Patent Publication Number: US-8122679-B2

Title: Non-combustible reinforced cementitious lightweight panels and metal frame system for a fire wall and other fire resistive assemblies

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a Continuation of U.S. patent application Ser. No. 11/334,549 filed Jan. 19, 2006 which claims the benefit of U.S. provisional patent application No. 60/646,996, filed Jan. 27, 2005, each incorporated herein by reference in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention relates generally to fire wall or other fire resistive assembly systems comprising metal framing and lightweight structural cementitious panels, termed here as SCP panels, in residential and commercial construction. The fire walls or other fire resistive assemblies may be horizontal (e.g., ceilings) or vertical (e.g. vertical walls). More particularly, the invention relates to a non-combustible fire wall or other fire resistive assembly system, having panels mechanically or adhesively fastened to steel frame fire wall or other fire resistive assembly systems. If desired the panels provide a shear resistant diaphragm. The system provides the following advantageous performance attributes when used with steel framing: non-combustibility, water durability, mold resistance, high specific strength and stiffness, economy of building design that results in speed of assembly, reduced foundation size due to reduced building weight, and increased ratios of useable building volume for a given building footprint. 
     BACKGROUND OF THE INVENTION 
     A fire wall is a particular class of building construction wall. Section 705 of the 2003 International Building Code, incorporated herein by reference in its entirety, states in general that each portion of a building separated by one or more fire walls that comply with the provisions of Section 705 shall be considered a separate building. The extent and location of such fire walls shall provide a complete separation. Where a fire wall also separates groups that are required to be separated by a fire barrier wall, the most restrictive requirements of each separation shall apply. Fire walls located on lot lines shall also comply with Section 503.2 of the 2003 International Building Code. Such fire walls (party walls) shall be constructed without openings. Fire walls shall have sufficient structural stability under fire conditions to allow collapse of construction on either side without collapse of the wall for the duration of time indicated by the required fire-resistance rating. Typical fire resistance ratings are 2 hours, 3 hours or 4 hours. 
     Another class of building wall is termed “fire barriers”. Section 706 of the 2003 International Building Code, incorporated herein by reference in its entirety, states in general that fire barriers for separation of shafts (also known as shaft walls), exits, exit passageways, horizontal exits or incidental use areas, to separate different occupancies, to separate a single occupancy into different fire areas, or to separate other areas where a fire barrier is required elsewhere in the 2003 International Building Code or the International Fire Code, shall comply with Section 706 of the 2003 International Building Code. Typical fire resistance ratings for fire barriers are 1 hour, 2 hours, 3 hours and 4 hours. 
     Local building codes and national standard practices require steps be taken in commercial and residential construction to slow the spread of fire through attics, crawlspaces, and other interior locations. Thus, where a fire wall (also known as an area separation wall or party wall) is specified for commercial or residential construction, materials and constructions are employed to meet these specifications. Fire walls or other fire resistive assemblies may be vertical or horizontal. For example, ceilings and sidewalls of a garage adjacent to the dwelling portion of a residential home are typically fire walls or fire barriers. 
     Residential fire walls or other fire resistive assembly systems meet three structural considerations. First, they form two separate membranes so that, in a fire, one side can collapse without compromising the entire fire barrier. Second, the walls typically have details that insure that if the adjacent structure collapses in a fire, the fire wall will not collapse. Third, the walls are designed for a uniform lateral load of 5 psf to insure lateral stability. 
     Residential fire walls offer important, specialized construction to protect occupants from fire in multifamily townhouses and other attached dwellings. Not only should these assemblies provide rated fire protection, usually 2 hours, but they must also be designed to be structurally stable enough to withstand the collapse of an adjacent structure without losing their integrity as a wall. 
     Masonry has long been considered an acceptable material for residential fire walls because of its hardness and perceived strength. An alternative is comparably fire-rated gypsum drywall assemblies. 
     In addition to the above-discussed International Building Code, two principal code bodies that address the area separation-type fire/party walls are BOCA (See BOCA National Building Code/1990, Section 907.0.)—Building Officials &amp; Code Administrators International Inc. and SBCCI (See SBCCI Standard Building Code/1988 Paragraph 403.5.)—Southern Building Code Congress International. These code bodies identify such assemblies in their codes as either “fire wall,” “party wall” or “townhouse separation wall” or “area separation wall”. Each has essentially the same structural requirement: 
     “Such wall shall be continuous from the foundation to the underside of the roof sheathing . . . [or shall penetrate through the roof as a parapet].” (See BOCA National Building Code/1990, Section 907.0) and “Walls shall have sufficient structural stability under fire conditions to allow collapse of construction on either side without collapse of the wall . . . ” (See SBCCI Standard Building Code/1998 Paragraph 403.5). 
     For additional guidance, a widely accepted reference document is that of the National Concrete Masonry Assn. (NCMA), TEK 95, “Design Details for Concrete Masonry Fire Walls.” 
     This document recommends either a double wall or a single wall laterally supported for stability unless designed as a self-supporting cantilever. The document further states the wall be designed to withstand a uniform lateral load of 5 lb./sq. ft. (See NCMA-TEK 95, “Design Details for Concrete Masonry Fire Walls”). The double wall comprising two separate fire-rated walls is most frequently used in load-bearing situations since the fireside portion of the double wall can collapse with the adjoining structure leaving the opposing fire wall in place. 
     However, the common masonry fire wall configuration separating residential wood-frame construction is the single wall in a non-load bearing mode as a divider between the wood-frame construction on each side. Lateral support can be provided to stabilize the wall at intermediate floors and roofs but the lateral attachment to the structure is designed so that collapse of the fire-side structure will not cause the fire wall to fail. 
     The fire wall is not an impenetrable buttress as many expect, for a 5 lb./sq. ft. lateral design load (the stated recommendation of the NCMA-See NCMA-TEK 95, “Design Details for Concrete Masonry Fire Walls”) is no different than that of a common interior wall. Also, it is noteworthy to recognize that the code does not require resistance to collapse of the adjacent structure into the fire wall but rather that the fire wall remain standing after collapse. 
     A common field construction practices is the use of unreinforced hollow concrete masonry. These masonry fire walls are often cantilevered off the foundation without any lateral support at intermediate floors or roof. As a result they may not meet the required 5 lb./sq. ft. lateral load design when erected to necessary building heights. For instance, at a design load of 5 lb./sq. ft. the wall height capacity of unreinforced hollow 8-in. concrete masonry units (CMUs) is about 10.3 ft. (Calculated. Design assumptions: cantilevered; allowable flexural tensile stress 23 lb./sq. in., increased one-third for wind; 100 lb./cu. ft. hollow block, Section Modules S=81 (8-in. CMU) and 160 (12-in. CMU) per NCMA-TEK 2A, “Sizes and Shapes of Concrete Masonry Units”) when free standing as a cantilever and 18.0 ft. (See NCMA-TEK 63, “Partially Reinforced Concrete Masonry Walls”) when simply supported at roof or intermediate floor. If 12-in. CMUs are used, the heights increase to only 14.7 ft. (Calculated. Design assumptions: cantilevered; allowable flexural tensile stress 23 lb./sq. in., increased one-third for wind; 100 lb./cu. ft. hollow block, Section Modules S=81 (8-in. CMU) and 160 (12-in. CMU) per NCMA-TEK 2A, “Sizes and Shapes of Concrete Masonry Units”) and 25.4 ft. (See NCMA-TEK 95, “Design Details for Concrete Masonry Fire Walls”) respectively. See Maurice J. Marchello,  Gypsum Fire Wall&#39;s Efficiency Gives it Performance Edge , Form and Function, Issue 3 (1990) (also available at http://www.usg.com/Design_Solutions/2 — 2 — 8_separationwall.asp). 
     A masonry cavity fire wall is described in Technical Notes 21, Brick Masonry Cavity Walls, Technical Notes on Brick Construction, Brick Industry Association, Reston, Va. (August 1998).  FIG. 1  shows an embodiment of such a cavity wall  1 . Brick masonry cavity walls have two wythes of masonry separated by an air space connected by corrosion-resistant metal ties. The exterior masonry wythe  4  can be solid or hollow brick, while the interior masonry wythe  2  (shown as cinderblock) can be solid brick, hollow brick, structural clay tile, or hollow or solid concrete masonry units. The selection for each wythe depends on the required wall properties and features. A cavity of a spacing SS of 2 to 4½ in. (50 to 114 mm) between the two wythes  2 ,  4  may be either insulated (rigid board insulation  3  shown) or left as an air space. A clearance of a minimum distance S of 1 inch (2.5 mm) is provided between the rigid board insulation  3  and outer wythe  4 . The interior surface of the cavity wall  1  may be left exposed or finished in conventional ways. The outer wythe  4  may be provided with weep holes  6 . Flashing  7  may also be provided. 
     Some parts of the country use the term “reinforced cavity walls” to denote a multi-wythe masonry wall with grout placed between the wythes. This should actually be considered a multi-wythe grouted masonry wall. Since the definition of a cavity wall includes an air space, this type of wall is not truly a cavity wall. 
     Fire resistance ratings of brick masonry cavity walls range from 2 to 4 hours, depending upon the wall thickness and other factors. Due to their high fire resistance properties, brick walls are useful as fire walls or building separation walls for compartmentation in buildings. By using compartmentation, the spread of fire can be halted.  Technical Notes  16, Fire Resistance Cavity Walls, Technical Notes on Brick Construction, Brick Industry Association, Reston, Va. (April 2002) describes fire ratings and applicable design conditions. 
     Some important ASTM standards to understand are ASTM E-119 and C-36. ASTM E 119, Test Methods for Fire Tests of Building Construction and Materials, is the test standard that provides the hourly resistance ratings for wall, floors, roofs, beams, and columns based on adherence of fire exposure to a time-temperature curve. ASTM E-119 is a fire testing method in which an assembly must resist the fire exposure described for the desired classification time without passage of flame or gases hot enough to ignite cotton waste on the non-fire side. The method also entails a specific temperature rise during the test and a second partition specimen that must resist the effects of a hose stream after a fire test of one-half the time duration of the first test. Under E-119, wall and partitions having a fire rating of one hour or more must also be subjected to a hose stream test. The hose stream test has nothing to do with fire fighting practices or strategies. It is actually a convenient way to measure an assembly&#39;s ability to withstand lateral impact from falling debris during the fire endurance period and before active fire suppression efforts begin. 
     ASTM C-36 defines the standards for gypsum board (the product rather than a system containing gypsum board). The C-36 standard entails a variety of product standards that the product must be tested to meet, including composition of various types of gypsum board, flexural strength, humidified deflection, hardness, nail-pull resistance and dimensions. Although the only fire-related characteristics regular core gypsum board must have in ASTM C-36 are a noncombustible core and a maximum flame spread classification of 25, type “X” board, referred to as “special fire-resistant,” must meet specific fire-resistance standards. 
     To meet the ASTM C-36 standard for ½-in. type ‘X’ board, an assembly using the ½-in. type ‘X’ board on both sides of a load-bearing wood-stud wall must withstand an ASTM E-119 method fire test for 45 minutes. To meet the standard for ⅝-in. type “X” board, a similar assembly with ⅝-in. type “X” board must withstand a similar fire test for 1 hour. 
     Fire walls may be load bearing or non-load bearing. Unless otherwise noted, a load bearing wall is tested with a constant superimposed load applied to the specimen throughout the fire test to simulate 78% or more of the maximum allowable design load per the Fire Resistance Design Manual—Gypsum Systems, 17th edition, p. 8 Gypsum Association (2003). 
     An alternative way of determining the fire resistance of a cavity wall assembly is by using the calculated fire resistance method. This approach is approved by the model building codes for determining fire ratings of walls that are not physically tested by ASTM E 119 Test Methods for Fire Tests of Building Construction and Materials. The fire rating of cavity walls can be calculated using  Technical Notes  16B, Calculated Fire Resistance, Technical Notes on Brick Construction, Brick Industry Association, Reston, Va. [June 1991] (Reissued August 1991) 
     Masonry walls, while having good fire resistance, are heavy. An alternative to masonry construction is to construct fire walls by fastening flat modular units from wood or metal trusses or stud walls. 
     U.S. Pat. No. 6,226,946 to Stough et al. discloses the modular units, typically fire-rated gypsum board, are abutted edge to edge, and provide a barrier to flame and fire-fighting water. Typically gaps or seams between individual modules are covered to reduce the rate of flame and water penetration through the fire wall. 
     Two different area separation systems employing gypsum board are cavity-type USG Area Separation and solid-type USG Area Separation Walls. 
     Cavity-type area separation walls are used as commonly shared party walls and fire barriers with non-load-bearing framing. They consist of USG Steel C-H Studs and 1-in. SHEETROCK® Brand Gypsum Liner Panels set in USG Steel C-Runners and faced both sides with ½-in. SHEETROCK® Brand Gypsum Panels, FIRECODE C Core. 
     The solid system is built with two 1-in. SHEETROCK® Brand Gypsum Liner Panels installed vertically between 2-in. steel H-studs and C-runners. For sound attenuation and added fire protection, THERMAFIBER SAFB insulation can be added to both area separation wall systems. 
     Both systems function the same way. The fire resistant gypsum panels provide 2-hr. fire-rated performance (3-hr. rated USG Area Separation Walls systems are also available). The steel studs holding the gypsum panels are attached to the unit&#39;s wood framing using aluminum angle clips. When exposed to fire, these “break away” clips melt and break on the exposed side, allowing the burning wood frame to fall away. The fire barrier remains intact to protect adjacent units. 
     Break away fasteners, for example break away clips, are fasteners which attach fire walls (or fire barriers) to adjacent structures so that, in the event of a fire in the adjacent structure, the adjacent structure can fall away from the fire wall while the fire wall maintains its structural integrity throughout the fire. 
     Likewise, commercial construction employs fire walls. For example, a basic system has 25-ga., 2½-in, deep USG Steel C-H Studs, 1-in. SHEETROCK Brand Gypsum Liner Panels (which engage the flanges of the C-H studs) and two layers of ½-in. SHEETROCK Brand Gypsum Panels, FIRECODE C Core. IMPERIAL FIRECODE C Gypsum Panels can be used in place of the SHEETROCK Brand Panels if a veneer plaster finish is desired. The assembly of the system with the stud-flanges engaging the shaft wall liner panels is progressive and permits the entire assembly to be installed from the floor side of the shaft. This basic system is UL classified (UL Designs U 438, U459, U467, U469). The USG Cavity Shaft Walls are covered by all three model building codes (BOCA, ICBO and SBCCI) under National Evaluation Report NER-258. The system has been designed and tested using accepted engineering practices with deflection criteria of L/120, L/240 and L/360 clear partition heights. Additionally, limiting height tables for the system account for flexural and shear forces. Variations of the system have been fire tested up to 4 hours, including four UL design listings up to 2 hrs. Over the years the system has evolved. An original shaft wall system employed a solid gypsum wall using a steel H-stud. The next generation had a cavity created by using a steel box “T” stud. The next generation system uses a steel C-H stud that is lighter in weight and permits less heat and sound transmission than the previous type stud did. 
     U.S. Pat. No. 6,694,695 to Collins et al. discloses that, while wooden studs are formed of solid wood, typically having nominal cross section dimensions of two inches by four inches, the much greater structural strength of metal, such as twenty-gauge galvanized steel allows building studs to be employed which are not solid, but rather are hollow and have a channel or “C-shaped” cross section. To conform to the architectural plans and building materials developed over the years based on the use of wooden studs having specific cross sectional dimensions, commercially available metal studs are constructed with the same outer dimensions in which wooden studs have been manufactured for many years. Specifically, metal studs are typically formed of sheet metal bent to encompass a cross sectional area having nominal dimensions of two inches by four inches. 
     For ease of fabrication the metal studs are formed of sheet metal bent into a generally “U-shaped” cross section and in which a relatively broad central web is flanked by a pair of narrower sides that are bent at right angles to the web or base. The web typically has a uniform nominal width of either four inches or three and one half inches, and the sides of the U-shaped stud typically extend a nominal distance of two inches from the web. To enhance structural rigidity the edges of the sides of the metal stud are normally bent over into a plane parallel to and spaced from the plane of the web. These turned over edges of the side walls thereby form marginal lips which are typically one quarter to one half an inch in width. The finished stud therefore has a generally “C-shaped” cross section. 
     The overhead beams that extend along the tops of the studs in interior building wall construction have a U-shaped configuration. They are each formed with a horizontally disposed web from which a pair of side walls depend vertically on opposite sides of the web. The side walls embrace the sides of the vertical studs so that the upper extremities of the studs extend perpendicular into the concave, downwardly facing channel formed by the overhead beam. The spacing of the studs along the length of the beam is typically either sixteen or twenty-four inches. 
     One type of fire wall for commercial structures is known as an area separation fire wall/party wall system. USG Area Separation Fire Walls/Party Walls are used for constructing common walls with fire-resistive protection for adjacent properties. These lightweight, non-load-bearing gypsum drywall assemblies are designed as vertical fire barriers for fire walls and party walls separating occupancies in wood-frame apartments and townhouses. Large-size gypsum panels used in conjunction with steel studs and runners quickly become thin, space-saving walls offering excellent privacy. 
     Available in two basic systems both providing fire-resistant walls from ground level to roof: 
     Solid Type, with independently framed interior gypsum panel surfaces both sides of fire wall or party wall. Cavity Type, with integral interior gypsum panel surfaces for commonly shared party walls between apartments. Solid-Type wall has two 1″ thick SHEETROCK Brand Gypsum Liner Panels installed vertically between 2″ USG Steel C-Runners. Panel edges are inserted in 2″ USG Steel H-Studs spaced 24″ on center C-runners are installed at top and bottom of wall and back-to-back between vertical panels at a convenient height above each intermediate floor. H-Studs are attached on both sides to adjacent wood framing at intermediate floors, the bottom chords of attic trusses, and at the roof line with 0.063″ USG aluminum angle clips designed to break away when exposed to fire, thus permitting a fire-damaged structure to fall while the fire barrier remains intact. These USG aluminum break away clips are screw attached to studs and framing. 
     With aluminum angle clips attached on both sides of 25 gauge H-studs, the assemblies are suitable for spans (between clip angle supports) up to 10′ under 5 psf lateral load without exceeding L/240 allowable deflection (for walls with exterior exposure, see section 3.4 of the specification). 
     With 2″ THERMAFIBER Sound Attenuation Fire Blankets (SAFB) stapled each side of liner panels, the assembly has obtained a 3 hr. fire resistance rating allowing separate selection and construction of tenant walls. Cavity-Type Wall consists of steel C-H Studs and SHEETROCK Brand Gypsum Liner Panels set in steel runners and faced both sides with SHEETROCK Brand Gypsum Panels, Water-Resistant, FIRECODE C Core. Liner panels, 1″ thick, are erected vertically with ends set into 2½″ USG C-Runners and edges inserted into specially formed 2½″ USG Steel C-H Studs. C-runners are installed singly at top and bottom of wall and back-to-back between vertical liner panels on a line above each intermediate floor, the bottom chords of attic trusses, and at roof line. Aluminum clips, which attach the C-H Studs on both sides to adjacent wood framing, break away in the same fashion as with solid-type walls. To improve sound transmission loss, THERMAFIBER SAFB are inserted in the stud cavity and RC-1 Resilient Channels or equivalent may be used to isolate the face layer on the cavity side. 
     With aluminum angle clips attached on both sides of 212CH25 steel studs, the assemblies are suitable for spans (between clip angle supports) up to 10′ under 5 psf lateral load without exceeding L/240 allowable deflection (for walls with exterior exposure see section 3.4 of the specification). 
     Components used in these systems are designed to permit temporary exposure to inclement weather during construction. These systems may be used in buildings up to four stories high (44 feet) and with all common floor-ceiling heights found in multi-family housing. 
     Current USG Area separation wall systems are described in USG publication SA925 09250, Fire Wall/Party Wall area separation wall systems, a copy of which is APPENDIX I of U.S. provisional patent application No. 60/646,996 and incorporated herein by reference in its entirety. 
     Another important type of fire resistive structure is a shaft wall. Shaft walls are wall that enclose elevator shafts and other vertical shafts in a building. Should a fire occur, firefighters control the use of elevators while the stairwells provide the only means for occupant egress or rescue within a building. These walls must have the strength to withstand lateral loads and provide fire protection. A current shaft wall system is the USG SHEETROCK brand Cavity Shaft wall system. It provides up to 4-hour fire resistance and sound ratings up to 52 STC. It resists intermittent lateral loads and fatigue under cyclic lateral loading which is caused by elevators moving in the shaft. The assemblies are constructed of SHEETROCK brand gypsum liner panels friction fitted into USG SHEETROCK brand C-H studs in a progressive manner with SHEETROCK brand gypsum panels applied to the face. Typical shaft walls in a building include elevator shafts, stairwells, mechanical shafts (HVAC, plumbing, electrical, etc.), horizontal membranes or metal duct enclosures, and air return shafts (unlines). 
     Additional information on current USG shaft wall systems is provided by USG publication SA926 09250 Shaft Wall Systems, a copy of which is APPENDIX II of U.S. provisional patent application No. 60/646,996 and incorporated herein by reference in its entirety. 
     U.S. Pat. No. 6,620,487 to Tonyan et al., incorporated herein by reference in its entirety, discloses a reinforced, lightweight, dimensionally stable structural cement panel (SCP) capable of resisting shear loads when fastened to framing equal to or exceeding shear loads provided by plywood or oriented strand board panels. The panels employ a core of a continuous phase resulting from the curing of an aqueous mixture of calcium sulfate alpha hemihydrate, hydraulic cement, an active pozzolan and lime, the continuous phase being reinforced with alkali-resistant glass fibers and containing ceramic microspheres, or a blend of ceramic and polymer microspheres, or being formed from an aqueous mixture having a weight ratio of water-to-reactive powder of 0.6/1 to 0.7/1 or a combination thereof. At least one outer surface of the panels may include a cured continuous phase reinforced with glass fibers and containing sufficient polymer spheres to improve nailability or made with a water-to-reactive powders ratio to provide an effect similar to polymer spheres, or a combination thereof. However, U.S. Pat. No. 6,620,487 contains no teaching to specifically employ these shear panels in a fire wall system. 
     U.S. Pat. No. 6,241,815 to Bonen, incorporated herein by reference in its entirety, also discloses formulations useful for SCP panels. 
     U.S. patent application Ser. No. 10/666,294, incorporated herein by reference, discloses a multi-layer process for producing structural cementitious panels (SCP&#39;s or SCP panels), and SCP&#39;s produced by such a process. After one of an initial deposition of loosely distributed, chopped fibers or a layer of slurry upon a moving web, fibers are deposited upon the slurry layer. An embedment device mixes the recently deposited fibers into the slurry, after which additional layers of slurry, then chopped fibers are added, followed by more embedment. The process is repeated for each layer of the board, as desired. 
     There is a need for an improved economical, easy to assemble, durable and non-combustible total fire wall system. 
     SUMMARY OF THE INVENTION 
     The present invention relates to a fire wall or other fire resistive assembly system (fire barriers) for residential and light commercial construction including a metal frame and lightweight structural cementitious panel (SCP). This lightweight SCP panel is made from a mixture of inorganic binder and lightweight fillers. The present inventors have discovered that replacing typical fire-rated gypsum board with this selected SCP panel results in fire walls of increased strength and resistance to shear. This, for example, results in a fire wall better able to withstand forces exerted by water from a fire hose. The fire wall systems of the present invention are also suitable to make load bearing fire walls. Typical fire resistance ratings for fire walls are 2 hours, 3 hours and 4 hours. Typical fire resistance ratings for fire barriers are 1 hour, 2 hours, 3 hours and 4 hours. 
     In particular the present invention relates to SCP panels, mechanically and/or adhesively fastened to a fire wall or other fire resistive assembly light gauge cold formed metal framing system, which acts as a shear resistant diaphragm. Selecting a combination of a metal frame with SCP panels achieves a synergy of a completely non-combustible fire wall having shear resistance and water durability. By a fully non-combustible shear diaphragm on light gauge cold rolled (cold formed) metal frame is meant a system in which all elements pass ASTM E-136. For example, the fire wall system may include SCP panels employed with a metal framing system employing any standard light-gauge steel C-channels, U-channels, I-beams, square tubing, and light-gauge prefabricated building sections. 
     As the thickness of the board affects its physical and mechanical properties, e.g., weight, load carrying capacity, racking strength and the like, the desired properties vary according to the thickness of the board. Thus, the desired properties which a shear rated panel with a nominal thickness of 0.5 inches (12.7 mm) should meet include the following. 
     The SCP panel when tested according to ASTM 661 and American Plywood Association (APA) Test Method S-1 over a span of 16 inches (406.4 mm) on centers, should have an ultimate load capacity greater than 550 lbs (250 kg) under static loading, an ultimate load capacity greater than 400 lbs (182 kg) under impact loading and a deflection of less than 0.078 inches (1.98 mm) under both static and impact loading with a 200 lb (90.9 kg) load. 
     For use in fire wall or other fire resistive assembly system construction that also provide shear walls, SCP panels should meet building code standards for shear resistance, load capacity, water-induced expansion and resistance to combustion, as measured by recognized tests, such as ASTM E72, ASTM 661, and ASTM C 1185 or equivalent, as applied to structural plywood sheets. SCP panels are also tested under ASTM E-136 for non-combustibility—plywood does not meet this test. 
     The nominal racking shear strength of a 0.5 inch (12.7 mm) thick panel measured by the ASTM E72 test using the nail size and spacing described above should be at least 200 lbs/ft (about 300 kg/m), typically at least 720 lbs/ft (1072 kg/m). 
     A 4×8 ft, ½ inch thick panel (1.22×2.4 m, 12.7 mm thick) should weigh no more than 104 lbs (47 kg) and preferably no more than about 96 or 85 lbs (about 44 or 39 kg). 
     The panel should be capable of being cut with the circular saws used to cut wood. 
     The panel should be capable of being fastened to framing with nails or screws. 
     The panel should be machinable so that tongue and groove edges can be produced in the panel. 
     The panel should be dimensionally stable when exposed to water, i.e., it should expand as little as possible, preferably less than 0.1% as measured by ASTM C 1185. 
     The panel should not be biodegradable or subject to attack by insects or rot. 
     The panel should provide a bondable substrate for exterior finish systems. 
     The panel should be non-combustible as determined by ASTM E136. 
     After curing for 28 days, the flexural strength of a 0.75 inch (19. mm) thick SCP panel having a dry density of 65 lb/ft 3  (1041 kg/m 3 ) to 90 lb/ft 3  (1442 kg/m 3 ) or 65 lb/ft 3  (1041 kg/m 3 ) to 95 lb/ft 3  (1522 kg/m 3 ) after being soaked in water for 48 hours should be at least 1000 psi (7 MPa), e.g. at least 1300 psi (9 MPa) preferably at least 1650 psi (11.4 MPa), more preferably at least 1700 psi (11.7 MPa), as measured by ASTM C 947. The panel should retain at least 75% of its dry strength. 
     When used for walls, the nominal racking shear strength of a 0.5 inch (12.7 mm) thick panel measured by the ASTM E72 test using the appropriate metal studs, fastener, stud spacing and fastener spacing typically is at least 720 lbs per lineal foot (1072 kg per lineal meter). 
     The present SCP vertical wall diaphragm may have a higher specific racking shear strength and stiffness than a shear wall system of load bearing masonry. Specific racking shear strength is defined as the unit weight of a shear wall system in lbs/sq. ft. to satisfy a particular racking shear requirement (in lbs/linear foot). 
     For a given nominal wall racking shear strength specification, in the range between 200-1200 plf for a given wall thickness, the specific nominal wall racking shear strength of an SCP sheathed shear wall will be greater than a masonry shear wall of the same nominal thickness that meets the same racking shear requirement. For example, for a shear wall with a nominal thickness of 4″, an SCP/steel frame shear wall will weigh approximately 4 psf. A 4″ nominal thickness masonry wall (using lightweight CMU) will weigh approximately 30 psf. As a result, for a 4″ wall with a nominal racking shear strength requirement of 700 plf, the specific wall racking strength of the SCP is 175 plf/psf, the specific wall racking strength of the CMU wall is 23.3 plf/psf. The specific wall racking strength advantage of the SCP wall versus CMU is true over the full, range of racking strengths considered (200-1200 plf nominal) and for wall thicknesses of 4″ to 12″. 
     The present system having a vertical shear diaphragm on light gauge cold rolled metal frame also is typically water durable. Preferably the vertical shear diaphragm load carrying capacity of a system of the present invention will not be lessened by more than 25% (more preferably will not be lessened by more than 20%) when exposed to water in a test wherein a 2 inch head of water is maintained over a horizontally oriented diaphragm of ¾ inch thick SCP panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours. In this test, the 2 inch head is maintained by checking, and replenishing water, at 15 minute intervals. Then the system is reoriented vertically and the vertical shear diaphragm load carrying capacity of the system is measured. 
     Preferably the system of the present invention will not absorb more than 0.7 pounds per square foot of water when exposed to water in a test wherein a 2 inch head of water is maintained over ¾ inch thick SCP panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours. In this test, the 2 inch head is maintained by checking, and replenishing water, at 15 minute intervals. 
     Also, combining non-combustible SCP panels with metal framing results in an entire system that resists swelling due to moisture. Preferably in the system of the present invention a 10 foot wide by 20 foot long by ¾ inch thick diaphragm of the SCP panels attached to a 10 foot by 20 foot metal frame will not swell more than 5% when exposed to a 2 inch head of water maintained over the SCP panels fastened on the metal frame for a period of 24 hours. In this test, the 2 inch head is maintained by checking, and replenishing water, at 15 minute intervals. 
     Also, the present fire wall or other fire resistive assembly system of a diaphragm of SCP panel on metal frame leads to a mold and mildew resistant fire wall or other fire resistive assembly system. Preferably every component of the system of the present invention meets ASTM G-21 in which the system achieves approximately a rating of 1 and meets ASTM D-3273 in which the system achieves approximately a rating of 10. Preferably the system of the present invention supports substantially zero bacteria growth when clean. 
     Another preferred attribute of the present fire wall or other fire resistive assembly system of a diaphragm of SCP panel on metal frame is that preferably it is inedible to termites. 
     A potential advantage of the present system is that, due to its being lightweight and strong, the present fire wall or other fire resistive assembly system of a vertical diaphragm of ¾ inch thick SCP panel (or ½ inch thick SCP panel) on metal frame reduces foundation size due to reduced building weight. The lightweight nature of this system typically avoids the dead load associated with masonry systems. Less dead load also allows building comparable size structures on less stable soil possessing relatively low bearing capacities. 
     Building codes and design standards contain minimum thickness requirements for masonry shear walls. The minimum nominal thickness for masonry (CMU) shear walls in a one story building is 6 inches. The minimum thickness of masonry shear walls (CMU) for buildings more than 1 story is 8 inches. SCP with steel framing shear walls do not have a similar minimum requirement, and can be designed per established engineering principles at thicknesses of less than 8 inches for multi-story buildings, and at thicknesses of less than 6 inches for single story buildings. Using a 6 inch thick SCP/steel frame shear wall to replace an 8 inch thick masonry shear wall can result in a significant increase in useable building volume. 
     Typical compositions for embodiments of panels of the present invention which achieve the combination of low density, improved flexural strength, and nailability/cuttability comprise inorganic binder (examples—gypsum-cement, Portland cement or other hydraulic cements) having, distributed throughout the full thickness of the panel, selected glass fibers, lightweight fillers (examples—hollow glass microspheres, hollow ceramic microspheres and/or perlite uniformly), and superplasticizer/high-range water reducing admixtures (examples—polynapthalene sulfonates, poly acrylates, etc.). 
     The system of the present invention may employ single layer or multi-layer SCP panels. In the multi-layer SCP panel the layers may be the same or different. For example, the SCP panel may have an inner layer of a continuous phase and at least one outer layer of a continuous phase on each opposed side of the inner layer, wherein at least one outer layer on each opposed side of the inner layer has a higher percentage of glass fibers than the inner layer. This has the ability to stiffen, strengthen and toughen the panel. 
     A typical panel is made from a mixture of water and inorganic binder with the selected glass fibers, lightweight ceramic microspheres and superplasticizer throughout the mixture. 
     Other additives such as accelerating and retarding admixtures, viscosity control additives may optionally be added to the mixture to meet the demands of the manufacturing process involved. 
     A single or multi layer panel may also be provided with a sheet of mesh, e.g., fiber glass mesh if desired. 
     In embodiments having multiple (two or more) layers, the composition of the layers may be the same or different. For example, a multi-layer panel structure may be created to contain at least one outer layer having improved nailability and cutability. This is provided by using a higher water-to-reactive powder (defined below) ratio in making the outer layer(s) relative to the core of the panel. A small thickness of the skin coupled with a small dosage of polymer content may improve the nailability without necessarily failing the non-combustibility test. Of course, high dosages of polymer content would lead to failure of the product in the non-combustibility test. 
     In another multi-layer configuration, the SCP panel may have an inner layer of a continuous phase and at least one outer layer of a continuous phase on each opposed side of the inner layer, wherein at least one outer layer on each opposed side of the inner layer has a higher percentage of glass fibers than the inner layer. This has the ability to stiffen, strengthen and toughen the panel. 
     The glass fibers can be used alone or in combination with other types of non-combustible fibers such as steel fibers. 
     The SCP panels may be connected to the framing studs mechanically or by adhesive. Connecting the SCP panels to the studs may achieve a composite action such that the studs and panels work together to carry greater loads. 
     In its method respects, the present invention comprises a method of making the non-combustible fire wall or other fire resistive assembly system of the present invention, comprising placing the SCP panel on metal framing elements in a fire wall location. 
     The present invention also has an unexpected advantage in cold weather performance. Conventional cementitious panels can be brittle in cold weather. Thus, installing such panels in cold weather would require careful handling by the construction workers during installation. However, in the present system the SCP panels can preferably withstand being installed on metal framing elements when the ambient temperature is less than 32 degrees F. (0 degrees C.), or even less than 20 degrees F. (minus 7.5 degrees C.). This is a very significant advantage because it facilitates building in harsh climates in winter thus increasing builder productivity. The present SCP panels can preferably withstand being subjected to normal rough treatment during installation at these cold temperatures. For instance, at these cold temperatures placing the SCP panel may include a step of dropping the panel such that at least one end of the panel falls in free fall at least 2 feet, preferably at least 3 feet, e.g., 3 to 6 feet or 3 to 4 feet, without cracking. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a masonry cavity wall useful as a fire wall. 
         FIG. 2  is a perspective view of a metal stud wall employing a spacer member and studs of typical framing suitable for employing with a structural cementitious panel (SCP) panel in the non-combustible fire wall or other fire resistive assembly system of the present invention. 
         FIG. 3  is a schematic side view of a single layer SCP panel for employing with metal framing in the non-combustible fire wall or other fire resistive assembly system of the present invention. 
         FIG. 4  is a perspective view of a fire wall or other fire resistive assembly system of the invention having SCP panels on one side of a metal stud frame. 
         FIG. 5  is a perspective view of a fire wall or other fire resistive assembly system of the invention having SCP panels attached to opposing sides. 
         FIG. 6  shows a schematic side view of a multi-layer SCP panel for employing with metal framing in the non-combustible fire wall system of the present invention. 
         FIGS. 6A-6C  illustrate a typical design and dimensions of tongue and groove employed in a ¾ inch (19.1 mm) thick SCP panel (with dimensions in inches). 
         FIG. 7  is a side elevation of a non-combustible solid fire wall system of the present invention having SCP panels of  FIG. 3  supported on one side of the metal framing of  FIG. 5 . 
         FIG. 7A  is a side elevation of a non-combustible cavity wall of the present invention having SCP panels of  FIG. 5  supported on metal framings of  FIG. 5 . 
         FIG. 7B  is a top elevation of another embodiment of a non-combustible solid wall of the present invention having SCP panels supported on metal framing. 
         FIG. 7C  is a top elevation of another embodiment of a non-combustible cavity wall of the present invention having SCP panels supported on metal framing. 
         FIG. 7D  shows an elevator shaft wall employing SCP panels attached to metal frame elements. 
         FIG. 7E  shows a stairwell wall employing SCP panels attached to metal frame elements. 
         FIG. 7F  shows a mechanical shaft wall employing SCP panels attached to metal frame elements. 
         FIG. 7G  shows an air return shaft wall employing SCP panels attached to metal frame elements. 
         FIG. 7H  shows a top view of the SCP panels held in an H-C stud that may be employed for the walls of  FIGS. 7C-G . 
         FIG. 7I  shows the embodiment of  FIG. 7  modified to further comprise gypsum panels. 
         FIG. 7J  shows the embodiment of  FIG. 7   a  modified to further comprise gypsum panels. 
         FIG. 7K  shows a detailed illustration of a fire wall. 
         FIG. 8  shows assembled metal, e.g., steel, floor framing for use in an example of the present specification. 
         FIG. 9  shows attachment of the C-joist metal framing members to the header. 
         FIG. 10  shows an enlarged view of a portion of the frame of  FIG. 8 . 
         FIG. 11  shows a test SCP panel floor system configuration attached to the metal frame of  FIG. 8 . 
         FIGS. 12 ,  13 ,  14  and  15  show enlarged views of respective portions of the floor of  FIG. 11 . 
         FIG. 16  shows the frame of  FIG. 8  having the attached floor of  FIG. 9  mounted on a floor diaphragm testing apparatus. 
         FIG. 17  shows an enlarged view of a portion of the apparatus of  FIG. 16 . 
         FIG. 18  shows experimental load versus deflection data from an example employing the floor diaphragm testing apparatus of  FIG. 16 . 
         FIG. 19  shows a photograph of the SCP panel and metal frame floor mounted on the test apparatus of  FIG. 16  at design load. 
         FIG. 20  shows a photograph of the SCP panel and metal frame floor mounted on the test apparatus of  FIG. 16  at failure. 
         FIG. 21  is a diagrammatic elevational view of an apparatus suitable for performing a present process to make an SCP panel for use in the system of the present invention. 
         FIG. 22  is a perspective view of a slurry feed station of the type used in the process of  FIG. 21 . 
         FIG. 23  is a fragmentary overhead plan view of an embedment device suitable for use with the present process. 
         FIG. 24  shows a floor framing used in the AISI TS-7 tests. 
         FIG. 25  shows one of the SCP Floors used in the AISI TS-7 tests. 
         FIG. 26  shows the testing apparatus used in the AISI TS-7 tests. 
         FIG. 27  shows data from AISI TS-7 Cantilever Floor Diaphragm test using ¾ inch SCP panel with a 4 inch-12 inch fastening schedule. 
         FIG. 28  shows data from AISI TS-7 Cantilever Floor Diaphragm test using ¾ inch SCP panel compared to ¾ inch plywood with a 6 inch-12 inch fastening schedule. 
         FIG. 29  shows data from AISI TS-7 Cantilever Floor Diaphragm test using ¾ inch SCP panel with adhesive. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention relates to fire wall systems having SCP panels employed on metal frames. The frames may be any metal, e.g., steel or galvanized steel, framing systems suitable for supporting fire walls or other fire resistive assemblies. 
       FIG. 2  shows a metal stud wall “skeleton”  10  fabricated according to U.S. Pat. No. 6,694,695 to Collins et al. and suitable for combination with a SCP panel to achieve a fire wall system of the present invention. This metal frame system is merely provided as illustrative as other metal frames may also be employed. In this embodiment, the metal stud wall skeleton  10  includes a lower track  12 , a plurality of metal studs  20 , and at least one spacer member  40 . Wall panels, such as wallboard, may be secured in well-known manner to one or both sides of the metal studs  20  to close the wall and form the exterior surface or surfaces of the wall. However, the present invention advantageously selects SCP panels for the wallboard. 
     In this embodiment, the studs  20  are generally C-shaped. More particularly, the studs  20  have a web  22  and a pair of L-shaped flanges  24  perpendicular to the web  22 . There are also one or more openings  26  in the web  22 . Those of ordinary skill in the art will appreciate that the openings  26  heretofore have been provided in metal studs to permit electrical conduit and plumbing to be run within the stud wall. Since the openings  26  are located in the same position in the individual studs forming the wall as is conventional, the openings  26  are horizontally aligned with each other as shown in  FIG. 2 . 
     In the assembly of the metal stud wall  10 , the metal studs  20  are secured at one end  21  thereof to bottom track  12  by conventional fasteners  23  such as, for example, screws, rivets, etc. The bottom track  12  is also C-shaped with a central web portion  14  and two legs  16  protruding therefrom. In conventional construction situations, the web  14  of the bottom track  12  is commonly affixed to the floor with conventional fasteners such as screws, bolts, rivets, etc. 
     A stud spacer member  40  is inserted through the aligned openings  26 , provided through the webs  22  of the respective studs  20 , such that the notches  42  in the stud spacer member  40  are aligned with the web  22  of respective studs  20 , or vice versa. As will be discussed in further detail below, the stud spacer member  40  also functions to maintain the metal studs  20  at the prescribed spacing as during application of the wall panels to the studs  20  thereby eliminating the need to secure the top or another end  25  of each stud  20  to an upper channel or header (not shown). Additional spacer members  40  may be provided at different heights to add strength to the metal stud wall skeleton  10 . 
     A conventional metal wall stud suitable for use with wall frames of the present invention is constructed from 300 MPa mild steel strip material of 230 mm width and 0.9 mm thickness. 
       FIG. 3  is a schematic side view of a single layer SCP panel  20  for employing with metal framing in the system of the present invention. The principal starting materials used to make such SCP panels are inorganic binder, e.g., calcium sulfate alpha hemihydrate, hydraulic cement, and pozzolanic materials, lightweight filler, e.g., one or more of perlite, ceramic microspheres, or glass microspheres, as well as superplasticizer, e.g., polynapthalene sulphonates and/or poly acrylates, water, and optional additives. 
       FIG. 4  is a perspective view of a fire wall or other fire resistive assembly system of the invention of the invention having SCP panels  4  on one side of a metal frame  5 . 
       FIG. 5  is a perspective view of a fire wall or other fire resistive assembly system of the invention of the invention having respective SCP panels  4  attached to opposing sides of a metal frame  5 . 
     Calcium Sulfate Hemihydrate 
     Calcium sulfate hemihydrate, which may be used in panels of the invention, is made from gypsum ore, a naturally occurring mineral, (calcium sulfate dihydrate CaSO 4 .2H 2 O). Unless otherwise indicated, “gypsum” will refer to the dihydrate form of calcium sulfate. After being mined, the raw gypsum is thermally processed to form a settable calcium sulfate, which may be anhydrous, but more typically is the hemihydrate, CaSO 4 .½H 2 O. For the familiar end uses, the settable calcium sulfate reacts with water to solidify by forming the dihydrate (gypsum). The hemihydrate has two recognized morphologies, termed alpha hemihydrate and beta hemihydrate. These are selected for various applications based on their physical properties and cost. Both forms react with water to form the dihydrate of calcium sulfate. Upon hydration, alpha hemihydrate is characterized by giving rise to rectangular-sided crystals of gypsum, while beta hemihydrate is characterized by hydrating to produce needle-shaped crystals of gypsum, typically with large aspect ratio. In the present invention either or both of the alpha or beta forms may be used depending on the mechanical performance desired. The beta hemihydrate forms less dense microstructures and is preferred for low density products. The alpha hemihydrate forms more dense microstructures having higher strength and density than those formed by the beta hemihydrate. Thus, the alpha hemihydrate could be substituted for beta hemihydrate to increase strength and density or they could be combined to adjust the properties. 
     A typical embodiment for the inorganic binder used to make panels of the present invention comprises of hydraulic cement such as Portland cement, high alumina cement, pozzolan-blended Portland cement, or mixtures thereof. 
     Another typical embodiment for the inorganic binder used to make panels of the present invention comprises a blend containing calcium sulfate alpha hemihydrate, hydraulic cement, pozzolan, and lime. 
     Hydraulic Cement 
     ASTM defines “hydraulic cement” as follows: a cement that sets and hardens by chemical interaction with water and is capable of doing so under water. There are several types of hydraulic cements that are used in the construction and building industries. Examples of hydraulic cements include Portland cement, slag cements such as blast-furnace slag cement and super-sulfated cements, calcium sulfoaluminate cement, high-alumina cement, expansive cements, white cement, and rapid setting and hardening cements. While calcium sulfate hemihydrate does set and harden by chemical interaction with water, it is not included within the broad definition of hydraulic cements in the context of this invention. All of the aforementioned hydraulic cements can be used to make the panels of the invention. 
     The most popular and widely used family of closely related hydraulic cements is known as Portland cement. ASTM defines “Portland cement” as a hydraulic cement produced by pulverizing clinker consisting essentially of hydraulic calcium silicates, usually containing one or more of the forms of calcium sulfate as an interground addition. To manufacture Portland cement, an intimate mixture of limestone, argallicious rocks and clay is ignited in a kiln to produce the clinker, which is then further processed. As a result, the following four main phases of Portland cement are produced: tricalcium silicate (3CaO.SiO 2 , also referred to as C 3 S), dicalcium silicate (2CaO.SiO 2 , called C 2 S), tricalcium aluminate (3CaO.Al 2 O 3  or C 3 A), and tetracalcium aluminoferrite (4CaO.Al 2 O 3 .Fe 2 O 3  or C 4 AF). Other compounds present in minor amounts in Portland cement include calcium sulfate and other double salts of alkaline sulfates, calcium oxide, and magnesium oxide. Of the various recognized classes of Portland cement, Type III Portland cement (ASTM classification) is preferred for making the panels of the invention, because of its fineness it has been found to provide greater strength. The other recognized classes of hydraulic cements including slag cements such as blast-furnace slag cement and super-sulfated cements, calcium sulfoaluminate cement, high-alumina cement, expansive cements, white cement, rapidly setting and hardening cements such as regulated set cement and VHE cement, and the other Portland cement types can also be successfully used to make the panels of the present invention. The slag cements and the calcium sulfoaluminate cement have low alkalinity and are also suitable to make the panels of the present invention. 
     Fibers 
     Glass fibers are commonly used as insulating material, but they have also been used as reinforcing materials with various matrices. The fibers themselves provide tensile strength to materials that may otherwise be subject to brittle failure. The fibers may break when loaded, but the usual mode of failure of composites containing glass fibers occurs from degradation and failure of the bond between the fibers and the continuous phase material. Thus, such bonds are important if the reinforcing fibers are to retain the ability to increase ductility and strengthen the composite over time. It has been found that glass fiber reinforced cements do lose strength as time passes, which has been attributed to attack on the glass by the lime which is produced when cement is cured. One possible way to overcome such attack is to cover the glass fibers with a protective layer, such as a polymer layer. In general, such protective layers may resist attack by lime, but it has been found that the strength is reduced in panels of the invention and, thus, protective layers are not preferred. A more expensive way to limit lime attack is to use special alkali-resistant glass fibers (AR glass fibers), such as Nippon Electric Glass (NEG) 350Y. Such fibers have been found to provide superior bonding strength to the matrix and are, thus, preferred for panels of the invention. The glass fibers are monofilaments that have a diameter from about 5 to 25 microns (micrometers) and typically about 10 to 15 microns (micrometers). The filaments generally are combined into 100 filament strands, which may be bundled into rovings containing about 50 strands. The strands or rovings will generally be chopped into suitable filaments and bundles of filaments, for example, about 0.25 to 3 inches (6.3 to 76 mm) long, typically 1 to 2 inches (25 to 50 mm). 
     It is also possible to include other non-combustible fibers in the panels of the invention, for example, steel fibers are also potential additives. 
     Pozzolanic Materials 
     As has been mentioned, most Portland and other hydraulic cements produce lime during hydration (curing). It is desirable to react the lime to reduce attack on glass fibers. It is also known that when calcium sulfate hemihydrate is present, it reacts with tricalcium aluminate in the cement to form ettringite, which can result in undesirable cracking of the cured product. This is often referred to in the art as “sulfate attack.” Such reactions may be prevented by adding “pozzolanic” materials, which are defined in ASTM C618-97 as “ . . . siliceous or siliceous and aluminous materials which in themselves possess little or no cementitious value, but will, in finely divided form and in the presence of moisture, chemically react with calcium hydroxide at ordinary temperatures to form compounds possessing cementitious properties.” One often used pozzolanic material is silica fume, a finely divided amorphous silica which is the product of silicon metal and ferro-silicon alloy manufacture. Characteristically, it has a high silica content and a low alumina content. Various natural and man-made materials have been referred to as having pozzolanic properties, including pumice, perlite, diatomaceous earth, tuff, trass, metakaolin, microsilica, ground granulated blast furnace slag, and fly ash. While silica fume is a particularly convenient pozzolan for use in the panels of the invention, other pozzolanic materials may be used. In contrast to silica fume, metakaolin, ground granulated blast furnace slag, and pulverized fly ash have a much lower silica content and large amounts of alumina, but can be effective pozzolanic materials. When silica fume is used, it will constitute about 5 to 20 wt. %, preferably 10 to 15 wt. %, of the reactive powders (i.e., hydraulic cement, calcium sulfate alpha hemihydrate, silica fume, and lime). If other pozzolans are substituted, the amounts used will be chosen to provide chemical performance similar to silica fume. 
     Lightweight Fillers/Microspheres 
     The lightweight panels employed in systems of the present invention typically have a density of 65 to 90 pounds per cubic foot, preferably 65 to 85 pounds per cubic foot, more preferably 72 to 80 pounds per cubic foot. In contrast, typical Portland cement based panels without wood fiber will have densities in the 95 to 110 pcf range, while the Portland Cement based panels with wood fibers will be about the same as SCP (about 65 to 85 pcf). 
     To assist in achieving these low densities the panels are provided with lightweight filler particles. Such particles typically have an average diameter (average particle size) of about 10 to 500 microns (micrometers). More typically they have a mean particle diameter (mean particle size) from 50 to 250 microns (micrometers) and/or fall within a particle diameter (size) range of 10 to 500 microns. They also typically have a particle density (specific gravity) in the range from 0.02 to 1.00. Microspheres or other lightweight filler particles serve an important purpose in the panels of the invention, which would otherwise be heavier than is desirable for building panels. Used as lightweight fillers, the microspheres help to lower the average density of the product. When the microspheres are hollow, they are sometimes referred to as microballoons. 
     When the microspheres are hollow, they are sometimes referred to as microballoons. 
     The microspheres are either non-combustible themselves or, if combustible, added in sufficiently small amounts to not make the SCP panel combustible. Typical lightweight fillers for including in mixtures employed to make panels of the present invention are selected from the group consisting of ceramic microspheres, polymer microspheres, perlite, glass microspheres, and/or fly ash cenospheres. 
     Ceramic microspheres can be manufactured from a variety of materials and using different manufacturing processes. Although a variety of ceramic microspheres can be utilized as a filler component in the panels of the invention, the preferred ceramic microspheres of the invention are produced as a coal combustion by-product and are a component of the fly ash found at coal fired utilities, for example, EXTENDOSPHERES-SG made by Kish Company Inc., Mentor, Ohio or FILLITE® Brand ceramic microspheres made by Trelleborg Fillite Inc., Norcross, Ga. USA. The chemistry of the preferred ceramic microspheres of the invention is predominantly silica (SiO 2 ) in the range of about 50 to 75 wt. % and alumina (Al 2 O 3 ) in the range of about 15 to 40 wt. %, with up to 35 wt. % of other materials. The preferred ceramic microspheres of the invention are hollow spherical particles with diameters in the range of 10 to 500 microns (micrometers), a shell thickness typically about 10% of the sphere diameter, and a particle density preferably about 0.50 to 0.80 g/mL. The crushing strength of the preferred ceramic microspheres of the invention is greater than 1500 psi (10.3 MPa) and is preferably greater than 2500 psi (17.2 MPa). 
     Preference for ceramic microspheres in the panels of the invention primarily stems from the fact that they are about three to ten times stronger than most synthetic glass microspheres. In addition, the preferred ceramic microspheres of invention are thermally stable and provide enhanced dimensional stability to the panel of invention. Ceramic microspheres find use in an array of other applications such as adhesives, sealants, caulks, roofing compounds, PVC flooring, paints, industrial coatings, and high temperature-resistant plastic composites. Although they are preferred, it should be understood that it is not essential that the microspheres be hollow and spherical, since it is the particle density and compressive strength which provide the panel of the invention with its low weight and important physical properties. Alternatively, porous irregular particles may be substituted, provided that the resulting panels meet the desired performance. 
     The polymer microspheres, if present, are typically hollow spheres with a shell made of polymeric materials such as polyacrylonitrile, polymethacrylonitrile, polyvinyl chloride or polyvinylidine chloride, or mixtures thereof. The shell may enclose a gas used to expand the polymeric shell during manufacture. The outer surface of the polymer microspheres may have some type of an inert coating such as calcium carbonate, titanium oxides, mica, silica, and talc. The polymer microspheres have a particle density preferably about 0.02 to 0.15 g/mL and have diameters in the range 10 to 350 microns (micrometers). The presence of polymer microspheres may facilitate simultaneous attainment of low panel density and enhanced cutability and nailability. 
     Other lightweight fillers, for example glass microspheres, perlite or hollow alumino-silicate cenospheres or microspheres derived from fly ash, are also suitable for including in mixtures in combination with or in place of ceramic microspheres employed to make panels of the present invention. 
     The glass microspheres typically are made of alkali resistant glass materials and may be hollow. Typical glass microspheres are available from GYPTEK INC., Suite 135, 16 Midlake Blvd SE, Calgary, AB, T2X 2X7, CANADA. 
     In a first embodiment of the invention, only ceramic microspheres are used throughout the full thickness of the panel. The panel typically contains about 35 to 42 weight % of ceramic microspheres uniformly distributed throughout the thickness of the panel. 
     In a second embodiment of the invention, a blend of lightweight ceramic and glass microspheres is used throughout the full thickness of the panel. The volume fraction of the glass microspheres in the panel of the second embodiment of the invention will typically be in the range of 0 to 15% of the total volume of the dry ingredients, where the dry ingredients of the composition are the reactive powders (examples of reactive powders: hydraulic cement only; blend of hydraulic cement and pozzolan; or blend of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), ceramic microspheres, polymer microspheres, and alkali-resistant glass fibers. A typical aqueous mixture has a ratio of water-to-reactive powders from greater than 0.3/1 to 0.7/1. 
     If desired the panel may have a single layer as shown in  FIG. 3 . However, the panel typically is made by a process which applies multiple layers which, depending upon how the layers are applied and cured as well as whether the layers have the same or different compositions, may or may not in the final panel product retain distinct layers. 
       FIG. 6  shows a multi-layer structure of a panel  21  having layers  23 ,  25 ,  27  and  29 . In the multi-layer structure the composition of the layers may be the same or different. The typical thickness of the layer(s) ranges between about 1/32 to 1.0 inches (about 0.75 to 25.4 mm). Where only one outer layer is used, it typically will be less than ⅜ of the total panel thickness. 
       FIGS. 6A-6C  illustrate a typical design and dimensions of tongue and groove employed in a ¾ inch (19.1 mm) thick SCP panel  4 . 
     Typical Structures of Fire Walls and Other Fire Resistive Assemblies 
     As explained above,  FIG. 4  is a perspective view of a fire wall or other fire resistive assembly system of the invention having SCP panels  4  on one side of the metal frame  5 , and  FIG. 5  is a perspective view of a fire wall or other fire resistive assembly system of the invention of the invention having SCP panels  4  respectively attached to opposing sides of the metal frame  5 . 
       FIG. 7  is a side elevational view of single-layer SCP panels  4  of  FIG. 3  supported on metal framing  5  of  FIG. 5  in the system of the present invention. 
     One type of fire resistive assembly for which the present invention is suitable is as an area separation wall.  FIG. 7  shows a solid area separation wall of the present invention typically having a diaphragm of SCP panels  4  on both sides of a metal frame  5 . Area separation walls, especially the solid area separation walls, may have one side that falls away to keep the remaining frame and other diaphragms intact and standing. The SCP panels may be attached with conventional break away aluminium clips if desired to provide a wall in which one side may fall away while leaving the frame and or other walls intact.  FIG. 7  schematically shows fasteners  31  which could be break away clips or other fasteners. In the present invention the break away clips are optional because the SCP panel is not degraded by weather exposure and is stronger and longer lasting than conventional gypsum board. Thus, in practice the panels  4  may be mechanically or adhesively attached. The present invention preferably achieves a water durable fire wall that may also be a shear wall without having to provide bracing for the frame. 
       FIG. 7A  shows a cavity wall of the present invention having two parallel walls separated by a cavity  9 . A typical cavity  9  provides a 2 inch spacing. Each wall has diaphragms of SCP panels  4  on opposing sides of a metal frame  5 . 
     The fire resistant assemblies of the present invention may employ SCP panels many framing configurations. For example,  FIG. 7B  shows a top view of a solid area separation wall having two ¾ inch thick SCP panels  4  set between USG H-studs  1  that are 24 inch on center. The wall is positioned to provide a minimum of ¾ inch air space on both sides separating liner panels from adjacent framing (not shown). 
       FIG. 7C  shows a top view of cavity area separation wall of the present invention employing ½ or ¾ inch thick SCP panels  4  positioned in USG 25 gauge C-H studs  3  that are 24 inches on center. This system has a single layer of SCP panels  4  on each side applied vertically and screw attached. Panels  4 A may be gypsum panels, e.g., SHEETROCK Brand gypsum panels, or SCP panels. Joints of the panels  4 A are placed on opposing sides of the framing and the perimeter is caulked. 
     Another specialized use of the system of the present invention is as a shaft wall system. Thus, the shaft wall would have a metal frame to which SCP panels are attached. 
       FIG. 7D  shows an embodiment of a fire barrier wall employed as an elevator shaft wall having SCP panels  4  attached to metal frame elements  5 . Shaft walls with racking shear strengths in the range of 200 plf to 2000 plf (nominal ultimate racking strength) can be constructed using steel framing combined with SCP panels. Shaft walls of this type can be assembled in the following manner:
         The steel wall frame is constructed to the appropriate size adjacent to the shaft wall opening. The frame is typically built in the horizontal position and then “tilted up” into place in the shaft wall opening.   Any required shaft wall opening perimeter track and fasteners are installed to receive the shaft wall.   The first layer of SCP panel is attached to the metal frame, with the frame in the horizontal position. This layer of SCP panel is the layer that faces the shaft wall opening.   The shaft wall frame with 1 layer of SCP panel is “tilted up” and placed into position, covering the shaft wall opening.   The shaft wall frame with 1 layer of SCP panel is fastened to the shaft opening perimeter track and/or to the primary structure around the shaft opening.   The inside layer of the shaft wall is then applied to the steel shaft wall frame using mechanical fasteners. This inside wall panel can be an SCP panel (or more than 1 SCP panel), a gypsum panel (or more than 1 gypsum panel), or a combination of panel layers.       

