FIREBREAK SYSTEM FOR AREA SEPARATION

Abstract

A firewall consists of wallboards arranged in three or more layers. The wallboard may include gypsum, fiberglass, and / or vermiculite. The firewall may be reinforced with fasteners, such as mill screws, that secure the wallboard layers together. The firewall may be incorporated into an area partition wall in a manner that meets ASTM E119 or UL 263 standards.

Description

FIREBREAK SYSTEM FOR AREA SEPARATION uooo FIELD OF INVENTION This disclosure relates to area separation firewalls. More specifically, the disclosure relates to an improved firewall for use in area separation firewall systems, with this system including wider and thinner pieces of gypsum wallboard that are easier to fabricate and install compared to traditional 2.54 cm (1") thick shaft lining wallboard. BACKGROUND OF THE INVENTION International, state, regional, and local building codes require multifamily residential buildings to include certain fire protection elements, such as firewalls between residential units. The standard for qualifying fire-resistant systems is ASTM E119 (Standard Test Methods for Fire Testing of Building Construction and Materials) or ANSI / UL 263 (Standard for Fire Testing Safety of Building Construction Materials). During this test, an area separation firewall system is heated to 537.778 °C (1000 °F) and then raised to 1093.333 °C (2000 °F). The firewall must be able to withstand this heat for a specified period of time, such as two hours.Another aspect of this test is a hose stream test, in which a stream of pressurized water is directed at the fire-resistant vertical wall assembly after fire resistance exposure, simulating a fire being extinguished. The vertical firewall must be able to maintain its structural integrity and prevent water from penetrating it. For decades, multi-family residential firewalls have been constructed using two pieces of 2.54 cm (1 in) thick shaft cladding wallboard. These wallboards are particularly difficult to manufacture and often slow production by a factor of two or more. These thick wallboard pieces are also cumbersome, being only 0.6096 m (2j) wide, compared to the 1.2192 m (4j) width of other wallboard panels, in order to manage their weight. This reduced width results in increased material and labor costs when installing the firewall, as the two shaft cladding wallboard pieces must be joined to the next section using a metal H-bolt. Despite the long lifespan of these firewalls, little improvement has been made to the conventional design.Therefore, there remains a great need for an improved firewall wall board that can be efficiently manufactured and installed. BRIEF DESCRIPTION OF THE DRAWINGS Several embodiments of this disclosure will be better understood from the detailed description provided below and the accompanying drawings. In the drawings, similar reference numbers may indicate identical or functionally similar elements. The embodiments are described in detail below with reference to the accompanying figures, in which: FIGURE 1 is a top view of an area separation firewall according to a prior art modality. FIGURE 2 is a top view of an area separation firewall according to one modality of this disclosure. FIGURE 3 is a side view of an area separation firewall according to a modality of the present disclosure. FIGURE 4 is a side view of an area separation firewall according to another modality of this disclosure. FIGURE 5 is an opposite side view of the area separation firewall of FIGURE 3 or FIGURE 4. FIGURE 6 is a cross-sectional side view of an area separation firewall within an intermediate floor intersection according to an embodiment of the present disclosure. FIGURE 7 is a cross-sectional side view of an area separation firewall at a roof junction according to a modality of the present disclosure. FIGURE 8 is a top cross-sectional view of an area separation firewall at an exterior wall intersection according to a modality of this disclosure. FIGURE 9 is a graph showing the results of Example 1. FIGURE 10 is a graph showing the results of Example 2. DETAILED DESCRIPTION OF THE INVENTION The following disclosure provides many different modalities or examples. Specific examples of components and arrangements are described