly of any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, FE13, FE14, FE15, FE16, FE17, FE18, FE19, FE20, or FE21, wherein all of the gypsum fiberboards in both layers S1LF and S2LF include fibers having at least one primary orientation, preferably having at least two primary orientations that are perpendicular to each other, and more preferably the primary orientation further includes an orientation parallel to a major surface of the gypsum fiberboard.

[0086] Embodiment FE23: A wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, FE13, FE14, FE15, FE16, FE17, FE18, FE19, FE20, FE21, or FE22, wherein the assembly meets classification according to EN1522:1998 of at least FB4, preferably at least FB5, more preferably at least FB6, and most preferably at least FB7.

[0087] Embodiment FE24: A method of building a wall assembly comprising a substructure made of framing members and having building boards attached to two opposite sides of the substructure forming a first side of the wall and a second side of the wall, in particular a wall assembly according to any of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, FE13, FE14, FE15, FE16, FE17, FE18, FE19, FE20, FE21, FE22 or FE23, comprising: - positioning at least two framing members; - attaching at least one layer S1LF of gypsum fiberboard having a total thickness of at least 25 mm to a first side; - attaching at least one layer S1LG of gypsum board to a first side, the gypsum board comprising 1-5% by weight of polyvinyl acetate; - attaching at least one layer of gypsum fiberboard S2LF having a total thickness of at least 25 mm to the second side; - providing a cavity between two opposing sides, the cavity having a thickness of at least 40 mm and being filled with air or an insulating material.

[0088] Embodiment FE25: Use of a gypsum board in a wall assembly, in particular a wall assembly according to any one of embodiments FE1, FE2, FE3, FE4, FE5, FE6, FE7, FE8, FE9, FE10, FE11, FE12, FE13, FE14, FE15, FE16, FE17, FE18, FE19, FE20, FE21, FE22, or FE23, or in a wall assembly constructed according to embodiment FE24, wherein the gypsum board comprises 1-5% by weight of polyvinyl acetate, based on its solids content, relative to the weight of gypsum in the board, to achieve ballistic resistance of the wall assembly, preferably the ballistic resistance at least meets the classification FB6 according to EN1522:1998.

[0089] The invention is further illustrated in the figures, which are, however, not intended to limit the scope of the invention and its general teachings by the selected embodiments in the figures. [Brief description of the drawings]

[0090] [Figure 1] FIG. 2 is a schematic diagram of a vertical section of a wall assembly according to the present invention, having S1LF, S1LG and S2LF. [Diagram 2] FIG. 13 is a schematic diagram of an alternative embodiment of a wall assembly according to the present invention having S1LF, S1LG, S2LF, and S2LG. [Diagram 3] FIG. 13 is a schematic diagram of an alternative embodiment of a wall assembly according to the present invention having an S1LF, an S1LG, and an S2LF. [Figure 4] FIG. 13 is a schematic diagram of an alternative embodiment of a wall assembly according to the present invention having S1LF, S1LG, S2LF, and S2LG. [Diagram 5] FIG. 13 is a schematic diagram of an alternative embodiment of a wall assembly according to the present invention having S1LF, S1LG, S2LF, and S2LG. [Figure 6] FIG. 13 is a schematic diagram of an alternative embodiment of a wall assembly according to the present invention having S1LF, S1LG, S2LF, and S2LG. [Figure 7] Schematic diagram of an alternative embodiment of a wall assembly according to the present invention having S1LF, S1LG, S1LF2, S1LG2, S2LF, S2LG, S2LF2, and S2LG2. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0091] FIG. 1 shows an embodiment with both S1LF and S2LF as innermost layers, where S1LF and S2LF are attached directly to vertical framing members, e.g. metal or wood studs, preferably C-shaped or U-shaped metal studs. Here, a single layer of gypsum fiberboard with a thickness of 28 mm constitutes S1LF. Similarly, a single layer of gypsum fiberboard with a thickness of 28 mm constitutes S2LF. Alternatively, two sublayers of gypsum fiberboard with a thickness of 12.5 mm directly in contact with each other can result in a total thickness of 50 mm and replace a layer of gypsum fiberboard with a thickness of 28 mm. When layer S1LF consists of two sublayers of gypsum fiberboard, the innermost sublayer is attached directly to the vertical framing members, preferably by attachment means. Subsequent sublayers or layers are attached to the underlying layer or sublayer, preferably by attachment means. S1LG can be a single layer of gypsum board with a thickness of, for example, 12.5 mm or 15 mm. In this embodiment, S1LG is the outermost layer and S2LF is both the outermost and innermost layers. The attachment means are shown as nails. In the figures, headless nails are used to attach the gypsum board. However, this embodiment is not limited to headed or headless nails. Nails could be substituted with, for example, screws, staples, or adhesives as attachment means.

