FIRE-RATED WALL JOINT COMPONENT AND RELATED ASSEMBLIES

Abstract

A fire-rated component for a linear gap between a wall assembly and an adjacent structure. The component includes an elongate metal profile and a fire-rated board member. The elongate metal profile has a vertical leg, an upper leg and a lower leg. The upper leg extends in a first direction from an upper edge of the vertical leg. The lower leg extends in the first direction from a lower edge of the vertical leg. The fire-rated board member is positioned within a space defined by the vertical leg, the upper leg and the lower leg.

Description

CROSS-REFERENCE

This application claims the benefit of U.S. Application No.: 63/374,128, filed on Aug. 31, 2022, and is a continuation-in-part of U.S. application Ser. No.: 17/108,966, filed on Dec. 1, 2020, pending, which claims the benefit of U.S. Application No.: 62/942,423 filed on Dec. 2, 2019, the entireties of which are hereby incorporated by reference.

BACKGROUND

Field

This application is directed to fire-rated wall construction components for use in building construction joints.

Related Art

Fire-rated wall construction components and assemblies are commonly used in the building construction industry. These components and assemblies are aimed at preventing fire, heat, and smoke from leaving one portion of a building or room and entering another, usually through vents, joints in walls, or other openings. The components can incorporate fire-retardant materials which substantially block the path of the fire, heat, and/or smoke for at least some period of time in accordance with certain standards, such as UL-2079 “Test For Fire-rated Building Joints”.

Conventional fire-rated wall construction components are typically labor intensive and expensive to install. One example of a conventional fire block arrangement includes using a fire-resistant material such as mineral wool stuffed in the gaps within a head-of-wall assembly including deflection gaps between the top of the wall boards and the ceiling. Once the gaps are filled with the fire block material, a flexible coating such as a spray-on elastomeric coating can cover the entire head-of-wall to secure the fire block material in place. Over time and cycles of movement the flexible coating may degrade and cause cracks or flaking. As a result, it is possible that the fire-resistant material may become dislodged and thereby reduce the effectiveness of the fire block.

SUMMARY

One aspect of the present disclosure is a fire-rated component for a linear gap between a wall assembly and an adjacent structure. The component includes an elongate metal profile and a fire-rated board member. The elongate metal profile includes a vertical leg, an upper leg and a lower leg. The upper leg extends in a first direction from an upper edge of the vertical leg. The lower leg extends in the first direction from a lower edge of the vertical leg. The fire-rated board member is positioned within a space defined by the vertical leg, the upper leg and the lower leg to form a composite component.

According to another aspect, the upper leg includes a downward facing v-groove. According to another aspect, the upper leg includes an extended free end attachment leg. According to another aspect, an outward facing protrusion on the vertical leg rests against the drywall board of the framed wall assembly with the outward facing protrusion extending in a second direction, opposite the first direction. According to another aspect, the gypsum board member is adhesively attached with the vertical leg. According to another aspect, the lower leg includes a kick-out configured to retain a gypsum board member within the space. According to another aspect, the upper leg, the lower leg, the v-groove, and the kick-out are configured to exert a force against the gypsum board member to retain the gypsum board in the space. According to another aspect, the lower leg determines the thickness of the layer or layers of the gypsum board member. According to another aspect, the metal profile is formed from a unitary piece of sheet steel and bent to form the vertical leg. According to another aspect, the board member comprises a gypsum material.

In another aspect of the present disclosure, a building construction joint includes a wall assembly and an adjacent structure formed along a linear gap. A fire-rated component including an elongate metal profile and a fire-rated board member is positioned at a joint between the wall assembly and the adjacent structure to provide fire-blocking across the linear gap. According to another aspect, the adjacent structure is a ceiling and the wall assembly is a vertical wall.

According to another aspect, a fire-rated component for a linear gap between a wall assembly and an adjacent structure can comprise an elongate metal profile. The elongate metal profile can comprise a vertical leg, an upper leg, and a lower leg. The upper leg can extend in a first direction from an upper edge of the vertical leg. The lower leg can extend in the first direction from a lower edge of the vertical leg. The fire-rated board member can be positioned within a space defined by the vertical leg, the upper leg, and the lower leg. A gasket can be positioned between a wallboard of the wall assembly and the vertical leg. The gasket can be a fire blocking gasket. In some embodiments, the gasket can comprise vinyl. In some embodiments, a length of the gasket can be 8 feet. In some other embodiments, the length of the gasket can be between about 4 feet to about 10 feet. Other suitable values smaller than about 4 feet or larger than about 10 can also be utilized depending on a user's need. In some embodiments, the gasket can comprise flexible material.