       FIG. 7E  shows a stairwell wall employing SCP panels  4  attached to metal frame elements  5 . 
       FIG. 7F  shows a mechanical shaft wall employing SCP panels  4  attached to metal frame elements  5 . 
       FIG. 7G  shows an air return shaft wall employing SCP panels  4  attached to metal frame elements  5 . 
       FIG. 7H  shows a top view of cavity area separation wall of the present invention that may be employed in the embodiments of  FIGS. 7D-G . This employs ½ or ¾ inch thick SCP panels  4  positioned in USG 25 gauge C-H studs  3  that are 16 to 24 inches on center. This system has a single layer of SCP panels  4  on each side of the stud  3  applied vertically and screw attached. Panels  4 A may be SHEETROCK Brand Gypsum panels or SCP panels. 
       FIG. 7I  shows the embodiment of  FIG. 7  modified to further comprise gypsum or SCP panels  4 A. In the embodiment of  FIG. 7I , the SCP panels  4  are typically attached to the metal framing  5  by fasteners, such as screws (not shown) which do not break away. The SCP panels  4  are attached by screws (not shown) to break away angle clips  146  which in turn are attached by screws or nails (not shown) to studs  144 . The panels  4 A are attached by screws or nails (not shown) to the studs  144  and/or other studs (not shown) in a stud cavity  140 A. Other break away fasteners which break or melt away could substitute for the break away angle clips  146 . 
       FIG. 7J  shows the embodiment of  FIG. 7A , having the cavity  9  between opposed SCP panels  4 , modified to further comprise gypsum or SCP panels  4 A. In the embodiment of  FIG. 7J , the SCP panels  4  are typically attached to the metal framing  5  by fasteners, such as screws (not shown) which do not break away. The SCP panels  4  are attached by screws (not shown) to break away angle clips  146  which in turn are attached by screws or nails (not shown) to studs  144 . The panels  4 A are attached by screws or nails (not shown) to the studs  144  and/or other studs (not shown) in a stud cavity  140 A. Other break away fasteners which break or melt away could substitute for the break away angle clips  146 . 
       FIG. 7K  shows a detailed illustration of an embodiment of a fire wall  130 . Fire wall  130  extends from a roof deck  136  to a foundation (not shown). The fire wall  130  has SCP panels  134  on opposed sides of metal framing  132 . A space  140  is located between the stud cavity  140 A and the respective SCP panel  134 . 
     The roof deck  136  is supported by a roof rafters  133  (one shown) and roof trusses  143  (one shown). Fire blocking  148  is provided, between top plate studs  144 B and roof rafters  133 , on the opposed outer walls of the SCP panels  134 . 
     The floors  147  are supported by floor joists  131  which rest on 2×4 inch wooden studs  144 . Fire blocking  148  is provided, between sill plate studs  144 A and floor joists  131 , on the opposed outer walls of the SCP panels  134 . Horizontal gypsum ceiling panels  138  and vertical gypsum wall panels  145  are also provided. Sealant  139  is provided at a lower end of the vertical gypsum wall panels behind moldings  139 A. 
     Fire blocking  135  and fire blocking  137 , such as THERMAFIBER SAFB sound attenuating fiber blankets, may also be provided. A notable feature of this embodiment is that the aluminum angle clips  146  are attached by screws to the SCP panels  134  and studs, e.g., sill plate studs  144 A and top plate studs  144 B. The aluminum clips  146  can break away or melt in the event of a fire so the structure on fire can fall away from the SCP panels  134  of the fire wall. 
     Another fire resistive assembly of the present invention is a garage adjacent the living quarters of a house having walls and a ceiling built of SCP panels and metal framing. 
     Formulation of SCP Panels 
     The components used to make the shear resistant panels of the invention are hydraulic cement, calcium sulfate alpha hemihydrate, an active pozzolan such as silica fume, lime, ceramic microspheres, alkali-resistant glass fibers, superplasticizer (e.g., sodium salt of polynapthalene sulfonate), and water. Typically, both hydraulic cement and calcium sulfate alpha hemihydrate are present. Long term durability of the composite is compromised if calcium sulfate alpha hemihydrate is not present along with silica fume. Water/moisture durability is compromised when Portland cement is not present. Small amounts of accelerators and/or retarders may be added to the composition to control the setting characteristics of the green (i.e., uncured) material. Typical non-limiting additives include accelerators for hydraulic cement such as calcium chloride, accelerators for calcium sulfate alpha hemihydrate such as gypsum, retarders such as DTPA (diethylene triamine pentacetic acid), tartaric acid or an alkali salt of tartaric acid (e.g., potassium tartrate), shrinkage reducing agents such as glycols, and entrained air. 
     Panels of the invention will include a continuous phase in which alkali-resistant glass fibers and light weight filer, e.g., microspheres, are uniformly distributed. The continuous phase results from the curing of an aqueous mixture of the reactive powders, i.e., blend of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), preferably including superplasticizer and/or other additives. 
     Typical weight proportions of embodiments of the reactive powders (inorganic binder), e.g., hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan and lime, in the invention, based on dry weight of the reactive powders, are shown in TABLE 1. TABLE 1A lists typical ranges of reactive powders, lightweight filler, and glass fibers in compositions of the present invention. 
     