[0092] FIG. 2 shows a mirror symmetrical embodiment with S1LF and S2LF as the innermost layers and S1LG and S2LG as the outermost layers. Here, one layer of gypsum fiberboard with a thickness of 28 mm constitutes S1LF. Similarly, one layer of gypsum fiberboard with a thickness of 28 mm constitutes S2LF. S1LF and S2LF can be attached directly to the vertical framing members by attachment means. As in the embodiment of FIG. 1, two sub-layers of gypsum fiberboard with a thickness of 12.5 mm can constitute S1LF and / or S2LF. S1LG and S2LG are attached to the underlying layers S1LF and S2LF, respectively. The vertical framing members can be, for example, metal or wood studs, preferably C-shaped or U-shaped metal studs. The attachment means are shown as nails. In the figures, headless nails are used to attach the gypsum boards. However, this embodiment is not limited to headed or headless nails. The nails can be replaced by, for example, screws, staples, or adhesives as attachment means.

[0093] FIG. 3 illustrates an embodiment similar to that shown in FIG. 1. Here, S1LF is composed of two sub-layers of gypsum fiberboard, each of the two sub-layers having a thickness of 25 mm or 28 mm. The innermost sub-layer or layer is preferably attached directly by attachment means to a vertical framing member, for example a metal or wood stud, preferably a C-shaped or U-shaped metal stud. Subsequent sub-layers or layers are preferably attached to the underlying layer by attachment means. The attachment means are shown as nails. In the figures, headless nails are used to attach the gypsum board. However, this embodiment is not limited to headed or headless nails. Nails can be substituted, for example, with screws, staples, or adhesives as attachment means.

[0094] FIG. 4 shows an asymmetric wall assembly with S1LF and S1LG on a first side and S2LF and S2LG on a second side. S1LF consists of two sub-layers of gypsum fiberboard, while S2LF consists of only one layer of gypsum fiberboard. The gypsum fiberboard in these layers or sub-layers can have a thickness of, for example, 25 mm or 28 mm. The innermost sub-layer or layer is preferably attached by attachment means directly to a vertical framing member, for example a metal or wood stud, preferably a C-shaped or U-shaped metal stud. Subsequent sub-layers or layers are preferably attached by attachment means to the underlying layer. The attachment means are shown as nails. In the figures, headless nails are used to attach the gypsum boards. However, this embodiment is not limited to headed or headless nails. The nails can be substituted by, for example, screws, staples, or adhesives as attachment means.

[0095] FIG. 5 shows a mirror symmetric wall assembly with S1LF and S1LG on a first side and S2LF and S2LG on a second side. S1LF and S2LF have the same thickness. Similarly, S1LG and S2LG have the same thickness. Both S1LF and S2LF consist of two sub-layers of gypsum fiberboard. The gypsum fiberboard in these sub-layers can have a thickness of, for example, 25 mm or 28 mm. The innermost sub-layer or layer is preferably attached directly by attachment means to a vertical framing member, for example a metal or wood stud, preferably a C-shaped or U-shaped metal stud. Subsequent sub-layers or layers are preferably attached to the underlying layer by attachment means. The attachment means are shown as nails. In the figures, headless nails are used to attach the gypsum boards. However, this embodiment is not limited to headed or headless nails. The nails can be substituted, for example, with screws, staples, or adhesives as attachment means.