The foregoing summaries are illustrative only and are not intended to be limiting. Other aspects, features, and advantages of the systems' devices and methods and/or other subject matter described in this application will become apparent in the teaching set forth below. The summaries provided introduce a selection of some of the concepts of this disclosure. The summary is not intended to identify key or essential features of any subject matter described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

Various examples are depicted in the accompanying drawings for illustrative purposes and should in no way be interpreted as limiting the scope of the examples. Various features of different disclosed examples can be combined to form additional examples which are part of this disclosure.

FIG. 1 illustrates a cross section of a head-of-wall assembly including a composite fire-blocking component.

FIG. 2A shows a cross-section of the head-of-wall assembly in a fully closed configuration.

FIG. 2B shows a cross-section of the head-of-wall assembly in a fully opened configuration.

FIG. 3 shows a cross-section of the composite fire-blocking component including a metal profile and board member.

FIG. 4 shows a cross-section of an elongate metal profile.

FIG. 5 shows a cross-section of the composite fire-blocking component including a gasket.

FIG. 6 illustrates a cross section of a head-of-wall assembly including a composite fire-blocking component including a gasket.

FIG. 7 is a sectional view of a fire block component.

FIG. 8 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component of FIG. 7.

FIG. 9 is a sectional view of an alternative fire block component.

FIG. 10 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component of FIG. 9.

FIG. 11 is a sectional view of another alternative fire block component.

FIG. 12 is a sectional view of another alternative fire block component.

FIG. 13 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component of FIG. 12.

FIG. 14 is a sectional view of a head-of-wall portion of a wall assembly including the fire block component of FIG. 12 in action.

FIG. 15 is a sectional view of a head-of-wall portion of a wall assembly including a prior art fire proofing arrangement.

DETAILED DESCRIPTION

FIGS. 1-2B illustrate a building construction joint between a wall assembly and an adjacent structure having a linear gap in the form of a head-of-wall assembly 100. The embodiments disclosed herein often are described in the context of an interior of a building and configured for preventing passage of smoke and/or fire between adjacent rooms in an elevated-temperature environment. However, the embodiments herein can be applied to wall systems configured for other types of environments as well, such as for exterior wall applications, and can include different and/or additional components and types of materials other than those described herein.

The head-of-wall assembly 100 can generally include an overhead structure or ceiling 105. The ceiling 105 can be generally formed in a horizontal plane and/or include one or more flutes or grooves therein. The ceiling 105 can be a floor of a higher level of a building. The head-of-wall assembly 100 can include a header track or channel 107. The channel 107 can include a web 107a to which are attached one or more flanges 107b, 107c. The first and second flanges 107b, 107c can extend from opposite ends of the web 107a in the same direction to form a generally u-shaped cross section. Optionally, the channel 107 can be a deep leg header track.

One or more studs 109 forming the wall can be received within the channel 107 between the first and second flanges 107b, 107c. The first and second flanges 107b, 107c can include slots to which fasteners can be received to attach the channel 107 with the studs 109. The slots can be oriented generally orthogonal to a length of the channel 107. The studs 109 can be attached with the channel 107 via fasteners through the slots of the flanges 107b, 107c.

One or more wall board members (e.g., gypsum drywall) 111, 113 can be attached with the studs 109 to form the wall. Assembly of the wall boards 111, 113 with the studs 109 can define a deflection gap 101 between the ceiling 105 and upper ends of the wall boards 111, 113. The deflection gap 101 can vary in width depending on the relative position of the wall (e.g., wall boards 111, 113 and the studs 109) and the ceiling 105. The head-of-wall assembly 100 can cycle between a more closed position (such as the fully closed position in FIG. 2A) and a more open position (such as the fully open position in FIG. 2B). The dynamic nature of the head-of-wall assembly 100 can accommodate seismic or thermal forces or other movements of the building within which the head-of-wall assembly 100 is included.

The head-of-wall assembly 100 can include a fire-rated composite component 10. The composite component 10 can generally be configured to cover the deflection gap 101 to provide fire, smoke, heat and/or sound insulation and facilitate unencumbered movement of the joint. The component 10 can include an elongate metal profile 12 and a board member 14. The board member 14 can comprise a fire-rated material, such as a gypsum drywall material. In certain implementations, the board member 14 can adhesively attached or otherwise mechanically secured with the metal profile 12 to form the composite component 10.

The composite component 10 can be installed over the outer surface of the wall boards 111, 113 and/or the flanges 107b, 107c on the framed wall assembly once the drywall assembly is completed. The component 10 can be attached with the ceiling 105 by one or more fasteners 103, such as metal screws, adhesives, staples or other fasteners. The fasteners 103 can extend through the metal profile 12. The fire board member 14 can insulate the metal profile 12, while the metal profile 12 provides a constant fire block as it will not melt during the fire test of UL 2079. The combination of these two materials provides long lasting fire protection. In addition, drywall used in the board member 14 is less expensive than other fire-resistant materials, such as intumescent materials, that are often used in head-of-wall assemblies or other gaps of a building construction joint.