below to simplify this disclosure. Of course, these are only examples and are not intended to be exhaustive. Additionally, this disclosure may repeat reference numbers and / or letters in the various examples. This repetition is for the sake of simplicity and clarity and does not, in itself, dictate a relationship between the various modalities and / or configurations discussed. FIGURE 1 is a top view of a conventional separation firewall MA / a / ZUZZ / UI uooo 2-hour areas 10. The area separation firebreak 10 includes a pair of opposing interior walls 5, each of which is supported by a series of studs 4, which are usually made of wood. Between the interior walls 5 is a firebreak 8 separated from the studs 4 by an air space 7, which can be approximately 1.905 cm (3 / 4'j). The firebreak 8 includes panels of two wallboard thicknesses comprising two 2.54 cm (1) thick wallboards 3. Each wallboard 3 can have a width of approximately 0.6096 m (2j). The panels of the firebreak 8 are joined together by H-studs 2 and one end panel of the firebreak 8 is capped with a C-stud 1. The C-studs 1 and the H-studs 2 can be made of metal, such as steel.The H-bolts are attached to the wooden structure using clamps 6, which are usually made of aluminum and are configured to detach if the wooden structure collapses in a fire, thus leaving the firebreak 8 standing. Figure 2 is a top view of a 2-hour area separation firewall 100 according to an embodiment of the present disclosure. The area separation firewall 100 includes a pair of opposing interior walls 50, each supported by a series of studs (framework) 40, typically made of wood or metal. The studs 40 are spaced a maximum distance W2 of approximately 0.6096 m (2 ft). Between the interior walls 50 is a firewall 80 separated from the studs 40 by an air gap 70 of a minimum of 1.905 cm (¾ in). The firewall 80 includes panels of four wallboards of thickness 30, each having a nominal thickness of, for example, less than 2.54 cm (1 in) or approximately 1.27 cm (0.5 in). Consequently, the 80 firewall can be as thick as a traditional firewall with two 2.54 cm (1 in) thick wallboard pieces. Each 30 wallboard can have a W1 width greater than 0.6096 m (2j), approximately 0.9144 m (3j), approximately 1.0668 (3.5'), approximately 1.2192 m (4j), or more than 1.2192 m (4j). The increased width of the 30 wall boards is possible thanks to the thinner profile, so the 30 wall boards can be as heavy as traditional wall boards. The 80 firestop panels are joined together by H 20 studs, and one end panel of the 80 firestop is capped with a C 10 channel, such as a 5.08 cm (2") C stud. The 80 firestop can be friction-fitted at each of the C 10 studs and the H 20 studs. The H 20 studs and / or the C 10 studs can be fixed to the 40 timber frame with aluminum clamps. 60. In some versions, the clamps 60 are made of aluminum and are designed to melt or break if the wooden structure 40 collapses in a fire, thus leaving the firewall 80 standing. In any embodiment, the material used for Wallboard 30 is typically more fire-resistant than that used for Interior Walls 50. In some embodiments, Wallboard 30 may be composed of gypsum, fiberglass, and vermiculite. In one or more embodiments, Wallboard 30 comprises one or more of a dispersant, a fire retardant, a chelating agent, a soap, a binder or adhesive, an accelerator, a surfactant, an acid, a stabilizing agent, and / or a foaming agent. In some embodiments, the dispersant may include polynaphthalene sulfonate in a sodium or calcium saline solution (with a solids content of 2 to 80%). In some embodiments, the binder or adhesive may include starch, such as acid-modified corn starch (AMCS) or pregelatinized corn starch. In some forms, the retarder or chelating agent may include pentasodium diethylenetriamine-pentaacetate.In some embodiments, the acid may include boric acid. In some embodiments, the stabilizing agent is sodium trimetaphosphate (STMP). In some embodiments, the soap, surfactant, and / or foaming agent may include ammonium alkyl ether sulfate. In one embodiment, the wallboard may have the following formulation: Table 1: MA / a / ZUZZ / UI uooo Component Content (lbs. / msf) Retarder 0.02 - 4.0 Stucco 1300-1700 Soap 1.0-7.0 Starch 3.0-12.0 Vermiculite 