[0096] FIG. 6 shows an embodiment similar to that of FIG. 1. Here, both S1LF and S2LF consist of two sublayers of gypsum fiberboard. The gypsum fiberboard in these sublayers can have a thickness of, for example, 25 mm or 28 mm. S1LG and S2LG also consist of two sublayers. The sublayers of S1LG and S2LG can have a thickness of, for example, 12.5 mm or 15 mm. The innermost sublayer or layer is preferably attached directly by attachment means to a vertical framing member, for example a metal or wood stud, preferably a C-shaped or U-shaped metal stud. Subsequent sublayers or layers are preferably attached to the underlying layer by attachment means. The attachment means are shown as nails. In the figures, headless nails are used to attach the gypsum boards. However, this embodiment is not limited to headed or headless nails. The nails can be substituted, for example, with screws, staples, or adhesives as attachment means.

[0097] FIG. 7 shows an embodiment having S1LF, S1LG, S1LF2, S1LG2, S2LF, S2LG, S2LF2, and S2LG2. S1LF, S1LF2, S2LF, and S2LF2 can have thicknesses of, for example, 25 mm or 28 mm. S1LG, S1LG2, S2LG, and S2LG2 can have thicknesses of, for example, 12.5 mm or 15 mm. The innermost sublayer or layer is preferably attached directly to a vertical framing member, for example a metal or wood stud, preferably a C-shaped or U-shaped metal stud, by an attachment means. Subsequent sublayers or layers are preferably attached to the underlying layer by an attachment means. The attachment means are shown as nails. In the figures, headless nails are used to attach the gypsum board. However, this embodiment is not limited to headed or headless nails. The nails can be substituted, for example, with screws, staples, or adhesives as attachment means. EXAMPLES

[0098] Again, no unnecessarily limiting of the invention is intended: Where the effects of particular features are shown, the actual selected parameters of the samples (such as dimensions or components) are not intended to limit the invention to each embodiment, and this is not necessary.

[0099] The gypsum fiberboard used in all examples was a gypsum fiberboard known in the art having a gypsum content of 90% to 95% by weight, based on the weight of the board, in this particular case about 93% by weight, and a cellulose fiber content of 8% to 11% by weight, based on the gypsum in the board, in this particular case about 10% by weight. The gypsum fiberboard had a density of 1500±50 kg / m3. The gypsum board in all examples was a gypsum board known in the art having a gypsum content of 90% to 97% by weight, based on the weight of the board, in this particular case about 95% by weight, and a density of 960±20 kg / m3. As is common in the art, the gypsum board had a paper liner of 200 g / m2 to 180 g / m2 and contained 0.4% to 1.0% glass fiber and 0.1% to 0.4% starch by weight, in this particular case about 0.6% glass fiber and about 0.2% starch by weight, all based on the gypsum in the board. In addition, the gypsum board contained 2.0% to 3.5% polyvinyl acetate by weight of its solids, in this particular case 2.9% polyvinyl acetate by weight, based on the weight of the gypsum in the board. The reinforcing studs used were C-shaped, had a steel gauge of 1.00 mm, had a web of 70 mm, one flange was 42 mm, the other flange was 46 mm, and the cavity thickness was about 70 mm. The reinforcing rails were U-shaped and had a steel gauge of 1.00 mm and a flange of 45 mm, although any flange between 40 mm and 65 mm is suitable, for example 52 mm or 57 mm. For the tests, the studs were placed 500 mm apart from each other in a wooden frame. Bullets according to EN 1522:1998 were used. The boards were staggered to ensure that the joints between boards in one layer never overlapped the joints between boards in the next layer. All tests were carried out in accordance with EN 1523:1998.