The metal profile 12 can come in standard lengths (e.g., 10′, 12′, etc.). As shown further in the cross-section of FIG. 3, the metal profile 12 can include a single sheet of metal, such as steel. The metal profile 12 can include a plurality of bends to form the metal profile shape. The metal profile 12 can include a vertical leg 16, an upper leg 24, and/or a lower leg 20. The vertical leg 16 can have a length L extending from the upper leg 24 to the lower leg 20. The length L can vary depending on the size of the head-of-wall deflection gap 101 and the overall dynamic movement needed. The length L can generally be between about 1″ and 6″. The vertical leg 16 can comprise a flattened portion of the metal profile 12. Alternatively, the vertical leg 16 can comprise one or more strengthening features such as grooves or ribs.

The upper leg 24 can couple with the vertical leg 16 at a corner 34. The upper leg 24 can generally form perpendicular angle with the vertical leg 16. The upper leg 24 can extend from the corner 34 in a first (e.g., rightward) direction. The upper leg 24 can be a horizontal leg. The upper leg 24 can be approximately 1.5″-3.5″ in length.

The upper leg 24 can include a groove 22. The groove 22 can be shaped as a v-groove, u-groove, or other form factor. The groove 22 can include an open end facing upwards and outwards. The groove 22 can provide structural strength to the metal profile 12 and to the upper leg 24. Other retention features and/or strengthening features could also be used. The groove 22 can extend downwardly towards the lower leg 20. The groove 22 can divide the upper leg into an inner portion 25 and an outer portion 26. The inner portion 25 can be in-line with the outer portion 26. The inner portion 25 can have a width W1 from the corner to the groove 22 (e.g., approximately 0.625″). The outer portion 26 can include an attachment portion of the metal profile 12. The outer portion 26 can have a width of approximately 1.25″. The attachment can include one or more holes or other mechanism to allow an installer to attach the metal profile 12 to the ceiling 105 (or other adjoining structure).

The lower leg 20 can couple with the vertical leg 16 at a corner 30. The lower leg 20 can generally form perpendicular angle with the vertical leg 16. The lower leg 20 can extend from the corner 30 in the first (e.g., rightward) direction. The lower leg 20 can extend in the same direction as the upper leg 24. The lower leg 20 can be a horizontal leg.

The lower leg 20 can include a kick-out 32. The kickout 32 can be on a free end of the lower leg 20. The kickout 32 can include an upturned retention lip or portion of the lower leg 20 (e.g., towards the upper leg 24). The kick-out 32 can be angled upwardly towards the upper leg 24. The lower leg 20 can include a width W2 from the corner 30 to the free end or the kickout 32. The width W2 can optionally be the same as the width W1.

The lower leg 20, the vertical leg 16, and the upper leg 24 can form an inner, partially enclosed space. The inner space can receive and secure the board member 14. The board member 14 can comprise a fire-rated drywall member. The board member 14 can comprise one or more layers of material. The board member 14 can be a rip of drywall comprising a gypsum material. The board member 14 can include a generally rectangular-shaped profile. The board member 14 can nest within the inner space between the upper leg 24, the vertical leg 16, and the lower leg 20. Preferably, the width W1 of the upper leg 24 and the width W2 of the lower leg 20 can be sized to accommodate a width W3 of the board member 14. The kickout 32 and/or the groove 22 can exert an inward force on the board member 14 to help retain the board member 14 within the inner space and/or against the vertical leg 16. In certain implementations, the width W1 can be the same as width W2 and correspond to the width W3 of the board member 14. The widths W1, W2 can limit the W3 of the board member 14 that can be used in the composite component 10.

An interior side of the board member 14 can be glued to the vertical leg 16 with an adhesive or secured with a mechanical fastener. The adhesive can secure the board member 14 within the inner space of the metal profile 12. The kickout 32 and/or groove 22 can also retain the board member in place within the metal profile and ensure it will not fall out during a fire that may compromise the adhesive. The groove 22 and/or kickout 32 can be shaped in any suitable shape for retention of the board member 14 and/or strengthening of the composite 10.

The corner 30 can include an inward facing protrusion (e.g., towards the wall boards 111, 113) that sticks out further than the interior surface of the vertical leg 16 (e.g., approximately 0.125″). The inward facing protrusion can be formed of a bend in the metal of the metal profile 12. In the installed position with the head-of-wall assembly 100, the protrusion can provide a sealing point against one of the board members 111, 113 of the framed wall assembly. This protrusion can also allow the wall to cycle up and down, as is needed in order to pass the UL-2079 “Test For Fire-rated Building Joints” without causing any damage to the drywall on the framed wall assembly. In other configurations, one or both of the protrusion of the corner 30 and kickout 32 can be omitted.