25.0-65.0 Fiberglass 3.0-16.0 Core Adhesive 6.0-25.0 Dispersing Agent 1.0-8.0 Foaming Agent 0.01 - 5.0 Boric Acid 0.02-5.0 STMP 1.50-9.0 Accelerator 6.0-15.0 Average Weight 1950-2100 In one or more configurations, the wallboard 30 may be a commercially available wallboard from American Gypsum sold under the trade name M-BLOC® Ekcel ©TYRE X. In some configurations, the interior walls 50 may be formed from 1.27 cm (1 / 21 in) thick gypsum boards, available from American Gypsum under the trade names LIGHTROC® or CLASSICROC®. Because the firewall 80 is typically installed before the roof and exterior walls are completed, the wallboard 30 may be exposed to the elements for a period of time. As such, in some configurations, an exterior surface of the wallboard 30 may be coated with a mold- and moisture-resistant paper. Returning to FIGURE 3, each panel of four wallboards can be supported at the top and bottom by a channel at C 12. The wallboard pieces 30 each have a height H4 that corresponds to the height of the stud at H 20 in use. As will be described in more detail below, the area partition wall 100 will typically extend through all floors of the building and therefore will have a height that is generally equivalent to the height of the building. To provide additional support to the wallboards 30, 2.54 cm-1.27 cm (1-1 / 2") Type G lamination screws 94 are installed to fasten the four layers of wallboard 30 together. In some embodiments, the fasteners 94 are nails, screws, or an adhesive. When fasteners 94 are used, they may be configured in a random assortment or in a pattern 90.In the configuration shown in FIGURE 3, the fasteners 94 are equally spaced within the pattern 90, and the pattern 90 is spaced from the edges of the wall board 30. Specifically, within the pattern 90, the fasteners 94 are spaced by a lateral distance D2 and a vertical distance H2. The distances D2 and H2 may be equal or different. In some configurations, the distance D2 is less than the distance H2. In other configurations, the distance D2 is greater than the distance H2. The pattern 90 is spaced from the vertical edges of the wall board 30 by distances Di and D3, which may be equal or different. In some configurations, one or both distances Di and D3 are equal to the distance D2. The pattern 90 is spaced from the horizontal edges of the wall board 30 by distances H1 and H3, which may be equal or different.In some modalities, the distances Di, D2, D3, H1, K2 and H3 are each, independently, from approximately 7.62 cm (3) to approximately 91.44 cm (36), from approximately 15.24 cm (6) to approximately 60.96 cm (24), from approximately 30.48 cm (12) to approximately 76.2 cm (30), from approximately 50.8 cm (20) to approximately 91.44 cm (36), from approximately 40.64 cm (16), from approximately 60.96 cm (24) or from approximately 30.48 cm (12). With reference to FIGURE 4, an alternative pattern 90A is shown. In FIG. 4, pattern 90A is separated from the edges of wallboard 30 by distances D5 and D7, which may be equal or different from each other. Pattern 90A includes a center column of fasteners 94 separated from the outer columns of fasteners 94 by distances D5 and D6, which may be equal or different from each other. In some modalities, the distances D4, D5, D6 and D7 are each, independently, from approximately 7.62 cm (3) to approximately 91.44 cm (36), from approximately 15.24 cm (6) to approximately 60.96 cm (24), from approximately 30.48 cm (12) to approximately 76.2 cm (30), from approximately 50.8 cm (20) to approximately 91.44 cm (36), from approximately 40.64 cm (16), from approximately 60.96 cm (24) or from approximately 30.48 cm (12). Returning to FIGURE 5, an opposite side of the wallboard panel 30 may also include a set of fasteners 94. In some embodiments, the fasteners 94 are arranged in a second pattern 92, which may be the same as or different from pattern 90. In FIG. 4, pattern 92 is distinct from, but complementary to, pattern 90. Arranging the fasteners 94 in this way provides excellent structural support while conserving materials. The fasteners 94 are spaced from each other within pattern 92 by a lateral distance Dg and a vertical distance Hg. Although the embodiment shown includes the same vertical spacing for patterns 90 and 