Patent Publication Number: US-6216404-B1

Title: Slip joint and hose stream deflector assembly

Description:
This application claims benefit of provisional Application No. 60/105,733 filed Oct. 26, 1998. 
    
    
     BACKGROUND OF INVENTION 
     1. Field of Invention 
     This invention relates to wall and partition construction with either load bearing or non-load bearing wall design criteria in single or multi-story buildings where there is a need to confine a fire and prevent its spreading. 
     2. Description of the Prior Art 
     In normal building construction, particularly of the multi-story type, and more particularly in such construction where corrugated metal with or without concrete are formed into slabs and decks to form successive floors and/or roof assemblies. There is a physical condition and design criteria that floor slabs and/or roof decks must follow which allows for deflection or “sag”, due to the passage of time or as a reaction to specific live loads, dead loads, or some other catastrophic building movement i.e. earthquakes, wind, fire, etc. In the construction of such buildings, partitions are designed and installed, in general practice, to either withstand these forces or to accommodate the anticipated movement. These partitions may be comprised of gypsum lath and plaster, wallboard with metal or wood framing, masonry units of various sizes, concrete, and a host of other material including but not limited to cement boards, fiber boards, and other well-known materials. Variability in the deflection or “sag” of the concrete ceiling or floor construction creates unique problems in the installation of partitions. Problems relating specifically to the vertical movement of the slab deflection and specifically to the partition construction have been addressed in prior art. However, there is a problem which remains with these walls or partitions as to their ability to insure the integrity of their specified fire rating or fire resistancy in accordance with national and local fire codes. 
     In the construction industry this is a particularly difficult and time consuming detail in the construction of the fire rated partitions or walls required by code. Specifically wherein the underside of the ceiling or floor are usually comprised of a corrugated or preformed metal substrate over which the concrete is poured in a manner to form the successive floors and/or concomitant ceilings of a one story or multi-story building, or wherein the underside of the ceiling or roof comprises a corrugated or preformed metal substrate over which insulation and roofing materials are placed in such a manner to form a roof assembly. The non-load bearing interior walls are oftentimes running perpendicular to the corrugations and/or fluted substrate which forms the ceiling and thus presents a wall/ceiling joint having a plurality of apertures therethrough at the intersecting line. In other situations the non-load bearing interior wall may find itself running directly parallel or partially offset of parallel to the corrugated substrate such that there may in fact be a longitudinal gap between the top of the non-load bearing wall and the undersurface of the ceiling. Thirdly, the partitions in some instances may run oblique to the direction of the corrugations and/or flutes creating a plurality of apertures therethrough at the intersecting line each having its own unique size, shape, and depth. 
     Fire rated walls, by code and definition, are required to maintain their specified rating from the base of the floor to the underside of the deck or ceiling above. The deck as stated, comes in various sizes and oftentimes irregular shapes. The current performance criteria for a fire rated wall is found in UL Test Procedure 2079 which establishes minimal performance requirements for this design condition. The test procedure is designed to provide evidence of minimal performance in the following areas. 
     The first test is commonly referred to as cycling. This test is designed to simulate the movement that a building experiences through settling, temperature expansion and contraction, normal occupancy vibrations and possibly vibration of a construction origin. Specifically it calls for a vertical cycling movement of one half inch at ten cycles per minute for fifty minutes. 
     The second minimal performance requirement is that of temperature. This test is designed to simulate the expected temperature potential of a fire condition. Specifically it calls for a hot side of approximately 1,850° F. with a cool side maximum temperature increase of 250° above ambient for a period of two hours. 
     The third test requirement is referred to as hose stream. This test is designed to give a measure of the toughness of the fire flashing by simulating the effects of a water bath somewhat akin to that of a fireman&#39;s hose stream. Specifically the test calls for a two inch stream of water at 125 pounds of pressure at 30 feet for a second and a half per square foot of sample. To meet this test, the assembly must pass all three requirements. 