In the installed configuration within the head-of-wall assembly 100, the board member 14 can be nested within the inner space of the metal profile 12. The upper leg 24 can abut against and attached with the ceiling 105 (e.g., by fastener 103). The vertical leg 16 can abut an upper end of the wall board 113 and cover the deflection gap 101. The protrusion of the corner 30 can abut the outer face of the wall board 113 to provide a seal therewith. The wall board 113 can cycle behind the installed composite component 10 between open and closed configurations.

FIG. 4 illustrates an alternative metal profile 12. The metal profile 12 can include a vertical leg 16, an upper leg 24, and a lower leg 20, like the metal profile 12 previously described. An upward facing protrusion can be formed of a bent portion of the material of the metal profile 12 on the upper leg 24 (e.g., approximately 0.125″). The upward facing protrusion can be directed or extend generally upwardly. In the installed configuration, the protrusion can contact and provide a sealing point against the ceiling 105 of the assembly 100. In the installed configuration within the head-of-wall assembly 100, the upper leg 24 can abut against and attached with the ceiling 105. The upward facing protrusion of the corner 30 can abut the ceiling 105 to provide a seal therewith. The wall board 113 can cycle behind the installed composite component 10 between open and closed configurations.

FIG. 5 shows a cross-section of a composite fire-blocking component including a gasket. In some embodiments, the inner portion 25 can define a plane and the outer portion 26 can extend from the said plane. For example, the outer portion 26 can extend from the said plane at an offset angle 29. The offset angle 29 can comprise different values. For example, the offset angle 29 can be about 2 degrees or about 5 degrees or any value between about 2 degrees and about 5 degrees. In some configurations, the offset angle 29 can be less than 2 degrees or greater than 5 degrees or can be any other value or incremental value to accommodate a user's need. In some configurations, the inner portion 25 and the outer portion 26 can lie in a single plane or substantially lie within a single plane. The outer portion 26 can be positioned on one side of the groove 22 and the inner portion 25 can be positioned on an opposite side. The outer portion 26 can have an extended free end. The extended free end of the outer portion 26 can be flexible and/or movable. The outer portion 26 can extend upwardly or downwardly with respect to the plane that defines the inner portion 25.

FIG. 6 illustrates a cross section of a head-of-wall assembly including a composite fire-blocking component 10, which includes a gasket 18. The gasket 18 can be positioned between the vertical leg 16 and the wallboard 111 (or 113). The gasket 18 can be attached to the vertical leg 16. In some embodiments, the gasket 18 can be attached to the vertical leg 16 during the manufacturing process. The gasket 18 can be attached to the vertical leg 16 through a variety of means. For example, the gasket 18 can be adhesively attached to the vertical leg 16, or it can be mechanically fastened to the vertical leg 16 or it can be coupled with the vertical leg 16 using a double-sided tape. In some other embodiments, the gasket 18 can be manufactured as a separate piece and installed in the field between the vertical leg 16 and the wallboard 111 or 113. For example, the gasket 18 can be attached separately to the wallboard 111 (or 113).

The gasket 18 can be manufactured to have a variety of different widths, lengths, and depths to accommodate a user's need. For example, the gasket 18 can have a width of about 1/16 inch or about ⅛ inch or about ⅜ inch or about ½ inch or about ¾ inch or about 1 inch or any other widths smaller than 1/16 inch or larger than 1 inch or any increment in between 1/16 inch and 1 inch. The gasket 18 can have a length of about 4 feet or about 6 feet or about 8 feet or about 10 feet or any other lengths smaller than about 4 feet or larger than about 10 feet or any increment between about 4 feet and 10 feet. The gasket 18 can have a thickness of about 1/16 inch or about ⅛ inch or about 3/16 inch or about ½ inch or any other widths smaller than 1/16 inch or larger than ½ inch or any increment in between 1/16 inch and ½ inch. In some embodiments, the gasket 18 has a length that corresponds to a length of the composite component 10. For example, the gasket 18 can be a continuous gasket that is attached to the metal profile 10 of the composite component 10 and runs along the wallboard 111 (or 113) between the composite component 10 and the wallboard 111 (or 113). In some other embodiments, the gasket 18 can be manufactured as separate individual pieces of different or equal length that are coupled to the metal profile 10 of the composite component 10. The gasket 18 can comprise one or more of a variety of different materials. For example, the gasket 18 can comprise rubber, vinyl, silicone, foam, or other similar materials. The gasket 18 can comprise from materials that are generally flexible or have reduced stiffness so that the gasket 18 can flex in response to a pressure. In some configurations, the gasket 18 is a closed cell foam material. In some other configurations, other suitable materials such as open cell foam, flexible vinyl, intumescent material or the like can also be used. The gasket 18 can have a solid cross section or a hollow cross section.