       
         
           
               
               
               
             
               
                 TABLE 1 
               
             
            
               
                   
               
               
                   
                 Weight Proportion (%) 
                   
               
            
           
           
               
               
               
               
            
               
                   
                 Reactive Powder 
                 Broad 
                 Typical 
               
               
                   
               
               
                   
                 Hydraulic Cement 
                 20-55 
                 25-40 
               
               
                   
                 Calcium Sulfate Alpha 
                 35-75 
                 45-65 
               
               
                   
                 Hemihydrate 
                   
                   
               
               
                   
                 Pozzolan 
                  5-25 
                 10-15 
               
               
                   
                 Lime 
                 up to 3.5 or 
                 0.75-1.25 
               
               
                   
                   
                 0.2 to 3.5 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
             
               
                 TABLE 1A 
               
               
                   
               
               
                   
                 Typical Weight 
                 Typical Weight 
               
               
                 SCP Composition (dry basis) 
                 Proportion (%) 
                 Proportion (%) 
               
               
                   
               
             
            
               
                 Reactive Powder 
                 35-70 
                 35-68 
               
               
                 Lightweight Filler 
                 20-50 
                 23-49 
               
               
                 Glass Fibers 
                  5-20 
                  5-17 
               
               
                   
               
            
           
         
       
     
     Lime is not required in all formulations of the invention, but it has been found that adding lime provides superior panels and it usually will be added in amounts greater than about 0.2 wt. %. Thus, in most cases, the amount of lime in the reactive powders will be about 0.2 to 3.5 wt. %. 
     In the first embodiment of the invention, the dry ingredients of the composition will be the reactive powders (i.e., blend of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), ceramic microspheres and alkali-resistant glass fibers, and the wet ingredients of the composition will be water and superplasticizer. The dry ingredients and the wet ingredients are combined to produce the panel of the invention. The ceramic microspheres are uniformly distributed in the matrix throughout the full thickness of the panel. Of the total weight of dry ingredients, the panel of the invention is formed from about 49 to 56 wt. % reactive powders, 35 to 42 wt. % ceramic microspheres and 7 to 12 wt. % alkali-resistant glass fibers. In a broad range, the panel of the invention is formed from 35 to 58 wt. % reactive powders, 34 to 49 wt. % lightweight filler, e.g., ceramic microspheres, and 6 to 17 wt. % alkali-resistant glass fibers of the total dry ingredients. The amounts of water and superplasticizer added to the dry ingredients will be sufficient to provide the desired slurry fluidity needed to satisfy processing considerations for any particular manufacturing process. The typical addition rates for water range between 35 to 60% of the weight of reactive powders and those for superplasticizer range between 1 to 8% of the weight of reactive powders. 
     The glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers), preferably about 10 to 15 microns (micrometers). The monofilaments typically are combined in 100 filamet strands, which may be bundled into rovings of about 50 strands. The length of the glass fibers will typically be about 0.25 to 1 or 2 inches (6.3 to 25 or 50 mm) or about 1 to 2 inches (25 to 50 mm) and broadly about 0.25 to 3 inches (6.3 to 76 mm). The fibers have random orientation, providing isotropic mechanical behavior in the plane of the panel. 
     The second embodiment of the invention contains a blend of ceramic and glass microspheres uniformly distributed throughout the full thickness of the panel. Accordingly, in the second embodiment of the invention, the dry ingredients of the composition will be the reactive powders (hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), ceramic microspheres, glass microspheres, and alkali-resistant glass fibers, and the wet ingredients of the composition will be water and superplasticizer. The dry ingredients and the wet ingredients will be combined to produce the panel of the invention. The volume fraction of the glass microspheres in the panel will typically be in the range of 7 to 15% of the total volume of dry ingredients. Of the total weight of dry ingredients, the panel of the invention is formed from about 54 to 65 wt. % reactive powders, 25 to 35 wt. % ceramic microspheres, 0.5 to 0.8 wt. % glass microspheres, and 6 to 10 wt. % alkali-resistant glass fibers. In the broad range, the panel of the invention is formed from 42 to 68 wt. % reactive powders, 23 to 43 wt. % lightweight fillers, e.g., ceramic microspheres, 0.2 to 1.0 wt. % glass microspheres, and 5 to 15 wt. % alkali-resistant glass fibers, based on the total dry ingredients. The amounts of water and superplasticizer added to the dry ingredients will be adjusted to provide the desired slurry fluidity needed to satisfy the processing considerations for any particular manufacturing process. The typical addition rates for water range between 35 to 70% of the weight of reactive powders, but could be greater than 60% up to 70% (weight ratio of water to reactive powder of 0.6/1 to 0.7/1), preferably 65% to 75%, when it is desired to use the ratio of water-to-reactive powder to reduce panel density and improve cutability. The amount of superplasticizer will range between 1 to 8% of the weight of reactive powders. The glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers), preferably about 10 to 15 microns (micrometers). They typically are bundled into strands and rovings as discussed above. The length of the glass fibers typically is about 1 to 2 inches (25 to 50 mm) and broadly about 0.25 to 3 inches (6.3 to 76 mm). The fibers will have random orientation providing isotropic mechanical behavior in the plane of the panel. 
     In the third embodiment of the invention, a multi-layer structure in the panel is created where the outer layer(s) have improved nailability (fastening ability)/cutability. This is achieved by increasing the water-to-cement ratio in the outer layer(s), and/or changing the amount of filler, and/or adding an amount of polymer microspheres sufficiently small such that the panel remains noncombustible. The core of the panel will typically contain ceramic microspheres uniformly distributed throughout the layer thickness or alternatively, a blend of one or more of ceramic microspheres, glass microspheres and fly ash cenospheres. 
     The dry ingredients of the core layer of this embodiment of the present invention will be the reactive powders (typically hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), lightweight filler particles (typically microspheres such as ceramic microspheres alone or one or more of ceramic microspheres, glass microspheres and fly ash cenospheres), and alkali-resistant glass fibers, and the wet ingredients of the core layer are water and superplasticizer. The dry ingredients and the wet ingredients will be combined to produce the core layer of the panel of the invention. Of the total weight of dry ingredients, the core of the panel of the invention preferably is formed from about 49 to 56 wt. % reactive powders, 35 to 42 wt. % hollow ceramic microspheres and 7 to 12 wt. % alkali-resistant glass fibers, or alternatively, about 54 to 65 wt. % reactive powders, 25 to 35 wt. % ceramic microspheres, 0.5 to 0.8 wt. % glass microspheres or fly ash cenospheres, and 6 to 10 wt. % alkali-resistant glass fibers. In the broad range, the core layer of the panel of this embodiment of the present invention is typically formed by about 35 to 58 wt. % reactive powders, 34 to 49 wt. % lightweight fillers, e.g., ceramic microspheres, and 6 to 17 wt. % alkali-resistant glass fibers, based on the total dry ingredients, or alternatively, about 42 to 68 wt. % of reactive powders, 23 to 43 wt. % ceramic microspheres, up to 1.0 wt. %, preferably 0.2 to 1.0 wt. %, other lightweight filler, e.g., glass microspheres or fly ash cenospheres, and 5 to 15 wt. % alkali-resistant glass fibers. The amounts of water and superplasticizer added to the dry ingredients will be adjusted to provide the desired slurry fluidity needed to satisfy the processing considerations for any particular manufacturing process. The typical addition rates for water will range between 35 to 70% of the weight of reactive powders but will be greater than 60% up to 70% when it is desired to use the ratio of water-to-reactive powders to reduce panel density and improve nailability and those for superplasticizer will range between 1 to 8% of the weight of reactive powders. When the ratio of water-to-reactive powder is adjusted, the slurry composition will be adjusted to provide the panel of the invention with the desired properties. 
     There is generally an absence of polymer microspheres and an absence of polymer fibers, e.g. poly vinyl alcohol fibers, that would cause the SCP panel to become combustible. 
     The dry ingredients of the outer layer(s) of this embodiment of the present invention will be the reactive powders (typically hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), lightweight filler particles (typically microspheres such as ceramic microspheres alone or one or more of ceramic microspheres, glass microspheres and fly ash cenospheres), and alkali-resistant glass fibers, and the wet ingredients of the outer layer(s) will be water and superplasticizer. The dry ingredients and the wet ingredients are combined to produce the outer layers of the panel of the invention. In the outer layer(s) of the panel of this embodiment of the present invention, the amount of water is selected to furnish good fastening and cutting ability to the panel. Of the total weight of dry ingredients, the outer layer(s) of the panel of the invention preferably are formed from about 54 to 65 wt. % reactive powders, 25 to 35 wt. % ceramic microspheres, 0 to 0.8 wt. % glass microspheres, and 6 to 10 wt. % alkali-resistant glass fibers. In the broad range, the outer layers of the panel of the invention are formed from about 42 to 68 wt. % reactive powders, 23 to 43 wt. % ceramic microspheres, up to 1.0 wt. % glass microspheres (and/or fly ash cenospheres), and 5 to 15 wt. % alkali-resistant glass fibers, based on the total dry ingredients. The amounts of water and superplasticizer added to the dry ingredients are adjusted to provide the desired slurry fluidity needed to satisfy the processing considerations for any particular manufacturing process. The typical addition rates for water range between 35 to 70% of the weight of reactive powders and particularly greater than 60% up to 70% when the ratio of water-to-reactive powders is adjusted to reduce panel density and improve nailability, and typical addition rates for superplasticizer will range between 1 to 8% of the weight of reactive powders. The preferable thickness of the outer layer(s) ranges between 1/32 to 4/32 inches (0.8 to 3.2 mm) and the thickness of the outer layer when only one is used will be less than ⅜ of the total thickness of the panel. 
     In both the core and outer layer(s) of this embodiment of the present invention, the glass fibers are monofilaments having a diameter of about 5 to 25 microns (micrometers), preferably 10 to 15 microns (micrometers). The monofilaments typically are bundled into strands and rovings as discussed above. The length typically is about 1 to 2 inches (25 to 50 mm) and broadly about 0.25 to 3 inches (6.3 to 76 mm). The fiber orientation will be random, providing isotropic mechanical behavior in the plane of the panel. 
     The invention also includes a fourth embodiment of a multi-layer panel having a density of 65 to 90 pounds per cubic foot and capable of resisting shear loads when fastened to framing and comprising a core layer of a continuous phase resulting from the curing of an aqueous mixture, a continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 35 to 70 weight % reactive powder, 20 to 50 weight percent lightweight filler, and 5 to 20 weight % glass fibers, the continuous phase being reinforced with glass fibers and containing the lightweight filler particles, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers); and at least one outer layer of respectively another continuous phase resulting from the curing of an aqueous mixture comprising, on a dry basis, 35 to 70 weight % reactive powder, 20 to 50 weight percent lightweight filler, and 5 to 20 weight % glass fibers, the continuous phase being reinforced with glass fibers and containing the lightweight filler particles, the lightweight filler particles having a particle specific gravity of from 0.02 to 1.00 and an average particle size of about 10 to 500 microns (micrometers) on each opposed side of the inner layer, wherein the at least one outer layer has a higher percentage of glass fibers than the inner layer. 
     Making a Panel of the Invention 
     The reactive powders, e.g., blend of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), and lightweight filler, e.g., microspheres, are blended in the dry state in a suitable mixer. 
     Then, water, a superplasticizer (e.g., the sodium salt of polynapthalene sulfonate), and the pozzolan (e.g., silica fume or metakaolin) are mixed in another mixer for 1 to 5 minutes. If desired, a retarder (e.g., potassium tartrate) is added at this stage to control the setting characteristics of the slurry. The dry ingredients are added to the mixer containing the wet ingredients and mixed for 2 to 10 minutes to form smooth homogeneous slurry. 
     The slurry is then combined with glass fibers, in any of several ways, with the objective of obtaining a uniform slurry mixture. The cementitious panels are then formed by pouring the slurry containing fibers into an appropriate mold of desired shape and size. If necessary, vibration is provided to the mold to obtain good compaction of material in the mold. The panel is given required surface finishing characteristics using an appropriate screed bar or trowel. 
     One of a number of methods to make multi-layer SCP panels is as follows. The reactive powders, e.g., blend of hydraulic cement, calcium sulfate alpha hemihydrate, pozzolan, and lime), and lightweight filler, e.g., microspheres, are blended in the dry state in a suitable mixer. Then, water, a superplasticizer (e.g., the sodium salt of polynapthalene sulfonate), and the pozzolan (e.g., silica fume or metakaolin) are mixed in another mixer for 1 to 5 minutes. If desired, a retarder (e.g., potassium tartrate) is added at this stage to control the setting characteristics of the slurry. The dry ingredients are added to the mixer containing the wet ingredients and mixed for 2 to 10 minutes to form a smooth homogeneous slurry. 
     The slurry may be combined with the glass fibers in several ways, with the objective of obtaining a uniform mixture. The glass fibers typically will be in the form of rovings that are chopped into short lengths. In a preferred embodiment, the slurry and the chopped glass fibers are concurrently sprayed into a panel mold. Preferably, spraying is done in a number of passes to produce thin layers, preferably up to about 0.25 inches (6.3 mm) thick, which are built up into a uniform panel having no particular pattern and with a thickness of ¼ to 1 inch (6.3 to 25.4 mm). For example, in one application, a 3×5 ft (0.91×1.52 m) panel was made with six passes of the spray in the length and width directions. As each layer is deposited, a roller may be used to assure that the slurry and the glass fibers achieve intimate contact. The layers may be leveled with a screed bar or other suitable means after the rolling step. Typically, compressed air will be used to atomize the slurry. As it emerges from the spray nozzle, the slurry mixes with glass fibers that have been cut from a roving by a chopper mechanism mounted on the spray gun. The uniform mixture of slurry and glass fibers is deposited in the panel mold as described above. 
     If desired the outer surface layers of the panel may contain polymer spheres, or be otherwise constituted, in order that the fasteners used to attach the panel to framing can be driven easily. The preferable thickness of such layers will be about 1/32 inches to 4/32 inches (0.8 to 3.2 mm). The same procedure described above by which the core of the panel is made may be used to apply the outer layers of the panel. 
     Other methods of depositing a mixture of the slurry and glass fibers will occur to those familiar with the panel-making art. For example, rather than using a batch process to make each panel, a continuous sheet may be prepared in a similar manner, which after the material has sufficiently set, can be cut into panels of the desired size. The percentage of fibers relative to the volume of slurry typically constitutes approximately in the range of 0.5% to 3%, for example 1.5%. Typical panels have a thickness of about ¼ to 1½ inches (6.3 to 38.1 mm). 
     Another method of making panels of the present invention is by using the process steps disclosed in U.S. patent application Ser. No. 10/666,294 incorporated herein by reference. U.S. patent application Ser. No. 10/666,294, incorporated herein by reference, discloses after one of an initial deposition of loosely distributed, chopped fibers or a layer of slurry upon a moving web, fibers are deposited upon the slurry layer. An embedment device compacts the recently deposited fibers into the slurry, after which additional layers of slurry, then chopped fibers are added, followed by more embedment. The process is repeated for each layer of the board, as desired. Upon completion, the board has a more evenly distributed fiber component, which results in relatively strong panels without the need for thick mats of reinforcing fibers, as taught in prior art production techniques for cementitious panels. 
     More specifically, U.S. patent application Ser. No. 10/666,294 discloses a multi-layer process for producing structural cementitious panels, including: (a.) providing a moving web; (b.) one of depositing a first layer of loose fibers and (c.) depositing a layer of settable slurry upon the web; (d.) depositing a second layer of loose fibers upon the slurry; (e.) embedding the second layer of fibers into the slurry; and (f.) repeating the slurry deposition of step (c.) through step (d.) until the desired number of layers of settable fiber-enhanced slurry in the panel is obtained. 
       FIG. 21  is a diagrammatic elevational view of an apparatus which is suitable for performing the process of U.S. patent application Ser. No. 10/666,294. Referring now to  FIG. 21 , a structural panel production line is diagrammatically shown and is generally designated  310 . The production line  310  includes a support frame or forming table  312  having a plurality of legs  313  or other supports. Included on the support frame  312  is a moving carrier  314 , such as an endless rubber-like conveyor belt with a smooth, water-impervious surface, however porous surfaces are contemplated. As is well known in the art, the support frame  312  may be made of at least one table-like segment, which may include designated legs  313 . The support frame  312  also includes a main drive roll  316  at a distal end  318  of the frame, and an idler roll  320  at a proximal end  322  of the frame. Also, at least one belt tracking and/or tensioning device  324  is preferably provided for maintaining a desired tension and positioning of the carrier  314  upon the rolls  316 ,  320 . 
     Also, in the preferred embodiment, a web  326  of Kraft paper, release paper, and/or other webs of support material designed for supporting slurry prior to setting, as is well known in the art, may be provided and laid upon the carrier  314  to protect it and/or keep it clean. However, it is also contemplated that the panels produced by the present line  310  are formed directly upon the carrier  314 . In the latter situation, at least one belt washing unit  328  is provided. The carrier  314  is moved along the support frame  312  by a combination of motors, pulleys, belts or chains which drive the main drive roll  316  as is known in the art. It is contemplated that the speed of the carrier  314  may vary to suit the application. 
     In the apparatus of  FIG. 21 , structural cementitious panel production is initiated by one of depositing a layer of loose, chopped fibers  330  or a layer of slurry upon the web  326 . An advantage of depositing the fibers  330  before the first deposition of slurry is that fibers will be embedded near the outer surface of the resulting panel. A variety of fiber depositing and chopping devices are contemplated by the present line  310 , however the preferred system employs at least one rack  331  holding several spools  332  of fiberglass cord, from each of which a cord  334  of fiber is fed to a chopping station or apparatus, also referred to as a chopper  336 . 
     The chopper  336  includes a rotating bladed roll  338  from which project radially extending blades  340  extending transversely across the width of the carrier  314 , and which is disposed in close, contacting, rotating relationship with an anvil roll  342 . In the preferred embodiment, the bladed roll  338  and the anvil roll  342  are disposed in relatively close relationship such that the rotation of the bladed roll  338  also rotates the anvil roll  342 , however the reverse is also contemplated. Also, the anvil roll  342  is preferably covered with a resilient support material against which the blades  340  chop the cords  334  into segments. The spacing of the blades  340  on the roll  338  determines the length of the chopped fibers. As is seen in  FIG. 21 , the chopper  336  is disposed above the carrier  314  near the proximal end  322  to maximize the productive use of the length of the production line  310 . As the fiber cords  334  are chopped, the fibers  330  fall loosely upon the carrier web  326 . 
     Next, a slurry feed station, or a slurry feeder  344  receives a supply of slurry  346  from a remote mixing location  347  such as a hopper, bin or the like. It is also contemplated that the process may begin with the initial deposition of slurry upon the carrier  314 . The slurry is preferably comprised of varying amounts of Portland cement, gypsum, aggregate, water, accelerators, plasticizers, foaming agents, fillers and/or other ingredients, and described above and in the patents listed above which have been incorporated by reference for producing SCP panels. The relative amounts of these ingredients, including the elimination of some of the above or the addition of others, may vary to suit the use. 
     While various configurations of slurry feeders  344  are contemplated which evenly deposit a thin layer of slurry  346  upon the moving carrier  314 , the preferred slurry feeder  344  includes a main metering roll  348  disposed transversely to the direction of travel of the carrier  314 . A companion or back up roll  350  is disposed in close parallel, rotational relationship to the metering roll  348  to form a nip  352  there between. A pair of sidewalls  354 , preferably of non-stick material such as Teflon® brand material or the like, prevents slurry  346  poured into the nip  352  from escaping out the sides of the feeder  344 . 
     The feeder  344  deposits an even, relatively thin layer of the slurry  346  upon the moving carrier  314  or the carrier web  326 . Suitable layer thicknesses range from about 0.05 inch to 0.20 inch. However, with four layers preferred in the preferred structural panel produced by the present process, and a suitable building panel being approximately 0.5 inch, an especially preferred slurry layer thickness is approximately 0.125 inch. 
     Referring now to  FIGS. 21 and 22 , to achieve a slurry layer thickness as described above, several features are provided to the slurry feeder  344 . First, to ensure a uniform disposition of the slurry  346  across the entire web  326 , the slurry is delivered to the feeder  344  through a hose  356  located in a laterally reciprocating, cable driven, fluid powered dispenser  358  of the type well known in the art. Slurry flowing from the hose  356  is thus poured into the feeder  344  in a laterally reciprocating motion to fill a reservoir  359  defined by the rolls  348 ,  350  and the sidewalls  354 . Rotation of the metering roll  348  thus draws a layer of the slurry  346  from the reservoir. 
     Next, a thickness monitoring or thickness control roll  360  is disposed slightly above and/or slightly downstream of a vertical centerline of the main metering roll  348  to regulate the thickness of the slurry  346  drawn from the feeder reservoir  357  upon an outer surface  362  of the main metering roll  348 . Also, the thickness control roll  360  allows handling of slurries with different and constantly changing viscosities. The main metering roll  348  is driven in the same direction of travel “T” as the direction of movement of the carrier  314  and the carrier web  326 , and the main metering roll  348 , the backup roll  350  and the thickness monitoring roll  360  are all rotatably driven in the same direction, which minimizes the opportunities for premature setting of slurry on the respective moving outer surfaces. As the slurry  346  on the outer surface  362  moves toward the carrier web  326 , a transverse stripping wire  364  located between the main metering roll  348  and the carrier web  326  ensures that the slurry  346  is completely deposited upon the carrier web and does not proceed back up toward the nip  352  and the feeder reservoir  359 . The stripping wire  364  also helps keep the main metering roll  348  free of prematurely setting slurry and maintains a relatively uniform curtain of slurry. 
     A second chopper station or apparatus  366 , preferably identical to the chopper  336 , is disposed downstream of the feeder  344  to deposit a second layer of fibers  368  upon the slurry  346 . In the preferred embodiment, the chopper apparatus  366  is fed cords  334  from the same rack  331  that feeds the chopper  336 . However, it is contemplated that separate racks  331  could be supplied to each individual chopper, depending on the application. 
     Referring now to  FIGS. 21 and 23 , next, an embedment device, generally designated  370  is disposed in operational relationship to the slurry  346  and the moving carrier  314  of the production line  310  to embed the fibers  368  into the slurry  346 . While a variety of embedment devices are contemplated, including, but not limited to vibrators, sheep&#39;s foot rollers and the like, in the preferred embodiment, the embedment device  370  includes at least a pair of generally parallel shafts  372  mounted transversely to the direction of travel “T” of the carrier web  326  on the frame  312 . Each shaft  372  is provided with a plurality of relatively large diameter disks  374  which are axially separated from each other on the shaft by small diameter disks  376 . 
     During SCP panel production, the shafts  372  and the disks  374 ,  376  rotate together about the longitudinal axis of the shaft. As is well known in the art, either one or both of the shafts  372  may be powered, and if only one is powered, the other may be driven by belts, chains, gear drives or other known power transmission technologies to maintain a corresponding direction and speed to the driving roll. The respective disks  374 ,  376  of the adjacent, preferably parallel shafts  372  are intermeshed with each other for creating a “kneading” or “massaging” action in the slurry, which embeds the fibers  368  previously deposited thereon. In addition, the close, intermeshed and rotating relationship of the disks  372 ,  374  prevents the buildup of slurry  346  on the disks, and in effect creates a “self-cleaning” action which significantly reduces production line downtime due to premature setting of clumps of slurry. 
     The intermeshed relationship of the disks  374 ,  376  on the shafts  372  includes a closely adjacent disposition of opposing peripheries of the small diameter spacer disks  376  and the relatively large diameter main disks  374 , which also facilitates the self-cleaning action. As the disks  374 ,  376  rotate relative to each other in close proximity (but preferably in the same direction), it is difficult for particles of slurry to become caught in the apparatus and prematurely set. By providing two sets of disks  374  which are laterally offset relative to each other, the slurry  346  is subjected to multiple acts of disruption, creating a “kneading” action which further embeds the fibers  368  in the slurry  346 . 
     Once the fibers  368  have been embedded, or in other words, as the moving carrier web  326  passes the embedment device  370 , a first layer  377  of the SCP panel is complete. In the preferred embodiment, the height or thickness of the first layer  377  is in the approximate range of 0.05-0.20 inches. This range has been found to provide the desired strength and rigidity when combined with like layers in a SCP panel. However, other thicknesses are contemplated depending on the application. 
     To build a structural cementitious panel of desired thickness, additional layers are needed. To that end, a second slurry feeder  378 , which is substantially identical to the feeder  344 , is provided in operational relationship to the moving carrier  314 , and is disposed for deposition of an additional layer  380  of the slurry  346  upon the existing layer  377 . 
     Next, an additional chopper  382 , substantially identical to the choppers  336  and  366 , is provided in operational relationship to the frame  312  to deposit a third layer of fibers  384  provided from a rack (not shown) constructed and disposed relative to the frame  312  in similar fashion to the rack  331 . The fibers  384  are deposited upon the slurry layer  380  and are embedded using a second embedment device  386 . Similar in construction and arrangement to the embedment device  370 , the second embedment device  386  is mounted slightly higher relative to the moving carrier web  314  so that the first layer  377  is not disturbed. In this manner, the second layer  380  of slurry and embedded fibers is created. 
     Referring now to  FIG. 21 , with each successive layer of settable slurry and fibers, an additional slurry feeder station  344 ,  378 ,  402  followed by a fiber chopper  336 ,  366 ,  382 ,  404  and an embedment device  370 ,  386 ,  406  is provided on the production line  310 . In the preferred embodiment, four total layers (see for example, the panel  101  of  FIG. 29 ) are provided to form the SCP panel. Upon the disposition of the four layers of fiber-embedded settable slurry as described above, a forming device  394  is preferably provided to the frame  312  to shape an upper surface  396  of the panel. Such forming devices  394  are known in the settable slurry/board production art, and typically are spring-loaded or vibrating plates which conform the height and shape of the multi-layered panel to suit the desired dimensional characteristics. 
     The panel which is made has multiple layers (see for example layers  23 ,  25 ,  27 ,  29  of panel  21  of  FIG. 6 ) which upon setting form an integral, fiber-reinforced mass. Provided that the presence and placement of fibers in each layer are controlled by and maintained within certain desired parameters as is disclosed and described below, it will be virtually impossible to delaminate the panel. 
     At this point, the layers of slurry have begun to set, and the respective panels are separated from each other by a cutting device  398 , which in the preferred embodiment is a water jet cutter. Other cutting devices, including moving blades, are considered suitable for this operation, provided that they can create suitably sharp edges in the present panel composition. The cutting device  398  is disposed relative to the line  310  and the frame  312  so that panels are produced having a desired length, which may be different from the representation shown in  FIG. 21 . Since the speed of the carrier web  314  is relatively slow, the cutting device  398  may be mounted to cut perpendicularly to the direction of travel of the web  314 . With faster production speeds, such cutting devices are known to be mounted to the production line  310  on an angle to the direction of web travel. Upon cutting, the separated panels  321  are stacked for further handling, packaging, storage and/or shipment as is well known in the art. 
     In quantitative terms, the influence of the number of fiber and slurry layers, the volume fraction of fibers in the panel, and the thickness of each slurry layer, and fiber strand diameter on fiber embedment efficiency has been investigated. In the analysis, the following parameters were identified: 
     v T =Total composite volume 
     v s =Total panel slurry volume 
     v f =Total panel fiber volume 
     v f,l =Total fiber volume/layer 
     v T,l =Total composite volume/layer 
     v s,l =Total slurry volume/layer 
     N l =Total number of slurry layers; Total number of fiber layers 
     V f =Total panel fiber volume fraction 
     d f =Equivalent diameter of individual fiber strand 
     l f =Length of individual fiber strand 
     t=Panel thickness 
     t l =Total thickness of individual layer including slurry and fibers 
     t s,l =Thickness of individual slurry layer 
     n f,l , n f1,l , n f2,l =Total number of fibers in a fiber layer 
     s f,l   P , s f,l   P , s f2,1   P =Total projected surface area of fibers contained in a fiber layer 
     S f,l   P , S f1,l   P , S f2,l   P =Projected fiber surface area fraction for a fiber layer. 
     Projected Fiber Surface Area Fraction, S f,l   P    
     Assume a panel composed of equal number of slurry and fiber layers. Let the number of these layers be equal to N l , and the fiber volume fraction in the panel be equal to V f . 
     In summary, the projected fiber surface area fraction, S f,l   P  of a layer of fiber network being deposited over a distinct slurry layer is given by the following mathematical relationship: 
     