92, the respective vertical spacings may be, for example, offset by a distance of approximately 7.62 cm (3 in), approximately 15.24 cm (6 in), approximately 22.86 cm (9 in), or approximately 30.48 cm (12 in). In other modalities, the Dg distance is greater than the Dg distance.In some configurations, the distance Dg is less than the distance Dg. In still other configurations, the distance Dg is equal to the distance Dg. The 92 pattern is spaced from the vertical edges of the wallboard 30 by the distances De and Dio, which may be equal or different. In some configurations, one or both distances Ds and Dw are equal to the distance Dg. In some modalities, the distances Ds, Dg, and Dio are each, independently, approximately 7.62 cm (3 in) to approximately 91.44 cm (36 in), approximately 15.24 cm (6 in) to approximately 60.96 cm (24 in), approximately 30.48 cm (12 in) to approximately 76.2 cm (30 in), approximately 50.8 cm (20 in) to approximately 91.44 cm (36 in), approximately 40.64 cm (16 in), approximately 60.96 cm (24 in), or approximately 30.48 cm (12 in). In one modality, the distance Di is approximately 30.48 cm (12 in), the distance D2 is approximately 91.44 cm (36 in), and the distance D3 is approximately 30.48 cm (12), the distance D4 is approximately 30.48 cm (12), the distance D5 is approximately 30.48 cm (12), the distance D6 is approximately 30.48 cm (12), the distance D7 is approximately 30.48 cm (12), the distance D8 is about 40.64 cm (16), the distance Dg is approximately 40.64 cm (16), the distance Dw is approximately 40.64 cm (16), the distance Hi is approximately 30.48 cm (12), the distance H2 is approximately 60.96 cm (24), the distance H3 is approximately 30.48 cm (12), and the distance H4 is approximately 3.048m (10'). In any of the above embodiments, the fasteners 94 may be spaced such that any fastener 94 has at least one adjacent fastener 94 within a specified maximum distance. At least one adjacent fastener 94 may be on the same side of wallboard 30 as any fastener 94 or may include fasteners 94 on the opposite side of wallboard 30. In some embodiments, the specified maximum distance is approximately 15.24 cm (6 in) to approximately 60.96 cm (24 in), approximately 20.32 cm (8 in), approximately 30.48 cm (12 in), approximately 35.56 cm (14 in), approximately 40.64 cm (16 in), approximately 45.72 cm (18 in), approximately 50.8 cm (20 in), approximately 55.88 cm (22 in), or approximately 60.96 cm (24 in). With reference to FIGURE 6, in multi-story buildings, the area separation wall 100 may need to span an intermediate floor crossing. As shown, an air gap 70 is maintained along the entire length of the area separation wall 100. In some embodiments, additional fire-blocking material 32 may be required near the floor joists 46. The fire-blocking material 32 may comprise, for example, a gypsum wallboard (as described for wallboard 30) or mineral fiber insulation. Insulation 48, such as fiberglass block, may be placed as required between interior walls 50. Between levels 80a and 80b of the firestop 80, two studs C 10 may be placed back-to-back.Although the joint (at bolts C 10) between levels 80a and 80b is shown in a position above the upper floor 52a, the joint may be between floor 52a and roof 52b or below roof 52b. In some configurations, caulking or other sealant may be used at the joint to create a smoke-tight seal. Next, returning to FIGURE 7, the area separation firebreak 100 is shown at a junction with a roof deck 56. The roof deck 56 includes the roofing 56a. In some embodiments, a layer 54 is required beneath the roof deck 56, where the layer 54 may be, for example, a wallboard layer as described above. In some embodiments, the layer 54 is approximately 1.5875 cm (5 / 8 in) thick. An O-channel 10 may cover the firebreak 80 where it meets the roof deck 56. At this point, caulking or other sealant may be used to create a smoke-tight joint. In some embodiments, additional fire-blocking material 32 may be required near the structure 44 (including the roof joists). The fire-blocking material 32 may be as described above. With reference to FIGURE 8, the area separation wall 100 is shown at a junction with an exterior wall 58. In some embodiments, a sheathing layer 48 may be included within