FIG. 15 illustrates a head-of-wall portion of a shaft wall assembly 50 including a prior art fire proofing arrangement 52. The wall assembly 50 extends in a vertical direction between a lower horizontal structure (e.g., a floor) and an upper horizontal structure 54 (e.g., a ceiling or floor of an upper level). The wall assembly 50 includes a lower or footer track (the floor and footer track are not shown) connected to the lower horizontal structure, a header track 56 connected to the upper horizontal structure 54, and a plurality of studs 58 that extend between the header track 56 and the footer track. The wall assembly 50 also includes a shaft liner 60 connected to the plurality of studs 58 and positioned on the shaft side of the wall assembly 50 adjacent the shaft. The shaft liner 60 can be comprised of a plurality of (e.g., one inch thick) gypsum or drywall panels. The shaft liner 60 is located with the studs 58 within the header track 56 (and footer track). Wallboard panels 62 (e.g., gypsum or drywall panels) are connected to the plurality of studs 58 on a side opposite the shaft liner 60. The wallboard panels 62 are located outside the header track 56 (and footer track).

The illustrated upper horizontal structure 54 has a lower surface defined by a fluted deck pan, which results in a plurality of linear spaces or flutes extending along the lower surface above the wall assembly 50. In the illustrated prior art fire proofing arrangement 52, a mineral wool plug 64 is positioned in the flute above the wall assembly 50. An elongate mineral wool plug 66 is positioned above the wallboard panels 62. Flexible fire sealant caulk 68 is applied in the gap above the shaft liner 60. The fire sealant caulk 68 is applied after assembly of the shaft liner 60 and the plurality of studs 58 and before assembly of the wallboard panels 62. Nonetheless, application of the fire sealant caulk 68 is difficult due to the presence of the studs 58 and because the gap is located on the shaft side of the wall assembly 50 opposite the accessible side of the wall assembly 50 from which the fire sealant caulk 68 is introduced. A flexible fire spray layer 70 is provided to each side of the wall assembly 50 extending from the upper horizontal structure 54 to the wallboard panels 62 on the non-shaft side and from the upper horizontal structure 54 to the header track 56 on the shaft side of the wall assembly 50.

FIG. 7 illustrates a fire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components. In particular, the fire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall. The fire block component 100 includes a header track 102 having a web 104, a first downwardly extending leg 106, and a second downwardly-extending leg 108 that cooperate to form a downward-facing generally C-shaped channel in a section view. The header track 102 has two additional retention legs 110, 112 on one side to receive a rip of a fire-resistant material 120, such as gypsum or drywall wallboard or an insulating fire blocking material (hereinafter “drywall”). When the drywall 120 is laminated or adhered to the steel profile, it insulates the steel and creates a superior fire block that inhibits heat transfer from one side to the other side of the wall assembly 50 (See e.g., FIG. 8 for wall assembly 50).

In the illustrated arrangement, the fire block component 100 is constructed (e.g., bent) from a single piece of steel. The portion of the fire block component 100 forming the upper retention leg 110 is a double-wall portion having the piece of steel doubled over on itself. However, in other embodiments, the fire block component 100 could be formed from multiple pieced connected to one another to form the final shape. The web 104 can define an uppermost surface of the component 100. The lower retention leg 112 can be aligned with a bottom terminal edge of the first downwardly-extending leg 106. The legs 110, 112 can be parallel or substantially parallel with one another. As indicated by the C-shape, the first leg 106 and the second leg 108 can be parallel or substantially parallel with one another and perpendicular or substantially perpendicular with the web 104. Substantially in this context can mean within normal manufacturing variations for the process used to form the component 100, such as roll-forming, for example.

The drywall 120 preferably is coupled to the header track 102 such that the drywall 120 is securely held in place during transportation, assembly and during the life of the associated wall assembly 50. The drywall 120 preferably is installed during the manufacturing process. However, in some embodiments, the drywall 120 could be installed in the field during or after the construction of the wall assembly 50. The drywall 120 can be secured to the header track 102 by any suitable arrangement, including mechanical connection (e.g., snap-fit retention or interference fit with the retention legs 110, 112 or other portion of the header track 102). In the illustrated arrangement, the drywall 120 is adhered to the header track 102, such as with double-sided tape 122. However, other suitable adhesives could also be used. The upper retention leg 110 and/or the lower retention leg 112 can have inwardly extending returns that extend towards one another and the space that receives the drywall 120 to retain or assist in retaining the drywall 120 in place.

The fire block component 100 can have any suitable dimensions. For example, the legs 106, 108 can have a length from the web 104 to the free ends of between about 2 inches and 4 inches, including any particular dimension or range of dimensions therebetween. The web 104 can have a width between the legs 106, 108 of between about 2.5 inches to about 6 inches, including any particular dimension or range of dimensions therebetween, such as about 4 inches. The overall length of the fire block component 100 can be any suitable length to allow for convenient transportation and handling in the field, such as between about 8 feet and 16 feet, for example and without limitation.