       
         
           
             
               S 
               
                 f 
                 , 
                 l 
               
               P 
             
             = 
             
               
                 
                   4 
                   ⁢ 
                   
                     V 
                     f 
                   
                   ⁢ 
                   t 
                 
                 
                   π 
                   ⁢ 
                   
                       
                   
                   ⁢ 
                   
                     N 
                     l 
                   
                   ⁢ 
                   
                     d 
                     f 
                   
                 
               
               = 
               
                 
                   4 
                   ⁢ 
                   
                     V 
                     f 
                   
                   * 
                   
                     t 
                     
                       s 
                       , 
                       l 
                     
                   
                 
                 
                   π 
                   ⁢ 
                   
                       
                   
                   ⁢ 
                   
                     
                       d 
                       f 
                     
                     ⁡ 
                     
                       ( 
                       
                         1 
                         - 
                         
                           V 
                           f 
                         
                       
                       ) 
                     
                   
                 
               
             
           
         
       
     
     where, V f  is the total panel fiber volume fraction, t is the total panel thickness, d f  is the diameter of the fiber strand, N l  is the total number of fiber layers and t s,l  is the thickness of the distinct slurry layer being used. 
     Accordingly, to achieve good fiber embedment efficiency, the objective function becomes keeping the fiber surface area fraction below a certain critical value. It is noteworthy that by varying one or more variables appearing in the Equations 8 and 10, the projected fiber surface area fraction can be tailored to achieve good fiber embedment efficiency. 
     Different variables that affect the magnitude of projected fiber surface area fraction are identified and approaches have been suggested to tailor the magnitude of “projected fiber surface area fraction” to achieve good fiber embedment efficiency. These approaches involve varying one or more of the following variables to keep projected fiber surface area fraction below a critical threshold value: number of distinct fiber and slurry layers, thickness of distinct slurry layers and diameter of fiber strand. 
     Based on this fundamental work, the preferred magnitudes of the projected fiber surface area fraction, S f,l   P  have been discovered to be as follows: 
     Preferred projected fiber surface area fraction, S f,l   P &lt;0.65 
     Most preferred projected fiber surface area fraction, S f,l   P &lt;0.45 
     For a design panel fiber volume fraction, V f , achievement of the aforementioned preferred magnitudes of projected fiber surface area fraction can be made possible by tailoring one or more of the following variables—total number of distinct fiber layers, thickness of distinct slurry layers and fiber strand diameter. In particular, the desirable ranges for these variables that lead to the preferred magnitudes of projected fiber surface area fraction are as follows: 
     Thickness of Distinct Slurry Layers in Multiple Layer SCP panels, t s,l    
     Preferred thickness of distinct slurry layers, t s,l ≦0.20 inches 
     More Preferred thickness of distinct slurry layers, t s,l ≦0.12 inches 
     Most preferred thickness of distinct slurry layers, t s,l ≦0.08 inches 
     Number of Distinct Fiber Layers in Multiple Layer SCP panels, N l    
     Preferred number of distinct fiber layers, N l ≧4 
     Most preferred number of distinct fiber layers, N l ≧6 
     Fiber Strand Diameter, d f    
     Preferred fiber strand diameter, d f ≧30 tex 
     Most preferred fiber strand diameter, d f ≧70 tex 
     Properties 
     The SCP panel metal frame system of the present invention preferably has one or more of the properties listed in TABLES 2A-2D. The properties are for ½ inch (12.7 mm) thick SCP panel unless otherwise indicated. 
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 2A 
               
               
                   
               
               
                   
                 ASTM 
                   
                 Preferred 
                   
                   
               
               
                 Physical 
                 Test 
                   
                 Target 
                 Typical 
                   
               
               
                 Characteristics 
                 Method 
                 Unit 
                 Value 
                 Range 
                 Notes 
               
               
                   
               
             
            
               
                 Non- 
                 E-136 
                 Weight 
                 ≦50% 
                 ≦50% 
                 From Sec. 8, 
               
               
                 Combustibility 
                   
                 Loss 
                   
                   
                 E-136 
               
               
                   
                   
                 Temp 
                 ≦54° F. 
                 ≦54°  
                 From Sec. 8, 
               
               
                   
                   
                 Rise 
                   
                   
                 E-136 
               
               
                   
                   
                 30 
                 No 
                 No 
                 From Sec. 8, 
               
               
                   
                   
                 seconds 
                 flaming 
                 flaming 
                 E-136 
               
               
                 Water 
                   
                   
                   
                   
                   
               
               
                 Durability 
                   
                   
                   
                   
                   
               
               
                 Flex. Strength 
                   
                   
                   
                   
                   
               
               
                 of Sheathing 
                   
                   
                   
                   
                   
               
               
                 Dry 
                 C-947 
                 psi 
                 ≧1800 
                 1400-3500 
                   
               
               
                 Wet 
                 C-947 
                 psi 
                 ≧1650 
                 1300-3000 
                   
               
               
                 AMOE of 
                   
                   
                   
                   
                   
               
               
                 Sheathing 
                   
                   
                   
                   
                   
               
               
                 Dry 
                   
                 ksi 
                 ≧700 
                  600-1000 
                   
               
               
                 Wet 
                   
                 ksi 
                 ≧600 
                 550-950 
                   
               
               
                 Screw 
                   
                   
                   
                   
                 (screw size; 
               
               
                 Withdrawal 
                   
                   
                   
                   
                 #8 wire 1 
               
               
                   
                   
                   
                   
                   
                 ⅝ inch screw  
               
               
                   
                   
                   
                   
                   
                 with 0.25 inch  
               
               
                   
                   
                   
                   
                   
                 diameter head 
               
               
                   
                   
                   
                   
                   
                 minimum) 
               
               
                 ½″ Panel-Dry 
                 D-1761 
                 pounds 
                 352 
                 250-450 
                 Equiv. to 
               
               
                   
                   
                   
                   
                   
                 American 
               
               
                   
                   
                   
                   
                   
                 Plywood  
               
               
                   
                   
                   
                   
                   
                 Assoc. (APA) 
               
               
                   
                   
                   
                   
                   
                 S-4 
               
               
                 ½″ Panel-Wet 
                 D-1761 
                 pounds 
                 293 
                 200-400 
                 % of force for 
               
               
                   
                   
                   
                   
                   
                 SCP relative to 
               
               
                   
                   
                   
                   
                   
                 OSB 82%; % 
               
               
                   
                   
                   
                   
                   
                 of force for 
               
               
                   
                   
                   
                   
                   
                 SCP relative 
               
               
                   
                   
                   
                   
                   
                 to Plywood 80% 
               
               
                 ¾″ Panel-Dry 
                 D-1761 
                 pounds 
                 522 
                 450-600 
                 Equiv. to 
               
               
                   
                   
                   
                   
                   
                 American 
               
               
                   
                   
                   
                   
                   
                 Plywood Assoc. 
               
               
                   
                   
                   
                   
                   
                 (APA) S-4 
               
               
                 ¾″ Panel-Wet 
                 D-1761 
                 pounds 
                 478 
                 450-550 
                 % of force for 
               
               
                   
                   
                   
                   
                   
                 SCP relative to 
               
               
                   
                   
                   
                   
                   
                 OSB 82%; % 
               
               
                   
                   
                   
                   
                   
                 of force for 
               
               
                   
                   
                   
                   
                   
                 SCP relative 
               
               
                   
                   
                   
                   
                   
                 to Plywood 80% 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 2B 
               
               
                   
               
               
                   
                 ASTM 
                   
                 Preferred 
                   
                   
               
               
                 Physical 
                 Test 
                   
                 Target 
                   
                   
               
               
                 Characteristics 
                 Method 
                 Unit 
                 Value 
                 Typical Range 
                 Notes 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 Lateral Screw 
                   
                   
                   
                   
                 Screw size: #8 wire 1⅝ 
               
               
                 Resistance 
                   
                   
                   
                   
                 inch screw with 0.25 inch 
               
               
                   
                   
                   
                   
                   
                 diameter head minimum 
               
               
                 ½″ Panel-Dry 
                 D-1761 
                 pounds 
                 445 
                 350-550 
                 Equiv. to APA S-4 
               
               
                 ½″ Panel-Wet 
                 D-1761 
                 pounds 
                 558 
                 400-650 
                 % of force for SCP 
               
               
                   
                   
                   
                   
                   
                 relative to OSB 73; % of 
               
               
                   
                   
                   
                   
                   
                 force for SCP relative to 
               
               
                   
                   
                   
                   
                   
                 Plywood 82% 
               
               
                 ¾″ Panel-Dry 
                 D-1761 
                 pounds 
                 414 
                 400-500 
                 Equiv. to APA S-4 
               
               
                 ¾″ Panel-Wet 
                 D-1761 
                 pounds 
                 481 
                 400-500 
                 % of force for SCP 
               
               
                   
                   
                   
                   
                   
                 relative to OSB 73; % of 
               
               
                   
                   
                   
                   
                   
                 force for SCP relative to 
               
               
                   
                   
                   
                   
                   
                 Plywood 82% 
               
               
                 Static &amp; Impact Test 
                   
                   
                   
                   
                   
               
               
                 (¾ inch thick SCP) 
                   
                   
                   
                   
                   
               
               
                 Ultimate 
                   
                   
                   
                   
                   
               
               
                 Static 
                 E-661 
                 pounds 
                 1286 
                 1000-1500 
                 APA S-1; 16 inch o.c. 
               
               
                   
                   
                   
                   
                   
                 Span Rating ≧550 lbs. 
               
               
                 Following 
                 E-661 
                 pounds 
                 2206 
                 1500-3000 
                 APA S-1; 16 inch o.c. 
               
               
                 Impact 
                   
                   
                   
                   
                 Span Rating ≧400 lbs 
               
               
                 Deflection under 200 
                   
                   
                   
                   
                   
               
               
                 lb. Load 
                   
                   
                   
                   
                   
               
               
                 Static 
                 E-661 
                 inches 
                 0.014 
                 0.010-0.060 
                 APA S-1; 16 inch o.c. 
               
               
                   
                   
                   
                   
                   
                 Span Rating ≦0.078″ 
               
               
                 Following 
                 E-661 
                 inches 
                 0.038 
                 0.020-0.070 
                 APA S-1; 16 inch o.c. 
               
               
                 Impact 
                   
                   
                   
                   
                 Span Rating ≦0.078″ 
               
               
                 Uniform Load 
                   
                   
                   
                   
                   
               
               
                 ¾″ Panel-Dry 
                   
                 psf 
                 330 
                 300-450 
                 16 inch o.c. 
               
               
                   
                   
                   
                   
                   
                 Span Rating ≧330 psf 
               
               
                 Linear Expansion 
                   
                   
                   
                   
                   
               
               
                 ½″ to ¾″ 
                 APA P-1 
                 % 
                 ≦0.1 
                 ≦0.1 
                 APA P-1 requires ≦0.5% 
               
               
                 Panel 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 2C 
               
               
                   
               
               
                   
                 ASTM 
                   
                 Preferred 
                   
                   
               
               
                 Physical 
                 Test 
                   
                 Target 
                   
                   
               
               
                 Characteristics 
                 Method 
                 Unit 
                 Value 
                 Typical Range 
                 Notes 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 Water Absorption 
                   
                   
                   
                   
                   
               
               
                 ½″ Panel 
                 APA 
                 % 
                 11.8 
                  7 to 15 
                 % water absorption of 
               
               
                   
                 PRP-108 
                   
                   
                   
                 SCP relative to ½ inch 
               
               
                   
                   
                   
                   
                   
                 thick OSB: 51.5%, 
               
               
                   
                   
                   
                   
                   
                 % water absorption of 
               
               
                   
                   
                   
                   
                   
                 SCP relative to ½ inch 
               
               
                   
                   
                   
                   
                   
                 thick Plywood: 46.2% 
               
               
                 ¾″ Panel 
                 APA 
                 % 
                 10.8 
                  7 to 15 
                 % water absorption of 
               
               
                   
                 PRP-108 
                   
                   
                   
                 SCP relative to 
               
               
                   
                   
                   
                   
                   
                 OSB: 51.3%, 
               
               
                   
                   
                   
                   
                   
                 % water absorption of 
               
               
                   
                   
                   
                   
                   
                 SCP relative to 
               
               
                   
                   
                   
                   
                   
                 Plywood: 48.1% 
               
               
                 Thickness Swell 
                   
                   
                   
                   
                   
               
               
                 ½″ Panel 
                 APA 
                 % 
                 2.3 
                 1 to 5 
                 % water absorption of 
               
               
                   
                 PRP-108 
                   
                   
                   
                 SCP relative to ½ inch 
               
               
                   
                   
                   
                   
                   
                 thick OSB: 22.2%, 
               
               
                   
                   
                   
                   
                   
                 % water absorption of SCP 
               
               
                   
                   
                   
                   
                   
                 relative to ½ inch 
               
               
                   
                   
                   
                   
                   
                 thick Plywood: 7.8% 
               
               
                 ¾″ Panel 
                 APA 
                 % 
                 2.4 
                 1 to 5 
                 % water absorption of 
               
               
                   
                 PRP-108 
                   
                   
                   
                 SCP relative to 
               
               
                   
                   
                   
                   
                   
                 OSB: 22.2%, 
               
               
                   
                   
                   
                   
                   
                 % water absorption of 
               
               
                   
                   
                   
                   
                   
                 SCP relative to 
               
               
                   
                   
                   
                   
                   
                 Plywood: 7.8% 
               
               
                 Mold &amp; Bacteria 
                   
                   
                   
                   
                   
               
               
                 Resistance 
                   
                   
                   
                   
                   
               
               
                 ½ to ¾″ Panel 
                 G-21 
                   
                 1 
                 0 to 1 
                 OSB &amp; Plywood have 
               
               
                   
                   
                   
                   
                   
                 food source 
               
               
                 ½ to ¾″ Panel 
                 D-3273 
                   
                 10 
                 10 
                 OSB &amp; Plywood have 
               
               
                   
                   
                   
                   
                   
                 food source 
               
               
                 Termite Resistance 
                   
                   
                   
                   
                   
               
               
                 ½ to ¾″ Panel 
                   
                   
                 No food 
                 No food 
                   
               
               
                   
                   
                   
                 source 
                 source 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
               
               
               
             
               
                 TABLE 2D 
               
               
                   
               
               
                   
                 ASTM 
                   
                 Preferred 
                   
                   
               
               
                 Physical 
                 Test 
                   
                 Target 
                 Typical 
                   
               
               
                 Characteristics 
                 Method 
                 Unit 
                 Value 
                 Range 
                 Notes 
               
               
                   
               
             
            
               
                 Horizontal 
                   
                   
                   
                   
                   
               
               
                 Design Shear 
                   
                   
                   
                   
                   
               
               
                 Capacity 
                   
                   
                   
                   
                   
               
               
                 of the SCP 
                   
                   
                   
                   
                   
               
               
                 Diaphragm 
                   
                   
                   
                   
                   
               
               
                 ¾″ Panel- 
                 E-455 
                 pounds 
                 487.2 
                 300-1000 
                 Performance 
               
               
                 10′ × 20′ Roof 
                   
                 per 
                   
                 Typically  
                 relates to 
               
               
                   
                   
                 linear 
                   
                 400-800 
                 panel  
               
               
                   
                   
                 foot 
                   
                   
                 properties,  
               
               
                   
                   
                   
                   
                   
                 joist depth &amp; 
               
               
                   
                   
                   
                   
                   
                 spacing and  
               
               
                   
                   
                   
                   
                   
                 fastener type 
               
               
                   
                   
                   
                   
                   
                 and spacing 
               
               
                 System Fire 
                   
                   
                   
                   
                   
               
               
                 Resistance 
                   
                   
                   
                   
                   
               
               
                 ⅝ to ¾″ 
                 E-119 
                 Time 
                 1 hr and 
                 1 to 1.5 hr. 
                 Nominal 4″ 
               
               
                 SCP Panel  
                   
                   
                 10 min. 
                   
                 deep stud, 
               
               
                 on one side of  
                   
                   
                   
                   
                 24″  
               
               
                 metal frame 
                   
                   
                   
                   
                 O.C., batt 
               
               
                   
                   
                   
                   
                   
                 insulation, 1 
               
               
                   
                   
                   
                   
                   
                 layer ⅝″ 
               
               
                   
                   
                   
                   
                   
                 FIRECODE 
               
               
                   
                   
                   
                   
                   
                 Gypsum  
               
               
                   
                   
                   
                   
                   
                 Board 
               
               
                   
                   
                   
                   
                   
                 available 
               
               
                   
                   
                   
                   
                   
                 from USG. 
               
               
                 ¾″ Panel 
                 E-119 
                 Time 
                 2 hr - 
                 2 hr. 
                 Nominal 10″  
               
               
                 SCP on one  
                   
                   
                 9 min. 
                   
                 deep joist, 
               
               
                 side of metal 
                   
                   
                   
                   
                 24″ 
               
               
                 frame 
                   
                   
                   
                   
                 O.C., batt 
               
               
                   
                   
                   
                   
                   
                 insulation, 1  
               
               
                   
                   
                   
                   
                   
                 layer ⅝″ - 
               
               
                   
                   
                   
                   
                   
                 FIRECODE 
               
               
                   
                   
                   
                   
                   
                 Gypsum  
               
               
                   
                   
                   
                   
                   
                 Board 
               
               
                   
                   
                   
                   
                   
                 available 
               
               
                   
                   
                   
                   
                   
                 from USG 
               
               
                   
               
            
           
         
       
     
     Horizontal Design Shear Capacity in Table 2D provides for a safety factor of 3. 
     A system having ⅜-¾ inch (9-19 mm), e.g. ½ inch (12.5 mm), thick SCP panels mechanically and/or adhesively laterally braced metal framing when tested according to ASTM E-72 typically has a nominal wall shear capacity (also known as nominal racking shear strength) of 200 to 1200, or 400 to 1200, or 800 to 1200 pounds per linear foot. 
     A typical ¾ inch (19 mm) thick panel when tested according to ASTM 661 and APA S-1 test methods over a span of 16 inches (406.4 mm) on centers, has an ultimate load capacity greater than 550 lb (250 kg), under static loading, an ultimate load capacity greater than 400 lb (182 kg) under impact loading, and a deflection of less than 0.078 inches (1.98 mm) under both static and impact loading with a 200 lb (90.9 kg) load. 
     Typically, the flexural strength of a panel having a dry density of 65 lb/ft 3  (1041 kg/m 3 ) to 90 lb/ft 3  (1442 kg/m 3 ) or 65 lb/ft 3  (1041 kg/m 3 ) to 95 lb/ft 3  (1522 kg/m 3 ) after being soaked in water for 48 hours is at least 1000 psi (7 MPa), e.g. 1300 psi (9 MPa), preferably 1650 psi (11.4 MPa), more preferably at least 1700 psi (11.7 MPa) as measured by the ASTM C 947 test. 
     Typically the SCP diaphragm results in the present fire wall or other fire resistive assembly system having a higher specific stiffness than a fire wall or other fire resistive assembly system of metal framing and gypsum wall board. Also, typically the present system provides higher specific stiffness than masonry fire wall systems. 
     Typically the vertical shear diaphragm load carrying capacity of the system will not be lessened by more than 25%, preferably not be lessened by more than 20%, when exposed to water in a test wherein a 2 inch head of water is maintained over a horizontally oriented ½ to ¾ inch thick SCP panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours and afterwards reoriented vertically and tested for Vertical shear diaphragm load carrying capacity. 
     Typically the system will not absorb more than 0.7 pounds per square foot of water when exposed to water in a test wherein a 2 inch head of water is maintained over ¾ inch thick SCP panels fastened on a 10 foot by 20 foot metal frame for a period of 24 hours. 
     Typically an embodiment of the present system having a 10 foot wide by 20 foot long by ¾ inch thick diaphragm of the SCP panels attached to a 10 foot by 20 foot metal frame will not swell more than 5% when exposed to a 2 inch head of water maintained over the SCP panels fastened on the metal frame for a period of 24 hours. 
     Typically, every component of the present system meets ASTM G-21 in which the system achieves approximately a 1 and meets ASTM D-3273 in which the system achieves approximately a 10. Also, typically the present system supports substantially zero bacteria growth when clean. Also, typically the present system is inedible to termites. 
     Due to its being lightweight and strong, this combination of the present fire wall or other fire resistive assembly system of a diaphragm of ¾ inch (19 mm) thick or ½ inch thick (13 mm) SCP panel on metal frame permits efficient use of building volume for a given building footprint to permit maximization of building volume for the given building footprint. The lightweight nature of this system avoids the dead load associated with masonry systems. Less dead load allows building comparable size structures on less stable soil. 
     EXAMPLES 
     An experiment was conducted for fire endurance testing on comparative structural sheathing in the small-scale horizontal furnace (SSHF). Five samples, ½ inch (13 mm). Structural Cement Panel (SCP) of a composition of the present invention, ¾ in. (19 mm) VIROC panel, ½ in. (13 mm) NOVATECH panel, 15/32 in. (12 mm) plywood (grade A-C) and 31/64 in. (12 mm) Oriented Strand Board (OSB), were tested as part of 4 ft. by 4 ft. assemblies. 
     Each assembly was constructed of metal framing,  358 , 20 gauge CR runners and ST studs spaced 24 in. on center. The test material was applied to the exposed surface and one layer of USG&#39;s SHEETROCK ⅝ in. (16 mm) FIRECODE Type SCX gypsum wallboard was applied to the unexposed surface for each of the five tests. The exposed surface material is applied perpendicular to the studs with a joint at the mid-span of the assembly. Thermocouples were placed in both cavities underside of the exposed panel and on the unexposed surface for temperature comparison of the assemblies. The furnace temperatures were controlled to the ASTM E119 Time/Temperature Curve. Temperature measurements were made of the finish rating and the unexposed surface for the duration of the test. Observations were made as to the estimated condition of the exposed surface during the test. Standard ASTM E119 temperature limits for the thermocouple readings were 250° F. (136° C.) above ambient for the average and 325° F. (183° C.) above ambient for the individual were used as control limits. 
     The purpose of the testing was to provide a relative comparison of the performance of product material in the fire test. The procedure does not provide a fire endurance rating for a system. 
     The formulation of the SCP panels used in the small-scale horizontal furnace test (Example 1 and Example 3) is as follows in TABLE 2E: 
     
       
         
           
               
               
               
             
               
                 TABLE 2E 
               
               
                   
               
               
                   
                 Ingredient 
                 Weight Proportion (%) 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                   
                 Reactive Powder Blend 
                   
               
               
                   
                 Portland Cement 
                 29 
               
               
                   
                 Calcium Sulfate Alpha Hemihydrate 
                 58 
               
               
                   
                 Silica Fume 
                 12 
               
               
                   
                 Lime 
                 1 
               
               
                   
                 SCP Cementitious Composition 
                   
               
               
                   
                 Portland Cement 
                 12.3 
               
               
                   
                 Calcium Sulfate Alpha Hemihydrate 
                 24.7 
               
               
                   
                 Silica Fume 
                 5.1 
               
               
                   
                 Lime 
                 0.4 
               
               
                   
                 Ceramic Microspheres 
                 26.4 
               
               
                   
                 Superplasticizer 
                 1.9 
               
               
                   
                 Water 
                 21.9 
               
               
                   
                 Alkali-Resistant Glass Fibers  1   
                 7.2 
               
               
                   
               
               
                   1  Weight proportion corresponds to 3.06% volume fraction of AR Glass Fibers in the composite 
               
               
                 Length of glass fibers used in the small-scale horizontal furnace test - 40 mm. 
               
            
           
         
       
     
     The results from testing of the five samples can be found in TABLE 3. Both the average (A) and the individual (I) readings are in minutes when the temperature criteria limits were exceeded during each test. The SCP board has a composition of a panel of the present invention. 
     
       
         
           
               
             
               
                 TABLE 3 
               
             
            
               
                   
               
               
                 Data Summary for Examples 1-5 
               
            
           
           
               
               
               
               
               
            
               
                   
                   
                   
                 Unexposed 
                 Exposed 
               
               
                 SSHF 
                   
                 Finish 
                 Surface 
                 Surface 
               
               
                 Example 
                   
                 Rating 
                 (Overlimit/ 
                 Condition: 
               
               
                 No. 
                 Sample ID 
                 (Minutes) 
                 Minutes) 
                 End of Test 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 1 
                 ½ in. (13 mm) 
                 09:24 
                 (A) 
                 46:05 
                 (A) 
                 Intact 
               
               
                   
                 SCP board 
                 10:05 
                 (1) 
                 46:16 
                 (I) 
                 Low 
               
               
                   
                   
                   
                   
                   
                   
                 Shrinkage 
               
               
                 2 
                 ¾ in. (19 mm) 
                 19:16 
                 (A) 
                 48:42 
                 (A) 
                 Intact 
               
               
                   
                 VIROC board 
                 21.52 
                 (I) 
                 47:49 
                 (I) 
                 Moderate 
               
               
                   
                   
                   
                   
                   
                   
                 Shrinkage 
               
               
                 3 
                 ½ in. (13 mm) 
                 12:52 
                 (A) 
                 46 42 
                 (A) 
                 Panel  
               
               
                   
                 NOVATECH 
                 13 27 
                 (I) 
                 47:13 
                 (I) 
                 Delamina- 
               
               
                   
                 board 
                   
                   
                   
                   
                 tion 
               
               
                   
                   
                   
                   
                   
                   
                 No Fall Off 
               
               
                 4 
                  15/32 in.  
                 6:40 
                 (A) 
                 23:42 
                 (A) 
                 Board Fall 
               
               
                   
                 (12 mm) 
                 7:10 
                 (I) 
                 23:31 
                 (I) 
                 Off 
               
               
                   
                 Plywood board 
                   
                   
                   
                   
                   
               
               
                   
                 (A-C Grade) 
                   
                   
                   
                   
                   
               
               
                 5 
                  31/64 in. 
                 6:50 
                 (A) 
                 24.25 
                 (A) 
                 Board Fall  
               
               
                   
                 (12 mm) OSB 
                 8:12 
                 (I) 
                 23:30 
                 (I) 
                 Off 
               
               
                   
                 board 
               
               
                   
               
            
           
         
       
     
     Example 1 
     Sample Construction 
     Size 48 in. (122 cm) by 48⅝ in. (124 cm) 
     Studs: 358 ST, 20 gauge Spacing: 24 in. (61 cm) on center 
     Runners: 358 CR, 20 gauge; Cavity: Void 
     Facing: (Fire Side) One layer ½ in. (13 mm) USG Structural Cement Panel (SCP)
         (Unexposed Side) One layer ⅝ in. (16 mm) SHEETROCK® FIRECODE® (Type X) panel       

     Table 4 lists the boards employed in this example as test materials. The boards were subjected to heating as presented in Table 5. Observations from this heating are presented in Table 6. 
     