the exterior wall 58. In some embodiments, the sheathing layer 58 is approximately 1.5875 cm (5 / 8 in) thick. A channel in C ινΐΛ / a / zuzz / ui uooo may cover the firestop 80 where it meets the exterior wall 58. At this point, caulking or another sealant may be used to create a smoke-tight joint. Although the 80 firewall is described herein as consisting of four pieces of 30 wallboard, the firewall may include, for example, three, five, or six pieces of 30 wallboard. In any configuration, the thickness of the 80 firewall can be maintained, for example, at approximately 2 by appropriately adjusting the thickness of the 30 wallboard. For example, three pieces of 30 wallboard may each have a thickness of approximately 1.69333 cm (2 / 3). According to the specifications in this disclosure, the 80 firestop can provide similar or improved fire protection compared to conventional firestops, while significantly reducing production and installation costs. As previously discussed, conventional 2.54 cm (1 in) thick and 0.6096 m (2 ft) wide wallboards can slow production by a factor of two or more. In contrast, the 30 wallboard disclosed herein does not cause such a reduction in production. Additionally, even though four pieces of 30 wallboard are used for each panel (compared to two in conventional firestops) and fasteners 94 are required, installation of the 80 firestop of this disclosure is still faster than that of conventional firestops. This is primarily because the wider pieces of 30 wallboard require fewer H-bolts 20. Examples Example 1; An area-separating firewall, generally as shown in Figure 2, was assembled using four pieces of W-thick wallboard for the firewall, G-type rolling screws as fasteners for the wallboard, 1.27 cm (1 / 2 in.) thick gypsum board for the interior walls, steel H-bolts, C-channels, wood studs spaced 40.64 cm (16 in.) apart, friction-fit fiberglass insulation blocks in the cavities between the wood studs, and regular 1.27 cm (1 / 2 in.) thick gypsum wallboard secured to the wood studs. This assembly was then tested in accordance with ASTM E90-09 (2016): Laboratory Measurement of Airborne Sound Transmission of Partitions and Building Elements.The results of this test are shown in Figure 9, where the Sound Transmission Class (STC) contour is shown as a double line, transmission loss (TL) as a single line, and STC deficiencies as a bar graph. This test resulted in an STC rating of 56, which corresponds to the STC contour shown. uooo Example 2: An area partition wall was erected as described in Example 1, except that the wood studs were spaced at 60.96 cm (24 in.) o'clock. This assembly was then tested in accordance with ASTM E90-09 (2016). The results of this test are shown in Figure 10. This test resulted in an STC rating of 61, which corresponds to the STC contour shown. Example 3: An area separation wall was assembled as described in Example 2. This assembly was then tested according to the standard, Fire Testing of Building Construction and Materials, UL 263 (ASTM E119), 143rd edition of August 5, 2021, and the standard, Standard Methods of Testing Fire Resistance of Building Construction and Materials CAN / ULC-S101-14, fifth edition, of December 2, 2020. The observations made during the fire test are summarized in Table 2. Table 2 ινΐΛ / a / zuzz / ui uooo Test Time, Min Exposed (E) or Unexposed (U) Surface Observations 0 U Measured speed on the unexposed surface of the test assembly was 0 FPS. 0 E&U Gas activated. 7 E Paper face of plaster has burned. Slight warping (wavy appearance) of exposed H-stud tabs. 24 E&U No significant change. Entire board in place. 34 E&U No significant change. Entire board in place. 46 E&U No significant change. Entire board in place. 60 E Exposed face layer moving away from north and south H-studs. Approximately 1.27 cm (0.5 in) at mid-height of the assembly. 74 E Exposed gypsum face layer has fallen off (1.2192 m (4 ft) span to the north). 76 E The 1.2192 m (4 ft) gypsum board to the south detached approximately 7.62 cm (3 in) at mid-height. (continuation) 85 E The 4-foot plaster frames to the north and south, the first two layers have fallen. 117 E& U The assembly could not support the load. 119 U Flame through the unexposed surface. 