FIG. 8 illustrates a shaft wall assembly 50 that incorporates the fire block component 100 of FIG. 7. As illustrated, the drywall rip 120 is located on the shaft side of the wall assembly 50, which obviates the need for fire sealant caulk above the shaft liner 60 thereby making the fire blocking of the head-of-wall faster and more convenient in comparison to the prior art arrangement of FIG. 15. A fire blocking element or material, such as a mineral wool plug 64 is positioned within the flute. A fire blocking element or material is positioned above the drywall boards 62. Any suitable fire blocking arrangements can be used, such as mineral wool (e.g., a mineral wool plug 66), or other fire blocking products, such as the Hot Rod, Fire Gasket, or Fire Bead fire block components sold by CEMCO.

FIG. 9 illustrates an alternative fire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components. In particular, the fire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall. The fire block component 100 can be similar to the other components 100 described herein. Accordingly, features or details that are not discussed can be the same as or similar to the corresponding features or details of other components 100 described herein, or can be of another suitable arrangement. The fire block component 100 includes an angle member 102 having a web 104 and a downwardly-extending leg 108 that cooperate to form a generally L-shaped channel in a section view. The L-shaped channel can be the same as or substantially similar to the portion of the component 100 of FIG. 7 that includes the drywall rip 120. The angle member 102 includes a pair of retention legs 110, 112 at upper and lower ends of the downwardly-extending leg 108. A space between the retention legs 110, 112 is configured to receive a rip of a fire-resistant material 120, such as gypsum or drywall board. When the drywall 120 is laminated or adhered to the steel profile, it insulates the steel and creates a superior fire block that inhibits heat transfer from one side to the other side of the wall assembly 50.

FIG. 10 illustrates a shaft wall assembly 50 that incorporates the fire block component 100 of FIG. 9. The angle member 102 allows the fire block component 100 to be secured to a standard shaft wall header track 80. Preferably, the fire block component 100 is secured to the header track 80 prior to assembly of the header track 80 to the upper horizontal structure 54. The fire block component 100 can be secured with a mechanical fastener, for example, a framing screw. However, other suitable arrangements can also be used, such as adhesives (e.g., double sided tape). The fire block component 100 could also be secured between the header track 80 and the upper horizontal structure 54 after the header track 80 is secured to the upper horizontal structure 54. The fire block component 100 could be held in place by frictional forces.

FIG. 11 illustrates an alternative fire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components. In particular, the fire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall. The fire block component 100 can be similar to the other components 100 described herein. Accordingly, features or details that are not discussed can be the same as or similar to the corresponding features or details of other components 100 described herein, or can be of another suitable arrangement.

The fire block component 100 includes a header track 102 having a web 104, a first downwardly extending leg 106, and a second downwardly-extending leg 108 that cooperate to form a downward-facing generally C-shaped channel in a section view. The header track 102 has a pair of spaced-apart retention legs 110, 112 on one side to receive a rip of a fire-resistant material 120, such as gypsum or drywall board. The fire block component 100 also includes an additional C-shaped channel member 130 that is received between the retention legs 110, 112 and to which the drywall 120 is attached (such as by double sided tape). The channel member 130 can be coupled to the header track 102 by any suitable arrangement, such as mechanical connection or an adhesive connection. The upper retention leg 110 and/or the lower retention leg 112 can have inwardly extending returns that extend towards one another and the space that receives the channel member 130 and the drywall 120 to retain or assist in retaining the channel member 130 and the drywall 120 in place. In addition or in the alternative, the upper and/or lower legs of the channel member 130 can have inwardly extending returns that extend towards one another and the space that receives the drywall 120 to retain or assist in retaining the drywall 120 in place.

Optionally, the downwardly-extending leg 108 can include a protrusion 132 or other set-off element that spaces the channel member 130 from the downwardly-extending leg 108 to create an air space therebetween. The presence of an air space may slow the transfer of heat from the non-shaft side of the fire block component 100 to the drywall 120 on the shaft side of the fire block component 100. The fire block component 100 of FIG. 11 can be assembled into a wall assembly in a manner similar to the wall assembly 50 of FIG. 8.

FIG. 12 illustrates an alternative fire block component 100 configured to provide a fire-rated construction gap or joint when used in combination with additional construction components. In particular, the fire block component 100 is well-suited for use in creating a fire-rated head-of-wall gap in a shaft wall. The fire block component 100 can be similar to the other components 100 described herein. Accordingly, features or details that are not discussed can be the same as or similar to the corresponding features or details of other components 100 described herein, or can be of another suitable arrangement.

The fire block component 100 includes a header track 102 having a web 104, a first downwardly extending leg 106, and a second downwardly-extending leg 108 that cooperate to form a downward-facing generally C-shaped channel in a section view. In some embodiments, the header track 102 can comprise a 20-gauge steel profile. The header track 102 has a pair of spaced-apart retention legs 110, 112 on one side to receive a rip of a fire-resistant material, such as gypsum or drywall board, in a space 120A. The first downwardly extending leg 106, the second downwardly extending leg 108, and/or the retention legs 110, 112 can be manufactured to any desirable dimension to accommodate a user's need. For example, in some embodiments, the first downwardly extending leg 106 can be about 1.5 inch, the second downwardly extending leg 108 can be about 3″, the retention legs 110 and/or 112 can be between about ¼ inch to about ⅝ inch.