       
         
           
               
             
               
                 TABLE 4 
               
             
            
               
                   
               
               
                 Example 1 Test Materials 
               
            
           
           
               
               
               
               
            
               
                   
                   
                   
                 SHEETROCK ® 
               
               
                   
                   
                   
                 Brand Wallboard 
               
               
                   
                   
                 ½″ (13 mm) SCP 
                 ⅝″ × 48″ × 120″ 
               
               
                   
                   
                 ½″ × 48″ × 96″ 
                 (16 mm × 122 cm × 
               
               
                   
                   
                 (13 mm × 122 cm × 
                 305 cm) 
               
               
                   
                   
                 244 cm) 
                 Type C 
               
               
                   
                   
               
               
                   
                 Lbs/1000 sq. ft 
                 2736 
                 2290 
               
               
                   
                 Average board 
                 0.528 (13.4) 
                 0.620 (15.7) 
               
               
                   
                 thickness, 
                   
                   
               
               
                   
                 in. (mm) 
                   
                   
               
               
                   
                 Average density, 
                 62.128 (0.995) 
                 44.332 (0.710) 
               
               
                   
                 pcf (g/cc) 
                   
                   
               
               
                   
                 Average panel 
                  22.46 (10.19) 
                  37.13 (16.84) 
               
               
                   
                 weight, 
                   
                   
               
               
                   
                 lbs. (kgs.) 
               
               
                   
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 5 
               
             
            
               
                   
               
               
                 Example 1 Temperature Information 
               
            
           
           
               
               
               
            
               
                   
                 Average 
                 Individual 
               
               
                   
               
               
                 Unexposed Surface 
                 324° F. (182° C.) 
                 399° F. (229° C.) 
               
               
                 Limiting Temperature Criteria 
                   
                   
               
               
                 Degrees 79° F. (29° C.) Ambient 
                   
                   
               
               
                 Unexposed Surface 
                 46:05 
                 TC #4 at 46:16 
               
               
                 Temperature Limits Reached 
                   
                   
               
               
                 Finish Rating 
                 323° F. (182° C.) 
                 398° F. (229° C.) 
               
               
                 Limiting Temperature Criteria 
                   
                   
               
               
                 Degrees 79° F. (29° C.) Ambient 
                   
                   
               
               
                 Finish Rating 
                  9:24 
                 TC #8 at 10:05 
               
               
                 Temperature Limits Reached 
               
               
                   
               
            
           
         
       
     
     FIRE TEST DURATION: 70 MIN. 0 SEC. 
     TEST TERMINATED: No Board Fall Off 
     
       
         
           
               
             
               
                 TABLE 6 
               
             
            
               
                   
               
               
                 Example 1 Observations 
               
            
           
           
               
               
               
            
               
                 Time 
                 Furnace 
                   
               
               
                 (Min:Sec) 
                 Pressure 
                 Observations 
               
               
                   
               
               
                  4:00 
                 +0.10 
                 The exposed board is very light tan in color. 
               
               
                 12:00 
                 +0.07 
                 Very light smoke and steam vapor emitting from 
               
               
                   
                   
                 unexposed surface. 
               
               
                 18:00 
                 +0.08 
                 Butt joint opening is at estimated 1/16 inch max. 
               
               
                   
                   
                 More smoke and steam vapor emitting from 
               
               
                   
                   
                 unexposed surface. 
               
               
                 22:00 
                 +0.08 
                 Very heavy smoke and steam vapor emitting from 
               
               
                   
                   
                 unexposed surface. Exposed board looks good and 
               
               
                   
                   
                 is in place. 
               
               
                 30:00 
                 +0.06 
                 Butt joint opening is at estimated ⅛ inch max. 
               
               
                 33:00 
                 +0.08 
                 Board sag in between the studs is at estimated ⅛ 
               
               
                   
                   
                 inch to ¼ inch max. 
               
               
                 38:00 
                 +0.07 
                 Light smoke and steam vapor emitting from 
               
               
                   
                   
                 unexposed surface. 
               
               
                 41:00 
                 +0.10 
                 Board sag in between the studs is at estimated ⅛ 
               
               
                   
                   
                 to ¼ inch max. 
               
               
                 48:00 
                 +0.07 
                 Butt joint opining is at 3/16 to ¼ inch max. 
               
               
                 51:00 
                 +0.08 
                 Board sag in between the studs is at estimated ½ 
               
               
                   
                   
                 inch max. 
               
               
                 53:00 
                 +0.09 
                 Can hear audible sound of paper burning on 
               
               
                   
                   
                 unexposed surface. 
               
               
                 63:00 
                 +0.08 
                 Board sag in between the studs is at estimated ½ 
               
               
                   
                   
                 to ⅝ inch max. 
               
               
                 70:00 
                   
                 Test terminated. No board fall off. 
               
               
                   
               
            
           
         
       
     
     Example 2 
     Sample Construction 
     Size 48 in. (122 cm) by 48⅝ in. (124 cm) 
     Studs: 358 ST, 20 gauge Spacing: 24 in. (61 cm) on center 
     Runners: 358 CR, 20 gauge; Cavity: Void 
     Facing: (Fire Side) One layer ¾ in. VIROC Board
         (Unexposed Side) One layer ⅝ in. (16 mm) SHEETROCK® FIRECODE® (Type X) panel       

     Table 7 lists the boards employed in this example as test materials. The boards were subjected to heating as presented in Table 8. Observations from this heating are presented in Table 9. 
     
       
         
           
               
             
               
                 TABLE 7 
               
             
            
               
                   
               
               
                 Example 2 Test Materials 
               
            
           
           
               
               
               
            
               
                   
                   
                 SHEETROCK ® 
               
               
                   
                 VIROC Board 
                 Brand Wallboard 
               
               
                   
                 ¾″ × 48″ × 48⅝″ 
                 ⅝″ × 48″ × 120″ 
               
               
                   
                 (13 mm × 122 cm × 
                 (16 mm × 122 cm × 305 cm)  
               
               
                   
                 124 cm) 
                 Type X 
               
               
                   
               
               
                 Lbs/1000 sq. ft 
                 — 
                 2290 
               
               
                 Average board 
                 0.760 (19)   
                 0.620 (15.7) 
               
               
                 thickness, 
                   
                   
               
               
                 inches (mm) 
                   
                   
               
               
                 Average density, 
                 83.00 (1.33) 
                 44.344 (0.710) 
               
               
                 pcf (g/cc) 
                   
                   
               
               
                 Average panel 
                  22.46 (10.19) 
                  37.13 (16.84) 
               
               
                 weight, 
                   
                   
               
               
                 lbs. (kgs.) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 8 
               
             
            
               
                   
               
               
                 Example 2 Temperature Information 
               
            
           
           
               
               
               
            
               
                   
                 Average 
                 Individual 
               
               
                   
               
               
                 Unexposed Surface 
                 323° F. (182° C.) 
                 398° F. (229° C.) 
               
               
                 Limiting Temperature Criteria 
                   
                   
               
               
                 Degrees 73° F. (26° C.) Ambient 
                   
                   
               
               
                 Unexposed Surface 
                 48:42 
                 TC #4 at 47:49 
               
               
                 Temperature Limits Reached 
                   
                   
               
               
                 Finish Rating 
                 325° F. (183° C.) 
                 400° F. (230° C.) 
               
               
                 Limiting Temperature Criteria 
                   
                   
               
               
                 Degrees 79° F. (29° C.) Ambient 
                   
                   
               
               
                 Finish Rating 
                 19:16 
                 TC #8 at 21:52 
               
               
                 Temperature Limits Reached 
               
               
                   
               
            
           
         
       
     
     FIRE TEST DURATION: 60 MIN. 0 SEC. 
     TEST TERMINATED: No Board Fall Off 
     
       
         
           
               
             
               
                 TABLE 9 
               
             
            
               
                   
               
               
                 Example 2 Observations 
               
            
           
           
               
               
               
            
               
                 Time 
                 Furnace 
                   
               
               
                 (Min:Sec) 
                 Pressure 
                 Observations 
               
               
                   
               
            
           
           
               
               
               
            
               
                  2:30 
                 +0.08 
                 The butt joint is smoking and is dark brown 
               
               
                   
                   
                 in color. Smoke emitting from unexposed 
               
               
                   
                   
                 surface. 
               
               
                  6:00 
                 +0.08 
                 Exposed board is charred and black in color. 
               
               
                   
                   
                 Butt joint opening is an estimated ⅛ inch west 
               
               
                   
                   
                 max. Board crack by perimeter by center stud. 
               
               
                  9:00 
                 +0.08 
                 Exposed board is lightly flaming on the entire 
               
               
                   
                   
                 surface. Butt joint opening is at estimated 
               
               
                   
                   
                  3/16 inch to ¼ inch max. Board sag is 
               
               
                   
                   
                 at estimated ¼ inch to ⅜ inch max. 
               
               
                 12:30 
                 +0.08 
                 Board sag is at estimated ½ inch to ¾ inch 
               
               
                   
                   
                 max. Butt joint opening is at estimated ½ inch 
               
               
                   
                   
                 max. and is peeling away towards fire. Surface 
               
               
                   
                   
                 is still lightly flaming. 
               
               
                 18:00 
                 +0.08 
                 Board is still flaming on entire surface. Smoke 
               
               
                   
                   
                 and steam vapor is emitting from unexposed 
               
               
                   
                   
                 surface. 
               
               
                 19:30 
                 +0.08 
                 Butt joint opening is at estimated 1 inch max.  
               
               
                   
                   
                 and peeling away. Board sag is estimated 1½  
               
               
                   
                   
                 inch max. Exposed board is still flaming. 
               
               
                 24:00 
                 +0.08 
                 Butt joint opening is at estimated 1½ to 2  
               
               
                   
                   
                 inches max. The west board has a crack across  
               
               
                   
                   
                 the center by stud. Centerboard screws have  
               
               
                   
                   
                 pulled away from center stud. 
               
               
                 29:00 
                 +0.08 
                 Crack opening in the center of the west board  
               
               
                   
                   
                 is at estimated ½ inch max. Board sag is at 
               
               
                   
                   
                 estimated 2½ to 3 inches max. The board is 
               
               
                   
                   
                 still flaming. Smoke and steam vapor are 
               
               
                   
                   
                 emitting from unexposed surface. 
               
               
                 34:00 
                 +0.07 
                 Board sag is at estimated 4 inches max. East  
               
               
                   
                   
                 board has a crack at the center by the stud. 
               
               
                 40:00 
                 +0.08 
                 West board is sagged towards fire an estimated  
               
               
                   
                   
                 5 inches max. East board crack opening is an  
               
               
                   
                   
                 estimated ⅝ inches max. Board is still 
               
               
                   
                   
                 flaming. 
               
               
                 43:00 
                 +0.08 
                 Board sample is peeling away towards fire at 
               
               
                   
                   
                 estimated 5-6 inches max. The sample cavity 
               
               
                   
                   
                 is peel seen due to board away. 
               
               
                 50:00 
                 +0.0 
                 Board sag is at estimated 6 to 7 inches max. 
               
               
                   
                   
                 and still peeling towards fire. Butt joint 
               
               
                   
                   
                 opening is at estimated 3 inches max. 
               
               
                   
                   
                 East and west center board cracks are at  
               
               
                   
                   
                 estimated 1½ inches max. 
               
               
                 60:00 
                   
                 Test terminated. No board fall off. 
               
               
                   
               
            
           
         
       
     
     Example 3 
     Sample Construction 
     Size 48 in. (122 cm) by 48⅝ in. (124 cm) 
     Studs: 358 ST, 20 gauge Spacing: 24 in. (61 cm) on center 
     Runners: 358 CR, 20 gauge; Cavity: Void 
     Facing: (Fire Side) One layer ½ inch NovaTech Board
         (Unexposed Side) One layer ⅝ in. (16 mm) SHEETROCK® FIRECODE® (Type X) panel.       

     Table 10 lists the boards employed in this example as test materials. The boards were subjected to heating as presented in Table 11. Observations from this heating are presented in Table 12. 
     
       
         
           
               
             
               
                 TABLE 10 
               
             
            
               
                   
               
               
                 Example 3 Test Materials 
               
            
           
           
               
               
               
            
               
                   
                   
                 SHEETROCK ® 
               
               
                   
                 NovaTech Board 
                 Brand Wallboard 
               
               
                   
                 ¾″ × 48″ × 48⅝″ 
                 ⅝″ × 48″ × 120″ 
               
               
                   
                 (13 mm × 122 cm × 
                 (16 mm × 122 cm × 305 cm) 
               
               
                   
                 124 cm) 
                 Type X 
               
               
                   
               
               
                 Lbs/1000 sq. ft 
                 3163 
                 2298 
               
               
                 Average board  
                 0.531 (13)  
                 0.620 (15.7) 
               
               
                 thickness, in. (mm) 
                   
                   
               
               
                 Average density, 
                 71.544 (1.15) 
                 44.517 (0.713) 
               
               
                 pcf (g/cc) 
                   
                   
               
               
                 Average panel  
                  25.90 (11.75) 
                 37.25 (16.9) 
               
               
                 weight, lbs. (kgs.) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 11 
               
             
            
               
                   
               
               
                 Example 3 TEMPERATURE INFORMATION 
               
            
           
           
               
               
               
            
               
                   
                 Average 
                 Individual 
               
               
                   
               
               
                 Unexposed Surface 
                 324° F. (182° C.) 
                 399° F. (229° C.) 
               
               
                 Limiting Temperature Criteria 
                   
                   
               
               
                 Degrees 74° F. (26° C.) Ambient 
                   
                   
               
               
                 Unexposed Surface 
                 46:42 
                 TC #2 at 47:13 
               
               
                 Temperature Limits Reached 
                   
                   
               
               
                 Finish Rating 
                 326° F. (183° C.) 
                 401° F. (231° C.) 
               
               
                 Limiting Temperature Criteria 
                   
                   
               
               
                 Degrees 76° F. (27° C.) Ambient 
                   
                   
               
               
                 Finish Rating 
                 12:52 
                 TC #8 at 13:27 
               
               
                 Temperature Limits Reached 
               
               
                   
               
            
           
         
       
     
     FIRE TEST DURATION: 70 MIN. 0 SEC. 
     TEST TERMINATED—Board Delamination, No Board Fall Off 
     
       
         
           
               
             
               
                 TABLE 12 
               
             
            
               
                   
               
               
                 Example 3 Observations 
               
            
           
           
               
               
               
            
               
                 Time 
                 Furnace 
                   
               
               
                 (Min:Sec) 
                 Pressure 
                 Observations 
               
               
                   
               
               
                  2:30 
                 +0.07 
                 Exposed south half of west board popped 
               
               
                   
                   
                 apart and delaminated and has fallen off. 
               
               
                   
                   
                 Estimated ¼ inch of board thickness is 
               
               
                   
                   
                 still in place at the cold junction. Exposed 
               
               
                   
                   
                 glass fibers are seen on remaining board. 
               
               
                  8:00 
                 +0.07 
                 Light smoke and steam vapor emitting from 
               
               
                   
                   
                 unexposed surface. 
               
               
                 18:00 
                 +0.08 
                 More smoke and steam vapor emitting from 
               
               
                   
                   
                 unexposedsurface. More board cracks by 
               
               
                   
                   
                 center stud screws 
               
               
                 24:00 
                 +0.07 
                 Heavy smoke and steam vapor emitting  
               
               
                   
                   
                 from unexposed surface. Butt joint is at 
               
               
                   
                   
                 estimated 3/16 to ¼ inch max. Northeast 
               
               
                   
                   
                 corner board is peeling away towards furnace 
               
               
                   
                   
                 and is estimated at ¼ inch max. Board 
               
               
                   
                   
                 thickness is falling off 
               
               
                 32:00 
                 +0.07 
                 Less smoke and steam vapor emitting from 
               
               
                   
                   
                 unexposed surface. 
               
               
                 35:00 
                 +0.07 
                 Butt joint opening is at estimated ⅜ inch max. 
               
               
                 37:00 
                 +0.08 
                 Estimated ¼ inch thick by 12 inch by 24 inch 
               
               
                   
                   
                 Board has fallen at corner of north east board 
               
               
                 45:30 
                 +0.08 
                 Very light smoke and steam vapor is emitting 
               
               
                   
                   
                 from unexposed surface. Exposed board sag 
               
               
                   
                   
                 is at estimated ½ to ⅝ inch max 
               
               
                 53:00 
                 +0.07 
                 Butt joint opening is at estimated ⅜ inch 
               
               
                   
                   
                 to ½ inch max. 
               
               
                 57:00 
                 +0.08 
                 Unexposed wall board is starting to get 
               
               
                   
                   
                 brown in color over butt joint location. 
               
               
                   
                   
                 Very little smoke and steam vapor 
               
               
                   
                   
                 emitting from unexposed surface 
               
               
                 61:00 
                 +0.07 
                 Board sag is at estimated 1 to 1½ 
               
               
                   
                   
                 inches max. 
               
               
                 63:00 
                 +0.10 
                 Hair cracks starting on southeast section 
               
               
                   
                   
                 of board 
               
               
                 65:00 
                 +0.09 
                 Butt joint opening is at estimated 
               
               
                   
                   
                 ½ inches max. 
               
               
                 67:00 
                 +0.10 
                 More exposed board peeling at northeast  
               
               
                   
                   
                 section. Total board delamination is 
               
               
                   
                   
                 an estimated 15% max 
               
               
                 70:00 
                   
                 Test terminated. Some board delamination. 
               
               
                   
                   
                 No board fall off. 
               
               
                   
               
            
           
         
       
     
     Example 4 
     Sample Construction 
     Size 48 in. (122 cm) by 48⅝ in. (124 cm) 
     Studs: 358 ST, 20 gauge; Spacing: 24 in. (61 cm) on center 
     Runners: 358 CR, 20 gauge; Cavity: Void 
     Facing: (Fire Side) One layer 15/32 inch (12 mm) Plywood (A/C) Board
         (Unexposed Side) One layer ⅝ in. (16 mm) SHEETROCK® FIRECODE® (Type X) panel.       

     Table 13 lists the boards employed in this example as test materials. The boards were subjected to heating as presented in Table 14. Observations from this heating are presented in Table 15. 
     
       
         
           
               
             
               
                 TABLE 13 
               
             
            
               
                   
               
               
                 Example 4 Test Materials 
               
            
           
           
               
               
               
            
               
                   
                   
                 SHEETROCK ® 
               
               
                   
                   
                 Brand Wallboard 
               
               
                   
                 Plywood Board 
                 ⅝″ × 48″ × 120″ 
               
               
                   
                  15/32″ × 48″ × 48⅝″ 
                 (16 mm × 122 cm × 
               
               
                   
                 (16 mm × 122 cm × 
                 305 cm) 
               
               
                   
                 124 cm) 
                 Type X 
               
               
                   
               
               
                 Lbs/1000 sq. ft 
                 1644 
                 2283 
               
            
           
           
               
               
               
               
            
               
                 Average board 
                 0.499 
                 (12.6 mm) 
                 0.619 (16)   
               
               
                 thickness, in. (mm) 
                   
                   
                   
               
               
                 Average density, 
                 39.544 
                 (0.633) 
                 44.242 (0.709) 
               
               
                 pcf (g/cc) 
                   
                   
                   
               
               
                 Average panel 
                 52.50 
                 (28.8) 
                  37.00 (16.78) 
               
               
                 weight, lbs. (kgs.) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 14 
               
             
            
               
                   
               
               
                 Example 4 Temperature Information 
               
            
           
           
               
               
               
            
               
                   
                 Average 
                 Individual 
               
               
                   
               
               
                 Unexposed Surface 
                 323° F. (182° C.) 
                 398° F. (229° C.) 
               
               
                 Limiting Temperature Criteria 
                   
                   
               
               
                 Degrees 73° F. (26° C.) Ambient 
                   
                   
               
               
                 Unexposed Surface 
                 23:42 
                 TC #3 at 23:31 
               
               
                 Temperature Limits Reached 
                   
                   
               
               
                 Finish Rating 
                 325° F. (183° C.) 
                 400° F. (230° C.) 
               
               
                 Limiting Temperature Criteria 
                   
                   
               
               
                 Degrees 76° F. (27° C.) Ambient 
                   
                   
               
               
                 Finish Rating 
                  6:40 
                 TC #7 at 7:10  
               
               
                 Temperature Limits Reached 
               
               
                   
               
            
           
         
       
     
     FIRE TEST DURATION: 32 MIN. 0 SEC. 
     TEST TERMINATED: Board Fall Off 
     
       
         
           
               
             
               
                 TABLE 15 
               
             
            
               
                   
               
               
                 Example 4 Observations 
               
            
           
           
               
               
               
            
               
                 Time 
                 Furnace 
                   
               
               
                 (Min:Sec) 
                 Pressure 
                 Observations 
               
               
                   
               
               
                 0:30 
                 +0.06 
                 Exposed boards are black in color, burnt charred 
               
               
                   
                   
                 surface. 
               
               
                 2:00 
                 +0.04 
                 Heavy smoke emitting from unexposed surface. 
               
               
                 4:00 
                 +0.08 
                 Exposed boards are flaming. Very heavy smoke 
               
               
                   
                   
                 emitting from unexposed surface. 
               
               
                 6:00 
                 +0.08 
                 Butt joint opening is at estimated ¼ in. max. 
               
               
                 8:00 
                 +0.08 
                 Very heavy flaming seen through furnace view 
               
               
                   
                   
                 ports. Sample can not be seen. 
               
               
                 9:00 
                 +0.07 
                 Exposed ½ inch plywood has fallen in furnace. 
               
               
                   
                   
                 Cavity is now exposed. 
               
               
                 14:00  
                 +0.08 
                 Still very heavy smoke and steam vapor emitting 
               
               
                   
                   
                 from unexposed surface. 
               
               
                 19:00  
                 +0.08 
                 The exposed wallboard has hairline haze cracking 
               
               
                   
                   
                 seen from exposed cavity. 
               
               
                 28:00  
                 +0.07 
                 Less smoke and steam vapor emitting from 
               
               
                   
                   
                 unexposed surface. The unexposed side wallboard 
               
               
                   
                   
                 is now brown in color. 
               
               
                 32:00  
                   
                 Test terminated. Board has fallen off. 
               
               
                   
               
            
           
         
       
     
     Example 5 
     Sample Construction 
     Size 48 in. (122 cm) by 48⅝ in. (124 cm) 
     Studs: 358 ST, 20 gauge; Spacing: 24 in. (61 cm) on center 
     Runners: 358 CR, 20 gauge; Cavity: Void 
     Facing: (Fire Side) One layer 31/64 inch Oriented Strand Board (OSB) 
     (Unexposed Side) One layer ⅝ in. (16 mm) SHEETROCK® FIRECODE® (Type X) panel. 
     Table 16 lists the boards employed in this example as test materials. The boards were subjected to heating as presented in Table 17. Observations from this heating are presented in Table 18. 
     
       
         
           
               
             
               
                 TABLE 16 
               
             
            
               
                   
               
               
                 Example 5 Test Materials 
               
            
           
           
               
               
               
            
               
                   
                   
                 SHEETROCK ® 
               
               
                   
                   
                 Brand Wallboard 
               
               
                   
                 OSB Board 
                 ⅝″ × 48″ × 120″ 
               
               
                   
                  15/32″ × 48″ × 48⅝″ 
                 (16 mm × 122 cm ×  
               
               
                   
                 (12 mm × 122 cm × 
                 305 cm) 
               
               
                   
                 124 cm) 
                 Type X 
               
               
                   
               
               
                 Lbs/1000 sq. ft 
                 1644 
                 2283 
               
            
           
           
               
               
               
               
            
               
                 Average board 
                 0.499 
                 (12.6 mm) 
                 0.619 (0.157) 
               
               
                 thickness, in. (cm) 
                   
                   
                   
               
               
                 Average density, 
                 39.544 
                 (0.633) 
                 44.242 (0.709)  
               
               
                 pcf (g/cc) 
                   
                   
                   
               
               
                 Average panel 
                 52.50 
                 (28.8) 
                 37.00 (16.78) 
               
               
                 weight, lbs. (kgs.) 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 17 
               
             
            
               
                   
               
               
                 Example 5 Temperature Information 
               
            
           
           
               
               
               
            
               
                   
                 Average 
                 Individual 
               
               
                   
               
               
                 Unexposed Surface 
                 327° F. (184° C.) 
                 402° F. (231° C.) 
               
               
                 Limiting Temperature Criteria 
                   
                   
               
               
                 Degrees 77° F. (28° C.)Ambient 
                   
                   
               
               
                 Unexposed Surface 
                 24:25 
                 TC #3 at 23:30 
               
               
                 Temperature Limits Reached 
                   
                   
               
               
                 Finish Rating 
                 330° F. (186° C.) 
                 405° F. (233° C.) 
               
               
                 Limiting Temperature Criteria 
                   
                   
               
               
                 Degrees 80° F. (30° C.) Ambient 
                   
                   
               
               
                 Finish Rating 
                  6:50 
                 TC #8 at 8:12  
               
               
                 Temperature Limits Reached 
               
               
                   
               
            
           
         
       
     
     FIRE TEST DURATION: 32 MIN. 0 SEC. 
     TEST TERMINATED: Board Fall Off 
     
       
         
           
               
             
               
                 TABLE 18 
               
             
            
               
                   
               
               
                 Example 5 Observations 
               
            
           
           
               
               
               
            
               
                 Time 
                 Furnace 
                   
               
               
                 (Min:Sec) 
                 Pressure 
                 Observations 
               
               
                   
               
               
                  1:00 
                 +0.02 
                 Exposed board is smoking and black in color 
               
               
                  1:30 
                 +0.08 
                 Smoke is heavy, emitting from unexposed surface 
               
               
                  3:00 
                 +0.07 
                 The entire board is flaming. Surface is hard. 
               
               
                  5:00 
                 +0.08 
                 Butt joint opening is at estimated ⅛ to ¼ 
               
               
                   
                   
                 inches max. 
               
               
                  6:00 
                 +0.08 
                 Very heavy smoke emitting from unexposed surface. 
               
               
                  8:00 
                 +0.15 
                 Board sag is at estimated 1 inch max. Still is 
               
               
                   
                   
                 flaming. 
               
               
                  9:30 
                 +0.08 
                 Exposed board has fallen out. Remaining perimeter 
               
               
                   
                   
                 boards still flaming. Exposed wallboard is seen 
               
               
                   
                   
                 from exposed cavity. 
               
               
                 15:00 
                 +0.07 
                 Still heavy smoke and steam emitting from 
               
               
                   
                   
                 unexposed surface. 
               
               
                 19:00 
                 +0.08 
                 Board crack running along the center stud on the 
               
               
                   
                   
                 unexposed surface. 
               
               
                 23:00 
                 +0.07 
                 Smoke and steam is starting to decrease at 
               
               
                   
                   
                 unexposed surface. 
               
               
                 25:00 
                 +0.08 
                 Unexposed board crack running the stud length is 
               
               
                   
                   
                 at estimated ⅛ inches max. 
               
               
                 29:00 
                 +0.07 
                 Hairline haze cracking is seen on wallboard viewed 
               
               
                   
                   
                 from exposed cavity. 
               
               
                 31:00 
                 +0.07 
                 The unexposed surface wallboard is now dark brown 
               
               
                   
                   
                 in color. Little smoke and steam vapor emitting 
               
               
                   
                   
                 from unexposed surface. 
               
               
                 32:00 
                   
                 Test terminated. Board has fallen off. 
               
               
                   
               
            
           
         
       
     
     Example 6 
     This example determines the horizontal diaphragm strength of a single floor diaphragm constructed as explained below using a Prototype ¾ inch thick SCP panel by ASTM E 455-98 Static Load Testing of Framed Floor or Roof Diaphragm Construction for Buildings, single beam method. 
     Test Specimen Materials 
     A. Floor Diaphragm Materials: 
     Prototype ¾″ SCP—Structural Cement Panel of the present invention reinforced with fiberglass strands. A “V”-groove and tongue is located along the 8′ dimension of the 4′×8′ sheets. The formulation used in the SCP panel examples of this floor diaphragm test is listed in TABLE 18A. 
     
       
         
           
               
               
               
             
               
                 TABLE 18A 
               
               
                   
               
               
                   
                 Ingredient 
                 Weight Proportion (%) 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                   
                 Reactive Powder Blend 
                   
               
               
                   
                 Portland Cement 
                 29 
               
               
                   
                 Calcium Sulfate Alpha Hemihydrate 
                 58 
               
               
                   
                 Silica Fume 
                 12 
               
               
                   
                 Lime 
                 1 
               
               
                   
                 SCP Cementitious Composition 
                   
               
               
                   
                 Portland Cement 
                 12.2 
               
               
                   
                 Calcium Sulfate Alpha Hemihydrate 
                 24.4 
               
               
                   
                 Silica Fume 
                 5.1 
               
               
                   
                 Lime 
                 0.4 
               
               
                   
                 Ceramic Microspheres 
                 27.4 
               
               
                   
                 Superplasticizer 
                 1.9 
               
               
                   
                 Water 
                 24.2 
               
               
                   
                 Alkali-Resistant Glass Fibers  1   
                 4.4 
               
               
                   
               
               
                   1  Weight proportion corresponds to 1.8% volume fraction of Alkali Resistant Glass Fibers in the composite. 
               
               
                 Length of glass fibers used in the floor diaphragm test - 36 mm. 
               