[0100] Example 1 The following wall assembly passed the test for bulletproof class FB4 according to EN 1522:1998. 28 mm gypsum fibreboard was attached to both flanges of the reinforcing studs (steel gauge 1 mm) via ballistic nails (galvanized carbon steel, 50 mm shaft, diameter 2.5 mm - 2.8 mm). 12.5 mm gypsum board containing polyvinyl acetate was attached to the gypsum fibreboard via ballistic nails (galvanized carbon steel, 25 mm shaft, diameter 1.8 mm, headless). All nails were vertically spaced 10 cm from each other. Three studs of 1.0 m length were placed on the reinforcing rails (steel gauge 1 mm) with 50 cm spacing. Each rail had a length of 1.0 m. The gypsum fibreboard was cut to 410 mm x 1000 mm and 590 mm x 1000 mm and joined by tongue and groove joints to form an area of ​​1.0 m2. This was done on both sides of the wall assembly. The gypsum boards with polyvinyl acetate had sizes of 590mm x 300mm, 590mm x 700mm, 410mm x 300mm, 410mm x 700mm on one side and 410mm x 100mm, 410mm x 900mm, 590mm x 100mm, and 590mm x 900mm on the other side. The boards were joined to form a total area of ​​1.0 m2 on each side. The dimensions of the building boards and the distance between the studs and / or nails were selected to comply with the test requirements. They do not reflect typical building board dimensions. The joints crossed each other but did not completely overlap.

[0101] Example 2 The following wall assembly, containing different configurations on both sides of the wall, passed the test for bulletproof class FB5 according to EN 1522:1998 for shots fired towards both sides. On one side, a 28 mm gypsum fiberboard was attached to both flanges of a reinforcing stud (galvanized steel gauge 1.0 mm) via ballistic nails (galvanized carbon steel, 50 mm shaft, diameter 2.5 mm to 2.8 mm). A 28 mm thick gypsum fiberboard was attached to the underlying gypsum fiberboard via ballistic nails (galvanized carbon steel, 40 mm shaft, diameter 2.8 mm). A 12.5 mm thick gypsum board containing polyvinyl acetate was attached to the outermost gypsum fiberboard via ballistic nails (galvanized carbon steel, 25 mm shaft, diameter 1.8 mm, without head). On the other side, a 28 mm gypsum fiberboard was attached to the flange of a reinforcing stud (steel gauge 1.0 mm) via ballistic nails (galvanized carbon steel, 50 mm shaft, diameter 2.5 mm to 2.8 mm). A 12.5 mm gypsum board containing polyvinyl acetate was attached to the gypsum fiberboard via ballistic nails (galvanized carbon steel, 25 mm shaft, diameter 1.8 mm, headless). A second layer of 12.5 mm gypsum board containing polyvinyl acetate was attached to the underlying layer of gypsum fiberboard containing polyvinyl acetate via ballistic nails (galvanized carbon steel, 25 mm shaft, diameter 1.8 mm, headless). The nails were vertically spaced 10 cm apart from each other. Three studs of 1.0 m length were placed on the reinforcing rail (steel gauge 1 mm), spaced 50 cm apart. Each rail had a length of 1.0 m. The gypsum fibreboards were cut to the following sizes: 540mm x 1000mm, 460mm x 1000mm (first sub-layer on the first side), two boards of 500mm x 1000mm (second sub-layer on the first side), and 590mm x 1000mm, 410mm x 1000mm (second side). The boards of one sub-layer (first side) or layer (second side) were joined by tongue and groove joints to form an area of ​​1.0m2. The joints between the fibreboards ran horizontally. The boards were constructed such that none of the joints overlapped, regardless of whether they were placed on the first side or the second side.The gypsum boards containing polyvinyl acetate had sizes of 300 mm x 1000 mm, 700 mm x 1000 mm, 200 mm x 1000 mm, and 800 mm x 1000 mm in each layer or sub-layer. They were joined to form a total area of ​​1.0 m2. They were attached to a second sub-layer of underlying gypsum fiberboard. The joints between the gypsum boards ran vertically. The boards were constructed such that none of the joints overlapped, regardless of whether they were placed on the first side or the second side. Three shots were fired at the first side, which had two sub-layers of gypsum fiberboard 28 mm thick and one layer of gypsum board 12.5 mm thick. The dimensions of the building boards and the distance between the studs and / or nails were selected to comply with the test requirements. They do not reflect typical building board dimensions.