     In the past, attempting to fireproof the intersection of a non-load bearing ceiling wall and the ceiling above it, which might be of irregular shape, required individuals to move along the wall ceiling intersection from point to point and hand fill any of the apertures or openings which might be present with a fiber packing of 4 to 8 pounds density and then cover each side of the packing with a special fire caulk. This was not only time consuming and costly, but also did not always result in a uniform fill which would meet the criteria of the aforementioned test. 
     Applicant has developed a structural member and assembly which meets the aforesaid test criteria, is easily installed and would significantly reduces labor and installation costs, and has built in quality control points. 
     OBJECTS OF THE INVENTION 
     An object of the present invention is to provide for a novel structural member and assembly for interior walls or partitions on multi-story buildings which is reactive to the normal settling, temperature expansion and contraction and occupancy vibrations of such building without diminishing its fire grading capacity. 
     Another object of the present invention is to provide for a novel structural member and assembly which is fire resistant and as such, capable of isolating smoke and fire and preventing its spread. 
     A still further object of the present invention is to provide for a novel structural member and assembly which is resistant to the effects of direct pressure from a hose stream. 
     A still further object of the present invention is provide for a novel structural member and assembly which can be quickly installed and thus decrease time and labor costs. 
     A still further object of the present invention is to provide for a structural member and assembly which incorporates quality control points to insure proper installation. 
     SUMMARY OF THE INVENTION 
     An elongated C-shaped structural member having an intumescent thermal gasket positioned on its outer vertical face, and a plurality of positionable upstanding finger members on its upper horizontal face protrudable into the void of the deck above, the vertical face being juxtaposed against the wall or partition face, with the C-shaped channel member optionally secured to a transverse elongate structural member secured to the underside of the ceiling, the C-shaped structural member and upstanding fingers and void in the ceiling being encapsulated in a cementitious material. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     These and other objects of the present invention will become apparent particularly when taken in light of the following illustrations wherein: 
     FIG. 1 is a front partial perspective view of the structural member; 
     FIG. 1A is a rear partial perspective view of the structural member; 
     FIG. 2 is an exploded end view of the structural member with interior wall positioned parallel to the decking ribs; 
     FIG. 3 is an end view of the structural member and interior wall secured parallel to the decking ribs; 
     FIG. 4 is an end view of the structural member with interior wall secured perpendicular to the decking ribs. 
     FIG. 5 is a close up view of area A of FIG.  3 . 
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the structural member  10 , the subject matter of this patent application. Structural member  10  is generally C-shaped in cross-section having a vertical web member  12 , having longitudinal edges  14  and  16  and first side  18  and second side  19 . Depending outwardly from longitudinal edges  14  and  16  of first side  18  of web  12  are two flanges, an upper horizontal flange  20  and a lower horizontal flange  22 . Flanges  20  and  22  are preferably parallel to each other and form a 90 degree angle with web  12 . Upper horizontal flange  20  terminates with a longitudinal edge  24 . 
     There is formed an upper horizontal flange  20 , a plurality of spaced-apart displacable finger members  26 . Finger members  26  are formed in the manufacturing process of structural member  10  and each are formed by two cuts commencing along longitudinal edge  24  and extending into the web of flange  20 . The cuts  28  and  30  terminate at an equal distance into the web of flange  20  and the terminus points  33  and  34  of cuts  28  and  30  are connected by a perforated or embossed bend line  32 . As illustrated in FIG. 1A, the perforated or embossed bend line  32  allows the finger members  26  to be rotated and bent upwardly along the perforated or embossed bend line  32  so as to be substantially vertical to the web of flange  20 . 