            
           
         
       
     
     Fasteners—#8-18×1⅝″ long BUGLE HEAD GRABBER SUPER DRIVE™ screws spaced 6″ o.c. along the perimeter, and 12″ o.c. in the field of the panels. All fasteners were placed a minimum of ¾ inches in from panel edges and ½ inch in from seams. At panel corners the fasteners were inset 2 inches. 
     Adhesive—ENERFOAM SF polyurethane foam adhesive manufactured by Flexible Products Company of Canada, Inc. was applied to all butt-joints, and tongue and groove joints. One (1) ⅜″ bead was applied to the bottom of the groove before setting into place. A ⅜″ gap was left at the butt-joint to allow one (1) ⅜″ bead of adhesive to be applied in the gap, before sliding the joint together. 
     B. Floor Framing: 
       FIG. 8  shows assembled metal, e.g., steel, floor framing. This includes the following parts: 
     Transverse Joists  150 —16 gauge×10 inches deep×10 foot long Trade Ready™ Joists manufactured by Dietrich Industries. The joists were stamped Dietrich TDW5 W 10 IN×L 10 FT 28324013 16 GAUGE G60 50KSI. 
     Longitudinal Rim Track  152 —16 gauge×10 3/16″ deep×16′ long manufactured by Dietrich Industries with pre-bent joist attachment locations spaced at 24″ o.c. The track was stamped Dietrich TD16 W 9¼ IN×L 16 FT 28323858 16 GAUGE 3RD FI. 
     0.125″ thick×2″×2″ steel angles  154  ( FIG. 10 ) are located on each of the transverse end joists  156  spaced starting at the bearing side and spanning up to 3 inches from the load side angel and fixed to the respective end transverse joists with #10-1″ DRIVALL screws at 6″ o.c. 
     Fasteners: #10-16×¾″ long hex-head, DRIVALL screws for attaching framing; and #10-16×¾″ long wafer head, self-drilling screws for attaching to framing 6″ o.c. around the outermost edge and on both sides of the butt joints. 
     Test Specimen Construction 
     One (1) test sample was constructed to an overall dimension of 10′-0″×20′-0″.  FIG. 8  shows a perspective view of the metal frame. 
       FIG. 9  shows an enlarged view of a portion of the frame of  FIG. 8 . 
       FIG. 10  shows an enlarged view of a portion AA of the frame of  FIG. 8 . 
       FIG. 11  shows a top view of the SCP panels  120  (with panel dimensions), but manufactured to have tongue and groove edges (not shown) similar to those of  FIG. 6A , attached to the metal frame. 
       FIGS. 12 ,  13 ,  14  and  15  show enlarged views of respective portions BB, CC, DD and EE of the floor of  FIG. 11 . 
     A. The joists were attached to the rim track using three (3) hex head #10-16×¾″ long Drivall screws into the side of the joist through the pre-bent tab and one (1) #10-16×¾″ long wafer head self-drilling screws through the top of rim track into the joist, at each end. 0.078″ thick×1½″×4″ steel angles  151  which are 5″ long were also fastened to the respective joist 1″ o.c. with ¾ inch long DRIVALL screws and one ¾ inch long DRIVALL screw to the rim track. 
     B. 1½ inch×2⅝ inch×21¾ inch KATZ blocking  158  with a 2 inch long×1¾ inch tab on each end was fastened to the bottom of the joists across the center line of the floor. The blocking  158  was attached using (1) #10-16×¾″ long Drivall screw through the end of each Katz blocking member  158 . In particular, the Katz blocking  158  is located between transverse joints  50  by being positioned staggered on either side of the midpoint and attached by one #10-16×¾ inch long DRIVALL screw per tab. 
     C. Additional horizontal blocking was added, in two locations, to the rim track  152  on the load side to strengthen the rim track  152  for point loading purposes. Namely, 24 inch blocking  157  for load support is provided along the longitudinal rim track between a number of transverse joists  150 . 20 inch long blocking  159  is fixed between each transverse end joist and the respective penultimate transverse end joist generally along the longitudinal axis of the frame with four #10-16×¾ inch long DRIVALL screws on each end. 
     D. The frame was squared and then the prototype SCP panel was fastened to it as shown in  FIG. 11 . The prototype SCP was fastened at 6″ o.c. around the perimeter inset 2″ from the corners, and 12 inches o.c. in the field with #8-18×1⅝ inch long Bugle head GRABBER SUPER DRIVE™ screws (winged self drilling screws  162 ). Care was taken to ensure that the fasteners were kept flush or slightly below the surface of the prototype SCP and also did not strip out in the steel framing. At the butt-joints and tongue and groove locations, a ⅜ inch bead of ENERFOAM SF polyurethane foam adhesive manufactured by Flexible Products Company of Canada, Inc. was applied in the joint. 
     E. ⅛″×2″×2″ angle iron was then fastened to the end joists flush to the bottom of the joists to minimize crumpling of the joists at the bearings and to represent the top plate member. An additional 6 inches long angle was fastened at the bearing side of the end joists flush to the top of the joist also to minimize crumpling. 
     F. The test sample set for a minimum of 36 hours to allow the adhesive to cure. 
     G.  FIG. 16  shows the test sample  81 , made of frame  160  of  FIG. 8  having the attached floor  120  of  FIG. 9 , supported by appliance rollers  70  at 2 foot on center (o.c.) around the perimeter of the sample  160  on a concrete floor  98  ( FIG. 17 ). 
       FIG. 17  shows an enlarged view of portion FF of  FIG. 16 . A bearing support  74 ,  84  was placed at both ends of the test sample  81 . Three (3) loading cylinders  80  were located on the opposite side of the test sample  81 . The load was applied from the cylinders through steel-beams, to six (6) 18″ bearing blocks to uniformly apply the load to the floor test sample  81 . Five (5) dial indicators were placed along the bearing side of the test sample  81  to measure deflections.  FIG. 17  shows hold down  92  provided with spacers  90 . A gap  96  of about ⅛ inch, and an 18 inch load block  94 . The hold down  92  is mounted in cement  98 . Another hold down  82  is provided at the other end of the test sample  81 . The hold down  92  is supported on solid rollers  72 . 
     Test Equipment 
     A. Three (3) ENERPAC Model P-39 hydraulic hand pumps. 
     B. Three (3) ENERPAC Model RC-1010 hydraulic cylinders. 
     C. Five dial indicators: 2 inches movement-0.001 inch increments. 
     D. Three (3) Omega digital meters. 
     E. Three (3) Omega pressure transducers. 
     F. Three (3) 6 ft. I-beams. 
     G. Five (5) rigid bearings bolted to floor. 
     Procedure 
     A. The loads were generated using three (3) 1½ inch diameter×10 inches stroke hydraulic cylinders, one at each load point. The applied forces were measured with three (3) digital meters and pressure transducers. A permanent record of the applied forces was made on the attached data sheets. 
     B. The loads were generated by applying hydraulic pressure to create mechanical force until the required load was indicated on the digital meters. 
     C. The entire floor assembly was loaded in increments of 700 lbs. Each load was held for 1 minute before the deflection readings were taken. After the 14,000 lbs. deflection reading was taken, the assembly was then loaded at a rate of approximately 2800 pounds per minute, until a failure occurred. 
       FIG. 19  shows a photograph of the SCP panel and metal frame floor mounted on the test apparatus of  FIG. 16  at design load. 
       FIG. 20  shows a photograph of the SCP panel and metal frame floor mounted on the test apparatus of  FIG. 16  at failure. 
     Test Results 
     TABLE 19 shows the results of a Floor Diaphragm Test of applying loads to the above-described entire floor assembly. The floor having a width of 120 inches. 
     Using a factor of safety of 3.0 the following values were obtained. 
     Ultimate Load=14,618.5 lbs./10.0 ft.=1,461.8 PLF (pounds per linear foot) 
     Design Shear=1461.8/3.0 safety factor=487.2 PLF 
     Design shear is calculated by dividing the ultimate load by a safety factor of 3. 
     Table 20 shows Resultant Deflection occurring due to the application of loads to the floor.  FIG. 18  graphs the data of Table 20.  FIG. 18  shows experimental load versus deflection data from the floor diaphragm test using ¾ inch structural cement panel (SCP panel) employing the floor diaphragm testing apparatus of  FIG. 16 . 
     Table 21 shows average bearing deflection from applying loads at bearing points to the test sample floor. 
     Based on the data obtained from this single test sample a design shear of 487.2 PLF (pounds per linear foot) can be achieved from the above-described single floor diaphragm sample constructed as follows: 
     
       
         
           
               
             
               
                 TABLE 19 
               
             
            
               
                   
               
               
                 Floor Diagram Test 
               
               
                 Floor Width: 120 inches; Design Load: 420 P.L.F. (estimated) 
               
            
           
           
               
               
            
               
                   
                 Floor Test Loads 
               
            
           
           
               
               
               
               
               
            
               
                 Loading 
                 Total Ceiling 
                 Load No. 1 
                 Load No. 2 
                 Load No. 3 
               
               
                 Increments 
                 Load (lbs.) 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
               
               
                   
               
            
           
           
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0 
                 0 
                 0 
               
               
                 1 
                 700 
                 233 
                 233 
                 233 
               
               
                 2 
                 1400 
                 467 
                 467 
                 467 
               
               
                 3 
                 2100 
                 700 
                 700 
                 700 
               
               
                 4 
                 2800 
                 933 
                 933 
                 933 
               
               
                 5 
                 3500 
                 1167 
                 1167 
                 1167 
               
               
                 6 
                 4200 
                 1400 
                 1400 
                 1400 
               
               
                 7 
                 4900 
                 1633 
                 1633 
                 1633 
               
               
                 8 
                 5600 
                 1867 
                 1867 
                 1867 
               
               
                 9 
                 6300 
                 2100 
                 2100 
                 2100 
               
               
                 10 
                 7000 
                 2333 
                 2333 
                 2333 
               
               
                 11 
                 7700 
                 2567 
                 2567 
                 2567 
               
               
                 Design Load 
                 8400 
                 2800 
                 2800 
                 2800 
               
               
                 13 
                 9100 
                 3033 
                 3033 
                 3033 
               
               
                 14 
                 9800 
                 3267 
                 3267 
                 3267 
               
               
                 15 
                 10500 
                 3500 
                 3500 
                 3500 
               
               
                 16 
                 11200 
                 3733 
                 3733 
                 3733 
               
               
                 17 
                 11900 
                 3967 
                 3967 
                 3967 
               
               
                 18 
                 14000 
                 4667 
                 4667 
                 4667 
               
               
                 Ultimate Load 
                 29237 
                 9717 
                 9750 
                 9770 
               
               
                   
               
               
                 Design Load 487.3 P.L.F. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 20 
               
             
            
               
                   
               
               
                 Temp. &amp; Humidity During Construction: 71 deg. F./32% Temp. &amp; 
               
               
                 Humidity During Test: 73 deg. F./35% 
               
               
                 Sample Description: Prototype ¾ inch SCP adhered to 16 gauge - 
               
               
                 10 inches steel joists, using ENERFOAM SF polyurethane foam adhesive 
               
            
           
           
               
               
            
               
                   
                 Floor Test Loads 
               
            
           
           
               
               
               
               
               
            
               
                 Time 
                   
                   
                 Clear Span 
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Load/ 
                 Loading 
                 Load 
                 Indicator #2 
                 Indicator #3 
                 Indicator #4 
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
               
            
               
                 Reading 
                 Increment 
                 (lbs.) 
                 Reading 
                 Deflection 
                 Reading 
                 Defl. 
                 Reading 
                 Defl. 
                 RD* 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
               
            
               
                 9:30 
                 No Load 
                 0 
                 0.100 
                   
                 0.100 
                   
                 0.100 
                   
                   
               
               
                 9:31/9:32 
                 1 
                 700 
                 0.168 
                 0.068 
                 0.155 
                 0.055 
                 0.133 
                 0.033 
                 0.003 
               
               
                 9:33/9:34 
                 2 
                 1400 
                 0.185 
                 0.085 
                 0.169 
                 0.069 
                 0.151 
                 0.051 
                 0.005 
               
               
                 9:35/9:36 
                 3 
                 2100 
                 0.203 
                 0.103 
                 0.185 
                 0.085 
                 0.163 
                 0.063 
                 0.009 
               
               
                 9:37/9:38 
                 4 
                 2800 
                 0.219 
                 0.119 
                 0.199 
                 0.099 
                 0.174 
                 0.074 
                 0.013 
               
               
                 9:39/9:40 
                 5 
                 3500 
                 0.231 
                 0.131 
                 0.210 
                 0.110 
                 0.184 
                 0.084 
                 0.016 
               
               
                 9:41/9:42 
                 6 
                 4200 
                 0.242 
                 0.142 
                 0.222 
                 0.122 
                 0.194 
                 0.094 
                 0.021 
               
               
                 9:43/9:44 
                 7 
                 4900 
                 0.253 
                 0.153 
                 0.233 
                 0.133 
                 0.204 
                 0.104 
                 0.025 
               
               
                 9:45/9:46 
                 8 
                 5600 
                 0.265 
                 0.165 
                 0.244 
                 0.144 
                 0.214 
                 0.114 
                 0.030 
               
               
                 9:47/9:48 
                 9 
                 6300 
                 0.276 
                 0.176 
                 0.255 
                 0.155 
                 0.224 
                 0.124 
                 0.034 
               
               
                 9:49/9:50 
                 10 
                 7000 
                 0.288 
                 0.188 
                 0.267 
                 0.167 
                 0.234 
                 0.134 
                 0.039 
               
               
                 9:51/9:52 
                 11 
                 7700 
                 0.300 
                 0.200 
                 0.279 
                 0.179 
                 0.244 
                 0.144 
                 0.045 
               
               
                 9:53/9:54 
                 Design 
                 8400 
                 0.311 
                 0.211 
                 0.290 
                 0.190 
                 0.255 
                 0.155 
                 0.050 
               
               
                   
                 Load 
               
               
                 9:55/9:56 
                 13 
                 9100 
                 0.321 
                 0.221 
                 0.302 
                 0.202 
                 0.264 
                 0.164 
                 0.057 
               
               
                 9:57/9:58 
                 14 
                 9800 
                 0.334 
                 0.234 
                 0.314 
                 0.214 
                 0.275 
                 0.175 
                 0.062 
               
               
                  9:59/10:00 
                 15 
                 10500 
                 0.346 
                 0.246 
                 0.327 
                 0.227 
                 0.290 
                 0.190 
                 0.067 
               
               
                 10:01/10:02 
                 16 
                 11200 
                 0.359 
                 0.259 
                 0.343 
                 0.243 
                 0.306 
                 0.206 
                 0.076 
               
               
                 10:03/10:04 
                 17 
                 11900 
                 0.373 
                 0.273 
                 0.360 
                 0.260 
                 0.327 
                 0.227 
                 0.084 
               
               
                 10:05/10:06 
                 18 
                 14000 
                 0.412 
                 0.312 
                 0.413 
                 0.313 
                 0.387 
                 0.287 
                 0.111 
               
               
                   
               
               
                 Mode of Failure: End #2 - butt joint separation on the 4′ sheet in the middle row, and at the 95-½″ sheet on the load side as the tongue and groove joint slipped. Secondary Failure - Board shear approximately 6′ in from the end on the bearing side (See FIG. 20). 
               
               
                 *The RD (resultant deflection) is equal to the average deflection of the bearings minus the greatest point of deflection across the clear span. FIG. 18 shows the data graphically. 
               
            
           
         
       
     
     
       
         
           
               
               
               
               
               
             
               
                 TABLE 21 
               
             
            
               
                   
               
               
                 Time 
                   
                   
                 Bearing Points 
                 Average 
               
            
           
           
               
               
               
               
               
               
            
               
                 Load/ 
                 Loading 
                 Load 
                 Indicator #1 
                 Indicator #5 
                 Bearing 
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                 Reading 
                 Increment 
                 (lbs.) 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                 9:30 
                 No Load 
                 0 
                 0.000 
                   
                 0.100 
                   
                   
               
               
                 9:31/9:32 
                 1 
                 700 
                 0.080 
                 0.080 
                 0.125 
                 0.025 
                 0.053 
               
               
                 9:33/9:34 
                 2 
                 1400 
                 0.096 
                 0.096 
                 0.132 
                 0.032 
                 0.064 
               
               
                 9:35/9:36 
                 3 
                 2100 
                 0.113 
                 0.113 
                 0.138 
                 0.038 
                 0.076 
               
               
                 9:37/9:38 
                 4 
                 2800 
                 0.127 
                 0.127 
                 0.145 
                 0.045 
                 0.086 
               
               
                 9:39/9:40 
                 5 
                 3500 
                 0.137 
                 0.137 
                 0.151 
                 0.051 
                 0.094 
               
               
                 9:41/9:42 
                 6 
                 4200 
                 0.145 
                 0.145 
                 0.158 
                 0.058 
                 0.102 
               
               
                 9:43/9:44 
                 7 
                 4900 
                 0.152 
                 0.152 
                 0.165 
                 0.065 
                 0.109 
               
               
                 9:45/9:46 
                 8 
                 5600 
                 0.158 
                 0.158 
                 0.171 
                 0.071 
                 0.115 
               
               
                 9:47/9:48 
                 9 
                 6300 
                 0.166 
                 0.166 
                 0.177 
                 0.077 
                 0.122 
               
               
                 9:49/9:50 
                 10 
                 7000 
                 0.174 
                 0.174 
                 0.183 
                 0.083 
                 0.129 
               
               
                 9:51/9:52 
                 11 
                 7700 
                 0.179 
                 0.179 
                 0.190 
                 0.090 
                 0.135 
               
               
                 9:53/9:54 
                 Design 
                 8400 
                 0.185 
                 0.185 
                 0.195 
                 0.095 
                 0.140 
               
               
                   
                 Load 
               
               
                 9:55/9:56 
                 13 
                 9100 
                 0.191 
                 0.191 
                 0.200 
                 0.100 
                 0.146 
               
               
                 9:57/9:58 
                 14 
                 9800 
                 0.197 
                 0.197 
                 0.207 
                 0.107 
                 0.152 
               
               
                  9:59/10:00 
                 15 
                 10500 
                 0.203 
                 0.203 
                 0.217 
                 0.117 
                 0.160 
               
               
                 10:01/10:02 
                 16 
                 11200 
                 0.208 
                 0.208 
                 0.226 
                 0.126 
                 0.167 
               
               
                 10:03/10:04 
                 17 
                 11900 
                 0.214 
                 0.214 
                 0.238 
                 0.138 
                 0.176 
               
               
                 10:05/10:06 
                 18 
                 14000 
                 0.227 
                 0.227 
                 0.278 
                 0.178 
                 0.203 
               
               
                   
               
            
           
         
       
     
     Example 7 
     This example determines the effect of water exposure on the horizontal diaphragm strength of an assembly using ¾″ inch thick SCP panel by ASTM E455-98 Static Load Testing of Framed Floor or Roof Diaphragm Construction for Buildings, single beam method. 
     Test Specimen Materials 
     A. Floor Diaphragm Materials: 
     ¾ inch SCP panel reinforced with fiberglass strands. A “V”-groove and tongue are located along the 8′ dimension of the 4 foot×8 foot sheets. 
     Fasteners employed included #8-18×1⅝ inch long Bugle head GRABBER SUPER DRIVE screws, available for GRABBER Construction Products, spaced 6 inches on center along the perimeter, and 12 inches on center in the field of the panels. All fasteners were placed a minimum of ¾ inches in from the panel edges and ½ inches from the seams. At panel corners the fasteners were inset 2 inches. See  FIG. 11  for fastener locations. 
     B. Floor Framing: 
     Joists included CSJ 16 gauge×8 inches deep×10 foot rim track manufactured by Dietrich Industries. 
     Test Specimen Construction 
     Four (4) test samples were constructed to an overall dimension of 10′-0″×20′-0″ as was the test sample described above in Example 6.  FIG. 8  shows a perspective of the metal frame. 
     However, the frame was squared and then the prototype SCP panel was fastened to it as shown in  FIG. 11 . The prototype SCP was fastened at 6″ o.c. around the perimeter and inset 2″ from the corners, 12″ o.c. in the field with #8-18×1⅝″ long Bugle head Grabber SuperDrive screws (winged self drilling screws  162 ). Care was taken to ensure that the fasteners were kept flush or slightly below the surface of the prototype SCP and also did not strip out in the steel framing. In contrast to the test sample of Example 6, at the butt-joints and tongue and groove locations, a ⅜ inch bead of ENERFOAM SF polyurethane foam adhesive manufactured by Flexible Products Company of Canada, Inc. was not applied in the joint. 
     Test Equipment 
     A. Four (4) ENERPAC Model P-39 hydraulic hand pumps 
     B. Four (4) ENERPAC Model RC-1010 hydraulic cylinders 
     C. Five (5) dial indicators 2″ movement—0.001 increments 
     D. Four (4) OMEGA digital meters 
     E. Four (4) OMEGA pressure transducers 
     F. Four (4) 6 ft I-Beams 
     G. Six (6) rigid bearings bolted to the floor 
     Procedure 
     A. Two of the test assemblies were tested in an “as received”, or dry condition and two samples were tested after a 1″ head of water was present for a minimum of 24 hours. 
     B. The loads were generated using four (4) 1½″ diameter hydraulic cylinders, one at each loading point. The applied forces were measured with four (4) calibrated digital meters and pressure transducers. A permanent record of the applied forces was made on the attached data sheets. 
     C. The loads were generated be applying hydraulic pressure to create mechanical force until the required load was indicated on the digital meters. 
     D. The entire floor assembly was loaded in increments of 700 lbs. Each load was held for 1 minute before the deflection readings were taken. After the 14000 lb deflection reading was taken, the assembly was then loaded at a rate of approximately 2800 pounds per minute, until a failure occurred. 
     Test Results 
     TABLES 22-38 and  FIGS. 24 and 25  show the results of the floor diaphragm tests of applying loads to the above described entire floor assembly. The floor having a width of 120 inches.  FIG. 24  shows the data of Dry Test 1 and Dry Test 2.  FIG. 25  shows data from Wet Test 1 and Wet Test 2. 
     Using a factor of safety of 3.0, the following values were obtained. 
     Average ultimate load of dry samples=15,908.2 lb/10 ft=1,590.8 PLF 
     Design Shear of dry samples=1,590.8 PLF/3.0 safety factor=530.2 PLF 
     Average ultimate load of wet samples=14,544.5 lb/10 ft=1,454.4 PLF 
     Design Shear of wet samples=1,454.4 PLF/3.0 safety factor=484.8 PLF 
     These results indicate than approximately a 91% retention of diaphragm strength after continuous exposure to water for a 24 hour time period. 
     
       
         
           
               
             
               
                 TABLE 22 
               
             
            
               
                   
               
               
                 Floor Diaphragm Test; Floor width 120 inches; 
               
               
                 Design Load 420 P.L.F. (Dry Test 1) 
               
            
           
           
               
               
            
               
                   
                 Floor Test Loads 
               
            
           
           
               
               
               
               
               
               
            
               
                   
                 Total Ceiling 
                 Load 
                 Load 
                 Load 
                 Load 
               
               
                 Loading 
                 Load 
                 No. 1 
                 No. 2 
                 No. 3 
                 No. 4 
               
               
                 Increments 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0 
                 0 
                 0 
                 0 
               
               
                 1 
                 700 
                 175 
                 175 
                 175 
                 175 
               
               
                 2 
                 1400 
                 350 
                 350 
                 350 
                 350 
               
               
                 3 
                 2100 
                 525 
                 525 
                 525 
                 525 
               
               
                 4 
                 2800 
                 700 
                 700 
                 700 
                 700 
               
               
                 5 
                 3500 
                 875 
                 875 
                 875 
                 875 
               
               
                 6 
                 4200 
                 1050 
                 1050 
                 1050 
                 1050 
               
               
                 7 
                 4900 
                 1225 
                 1225 
                 1225 
                 1225 
               
               
                 8 
                 5600 
                 1400 
                 1400 
                 1400 
                 1400 
               
               
                 9 
                 6300 
                 1575 
                 1575 
                 1575 
                 1575 
               
               
                 10 
                 7000 
                 1750 
                 1750 
                 1750 
                 1750 
               
               
                 11 
                 7700 
                 1925 
                 1925 
                 1925 
                 1925 
               
               
                 Design Load 
                 8400 
                 2100 
                 2100 
                 2100 
                 2100 
               
               
                 13 
                 9100 
                 2275 
                 2275 
                 2275 
                 2275 
               
               
                 14 
                 9800 
                 2450 
                 2450 
                 2450 
                 2450 
               
               
                 15 
                 10500 
                 2625 
                 2625 
                 2625 
                 2625 
               
               
                 16 
                 11200 
                 2800 
                 2800 
                 2800 
                 2800 
               
               
                 17 
                 11900 
                 2975 
                 2975 
                 2975 
                 2975 
               
               
                 18 
                 14000 
                 3500 
                 3500 
                 3500 
                 3500 
               
               
                 Ultimate Load 
                 28,665 
                 7,039 
                 7,317 
                 7,262 
                 7,047 
               
               
                   
               
               
                 Design Load 477.8 P.L.F. 
               
               
                 There are two design loads in this table. To set up the test and size the test equipment you initially hypothesize t first design load, here 420 P.L.F. The measured 477.8 P.L.F. is the actual Design Load determined from actual measurements and adding a safety factor. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 23 
               
             
            
               
                   
               
               
                 Floor Diaphragm Test (Dry Test 1) 
               
               
                 Clear Span 
               
            
           
           
               
               
               
               
               
               
            
               
                 Load 
                 Load 
                 Indicator #2 
                 Indicator #3 
                 Indicator #4 
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Increment 
                 (lbs.) 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 RD* 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0.154 
                 — 
                 0.084 
                 — 
                 0.094 
                 — 
                 — 
               
               
                 1 
                 700 
                 0.187 
                 0.033 
                 0.128 
                 0.044 
                 0.148 
                 0.054 
                 0.044 
               
               
                 2 
                 1400 
                 0.225 
                 0.071 
                 0.165 
                 0.081 
                 0.182 
                 0.088 
                 0.081 
               
               
                 3 
                 2100 
                 0.244 
                 0.090 
                 0.187 
                 0.103 
                 0.202 
                 0.108 
                 0.103 
               
               
                 4 
                 2800 
                 0.260 
                 0.106 
                 0.211 
                 0.127 
                 0.223 
                 0.129 
                 0.127 
               
               
                 5 
                 3500 
                 0.275 
                 0.121 
                 0.228 
                 0.144 
                 0.242 
                 0.148 
                 0.144 
               
               
                 6 
                 4200 
                 0.291 
                 0.137 
                 0.250 
                 0.166 
                 0.265 
                 0.171 
                 0.166 
               
               
                 7 
                 4900 
                 0.308 
                 0.154 
                 0.274 
                 0.190 
                 0.292 
                 0.198 
                 0.190 
               
               
                 8 
                 5600 
                 0.325 
                 0.171 
                 0.295 
                 0.211 
                 0.316 
                 0.222 
                 0.211 
               
               
                 9 
                 6300 
                 0.338 
                 0.184 
                 0.309 
                 0.225 
                 0.326 
                 0.232 
                 0.224 
               
               
                 10  
                 7000 
                 0.354 
                 0.200 
                 0.327 
                 0.243 
                 0.341 
                 0.247 
                 0.241 
               
               
                 11  
                 7700 
                 0.369 
                 0.215 
                 0.344 
                 0.260 
                 0.356 
                 0.262 
                 0.258 
               
               
                 Design 
                 8400 
                 0.386 
                 0.232 
                 0.362 
                 0.278 
                 0.372 
                 0.278 
                 0.276 
               
               
                 Load 
               
               
                 13  
                 9100 
                 0.402 
                 0.248 
                 0.380 
                 0.296 
                 0.385 
                 0.291 
                 0.293 
               
               
                 14  
                 9800 
                 0.425 
                 0.271 
                 0.405 
                 0.321 
                 0.410 
                 0.316 
                 0.313 
               
               
                 15  
                 10500 
                 0.454 
                 0.300 
                 0.442 
                 0.358 
                 0.449 
                 0.355 
                 0.325 
               
               
                 16  
                 11200 
                 0.495 
                 0.341 
                 0.490 
                 0.406 
                 0.502 
                 0.408 
                 0.348 
               
               
                 17  
                 11900 
                 0.512 
                 0.358 
                 0.521 
                 0.437 
                 0.535 
                 0.441 
                 0.367 
               
               
                 18  
                 14000 
                 0.569 
                 0.415 
                 0.596 
                 0.512 
                 0.614 
                 0.520 
                 0.422 
               
               
                   
               
               
                 Temp. and Humidity During Construction: 65° F./31% 
               
               
                 Temp. and Humidity During Test: 65° F./31% 
               
               
                 Sample Description ¾ inch SCP panel fastened to 16 gauge - 10 inch steel joints 
               
               
                 Mode of failure: Several of the butt-joints opened up in several locations causing cement board core failure at the fasteners along the edges of the cement board. 
               
               
                 *The RD (resultant deflection) is equal to the average deflection of the bearings minus the greatest point of deflection across the clear span. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 24 
               
             
            
               
                   
               
               
                 Floor Diaphragm Test (Dry Test 1) 
               
            
           
           
               
               
               
            
               
                   
                 Bearing Points 
                 Average 
               
            
           
           
               
               
               
               
            
               
                   
                 Indicator #1 
                 Indicator #5 
                 Bearing 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Load 
                 Load 
                   
                 Deflec- 
                   
                 Deflec- 
                 Deflec- 
               
               
                 Increment 
                 (lbs.) 
                 Reading 
                 tion 
                 Reading 
                 tion 
                 tion 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 lbs 
                 0.069 
                 — 
                 0.266 
                 — 
                 — 
               
               
                 1 
                 700 
                   
                 0.069 
                 0.000 
                 0.266 
                 0.000 
                 0.000 
               
               
                 2 
                 1400 
                   
                 0.069 
                 0.000 
                 0.266 
                 0.000 
                 0.000 
               
               
                 3 
                 2100 
                   
                 0.069 
                 0.000 
                 0.266 
                 0.000 
                 0.000 
               
               
                 4 
                 2800 
                   
                 0.069 
                 0.000 
                 0.266 
                 0.000 
                 0.000 
               
               
                 5 
                 3500 
                   
                 0.069 
                 0.000 
                 0.266 
                 0.000 
                 0.000 
               
               
                 6 
                 4200 
                   
                 0.069 
                 0.000 
                 0.266 
                 0.000 
                 0.000 
               
               
                 7 
                 4900 
                   
                 0.069 
                 0.000 
                 0.266 
                 0.000 
                 0.000 
               
               
                 8 
                 5600 
                   
                 0.069 
                 0.000 
                 0.266 
                 0.000 
                 0.000 
               
               
                 9 
                 6300 
                   
                 0.070 
                 0.001 
                 0.267 
                 0.001 
                 0.001 
               
               
                 10  
                 7000 
                   
                 0.072 
                 0.003 
                 0.267 
                 0.001 
                 0.002 
               
               
                 11  
                 7700 
                   
                 0.072 
                 0.003 
                 0.267 
                 0.001 
                 0.002 
               
               
                 Design 
                 8400 
                   
                 0.073 
                 0.004 
                 0.267 
                 0.001 
                 0.003 
               
               
                 Load 
               
               
                 13  
                 9100 
                   
                 0.075 
                 0.006 
                 0.267 
                 0.001 
                 0.004 
               
               
                 14  
                 9800 
                   
                 0.083 
                 0.014 
                 0.268 
                 0.002 
                 0.008 
               
               
                 15  
                 10500 
                   
                 0.094 
                 0.025 
                 0.307 
                 0.041 
                 0.033 
               
               
                 16  
                 11200 
                   
                 0.105 
                 0.036 
                 0.346 
                 0.080 
                 0.058 
               
               
                 17  
                 11900 
                   
                 0.107 
                 0.038 
                 0.369 
                 0.103 
                 0.071 
               
               
                 18  
                 14000 
                   
                 0.114 
                 0.045 
                 0.402 
                 0.136 
                 0.091 
               
               
                   
               
               
                 Bearing Indictors 2, 3 and 4 (labeled “Clear Span”) of Table 23 are the instruments along the test specimen in the area between the support points at the two opposed ends of the frame. 
               