[0102] Example 3 The following wall assembly passed the test for bulletproof class FB6 according to EN 1522:1998. 28 mm gypsum fibreboard was attached to both flanges of the reinforcing studs (steel gauge 1 mm) via ballistic nails (galvanized carbon steel, 50 mm shaft, diameter 2.5 mm to 2.8 mm). 28 mm gypsum fibreboard was attached to the underlying gypsum fibreboard via ballistic nails (galvanized carbon steel, 40 mm shaft, diameter 2.5 mm to 2.8 mm). 12.5 mm gypsum board with polyvinyl acetate was attached to the outermost gypsum fibreboard via ballistic nails (galvanized carbon steel, 25 mm shaft, diameter 1.8 mm, headless). The nails were vertically spaced 10 cm apart from each other. Three studs of 1.0 m length were placed on the reinforcing rails (steel gauge 1 mm) with 50 cm spacing. Each rail had a length of 1.0 m. The gypsum fiberboard was cut into two boards, 460mm x 1000mm, 540mm x 1000mm for the first sublayer on the first side, and 500mm x 1000mm for the second sublayer on the first side. On the second side, 410mm x 1000mm was joined with 590mm x 1000 to form the first sublayer, and the same size board was joined for the second sublayer. All fiberboards in this example had horizontal tongue and groove joints, and none of the joints overlapped. Each sublayer had a surface area of ​​1.0 m2. The gypsum boards with polyvinyl acetate had sizes of 300mm x 1000mm, 700mm x 1000mm in one layer on either side. The boards were joined to form a total area of ​​1.0 m2. All gypsum boards in this example were joined vertically, such that none of the joints overlapped. The joints between the fiberboards intersected but did not overlap the gypsum board joints. The dimensions of the building boards and the distance between the studs and / or nails were selected to meet the test requirements. They do not reflect typical building board dimensions.

[0103] In all three examples, the bullet flattened after penetrating the first side of the wall assembly. [Explanation of symbols]

[0104] 1 Wall Assembly 2 Vertical framing members 3. Mounting means 4 Cavity 5 S1LF (first side gypsum fiberboard layer) 6 S1LG (first side gypsum board layer) 7 S2LF (Second Side Gypsum Fiberboard Layer) 8 S2LG (Second side gypsum board layer) 9 S1LF2 (second layer of gypsum fiberboard on the first side) 10 S1LG2 (2nd layer of gypsum board on the 1st side) 11 S2LF2 (2nd layer of gypsum fiberboard on the 2nd side) 12 S2LG2 (2nd layer of gypsum board on the 2nd side)

Claims

1. A wall assembly (1) comprising a substructure made of framing members (2) with building boards attached to two opposite sides of said substructure to form a first side of a wall and a second side of the wall, - the first side of the wall comprises at least one layer S1LF (5) of at least one gypsum fiberboard, said layer S1LF having a total thickness of at least 25 mm; - the first side of the wall further comprises at least one layer S1LG (6) of at least one gypsum board, all of the gypsum boards of a layer S1LG comprising 1% to 5% by weight of polyvinyl acetate based on their solids content relative to the weight of the gypsum; - the second side of the wall comprises at least one layer S2LF (7) of at least one gypsum fibreboard, said at least one layer S2LF having a total thickness of at least 25 mm; - there is a cavity (4) between said first side and said second side, said cavity having a thickness of at least 40 mm and filled with air or with insulating material; Wall assembly (1).

2. 2. The wall assembly (1) of claim 1, wherein the second side further comprises at least one layer S2LG (8) of at least one gypsum board, any, some, or all of the gypsum boards of layer S2LG (8) comprising 1% to 5% by weight polyvinyl acetate based on its solids content relative to the weight of the gypsum.