120 E& U Gas out. As shown above, the assembly met the requirements for a 1.5-hour (90-minute) load-bearing wall. The finish rating is defined as the time required to raise the average temperature measured on the face of the wood studs closest to the fire by 121.111 °C (250 °F) or the time required to raise the temperature on the wood studs by 162.778 °C (325 °F) at any point. The average temperature measured on the wood studs was 21.6667 °C (71 °F) before the test. Therefore, the average limit temperature was 160.556 °C (321 °F), and the individual limit temperature was 202.222 °C (396 °F). The individual limit temperature occurred at 103 minutes. The average limit temperature was reached at 105 minutes. The initial average temperature of the unexposed surface was 21.6667 °C (71 °F). Therefore, based on the average temperature increase of 121.111 °C (250 °F) above the initial temperature and a maximum individual increase of 162.778 °C (325 °F) above the initial temperature, the average limiting temperature was 160.556 °C (321 °F) and the individual limiting temperature was 202.222 °C (396 °F). The individual limiting temperature occurred at 117 min. The average limiting temperature was reached at 118 min. No suspicious hot spots requiring the application of cotton residue or the wick thermocouple developed during the test. A duplicate assembly was then heated according to the above standards for 1 hour before a hose current test. Observations during heating are summarized in Table 3 below. Table 3: Test time, Hr:Min Exposed (E) or unexposed (U) surface Observations 0:00 E / U The measured speed on the unexposed surface of the test assembly was 0 FPS. 1:00 E / U No significant changes occurred. Gas off. The assembly was then subjected to the impact, cooling, and erosion of a 30 psi water stream applied through a 2.54 cm (0.3175 cm) diameter nozzle at a distance of 6.096 m (20 ft) for 2-1 / 2 min. During the hose stream test, water did not penetrate through the four layers of 5 x 1.27 cm (1 / 2 in) thick boards that formed the area separation wall. Furthermore, water did not penetrate beyond the unexposed surface during the 2-1 / 2 minute hose stream test. The assembly held the load throughout the 2-1 / 2 minute hose stream test. Although several embodiments have been shown and described, the disclosure is not limited to those embodiments and shall be understood to include all modifications and variations that would be obvious to a person skilled in the art. Therefore, it should be understood that the disclosure is not intended to be limited to the particular embodiments disclosed; rather, the intention is to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of the disclosure as defined in the appended claims.

Claims

1. A fire barrier, characterized in that it comprises: a wall board arranged in three or more layers, wherein the wall board comprises gypsum.

2. The firewall according to claim 1, characterized in that it further comprises metal bolts fixed to one or more edges of the wall panel.

3. The firebreak according to claim 1, characterized in that the wall panel further comprises vermiculite and fiberglass.

4. The firewall according to claim 1, characterized in that the firewall meets the standards of ASTM E119 or UL 263.

5. The firewall according to claim 1, characterized in that the firewall has a thickness of approximately 5.08 cm (2'j.

6. The firewall according to claim 1, characterized in that it further comprises fasteners that fix the three or more layers of wallboard together.

7. The firewall according to claim 6, characterized in that the fasteners are rolling screws.

8. The firewall according to claim 7, characterized in that the fasteners are located on opposite sides of the firewall and are arranged at regular intervals.

9. An area separation wall, characterized in that it comprises: a pair of interior walls supported on a structure and spaced apart from each other; the fire barrier according to claim 1 placed within a space between the pair of interior walls; and clamps that fix the fire barrier to the structure.

10. The area separation wall according to claim 9, characterized in that the area separation wall meets the standards of ASTM E119 or UL263.

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