               
                 Bearing Indicators 1 and 5 of Table 24 are at the support points of this test specimen. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 25 
               
             
            
               
                   
               
               
                 Floor Diaphragm Test; Floor width 120 inches; 
               
               
                 Design Load 420 P.L.F. (Dry Test 2) 
               
               
                 Floor Test Loads 
               
            
           
           
               
               
               
               
               
               
            
               
                   
                 Total Ceiling 
                 Load 
                 Load 
                 Load 
                 Load 
               
               
                 Loading 
                 Load 
                 No. 1 
                 No. 2 
                 No. 3 
                 No. 4 
               
               
                 Increments 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0 
                 0 
                 0 
                 0 
               
               
                 1 
                 700 
                 175 
                 175 
                 175 
                 175 
               
               
                 2 
                 1400 
                 350 
                 350 
                 350 
                 350 
               
               
                 3 
                 2100 
                 525 
                 525 
                 525 
                 525 
               
               
                 4 
                 2800 
                 700 
                 700 
                 700 
                 700 
               
               
                 5 
                 3500 
                 875 
                 875 
                 875 
                 875 
               
               
                 6 
                 4200 
                 1050 
                 1050 
                 1050 
                 1050 
               
               
                 7 
                 4900 
                 1225 
                 1225 
                 1225 
                 1225 
               
               
                 8 
                 5600 
                 1400 
                 1400 
                 1400 
                 1400 
               
               
                 9 
                 6300 
                 1575 
                 1575 
                 1575 
                 1575 
               
               
                 10 
                 7000 
                 1750 
                 1750 
                 1750 
                 1750 
               
               
                 11 
                 7700 
                 1925 
                 1925 
                 1925 
                 1925 
               
               
                 Design Load 
                 8400 
                 2100 
                 2100 
                 2100 
                 2100 
               
               
                 13 
                 9100 
                 2275 
                 2275 
                 2275 
                 2275 
               
               
                 14 
                 9800 
                 2450 
                 2450 
                 2450 
                 2450 
               
               
                 15 
                 10500 
                 2625 
                 2625 
                 2625 
                 2625 
               
               
                 16 
                 11200 
                 2800 
                 2800 
                 2800 
                 2800 
               
               
                 17 
                 11900 
                 2975 
                 2975 
                 2975 
                 2975 
               
               
                 18 
                 14000 
                 3500 
                 3500 
                 3500 
                 3500 
               
               
                 Ultimate Load 
                 34,968 
                 8,900 
                 8,653 
                 8,715 
                 8,700 
               
               
                   
               
               
                 Design Load 582.8 P.L.F. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 26 
               
             
            
               
                   
               
               
                 Floor Diaphragm Test (Dry Test 2) 
               
            
           
           
               
               
               
            
               
                   
                 Clear Span 
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 Load 
                 Load 
                 Indicator #2 
                 Indicator #3 
                 Indicator #4 
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Increment 
                 (lbs.) 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 RD* 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0.290 
                 — 
                 0.127 
                 — 
                 0.231 
                 — 
                 — 
               
               
                 1 
                 700 
                 0.322 
                 0.032 
                 0.156 
                 0.029 
                 0.250 
                 0.019 
                 0.028 
               
               
                 2 
                 1400 
                 0.342 
                 0.052 
                 0.178 
                 0.051 
                 0.270 
                 0.039 
                 0.050 
               
               
                 3 
                 2100 
                 0.365 
                 0.075 
                 0.202 
                 0.075 
                 0.292 
                 0.061 
                 0.073 
               
               
                 4 
                 2800 
                 0.381 
                 0.091 
                 0.222 
                 0.095 
                 0.312 
                 0.081 
                 0.092 
               
               
                 5 
                 3500 
                 0.398 
                 0.108 
                 0.244 
                 0.117 
                 0.334 
                 0.103 
                 0.113 
               
               
                 6 
                 4200 
                 0.414 
                 0.124 
                 0.265 
                 0.138 
                 0.354 
                 0.123 
                 0.133 
               
               
                 7 
                 4900 
                 0.429 
                 0.139 
                 0.285 
                 0.158 
                 0.375 
                 0.144 
                 0.152 
               
               
                 8 
                 5600 
                 0.446 
                 0.156 
                 0.307 
                 0.180 
                 0.396 
                 0.165 
                 0.173 
               
               
                 9 
                 6300 
                 0.463 
                 0.173 
                 0.328 
                 0.201 
                 0.415 
                 0.184 
                 0.192 
               
               
                 10  
                 7000 
                 0.478 
                 0.188 
                 0.345 
                 0.218 
                 0.433 
                 0.202 
                 0.209 
               
               
                 11  
                 7700 
                 0.493 
                 0.203 
                 0.363 
                 0.236 
                 0.450 
                 0.219 
                 0.225 
               
               
                 Design 
                 8400 
                 0.510 
                 0.220 
                 0.486 
                 0.259 
                 0.471 
                 0.240 
                 0.247 
               
               
                 Load 
               
               
                 13  
                 9100 
                 0.525 
                 0.235 
                 0.404 
                 0.277 
                 0.490 
                 0.259 
                 0.265 
               
               
                 14  
                 9800 
                 0.543 
                 0.253 
                 0.429 
                 0.302 
                 0.513 
                 0.282 
                 0.289 
               
               
                 15  
                 10500 
                 0.562 
                 0.272 
                 0.454 
                 0.327 
                 0.540 
                 0.309 
                 0.313 
               
               
                 16  
                 11200 
                 0.581 
                 0.291 
                 0.478 
                 0.351 
                 0.564 
                 0.333 
                 0.337 
               
               
                 17  
                 11900 
                 0.600 
                 0.310 
                 0.500 
                 0.373 
                 0.585 
                 0.354 
                 0.358 
               
               
                 18  
                 14000 
                 0.655 
                 0.365 
                 0.565 
                 0.438 
                 0.640 
                 0.409 
                 0.421 
               
               
                   
               
               
                 Temp. and Humidity During Construction: 70° F./50% 
               
               
                 Temp. and Humidity During Test: 70° F./48% 
               
               
                 Sample Description: ¾ inch SCP panel fastened to 16 gauge - 8 inch steel joints 
               
               
                 Mode of failure: Several of the butt-joints opened up in several locations causing cement board core failure at the fasteners along the edges of the cement board. 
               
               
                 *The RD (resultant deflection) is equal to the average deflection of the bearings minus the greatest point of deflection across the clear span. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 27 
               
             
            
               
                   
               
               
                 Floor Diagram Test (Dry Test 2) 
               
            
           
           
               
               
               
            
               
                   
                   
                 Average 
               
               
                   
                 Bearing Points 
                 Bearing 
               
            
           
           
               
               
               
               
               
            
               
                 Load 
                 Load 
                 Indicator #1 
                 Indicator #5 
                 Deflec- 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Increment 
                 (lbs.) 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 tion 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0.124 
                 — 
                 0.201 
                 — 
                 — 
               
               
                 1 
                 700 
                 0.125 
                 0.001 
                 0.202 
                 0.001 
                 0.001 
               
               
                 2 
                 1400 
                 0.125 
                 0.001 
                 0.203 
                 0.002 
                 0.002 
               
               
                 3 
                 2100 
                 0.127 
                 0.003 
                 0.203 
                 0.002 
                 0.003 
               
               
                 4 
                 2800 
                 0.128 
                 0.004 
                 0.203 
                 0.002 
                 0.003 
               
               
                 5 
                 3500 
                 0.129 
                 0.005 
                 0.204 
                 0.003 
                 0.004 
               
               
                 6 
                 4200 
                 0.131 
                 0.006 
                 0.205 
                 0.004 
                 0.005 
               
               
                 7 
                 4900 
                 0.132 
                 0.007 
                 0.206 
                 0.005 
                 0.006 
               
               
                 8 
                 5600 
                 0.134 
                 0.010 
                 0.206 
                 0.005 
                 0.007 
               
               
                 9 
                 6300 
                 0.136 
                 0.012 
                 0.207 
                 0.006 
                 0.009 
               
               
                 10  
                 7000 
                 0.137 
                 0.013 
                 0.208 
                 0.006 
                 0.009 
               
               
                 11  
                 7700 
                 0.139 
                 0.015 
                 0.208 
                 0.007 
                 0.011 
               
               
                 Design 
                 8400 
                 0.141 
                 0.017 
                 0.208 
                 0.007 
                 0.012 
               
               
                 Load 
               
               
                 13  
                 9100 
                 0.141 
                 0.017 
                 0.208 
                 0.007 
                 0.012 
               
               
                 14  
                 9800 
                 0.143 
                 0.019 
                 0.208 
                 0.007 
                 0.013 
               
               
                 15  
                 10500 
                 0.145 
                 0.021 
                 0.209 
                 0.008 
                 0.015 
               
               
                 16  
                 11200 
                 0.145 
                 0.021 
                 0.209 
                 0.008 
                 0.015 
               
               
                 17  
                 11900 
                 0.147 
                 0.023 
                 0.209 
                 0.008 
                 0.016 
               
               
                 18  
                 14000 
                 0.150 
                 0.026 
                 0.209 
                 0.008 
                 0.017 
               
               
                   
               
               
                 Temp. and Humidity During Construction: 70° F./50% 
               
               
                 Temp. and Humidity During Test: 70° F./48% 
               
               
                 Sample Description: ¾ inch SCP panel fastened to 16 gauge - 8 inch steel joints 
               
               
                 Mode of failure: Several of the butt-joints opened up in several locations causing cement board core failure at the fasteners along the edges of the cement board. 
               
               
                 *The resultant deflection is equal to the average deflection of the bearings minus the greatest point of deflection across the clear span. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 28 
               
             
            
               
                   
               
               
                 Floor Diaphragm Test (Wet Test 1); Floor 
               
               
                 width 120 inches; Design Load 420 P.L.F. 
               
               
                 Floor Test Loads 
               
            
           
           
               
               
               
               
               
               
            
               
                   
                 Total Ceiling 
                 Load 
                 Load 
                 Load 
                 Load 
               
               
                 Loading 
                 Load 
                 No. 1 
                 No. 2 
                 No. 3 
                 No. 4 
               
               
                 Increments 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0 
                 0 
                 0 
                 0 
               
               
                 1 
                 700 
                 175 
                 175 
                 175 
                 175 
               
               
                 2 
                 1400 
                 350 
                 350 
                 350 
                 350 
               
               
                 3 
                 2100 
                 525 
                 525 
                 525 
                 525 
               
               
                 4 
                 2800 
                 700 
                 700 
                 700 
                 700 
               
               
                 5 
                 3500 
                 875 
                 875 
                 875 
                 875 
               
               
                 6 
                 4200 
                 1050 
                 1050 
                 1050 
                 1050 
               
               
                 7 
                 4900 
                 1225 
                 1225 
                 1225 
                 1225 
               
               
                 8 
                 5600 
                 1400 
                 1400 
                 1400 
                 1400 
               
               
                 9 
                 6300 
                 1575 
                 1575 
                 1575 
                 1575 
               
               
                 10 
                 7000 
                 1750 
                 1750 
                 1750 
                 1750 
               
               
                 11 
                 7700 
                 1925 
                 1925 
                 1925 
                 1925 
               
               
                 Design Load 
                 8400 
                 2100 
                 2100 
                 2100 
                 2100 
               
               
                 13 
                 9100 
                 2275 
                 2275 
                 2275 
                 2275 
               
               
                 14 
                 9800 
                 2450 
                 2450 
                 2450 
                 2450 
               
               
                 15 
                 10500 
                 2625 
                 2625 
                 2625 
                 2625 
               
               
                 16 
                 11200 
                 2800 
                 2800 
                 2800 
                 2800 
               
               
                 17 
                 11900 
                 2975 
                 2975 
                 2975 
                 2975 
               
               
                 18 
                 14000 
                 3500 
                 3500 
                 3500 
                 3500 
               
               
                 Ultimate Load 
                 27,893 
                 7,097 
                 6,878 
                 6,850 
                 7,068 
               
               
                   
               
               
                 Design Load 464.9 P.L.F. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 29 
               
             
            
               
                   
               
               
                 Floor Diaphragm Comparison Test (Wet Test 1) 
               
            
           
           
               
               
               
            
               
                   
                 Clear Span 
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 Load 
                 Load 
                 Indicator #2 
                 Indicator #3 
                 Indicator #4 
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Increment 
                 (lbs.) 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 RD* 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0.211 
                 — 
                 0.185 
                 — 
                 0.268 
                 — 
                 — 
               
               
                 1 
                 700 
                 0.239 
                 0.028 
                 0.208 
                 0.023 
                 0.287 
                 0.019 
                 0.023 
               
               
                 2 
                 1400 
                 0.245 
                 0.034 
                 0.225 
                 0.040 
                 0.293 
                 0.025 
                 0.040 
               
               
                 3 
                 2100 
                 0.267 
                 0.056 
                 0.239 
                 0.054 
                 0.316 
                 0.048 
                 0.053 
               
               
                 4 
                 2800 
                 0.287 
                 0.076 
                 0.260 
                 0.075 
                 0.336 
                 0.068 
                 0.073 
               
               
                 5 
                 3500 
                 0.304 
                 0.093 
                 0.280 
                 0.095 
                 0.354 
                 0.086 
                 0.093 
               
               
                 6 
                 4200 
                 0.320 
                 0.109 
                 0.300 
                 0.115 
                 0.372 
                 0.104 
                 0.113 
               
               
                 7 
                 4900 
                 0.335 
                 0.124 
                 0.318 
                 0.133 
                 0.388 
                 0.120 
                 0.131 
               
               
                 8 
                 5600 
                 0.354 
                 0.143 
                 0.339 
                 0.154 
                 0.405 
                 0.137 
                 0.152 
               
               
                 9 
                 6300 
                 0.369 
                 0.158 
                 0.356 
                 0.171 
                 0.421 
                 0.153 
                 0.168 
               
               
                 10 
                 7000 
                 0.388 
                 0.177 
                 0.378 
                 0.193 
                 0.441 
                 0.173 
                 0.188 
               
               
                 11  
                 7700 
                 0.405 
                 0.194 
                 0.398 
                 0.213 
                 0.458 
                 0.190 
                 0.207 
               
               
                 Design 
                 8400 
                 0.430 
                 0.219 
                 0.426 
                 0.241 
                 0.481 
                 0.213 
                 0.230 
               
               
                 Load 
               
               
                 13  
                 9100 
                 0.469 
                 0.258 
                 0.463 
                 0.278 
                 0.508 
                 0.240 
                 0.252 
               
               
                 14  
                 9800 
                 0.500 
                 0.289 
                 0.497 
                 0.312 
                 0.536 
                 0.268 
                 0.275 
               
               
                 15  
                 10500 
                 0.521 
                 0.310 
                 0.522 
                 0.337 
                 0.558 
                 0.290 
                 0.298 
               
               
                 16  
                 11200 
                 0.545 
                 0.334 
                 0.549 
                 0.364 
                 0.582 
                 0.314 
                 0.323 
               
               
                 17  
                 11900 
                 0.569 
                 0.358 
                 0.579 
                 0.394 
                 0.610 
                 0.342 
                 0.351 
               
               
                 18  
                 14000 
                 0.635 
                 0.424 
                 0.668 
                 0.483 
                 0.692 
                 0.424 
                 0.431 
               
               
                   
               
               
                 Temp. and Humidity During Construction: 65° F./31% 
               
               
                 Temp. and Humidity During Test: 65° F./31% 
               
               
                 Sample Description ¾ inch SCP panel fastened to 16 gauge - 8 inch steel joints 
               
               
                 Several of the butt-joints opened up in several locations causing cement board core failure at the fasteners along the edges of the cement board. 
               
               
                 *The RD (resultant deflection) is equal to the average deflection of the bearings minus the greatest point of deflection across the clear span. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 30 
               
             
            
               
                   
               
               
                 Floor Diaphragm Test (Wet Test 1) 
               
            
           
           
               
               
               
            
               
                   
                   
                 Average 
               
               
                   
                 Bearing Points 
                 Bearing 
               
            
           
           
               
               
               
               
               
            
               
                 Load 
                 Load 
                 Indicator #1 
                 Indicator #5 
                 Deflec- 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Increment 
                 (lbs.) 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 tion 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0.199 
                 — 
                 0.341 
                 — 
                 — 
               
               
                 1 
                 700 
                 0.199 
                 0.000 
                 0.342 
                 0.001 
                 0.001 
               
               
                 2 
                 1400 
                 0.199 
                 0.000 
                 0.342 
                 0.001 
                 0.001 
               
               
                 3 
                 2100 
                 0.199 
                 0.000 
                 0.343 
                 0.002 
                 0.001 
               
               
                 4 
                 2800 
                 0.199 
                 0.000 
                 0.345 
                 0.004 
                 0.002 
               
               
                 5 
                 3500 
                 0.199 
                 0.000 
                 0.345 
                 0.004 
                 0.002 
               
               
                 6 
                 4200 
                 0.199 
                 0.000 
                 0.345 
                 0.004 
                 0.002 
               
               
                 7 
                 4900 
                 0.199 
                 0.000 
                 0.346 
                 0.005 
                 0.002 
               
               
                 8 
                 5600 
                 0.199 
                 0.000 
                 0.346 
                 0.005 
                 0.002 
               
               
                 9 
                 6300 
                 0.200 
                 0.001 
                 0.347 
                 0.006 
                 0.003 
               
               
                 10  
                 7000 
                 0.203 
                 0.004 
                 0.347 
                 0.006 
                 0.005 
               
               
                 11  
                 7700 
                 0.204 
                 0.005 
                 0.348 
                 0.007 
                 0.006 
               
               
                 Design 
                 8400 
                 0.214 
                 0.015 
                 0.348 
                 0.007 
                 0.011 
               
               
                 Load 
               
               
                 13  
                 9100 
                 0.244 
                 0.045 
                 0.349 
                 0.008 
                 0.027 
               
               
                 14  
                 9800 
                 0.265 
                 0.066 
                 0.349 
                 0.008 
                 0.037 
               
               
                 15  
                 10500 
                 0.268 
                 0.069 
                 0.350 
                 0.009 
                 0.039 
               
               
                 16  
                 11200 
                 0.272 
                 0.073 
                 0.351 
                 0.010 
                 0.042 
               
               
                 17  
                 11900 
                 0.275 
                 0.076 
                 0.352 
                 0.011 
                 0.044 
               
               
                 18  
                 14000 
                 0.289 
                 0.090 
                 0.355 
                 0.014 
                 0.052 
               
               
                   
               
               
                 Temp. and Humidity During Construction: 65° F./31% 
               
               
                 Temp. and Humidity During Test: 65° F./31% 
               
               
                 Sample Description ¾ inch SCP panel fastened to 16 gauge - 8 inch steel joints 
               
               
                 Several of the butt-joints opened up in several locations causing cement board core failure at the fasteners along the edges of the cement board. 
               
               
                 *The resultant deflection is equal to the average deflection of the bearings minus the greatest point of deflection across the clear span. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 31 
               
             
            
               
                   
               
               
                 Floor Diaphragm Test (Wet); Floor Width; 
               
               
                 Design Load 420 P.L.F. (Wet Test 2) 
               
               
                 Floor Test Loads 
               
            
           
           
               
               
               
               
               
               
            
               
                   
                 Total Ceiling 
                 Load 
                 Load 
                 Load 
                 Load 
               
               
                 Loading 
                 Load 
                 No. 1 
                 No. 2 
                 No. 3 
                 No. 4 
               
               
                 Increments 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
                 (lbs.) 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0 
                 0 
                 0 
                 0 
               
               
                 1 
                 700 
                 175 
                 175 
                 175 
                 175 
               
               
                 2 
                 1400 
                 350 
                 350 
                 350 
                 350 
               
               
                 3 
                 2100 
                 525 
                 525 
                 525 
                 525 
               
               
                 4 
                 2800 
                 700 
                 700 
                 700 
                 700 
               
               
                 5 
                 3500 
                 875 
                 875 
                 875 
                 875 
               
               
                 6 
                 4200 
                 1050 
                 1050 
                 1050 
                 1050 
               
               
                 7 
                 4900 
                 1225 
                 1225 
                 1225 
                 1225 
               
               
                 8 
                 5600 
                 1400 
                 1400 
                 1400 
                 1400 
               
               
                 9 
                 6300 
                 1575 
                 1575 
                 1575 
                 1575 
               
               
                 10 
                 7000 
                 1750 
                 1750 
                 1750 
                 1750 
               
               
                 11 
                 7700 
                 1925 
                 1925 
                 1925 
                 1925 
               
               
                 Design Load 
                 8400 
                 2100 
                 2100 
                 2100 
                 2100 
               
               
                 13 
                 9100 
                 2275 
                 2275 
                 2275 
                 2275 
               
               
                 14 
                 9800 
                 2450 
                 2450 
                 2450 
                 2450 
               
               
                 15 
                 10500 
                 2625 
                 2625 
                 2625 
                 2625 
               
               
                 16 
                 11200 
                 2800 
                 2800 
                 2800 
                 2800 
               
               
                 17 
                 11900 
                 2975 
                 2975 
                 2975 
                 2975 
               
               
                 18 
                 14000 
                 3500 
                 3500 
                 3500 
                 3500 
               
               
                 Ultimate Load 
                 30,285 
                 7,327 
                 7,707 
                 7,740 
                 7,511 
               
               
                   
               
               
                 Design Load 504.8 P.L.F. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 32 
               
             
            
               
                   
               
               
                 Floor Diaphragm Comparison Test (Wet Test 2) 
               
            
           
           
               
               
               
            
               
                   
                 Clear Span 
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 Load 
                 Load 
                 Indicator #2 
                 Indicator #3 
                 Indicator #4 
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 Increment 
                 (lbs.) 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 Reading 
                 Deflection 
                 RD* 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
               
            
               
                 No Load 
                 0 
                 0.166 
                 — 
                 0.136 
                 — 
                 0.129 
                 — 
                 — 
               
               
                 1 
                 700 
                 0.180 
                 0.014 
                 0.144 
                 0.008 
                 0.140 
                 0.011 
                 0.007 
               
               
                 2 
                 1400 
                 0.193 
                 0.027 
                 0.156 
                 0.020 
                 0.150 
                 0.021 
                 0.019 
               
               
                 3 
                 2100 
                 0.210 
                 0.044 
                 0.173 
                 0.037 
                 0.167 
                 0.038 
                 0.035 
               
               
                 4 
                 2800 
                 0.228 
                 0.062 
                 0.192 
                 0.056 
                 0.181 
                 0.052 
                 0.054 
               
               
                 5 
                 3500 
                 0.240 
                 0.074 
                 0.210 
                 0.074 
                 0.195 
                 0.066 
                 0.071 
               
               
                 6 
                 4200 
                 0.268 
                 0.102 
                 0.233 
                 0.197 
                 0.213 
                 0.084 
                 0.094 
               
               
                 7 
                 4900 
                 0.312 
                 0.146 
                 0.270 
                 0.134 
                 0.237 
                 0.108 
                 0.130 
               
               
                 8 
                 5600 
                 0.337 
                 0.171 
                 0.293 
                 0.157 
                 0.255 
                 0.126 
                 0.152 
               
               
                 9 
                 6300 
                 0.370 
                 0.204 
                 0.326 
                 0.190 
                 0.280 
                 0.151 
                 0.184 
               
               
                 10  
                 7000 
                 0.387 
                 0.221 
                 0.345 
                 0.209 
                 0.295 
                 0.166 
                 0.201 
               
               
                 11  
                 7700 
                 0.406 
                 0.240 
                 0.367 
                 0.231 
                 0.314 
                 0.185 
                 0.223 
               
               
                 Design 
                 8400 
                 0.423 
                 0.257 
                 0.386 
                 0.250 
                 0.330 
                 0.201 
                 0.241 
               
               
                 Load 
               
               
                 13  
                 9100 
                 0.440 
                 0.274 
                 0.406 
                 0.270 
                 0.351 
                 0.222 
                 0.260 
               
               
                 14  
                 9800 
                 0.451 
                 0.285 
                 0.427 
                 0.291 
                 0.368 
                 0.239 
                 0.279 
               
               
                 15  
                 10500 
                 0.471 
                 0.309 
                 0.448 
                 0.312 
                 0.387 
                 0.258 
                 0.298 
               
               
                 16  
                 11200 
                 0.491 
                 0.325 
                 0.468 
                 0.332 
                 0.405 
                 0.276 
                 0.316 
               
               
                 17  
                 11900 
                 0.512 
                 0.346 
                 0.494 
                 0.358 
                 0.429 
                 0.300 
                 0.341 
               
               
                 18  
                 14000 
                 0.569 
                 0.393 
                 0.553 
                 0.417 
                 0.482 
                 0.353 
                 0.396 
               
               
                   
               
               
                 Temp. and Humidity During Construction: 70° F./50% 
               
               
                 Temp. and Humidity During Test: 70° F./48% 
               
               
                 Sample Description: ¾ inch SCP panel fastened to 16 gauge - 8 inch steel joints 
               
               
                 Mode of failure: The butt-joints on the load side of the floor at end #1 opened up causing core failure to the cement board around the screws along the joint. The screws along the end joist at end #1 pulled through the cement board due to core 
               
               
                 *The resultant deflection is equal to the average deflection of the bearings minus the greatest point of deflection across the clear span. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 33 
               
             
            
               
                   
               
               
                 Floor Diaphragm Test (Wet Test 2) 
               
            
           
           
               
               
               
            
               
                   
                 Bearing Points 
                 Average 
               
            
           
           
               
               
               
               
               
            
               
                 Load 
                   
                 Indicator #1 
                 Indicator #5 
                 Bearing 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Incre- 
                 Load 
                   
                 Deflec- 
                   
                 Deflec- 
                 Deflec- 
               
               
                 ment 
                 (lbs.) 
                 Reading 
                 tion 
                 Reading 
                 tion 
                 tion 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                 No 
                 0 
                 lbs 
                 0.075 
                 — 
                 0.110 
                 — 
                 — 
               
               
                 Load 
               
               
                 1 
                 700 
                 lbs. 
                 0.077 
                 0.002 
                 0.110 
                 0.000 
                 0.001 
               
               
                 2 
                 1400 
                   
                 0.078 
                 0.003 
                 0.110 
                 0.000 
                 0.002 
               
               
                 3 
                 2100 
                   
                 0.078 
                 0.003 
                 0.111 
                 0.001 
                 0.002 
               
               
                 4 
                 2800 
                   
                 0.078 
                 0.003 
                 0.111 
                 0.001 
                 0.002 
               
               
                 5 
                 3500 
                   
                 0.079 
                 0.004 
                 0.112 
                 0.002 
                 0.003 
               
               
                 6 
                 4200 
                   
                 0.079 
                 0.004 
                 0.112 
                 0.002 
                 0.003 
               
               
                 7 
                 4900 
                   
                 0.080 
                 0.005 
                 0.113 
                 0.003 
                 0.004 
               
               
                 8 
                 5600 
                   
                 0.083 
                 0.008 
                 0.113 
                 0.003 
                 0.006 
               
               
                 9 
                 6300 
                   
                 0.084 
                 0.009 
                 0.114 
                 0.004 
                 0.007 
               
               
                 10  
                 7000 
                   
                 0.086 
                 0.011 
                 0.115 
                 0.005 
                 0.008 
               
               
                 11  
                 7700 
                   
                 0.087 
                 0.012 
                 0.115 
                 0.005 
                 0.009 
               
               
                 Design 
                 8400 
                   
                 0.089 
                 0.014 
                 0.115 
                 0.005 
                 0.010 
               
               
                 Load 
               
               
                 13  
                 9100 
                   
                 0.090 
                 0.015 
                 0.116 
                 0.006 
                 0.011 
               
               
                 14  
                 9800 
                   
                 0.092 
                 0.017 
                 0.118 
                 0.008 
                 0.013 
               
               
                 15  
                 10500 
                   
                 0.095 
                 0.020 
                 0.119 
                 0.009 
                 0.015 
               
               
                 16  
                 11200 
                   
                 0.097 
                 0.022 
                 0.120 
                 0.010 
                 0.016 
               
               
                 17  
                 11900 
                   
                 0.099 
                 0.024 
                 0.120 
                 0.010 
                 0.017 
               
               
                 18  
                 14000 
                   
                 0.105 
                 0.030 
                 0.123 
                 0.013 
                 0.022 
               
               
                   
               
               
                 Bearing Indictors 2, 3 and 4 (labeled “Clear Span”) of Table 32 are the instruments along the test specimen in the area between the support points at the two opposed ends of the frame. 
               