3. 3. The wall assembly (1) according to claim 1 or 2, wherein any, some or all of the gypsum boards of the layer S1LG (6) and / or all of the gypsum boards of the layer S2LG (8) further comprise glass fibres, preferably 0.5% to 2% by weight of glass fibres, more preferably 0.6% to 1% by weight of glass fibres relative to the weight of the gypsum in the boards.

4. 4. The wall assembly (1) according to any one of claims 1 to 3, wherein any, some or all of the gypsum boards of the layer S1LG (6) and / or all of the gypsum boards of the layer S2LG (8) further comprise 0.1% to 3% by weight of starch, preferably 0.1% to 1% by weight of starch, based on the weight of the gypsum present in the boards.

5. 5. The wall assembly (1) according to any one of claims 1 to 4, wherein any, some or all of the gypsum boards of the layer S1LG (6) and / or all of the gypsum boards of the layer S2LG (8) comprise 2% to 4% polyvinyl acetate by weight based on the solids content of the gypsum.

6. The wall assembly (1) according to any one of claims 1 to 5, wherein any, some or all of the gypsum fiberboards of both layers S1LF(5) and S2LF(7) have two adjacent tongue and two groove edges such that adjacent gypsum fiberboards can be joined by a tongue and groove joint, preferably all of the gypsum fiberboards of layers S1LF(5) and S2LF(7) have two adjacent tongue and two adjacent groove edges.

7. A wall assembly (1) according to any one of the preceding claims, wherein the framing members (2) are made from steel or wood, preferably steel, more preferably steel of at least 0.8mm gauge, most preferably steel of at least 1.0mm gauge.

8. A wall assembly (1) according to any one of the preceding claims, wherein said layer S1LF (5) and / or said layer S2LF (7) have a total thickness of at least 50 mm.

9. A wall assembly (1) according to any one of the preceding claims, wherein said layer S1LG (6) and / or said layer S2LG (8) have a total thickness of at least 24 mm.

10. 10. A wall assembly (1) according to any one of claims 8 or 9, wherein both layers S1LF (5) and S2LF (7) have a total thickness of at least 50 mm and said layer S1LG (6) has a total thickness of at least 24 mm.

11. A wall assembly (1) according to any one of the preceding claims, wherein the first side and the second side of the wall structure are mirror symmetrical.

12. The wall assembly (1) of any one of claims 1 to 11, wherein any, some or all of the gypsum fibre boards and all of the gypsum boards are attached to the sub-structure or underlying building board by attachment means (3), preferably said attachment means being nails, more preferably said attachment means being ballistic nails, most preferably said ballistic nails are made of galvanised carbon steel and / or are grooved and / or have a ballistic tip.

13. Wall assembly (1) according to any one of the preceding claims, wherein the layer S1LG (6) and / or the layer S2LG (8) are outermost layers.

14. 14. A method for building a wall assembly (1), in particular a wall assembly (1) according to any one of claims 1 to 13, comprising a substructure made of framing members (2) on two opposite sides of which building boards are attached to form a first side of a wall and a second side of the wall, comprising: - positioning at least two framing members (2); - attaching at least one layer S1LF (5) of gypsum fibreboard having a total thickness of at least 25 mm to said first side; - attaching at least one layer S1LG(6) of gypsum board to said first side, said gypsum board comprising 1% to 5% by weight of polyvinyl acetate; - attaching at least one layer S2LF (7) of gypsum fibreboard having a total thickness of at least 25 mm to said second side; - providing a cavity (4) between said two opposite sides, said cavity having a thickness of at least 40 mm and filled with air or with insulating material; A method comprising:

15. Use of gypsum boards in at least one layer S1LG (6) of a wall assembly (1), in particular a wall assembly (1) according to any one of claims 1 to 13 or a wall assembly (1) built according to claim 14, wherein any, some or all of said gypsum boards comprise 1% to 5% by weight of polyvinyl acetate based on their solids content relative to the weight of the gypsum in the board, in order to achieve ballistic resistance of the wall assembly, preferably said ballistic resistance meeting at least classification FB6 according to EN 1522:1998.

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