Fire-Rated Wall Header Track With Intumescent Seal
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Solution Overview
Problem
Current fire-rated wall systems fail to adequately seal head-of-wall gaps between wallboard and header tracks, and between ceiling/floor decks and header tracks, often requiring post-drywall installation of fire-resistant sealant, which is difficult to apply and inspect effectively.
Innovation Solution
A fire-retardant wall system with a header track incorporating a fire-retardant material strip that expands when exposed to heat, providing a seal between the track and adjacent components before and during expansion, thereby inhibiting air and smoke passage without the need for additional sealants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a header track with slots is used to permit wall stud movement, then the wall assembly can accommodate building movement and earthquakes, but fire-rated wall systems fail to adequately seal head-of-wall gaps between wallboard and header tracks
Solution Approach 1:
The header track is divided into two distinct functional segments: slots in the flanges for movement accommodation, and a separate fire-retardant material strip on the web for fire sealing. This segmentation allows each feature to perform its specialized function without interfering with the other.
Solution Approach 2:
A fire-retardant material strip is introduced as an intermediary element between the header track web and the wallboard/ceiling deck. This strip acts as a mediator that provides fire and smoke sealing while allowing the slots to continue enabling movement.
2Reliability
If fire-resistant sealant is applied after drywall installation to seal gaps, then fire and smoke passage can be inhibited, but the application becomes difficult and inspection becomes ineffective
Solution Approach 1:
The fire-retardant material strip is pre-installed on the header track web before wallboard installation. This preliminary action eliminates the need for difficult post-drywall sealant application and enables effective inspection, as the sealing feature is visible and accessible during construction.
Solution Approach 2:
The fire-retardant material strip is positioned to automatically seal gaps between the header track and wallboard or ceiling deck as these components are installed. The system serves itself by providing fire protection through its inherent design rather than requiring additional sealant application steps.
3Reliability
If intumescent material is placed only on the inner surface of a separate fire block device, then the device can expand to create a fire barrier, but the header track itself does not provide fire sealing
Solution Approach 1:
The fire-retardant material strip is directly attached to the header track web, merging the fire protection function with the structural header track. This integration eliminates the need for separate fire block devices and simplifies the overall wall assembly.
Solution Approach 2:
The header track is designed to perform multiple functions: structural support through the web and flanges, movement accommodation through slots in the flanges, and fire sealing through the fire-retardant material strip on the web. This multi-functionality reduces the number of separate components needed.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively seals gaps between wallboard and header tracks, and between ceiling/floor decks and header tracks, meeting UL 2079 test standards by using integrated fire-retardant material strips that expand to prevent smoke and fire passage, enhancing fire and smoke protection during initial wall framing.
Implementation Method 1
The fire-retardant material strip is configured to expand when exposed to heat
Implementation Method 2
Intumescent materials work well for this purpose, since they swell and char when exposed to flames, helping to create a barrier to the fire, heat, and/or smoke
Data Source
AI summary
The present application is directed toward fire-rated wall construction components and wall systems for use in building construction. Embodiments can include tracks for holding studs which incorporate various geometries capable of receiving fire-retardant material, including but not limited to intumescent material. The fire-retardant material can be attached to the tracks such that the fire-retardant material expands and seals gaps and/or areas between the tracks and wall components such as ceilings, floors, and drywall.