     In the preferable embodiment, the web  12  of C-shaped structural member  10  would be two and a half inches in width, the web of upper horizontal flange  20  would be one inch in width and the web of lower horizontal flange  22  would be one quarter inch in width. The finger members  26  would repeat themselves in two inch cycles with seven eights of an inch gap between cuts  28  and  30  of adjacent finger members  26 . Structural member  10  would be fabricated in lengths suitable for their application (i.e. 8 ft to 12 ft). Upper horizontal flange  20  and lower horizontal flange  22  are dimensioned to serve as quality control points with the application of cementious material as described hereafter. A visual inspection to insure their encapsulation is indicative that the wall or partition has been properly fire proofed. 
     In the embodiment illustrated in FIG. 1, the cuts  28  and  30  commence on longitudinal edge  24  of upper horizontal flange  20  and are convergent in nature terminating at perforated or embossed bend line  32  thus providing the resultant upstanding finger members  26  resembling an inverted truncated triangle. Preferably the height of finger members  26  when bent to the upstanding vertical position would be five eights of an inch. While the finger members  26  have been shown in the preferred embodiment in FIG. 1, their shape may vary from that shown, the only limitation being the void into which they are fit in the decking ribs as described hereafter. In addition, there may be preformed on the web of upper horizontal flange  20 , a plurality of apertures  37  for receipt of a fastening means. FIG. 1A illustrates the second side  19  of web  12  of C-shaped structural member  10  secured thereto an intumescent thermal gasket  36  which is preferably preapplied in the manufacturing process and will become evident when considering the following figures. 
     FIG. 2 is an exploded view of the structural member  10  in conjunction with a wall or partition which is installed parallel to the decking ribs of the ceiling. In a typical construction, ceiling  40  is comprised of a metal decking element  42  normally fabricated from steel. Decking element  42  is formed in a corrugated nature having a repeating pattern of crests  44  and troughs  46 . Decking member  42  is normally secured to the vertical and horizontal support members (not shown) of the structural frame. Decking member  42  would be overlaid with the cement or concrete  50  so as to form the floor  52  of the next successive story of the structure or in a single structure building, such a floor would actually be the roof. 
     The interior wall or partition  54  of the structure would extend from such a floor surface  52 A up to the underside of the next successive floor surface  52 . In many instances, the interior walls or partitions  54  would be positioned such that they ran parallel with repeating crests and troughs  44  and  46  respectively of metal decking member  42 . This is the situation illustrated in FIG. 2 wherein an interior wall or partition  54  extends from lower floor surface  52 A proximate to metal decking member  42 . The interior wall or partition is comprised of an internal structural support  56  having overlaid on both sides thereof, a wall surface  58  comprised of a composition which meets the necessary national and local fire codes such as gypsum board or the like. It can be seen from FIG. 2, that the interior wall or partition  54  may straddle a crest  44  of metal decking member  42  and thus provide for a pathway for smoke and fire to travel from one side of interior wall or partition  54  to the opposing side. Applicant&#39;s structural member  10  provides for an easy and economical way for the contractor to block this passageway and prevent such spread of fire and smoke in accordance with the applicable fire codes. 
     In FIG. 2, there would be positioned on both sides of interior wall or partition  40 , a structural member  10  in accordance with Applicant&#39;s teachings. The structural member  10  would be positioned with the intumescent gasket  36  juxtaposed against the outer surface  58  of partition  54 . Since wall or partition  54  extends across a trough  44  of metal decking member  42 , a transverse member  60  must be secured with a mechanical fastener  61  to the crests  44  of metal decking member  42 . With transverse member  60  installed, the structural member  10  of Applicant&#39;s invention can then be juxtaposed against the outer surfaces  58  of wall or partition  54  and secured to transverse member  60  by a plurality of threaded mechanical fasteners  63  extending through apertures  37 . Transverse member  60  is a planar member of such thickness and width and length so as to span the necessary troughs  44  so as to permit structural member  10  to be secured thereto. 