In some embodiments, the downwardly-extending leg 108 can include a strip 151. The strip 151 can be an intumescent strip or an intumescent tape. The strip 151 can comprise intumescent material and expand in response to heat. The strip 151 can comprise a variety of different widths, lengths, and thicknesses to accommodate a user's need. For example, the strip 151 can be about ½ inch wide and about 1.5 millimeter (˜0.059 inch) thick. The strip 151 can be coupled to the second downwardly-extending leg 108 through any appropriate means. For example, the strip 151 can be coupled to the second downwardly-extending leg 108 adhesively or with a double-sided tape. The strip 151 can be applied to the header track 102 in the factory during the manufacturing process or in the field. The fire block component 100 of FIG. 12 can be assembled into a wall assembly in a manner similar to the wall assembly 50 of FIG. 8.

FIG. 13 illustrates a shaft wall assembly 50 that incorporates the fire block component 100 of FIG. 12, including the strip 151, before the shaft wall assembly 50 is exposed to heat or fire. As illustrated, the drywall rip 120 is located on the shaft side of the wall assembly 50. which obviates the need for fire sealant caulk above the shaft liner 60 thereby making the fire blocking of the head-of-wall faster and more convenient in comparison to the prior art arrangement of FIG. 15. A strip 151 can be positioned in a first gap 141 between the shaft liner 60 and the second downwardly-extending leg 108. A second gap 142 can be positioned above the shaft liner 60.

FIG. 14 illustrates a shaft wall assembly 50 that incorporates the fire block component 100 of FIG. 12, including the strip 151, after the shaft wall assembly 50 is exposed to heat or fire. As discussed earlier, the strip 151 can comprise an intumescent material and can expand in response to heat. As it can be seen in FIG. 14, in use, the intumescent material can expand in an upward direction (for example towards the second gap 142) and/or in a downward direction (for example away from the second gap 142) and at least partially seal the space of the first gap 141 between the second downwardly extending leg 108 and the shaft liner 60.

Certain Terminology

Terms of orientation used herein, such as “top,” “bottom,” “proximal,” “distal,” “longitudinal,” “lateral,” and “end,” are used in the context of the illustrated example. However, the present disclosure should not be limited to the illustrated orientation. Indeed, other orientations are possible and are within the scope of this disclosure. Terms relating to circular shapes as used herein, such as diameter or radius, should be understood not to require perfect circular structures, but rather should be applied to any suitable structure with a cross-sectional region that can be measured from side-to-side. Terms relating to shapes generally, such as “circular,” “cylindrical,” “semi-circular,” or “semi-cylindrical” or any related or similar terms, are not required to conform strictly to the mathematical definitions of circles or cylinders or other structures, but can encompass structures that are reasonably close approximations.

Conditional language, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain examples include or do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more examples.

Conjunctive language, such as the phrase “at least one of X, Y, and Z,” unless specifically stated otherwise, is otherwise understood with the context as used in general to convey that an item, term, etc. may be either X, Y, or Z. Thus, such conjunctive language is not generally intended to imply that certain examples require the presence of at least one of X, at least one of Y, and at least one of Z.

The terms “approximately,” “about,” and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, in some examples, as the context may dictate, the terms “approximately,” “about,” and “substantially,” may refer to an amount that is within less than or equal to 10% of the stated amount. The term “generally” as used herein represents a value, amount, or characteristic that predominantly includes or tends toward a particular value, amount, or characteristic. As an example, in certain examples, as the context may dictate, the term “generally parallel” can refer to something that departs from exactly parallel by less than or equal to 20 degrees. All ranges are inclusive of endpoints.

Summary

Several illustrative examples of construction joints have been disclosed. Although this disclosure has been described in terms of certain illustrative examples and uses, other examples and other uses, including examples and uses which do not provide all of the features and advantages set forth herein, are also within the scope of this disclosure. Components, elements, features, acts, or steps can be arranged or performed differently than described and components, elements, features, acts, or steps can be combined, merged, added, or left out in various examples. All possible combinations and subcombinations of elements and components described herein are intended to be included in this disclosure. No single feature or group of features is necessary or indispensable.

Certain features that are described in this disclosure in the context of separate implementations can also be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation also can be implemented in multiple implementations separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations, one or more features from a claimed combination can in some cases be excised from the combination, and the combination may be claimed as a subcombination or variation of a subcombination.

Any portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in one example in this disclosure can be combined or used with (or instead of) any other portion of any of the steps, processes, structures, and/or devices disclosed or illustrated in a different example or flowchart. The examples described herein are not intended to be discrete and separate from each other. Combinations, variations, and some implementations of the disclosed features are within the scope of this disclosure.

While operations may be depicted in the drawings or described in the specification in a particular order, such operations need not be performed in the particular order shown or in sequential order, or that all operations be performed, to achieve desirable results. Other operations that are not depicted or described can be incorporated in the example methods and processes. For example, one or more additional operations can be performed before, after, simultaneously, or between any of the described operations. Additionally, the operations may be rearranged or reordered in some implementations. Also, the separation of various components in the implementations described above should not be understood as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated together in a single product or packaged into multiple products. Additionally, some implementations are within the scope of this disclosure.

Further, while illustrative examples have been described, any examples having equivalent elements, modifications, omissions, and/or combinations are also within the scope of this disclosure. Moreover, although certain aspects, advantages, and novel features are described herein, not necessarily all such advantages may be achieved in accordance with any particular example. For example, some examples within the scope of this disclosure achieve one advantage, or a group of advantages, as taught herein without necessarily achieving other advantages taught or suggested herein. Further, some examples may achieve different advantages than those taught or suggested herein.

Some examples have been described in connection with the accompanying drawings. The figures are drawn and/or shown to scale, but such scale should not be limiting, since dimensions and proportions other than what are shown are contemplated and are within the scope of the disclosed invention. Distances, angles, etc. are merely illustrative and do not necessarily bear an exact relationship to actual dimensions and layout of the devices illustrated. Components can be added, removed, and/or rearranged. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with various examples can be used in all other examples set forth herein. Additionally, any methods described herein may be practiced using any device suitable for performing the recited steps.

For purposes of summarizing the disclosure, certain aspects, advantages and features of the inventions have been described herein. Not all, or any such advantages are necessarily achieved in accordance with any particular example of the inventions disclosed herein. No aspects of this disclosure are essential or indispensable. In many examples, the devices, systems, and methods may be configured differently than illustrated in the figures or description herein. For example, various functionalities provided by the illustrated modules can be combined, rearranged, added, or deleted. In some implementations, additional or different processors or modules may perform some or all of the functionalities described with reference to the examples described and illustrated in the figures. Many implementation variations are possible. Any of the features, structures, steps, or processes disclosed in this specification can be included in any example.

In summary, various examples of construction joints and related methods have been disclosed. This disclosure extends beyond the specifically disclosed examples to other alternative examples and/or other uses of the examples, as well as to certain modifications and equivalents thereof. Moreover, this disclosure expressly contemplates that various features and aspects of the disclosed examples can be combined with, or substituted for, one another. Accordingly, the scope of this disclosure should not be limited by the particular disclosed examples described above, but should be determined only by a fair reading of the claims.

Claims

1. A fire-resistant component for providing a fire-block to a head-of-wall gap of a shaft wall, comprising:

a bent metal header component, comprising: a web; at least one downwardly-extending leg; and a pair of spaced-apart retention legs extending from opposing ends of one of the at least one downwardly-extending leg; and

a drywall strip positioned in a space between the retention legs.

2. The fire-resistant component of claim 1, wherein the at least one downwardly-extending leg comprises a pair of downwardly-extending legs spaced apart on opposite sides of the web.

3. The fire-resistant component of claim 1, wherein the drywall strip is secured to the header component.

4. The fire-resistant component of claim 1, further comprising a C-shaped channel that receives the drywall strip, wherein the C-shaped channel is received within the space between the retention legs.

5. The fire-resistant component of claim 4, wherein the one downwardly-extending leg comprises an intumescent strip located on an interior side of the C-shaped channel adjacent to a shaft liner.

6. The fire-resistant component of claim 1, wherein the header component is created from a single piece.

7. A shaft wall assembly comprising the fire-resistant component of claim 1.

8. The shaft wall assembly of claim 7, wherein the shaft wall assembly achieves a fire rating without fire sealant provided above the shaft liner between a shaft liner and the header component.

9. A fire-rated component for a linear gap between a wall assembly and an adjacent structure, the component comprising:

an elongate metal profile comprising a vertical leg, an upper leg and a lower leg, the upper leg extending in a first direction from an upper edge of the vertical leg, the lower leg extending in the first direction from a lower edge of the vertical leg;

a fire-rated gypsum board or an insulating fire blocking material positioned within a space defined by the vertical leg, the upper leg and the lower leg; and

a fire block gasket secured to the elongate metal profile such that in use it is positioned between a wallboard of the wall assembly and the vertical leg.

10. The fire-rated component of claim 9, wherein the gasket comprises a composite material of either open cell foam, flexible vinyl, or intumescent.

11. The fire-rated component of claim 9, wherein a length of the gasket is between 4 to 10 feet.

12. The fire-rated component of claim 9, wherein the gasket comprises flexible material.