     Finger members  26  would be rotatably positioned upwardly perpendicular to upper horizontal flange  20  of structural member  10  so as to extend into the trough areas  46  proximate the outer surfaces of wall or partition  54 . Finger members  26  may be so rotated either before or after installation depending upon the proximity of the crests  44 . In this regard it can be seen that transverse member  60  is secured to metal decking member  42  and structural member  10  is secured to transverse member  60  such that both are free to move with any sag or deflection of the ceiling member  40 . Despite such deflection or sag, intumescent gasket member  36  remains in close juxtaposed contact with the upper outer surface  58  of both sides of wall or partition  54 . 
     FIG. 3 is an end view of the structural member and interior wall of FIG. 2 in a secured position. Once the structural member  10 , wall or partition  54  have been positioned and structural member  10  has been secured to transverse member  60 , a fireproof cementious composition  62  is spray applied on both sides of wall or partition  54  such that structural member  10  is encapsulated in such cementious spray  62  and that all or a portion of the trough areas  46  on both sides of wall or partition  54  are filled with such cementious spray  62 . The cementious spray  62  may be readily applied by the contractor in a quick and easy fashion without the necessity of having a contractor specifically hand fill the void trough areas. The cementious spray  62  is applied from both sides of wall or partition  54  to insure that the fire code requirements heretofore set forth will be met after cementious material  62  has set. A suitable cementious material has been found to be Carboline Pyrocrete 239. 
     Referring to FIG. 4 there is disclosed an interior wall or partition  54  which is installed perpendicular to the crests  44  and troughs  46  of decking member  42 . In this particularly type of installation, transverse member  60  is not required. The construction proceeds in a similar manner as when the interior wall or partition  54  is installed parallel with the crests  44  and troughs  46  of decking member  42 . Structural member  10  and intumescent gasket  36  are positioned such that intumescent gasket  36  is juxtaposed against the outer surface  58  of interior wall or partition  54 . In this instance, metal fasteners  63  are utilized to secure structural member  10  directly into the surface of the crest member  44  of decking member  42 . Finger members  26  may then be rotated upwardly into the void of the respective troughs which the structural member  10  encounters as it runs perpendicular to the crests  44  and troughs  46  of metal decking member  42 . Thereafter, the cementious spray material  62  is utilized to encapsulate structural members  10  and the void areas in the troughs  46  and simultaneously encapsulating upstanding finger members  26 . 
     FIG. 5 is a close up view of area A of FIG. 3 so as to better provide an understanding of the manner in which the structural member cooperates with the interior wall or partition  54  and the transverse member  60  and decking member  42 . 
     FIG. 5 illustrates the fact that the interior wall  54  is not flush with the ceiling, but presents a slight gap to accommodate the sag or deflection of the ceiling/floor above. Structural member  10  is secured to transverse member  60  and the cementious spray material  62  is sprayed into trough  46  and also encapsulates structural member  10 . Upper horizontal flange  20  and lower horizontal flange  22  serve as quality control guides for the installation of the cementious spray material  62 . In other words the cementious spray material  62  should completely cover upper flange  20  and have a depth proximate lower flange  22  equal to the depths of lower flange  22 . 
     Structural member  10  has been illustrated with respect to an interior wall or partition running parallel or perpendicular to the crests and troughs of the ceiling. Structural member  10  would also have application in those instances where the interior wall or partition ran or was positioned at an angle to the crests and troughs of the ceiling. In that instance, structural member  10  may be secured directly to the crests of the ceiling member or in some instances, secured to transverse member  60  depending upon the angle of intersection. Finger members  26  would be disposed vertically to upper flange  20  into the intersected trough areas and the cementious spray material would be applied in a manner identical to that described with respect to a wall or partition running parallel or perpendicular to the crest and trough members. 
     While the present invention has been described with respect to the exemplary embodiments thereof, it will be recognized by those of ordinary skill in the art that many additions and modifications can be made without departing from the spirit and scope of the invention. Therefore it is manifestly intended that the invention be limited only by the claims and the equivalence thereof.