               
                 Bearing Indicators 1 and 5 of Table 33 are at the support points of this test specimen. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 34 
               
             
            
               
                   
               
               
                 Water Absorption Results - ¾ inch thick SCP panel 
               
            
           
           
               
               
               
               
               
            
               
                   
                 Weight 
                 Weight 
                   
                 Weight 
               
               
                   
                 Before 
                 After 
                 Weight 
                 Gain 
               
               
                 Specimen 
                 Soak 
                 Soak 
                 Gain 
                 Percentage 
               
               
                   
               
               
                 A 
                 2069.0 g 
                 2082.3 g 
                 13.3 g  
                 0.6% 
               
               
                 B 
                 2109.1 g 
                 2112.6 g 
                 3.5 g 
                 0.2% 
               
               
                 C 
                 2145.0 g 
                 2149.9 g 
                 4.9 g 
                 0.2% 
               
            
           
           
               
               
            
               
                 Average Water Absorption 
                 0.3% 
               
               
                   
               
               
                 This data is for moisture content tests done on specimens A, B and C which are 12 inch × 12 inch specimens of the SCP panel of the composition tested in the above “Wet” and “Dry” tests. In the moisture content tests the specimens are soaked 24 hours under a two inch head of water. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 35 
               
             
            
               
                   
               
               
                 Moisture Content ¾ inch thick SCP panel 
               
            
           
           
               
               
               
            
               
                   
                 Before Soak Test 
                 After Soak Test 
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                   
                   
                 Weight 
                   
                   
                 Weight 
                   
                   
               
               
                   
                   
                 of 
                   
                   
                 of 
               
               
                   
                   
                 samples 
                   
                   
                 samples 
               
               
                   
                 Weight 
                 before 
                 Weight 
                 Weight 
                 after 
                 Weight 
                 Weight 
               
               
                   
                 After 
                 soak 
                 Loss 
                 Loss 
                 soak 
                 Loss 
                 Loss 
               
               
                 Specimen 
                 Drying (g) 
                 (g) 
                 (g) 
                 Percentage 
                 (g) 
                 (g) 
                 Percentage 
               
               
                   
               
               
                 A 
                 1801.9 
                 2069.0 
                 267.1 
                 12.9% 
                 2082.3 
                 280.4 
                 13.5% 
               
               
                 B 
                 1875.5 
                 2109.1 
                 230.6 
                 10.9% 
                 2112.6 
                 234.1 
                 11.1% 
               
               
                 C 
                 1904.5 
                 2145.0 
                 240.5 
                 11.2% 
                 2149.9 
                 245.4 
                 11.4% 
               
               
                 Average 
                   
                   
                   
                 11.7% 
                   
                   
                 12.0% 
               
               
                 Moisture 
               
               
                 Content 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 36 
               
             
            
               
                   
               
               
                 Board Expansion ¾ inch thick SCP panel (dimensions in inches) 
               
            
           
           
               
               
               
               
               
               
               
            
               
                 Specimen 
                 Width 1 
                 Width 2 
                 Thick 1 
                 Thick 2 
                 Thick 3 
                 Thick 4 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
            
               
                 A - Before 
                 12.146 
                 11.907 
                 0.717 
                 0.715 
                 0.697 
                 0.704 
               
               
                 Soak 
               
               
                 A - After Soak 
                 12.146 
                 11.907 
                 0.717 
                 0.715 
                 0.697 
                 0.704 
               
               
                 Difference 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
               
               
                 B - Before 
                 12.072 
                 11.940 
                 0.710 
                 0.740 
                 0.732 
                 0.715 
               
               
                 Soak 
               
               
                 B - After Soak 
                 12.072 
                 11.940 
                 0.710 
                 0.740 
                 0.732 
                 0.715 
               
               
                 Difference 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
               
               
                 C - Before 
                 12.065 
                 11.970 
                 0.755 
                 0.740 
                 0.730 
                 0.750 
               
               
                 Soak 
               
               
                 C - After Soak 
                 12.065 
                 11.970 
                 0.755 
                 0.740 
                 0.730 
                 0.750 
               
               
                 Difference 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
               
               
                   
               
            
           
         
       
     
     Example 8 
     To determine the shear strength and shear stiffness of a floor diaphragm assembly using steel framing and SCP sheathing a test according to the AISI TS-7-02 Cantilever Test Method for Cold-Formed Steel Diaphragms was performed on ten (10) specimens. This data can be indicative of shear performance as a shear wall. 
       FIG. 24  shows a floor framing  400  used in the AISI TS-7 tests. 
     Floor Diaphragm Materials 
     Prototype ¾″ SCP—Structural Cement Panel reinforced with fiberglass strands. A “V”-groove and tongue is located along the 8′ dimension of the 4′×8′ sheets. 
     ¾″ Plywood— 23/32″ GP Plus, Tongue and Groove (Quick Fit). APA Rated Sturd-I-Floor™, Exposure 1, PS1-95 Underlayment, Sanded Face, PRP-108 and manufactured by Georgia Pacific Corporation. 
     Fasteners—#8-18×1⅝″ lg., winged driller Bugle head Grabber Super Drive™ (Lox drive) screws, Item No. CHS8158JBW spaced 4″, 6″ and 12″ o.c. along the perimeter, and 12″ o.c. in the field of the panels. All fasteners were placed a minimum of ¾″ in from panel edges and ½″ in from seams. At panel corners the fasteners were inset 2″. 
     Adhesive—PL Polyurethane Premium Construction Adhesive, manufactured by OSI Sealants. A ¼″ bead was applied to all framing members with a double bead applied at panel butt-joints. A minimum of 24 hours of cure time was provided prior to any loading. 
     Floor Framing 
     Joists—16 ga.×10″ deep×10′ long Trade Ready™ Joists manufactured by Dietrich Industries. The joists were stamped Dietrich TDJ5 W 9¼ IN×L 11 FT 10½ IN 14453223 16 GAUGE G60 50KSI. The average tested yield strength was 51.0 ksi. 
     Rim Track—16 ga.×10 3/16″ deep×16′ long with pre-bent joist attachment locations spaced at 24″ o.c. The track was stamped Dietrich D16 W 9¼ IN×L 16 FT 14453203 16 GAUGE G60. The average tested yield strength was 62.7 ksi. Fasteners—#10-16×¾″ long hex-head, Drivall screws. 
     Test Specimen Construction 
     Ten (10) test samples were constructed to an overall dimension of 11′-11″×12′-0″. The rim track had the prebent tabs at 16″ o.c. so, clip angles were welded at the 24″ o.c. spacing. 
     The joists were attached to the track using three (3) hex-head #10-16×¾″ lg. Drivall screws into the side of the joist through the pre-bent tab. A Simpson Strong-Tie Holdown Part No. S/HD15 was fastened to the Tension side of the floor using 48-#10×¾″ lg. hex-head self-drilling screws. A 6⅛″×16″ lg., 12 ga stud was attached to the compression joist using (14)—#10×¾″ long hex-head self-drilling screws. This was added as a stiffener to avoid crushing the end joist prior to diaphragm failure. The frame was squared and then the prototype SCP or plywood was fastened to it. The floor sheathing was fastened at 4″, 6″ or 12″ o.c. around the perimeter inset 2″ from the corners, and 12″ o.c. in the field with #8-18×1⅝″ lg. Bugle head Grabber Super Drive™ screws. Care was taken to ensure that the fasteners were kept flush or slightly below the surface of the floor sheathing and also did not strip out in the steel framing. See attached drawings no. B6-B11 for details. The test samples using adhesive were allowed to set for a minimum of 24 hours to provide the recommended adhesive to cure. 
       FIG. 25  shows one of the SCP Floors  420  used in the AISI TS-7 tests with adhesive placement. The boards  442  were SCP panels having 0.670 inch-0.705 inch thickness. View EE shows offset panels at a joint. View FF shows “V”-shaped ½ inch tongue and groove joint. View GG shows a corner. View HH shows where three SCP panels meet. View II shows a corner. 
     Test Set-Up 
       FIG. 26  shows the testing apparatus  450  used in the AISI TS-7 tests. Test apparatus  450  has two 8 inch×72 inch long loading beams  454 . A test specimen  452  is placed on 1 inch rollers  458  a steel plate  460  is provided under the rollers  458 . Arigid bearing  466  and test fixture  456  and I-beam fixture are also provided. A hydraulic cylinder  462  applies pressure to the test specimen  452 . 
     The test sample was positioned in the test fixture with one of the rim tracks set flush to the top of a 10″-30 lb./ft. C-channel. The rim track was then attached to the C-channel using a #12-24, T5 hex head screws spaced 12″ o.c. Two (2) 8″×72″ long I-beams were then attached to the other rim track, flush to the top, using #10×¾″ long hex-head self-drilling screws. The fasteners were set 6″ o.c. alternating sides of the I-beam flange. The I-beams were also bolted together. A hydraulic cylinder was positioned on a reaction beam in-line with the I-beams. 
     1″ diameter threaded rod was placed thru the Simpson Holdown and connected to the rigid steel fixture. No specific torque was applied to the coupling nuts on the threaded rod. The rim track on the load side was positioned on double sets of rollers spaced approximately 48″ apart. A hold down was placed over the sheathing on the compression side to prevent uplift. Two (2) 1″ diameter rollers were placed between the hold down tube and a steel plate on the floor sheathing. 
     Four (4) Linear transducers were placed on floor diaphragms assembly in the following locations: 
     #1—In-line with the Tension Joist, 
     #2—In-line with the fixed rim track, 
     #3—In-line with the loaded rim track on a clip angle, and 
     #4—In-line with the Compression Joist. 
     The Linear transducers and hydraulic pressure transducer were connected to a data acquisition system. 
     Test Equipment 
     Four (4) Linear transducers were placed on floor diaphragms assembly in the following locations: 
     One (1) ENERPAC Model P-39 hydraulic hand pumps. 
     Three (3) EnerPac Model RC-1010 hydraulic cylinders. 
     Four (4) Linear transducers. 
     Five (5) rigid bearings bolted to floor. 
     One (1) C10×30 rigid channel bolted to three (3) of the bearings. 
     One (1) Omega digital meter. 
     One (1) Omega pressure transducer. 
     Two (2) 6 ft. I-beams. 
     Procedure 
     The loads were generated using a hydraulic cylinder, at the load point. The applied forces were measured with data acquisition equipment, and a pressure transducer. A permanent record of the applied forces was made on the attached data sheets. The loads were generated by applying hydraulic pressure to create mechanical force until the required load was indicated on the digital meter. The entire floor assembly was loaded in at a constant rate until no further gain in load could be attained. 
     Test Results 
     TABLE 37 summarizes the test results. 
     
       
         
           
               
             
               
                 TABLE 37 
               
             
            
               
                   
               
               
                 Summary of Tests Nos. 1-10 
               
               
                 Specimen: ¾″ Prototype SCP (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws with various 
               
               
                 spacing around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
               
               
               
               
            
               
                   
                   
                   
                   
                 Sn Shear 
                 G′ Shear 
               
               
                   
                 Fastener 
                 Spacing 
                 Adhesive to 
                 Strength 
                 Stiffness 
               
               
                 Test No. 
                 Perimeter 
                 Field 
                 Framing 
                 (plf) 
                 (plf) 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 1 
                 4″ 
                 12″ 
                 No 
                 623.9 
                 241,328 
               
               
                 2 
                   
                   
                   
                 637.9 
                 178,433 
               
               
                 3 
                   
                   
                   
                 783.3 
                 147,670 
               
               
                 4 
                 6″ 
                 12″ 
                 No 
                 699.0 
                 202,407 
               
               
                 5 
                   
                   
                   
                 544.8 
                 121,526 
               
               
                 6 
                   
                   
                   
                 711.4 
                 107,653 
               
               
                 10 Plywood 
                   
                   
                   
                 527.9 
                 78,880 
               
               
                 7 
                 4″ 
                 12″ 
                 Yes 
                 1886.0 
                 581,716 
               
               
                 8 
                 6″ 
                   
                   
                 1612.5 
                 803,716 
               
               
                 9 
                 12″  
                   
                   
                 1327.0 
                 432,444 
               
               
                   
               
               
                 The rows defined in the failure descriptions are #1-#3 with #1 the load side and Spacing Field. See FIGS. 27-30 for details. 
               
            
           
         
       
     
       FIGS. 27-29  show Load in Pounds v. Displacement data used to generate the values in TABLE 37. In particular,  FIG. 27  shows data from AISI TS-7 Cantilever Floor Diaphragm test using ¾ inch SCP panel with a 4 inch-12 inch fastening schedule.  FIG. 28  shows data from AISI TS-7 Cantilever Floor Diaphragm test using ¾ inch SCP panel compared to ¾ inch plywood with a 6 inch-12 inch fastening schedule.  FIG. 29  shows data from AISI TS-7 Cantilever Floor Diaphragm test using ¾ inch SCP panel with adhesive. 
     TABLES 38-47 show in table form the data of  FIGS. 24 ,  25  and  26  for Test LP 804-3-0.001 inch increments. 
     
       
         
           
               
             
               
                 TABLE 38 
               
             
            
               
                   
               
               
                 Test No. 1: Specimen: ¾″ SCP (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws 
               
               
                 spaced 4″ o.c. around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
            
               
                 Load in 
                   
               
            
           
           
               
               
               
            
               
                 Pounds 
                 Deflection in Inches-Indicator Number 
                 Net Shear 
               
            
           
           
               
               
               
               
               
               
            
               
                 (lbf) 
                 1 
                 2 
                 3 
                 4 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 0 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
                 0.000 
               
               
                 214 
                 0.001 
                 −0.001 
                 0.015 
                 0.012 
                 0.003 
               
               
                 500 
                 0.001 
                 −0.003 
                 0.041 
                 0.032 
                 0.012 
               
               
                 723 
                 0.002 
                 −0.004 
                 0.061 
                 0.043 
                 0.019 
               
               
                 982 
                 0.004 
                 −0.006 
                 0.089 
                 0.046 
                 0.045 
               
               
                 1205 
                 0.005 
                 −0.006 
                 0.109 
                 0.049 
                 0.061 
               
               
                 1481 
                 0.007 
                 −0.007 
                 0.132 
                 0.052 
                 0.080 
               
               
                 1704 
                 0.008 
                 −0.007 
                 0.147 
                 0.055 
                 0.091 
               
               
                 1945 
                 0.009 
                 −0.006 
                 0.159 
                 0.057 
                 0.099 
               
               
                 2204 
                 0.011 
                 −0.004 
                 0.180 
                 0.061 
                 0.113 
               
               
                 2489 
                 0.012 
                 −0.003 
                 0.194 
                 0.063 
                 0.122 
               
               
                 2739 
                 0.013 
                 0.000 
                 0.211 
                 0.066 
                 0.131 
               
               
                 2980 
                 0.015 
                 0.004 
                 0.237 
                 0.070 
                 0.148 
               
               
                 3230 
                 0.017 
                 0.008 
                 0.259 
                 0.074 
                 0.160 
               
               
                 3498 
                 0.018 
                 0.013 
                 0.295 
                 0.079 
                 0.185 
               
               
                 3739 
                 0.020 
                 0.016 
                 0.328 
                 0.083 
                 0.210 
               
               
                 3997 
                 0.022 
                 0.020 
                 0.365 
                 0.087 
                 0.237 
               
               
                 4229 
                 0.023 
                 0.023 
                 0.407 
                 0.093 
                 0.269 
               
               
                 4488 
                 0.025 
                 0.025 
                 0.445 
                 0.096 
                 0.299 
               
               
                 4729 
                 0.027 
                 0.029 
                 0.493 
                 0.100 
                 0.338 
               
               
                 4961 
                 0.028 
                 0.033 
                 0.531 
                 0.104 
                 0.367 
               
               
                 5247 
                 0.030 
                 0.044 
                 0.600 
                 0.109 
                 0.418 
               
               
                 5461 
                 0.031 
                 0.050 
                 0.645 
                 0.112 
                 0.452 
               
               
                 5746 
                 0.033 
                 0.054 
                 0.710 
                 0.115 
                 0.509 
               
               
                 5987 
                 0.035 
                 0.059 
                 0.768 
                 0.119 
                 0.556 
               
               
                 2,995 (P) 
                 0.015 
                 0.004 
                 0.237 
                 0.070 
                 0.148 
               
               
                   
               
               
                 Test Conditions: 70° F.; 41% Relative Humidity 
               
               
                 Diaphragm Width 143 inches; Diaphragm Length 144 inches; Load Time (min:sec): 7:46 
               
               
                 Ultimate Load (Pn) = 7,486 lbs.; P = 0.4(Pn) = 2,995 lbs. 
               
               
                 Shear Strength (Sn) = 623.9; Shear Stiffness (G′) = 241,328 plf 
               
               
                 Failure: SCP failure on row #2 on the compression side around the screws. Both T&amp;G edges shifted due to screw shear and rotation into the SCP (typically limited to the fasteners at or within 12″ of the T&amp;G). SCP corner break on row #1 on the tension side at the T&amp;G location. Corner Break on all, but two, of row number 2 panels. Row #3 corner break at compression side T and G location. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 39 
               
             
            
               
                   
               
               
                 Test No. 2: Specimen: ¾″ SCP (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws spaced 4″ o.c. 
               
               
                 around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
            
               
                 Load in 
                   
               
            
           
           
               
               
               
            
               
                 Pounds 
                 Deflection in Inches-Indicator Number 
                 Net Shear 
               
            
           
           
               
               
               
               
               
               
            
               
                 (lbf) 
                 1 
                 2 
                 3 
                 4 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 0 
                 .000 
                 .000 
                 .000 
                 .000 
                 0.000 
               
               
                 232 
                 .002 
                 .003 
                 .051 
                 .047 
                 −0.001 
               
               
                 500 
                 .003 
                 .009 
                 .134 
                 .114 
                 0.009 
               
               
                 732 
                 .005 
                 .012 
                 .171 
                 .129 
                 0.027 
               
               
                 991 
                 .006 
                 .015 
                 .187 
                 .132 
                 0.036 
               
               
                 1196 
                 .007 
                 .019 
                 .212 
                 .136 
                 0.051 
               
               
                 1472 
                 .008 
                 .025 
                 .253 
                 .138 
                 0.083 
               
               
                 1722 
                 .009 
                 .032 
                 .284 
                 .142 
                 0.103 
               
               
                 1981 
                 .010 
                 .039 
                 .312 
                 .145 
                 0.119 
               
               
                 2222 
                 .012 
                 .046 
                 .342 
                 .150 
                 0.136 
               
               
                 2480 
                 .013 
                 .053 
                 .370 
                 .153 
                 0.152 
               
               
                 2739 
                 .015 
                 .061 
                 .410 
                 .157 
                 0.179 
               
               
                 2989 
                 .016 
                 .067 
                 .446 
                 .161 
                 0.203 
               
               
                 3167 
                 .016 
                 .073 
                 .469 
                 .163 
                 0.217 
               
               
                 3471 
                 .018 
                 .080 
                 .506 
                 .167 
                 0.242 
               
               
                 3702 
                 .019 
                 .084 
                 .530 
                 .170 
                 0.258 
               
               
                 3988 
                 .021 
                 .090 
                 .572 
                 .175 
                 0.289 
               
               
                 4238 
                 .022 
                 .094 
                 .604 
                 .177 
                 0.312 
               
               
                 4479 
                 .023 
                 .099 
                 .639 
                 .179 
                 0.340 
               
               
                 4684 
                 .024 
                 .103 
                 .668 
                 .182 
                 0.361 
               
               
                 4987 
                 .026 
                 .109 
                 .725 
                 .184 
                 0.407 
               
               
                 5219 
                 .027 
                 .113 
                 .761 
                 .188 
                 0.435 
               
               
                 5478 
                 .028 
                 .118 
                 .812 
                 .191 
                 0.476 
               
               
                 5745 
                 .029 
                 .122 
                 .870 
                 .197 
                 0.523 
               
               
                 5950 
                 .031 
                 .127 
                 .928 
                 .201 
                 0.570 
               
               
                 3,062 (P) 
                 .016 
                 .069 
                 .450 
                 .162 
                 0.204 
               
               
                   
               
               
                 Test Conditions: 67° F.; 45% Relative Humidity 
               
               
                 Diaphragm Width 143 inches; Diaphragm Length 144 inches; Load Time (min:sec): 10:11 
               
               
                 Ultimate Load (Pn) = 7,655 lbs.; P = 0.4(Pn) = 3,062 lbs. 
               
               
                 Shear Strength (Sn) = 637.9; Shear Stiffness (G′) = 178,433 plf 
               
               
                 Failure: SCP failure on row #2 on the compression side around the screws. Both T&amp;G edges shifted due to screw shear and rotation into the SCP (typically limited to the fasteners at or within 12″ of the T&amp;G). SCP corner break on row #1 on the tension side at the T&amp;G location. Corner Break on row #2 and Row #3 at the compression side T&amp;G location. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 40 
               
             
            
               
                   
               
               
                 Test No. 3: Specimen: ¾″ SCP (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws spaced 4″ o.c. 
               
               
                 around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
            
               
                 Load in 
                   
               
            
           
           
               
               
               
            
               
                 Pounds 
                 Deflection in Inches-Indicator Number 
                 Net Shear 
               
            
           
           
               
               
               
               
               
               
            
               
                 (lbf) 
                 1 
                 2 
                 3 
                 4 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 0 
                 .000 
                 .000 
                 .000 
                 .000 
                 .000 
               
               
                 232 
                 .001 
                 .007 
                 .069 
                 .059 
                 .002 
               
               
                 499 
                 .003 
                 .012 
                 .115 
                 .090 
                 .010 
               
               
                 749 
                 .005 
                 .018 
                 .152 
                 .096 
                 .033 
               
               
                 972 
                 .005 
                 .023 
                 .174 
                 .100 
                 .047 
               
               
                 1240 
                 .007 
                 .030 
                 .210 
                 .104 
                 .070 
               
               
                 1489 
                 .009 
                 .038 
                 .238 
                 .106 
                 .086 
               
               
                 1703 
                 .010 
                 .044 
                 .270 
                 .108 
                 .109 
               
               
                 1980 
                 .011 
                 .052 
                 .302 
                 .109 
                 .131 
               
               
                 2194 
                 .012 
                 .058 
                 .331 
                 .111 
                 .151 
               
               
                 2471 
                 .013 
                 .064 
                 .365 
                 .112 
                 .177 
               
               
                 2729 
                 .014 
                 .068 
                 .391 
                 .113 
                 .196 
               
               
                 2979 
                 .016 
                 .074 
                 .425 
                 .114 
                 .223 
               
               
                 3247 
                 .017 
                 .080 
                 .464 
                 .116 
                 .252 
               
               
                 3416 
                 .019 
                 .083 
                 .486 
                 .117 
                 .268 
               
               
                 3737 
                 .020 
                 .089 
                 .531 
                 .119 
                 .303 
               
               
                 3960 
                 .021 
                 .092 
                 .562 
                 .121 
                 .330 
               
               
                 4228 
                 .024 
                 .096 
                 .601 
                 .123 
                 .359 
               
               
                 4442 
                 .025 
                 .100 
                 .628 
                 .127 
                 .378 
               
               
                 4728 
                 .026 
                 .106 
                 .675 
                 .130 
                 .415 
               
               
                 4968 
                 .027 
                 .108 
                 .711 
                 .131 
                 .446 
               
               
                 5236 
                 .029 
                 .111 
                 .773 
                 .137 
                 .497 
               
               
                 5495 
                 .030 
                 .115 
                 .821 
                 .139 
                 .538 
               
               
                 5655 
                 .031 
                 .118 
                 .856 
                 .140 
                 .568 
               
               
                 5932 
                 .033 
                 .119 
                 .902 
                 .143 
                 .608 
               
               
                 3,760 (P) 
                 .020 
                 .089 
                 .531 
                 .119 
                 .303 
               
               
                   
               
               
                 Test Conditions: 67° F.; 45% Relative Humidity 
               
               
                 Diaphragm Width 143 inches; Diaphragm Length 144 inches; Load Time (min:sec): 7:58 
               
               
                 Ultimate Load (Pn) = 9,399 lbs.; P = 0.4(Pn) = 3,760 lbs. 
               
               
                 Shear Strength (Sn) = 783.9; Shear Stiffness (G′) = 147,670 plf 
               
               
                 Failure: SCP failure on row #2 on the compression side around the screws. Both T&amp;G edges shifted due to screw shear and rotation into the SCP (typically limited to the fasteners at or within 12″ of the T&amp;G). SCP corner break on row #1 on the tension side at the T&amp;G location. Butt-Joint separation on row #2 with SCP failure around the fasteners. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 41 
               
             
            
               
                   
               
               
                 Test No. 4: Specimen: ¾″ SCP (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws spaced 6″ o.c. 
               
               
                 around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
            
               
                 Load in 
                   
               
            
           
           
               
               
               
            
               
                 Pounds 
                 Deflection in Inches-Indicator Number 
                 Net Shear 
               
            
           
           
               
               
               
               
               
               
            
               
                 (lbf) 
                 1 
                 2 
                 3 
                 4 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 0 
                 .000 
                 .000 
                 .000 
                 .000 
                 .000 
               
               
                 232 
                 .000 
                 .003 
                 .038 
                 .016 
                 .019 
               
               
                 473 
                 .001 
                 .006 
                 .075 
                 .023 
                 .046 
               
               
                 714 
                 .002 
                 .008 
                 .111 
                 .028 
                 .073 
               
               
                 982 
                 .004 
                 .011 
                 .146 
                 .032 
                 .098 
               
               
                 1231 
                 .005 
                 .015 
                 .174 
                 .036 
                 .118 
               
               
                 1499 
                 .007 
                 .018 
                 .196 
                 .041 
                 .131 
               
               
                 1749 
                 .008 
                 .022 
                 .217 
                 .045 
                 .144 
               
               
                 1981 
                 .009 
                 .025 
                 .234 
                 .050 
                 .151 
               
               
                 2249 
                 .012 
                 .032 
                 .261 
                 .057 
                 .162 
               
               
                 2481 
                 .012 
                 .035 
                 .277 
                 .059 
                 .171 
               
               
                 2668 
                 .013 
                 .040 
                 .294 
                 .064 
                 .177 
               
               
                 2998 
                 .015 
                 .047 
                 .313 
                 .066 
                 .184 
               
               
                 3230 
                 .016 
                 .051 
                 .328 
                 .070 
                 .191 
               
               
                 3498 
                 .017 
                 .056 
                 .348 
                 .070 
                 .205 
               
               
                 3730 
                 .019 
                 .061 
                 .377 
                 .073 
                 .224 
               
               
                 3980 
                 .020 
                 .067 
                 .411 
                 .076 
                 .248 
               
               
                 4229 
                 .022 
                 .072 
                 .444 
                 .079 
                 .272 
               
               
                 4488 
                 .023 
                 .079 
                 .498 
                 .083 
                 .314 
               
               
                 4747 
                 .023 
                 .083 
                 .553 
                 .085 
                 .364 
               
               
                 4997 
                 .025 
                 .088 
                 .617 
                 .088 
                 .417 
               
               
                 5238 
                 .026 
                 .092 
                 .672 
                 .090 
                 .465 
               
               
                 5470 
                 .028 
                 .095 
                 .751 
                 .093 
                 .536 
               
               
                 5720 
                 .029 
                 .100 
                 .858 
                 .097 
                 .633 
               
               
                 5987 
                 .030 
                 .104 
                 .900 
                 .098 
                 .669 
               
               
                 3,355 (P) 
                 .017 
                 .053 
                 .337 
                 .070 
                 .198 
               
               
                   
               
               
                 Test Conditions: 70° F.; 41% Relative Humidity 
               
               
                 Diaphragm Width 143 inches; Diaphragm Length 144 inches; Load Time (min:sec): 7:12 
               
               
                 Ultimate Load (Pn) = 8,387 lbs.; P = 0.4(Pn) = 3,355 lbs. 
               
               
                 Shear Strength (Sn) = 699.0; Shear Stiffness (G′) = 202,407 plf 
               
               
                 Failure: All butt-joints separated with SCP failure around the fasteners. Fastener shear and rotation into the SCP along both T&amp;G edges (typically limited to the fasteners at or within 12″ of the T&amp;G). SCP failure around fasteners on Row #2 at the compression side. SCP corner breaks along both T&amp;G edges. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 42 
               
             
            
               
                   
               
               
                 Test No. 5: Specimen: ¾″ SCP (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws spaced 6″ o.c. 
               
               
                 around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
            
               
                 Load in 
                   
               
            
           
           
               
               
               
            
               
                 Pounds 
                 Deflection in Inches-Indicator Number 
                 Net Shear 
               
            
           
           
               
               
               
               
               
               
            
               
                 (lbf) 
                 1 
                 2 
                 3 
                 4 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 0 
                 .000 
                 .000 
                 .000 
                 .000 
                 .000 
               
               
                 249 
                 .001 
                 .001 
                 .016 
                 .001 
                 .013 
               
               
                 490 
                 .001 
                 .001 
                 .039 
                 .005 
                 .032 
               
               
                 748 
                 .002 
                 .000 
                 .067 
                 .011 
                 .054 
               
               
                 980 
                 .004 
                 .000 
                 .093 
                 .016 
                 .073 
               
               
                 1239 
                 .006 
                 .000 
                 .127 
                 .023 
                 .098 
               
               
                 1471 
                 .008 
                 .000 
                 .148 
                 .028 
                 .113 
               
               
                 1721 
                 .009 
                 .000 
                 .173 
                 .032 
                 .134 
               
               
                 1997 
                 .011 
                 −.001 
                 .212 
                 .036 
                 .167 
               
               
                 2184 
                 .012 
                 −.001 
                 .250 
                 .042 
                 .199 
               
               
                 2416 
                 .012 
                 −.001 
                 .278 
                 .044 
                 .225 
               
               
                 2746 
                 .014 
                 −.001 
                 .336 
                 .047 
                 .276 
               
               
                 2961 
                 .015 
                 −.002 
                 .378 
                 .049 
                 .316 
               
               
                 3237 
                 .015 
                 −.002 
                 .420 
                 .052 
                 .354 
               
               
                 3487 
                 .017 
                 −.002 
                 .463 
                 .056 
                 .391 
               
               
                 3746 
                 .019 
                 −.003 
                 .508 
                 .060 
                 .433 
               
               
                 3978 
                 .021 
                 −.004 
                 .553 
                 .063 
                 .474 
               
               
                 4209 
                 .022 
                 −.004 
                 .587 
                 .065 
                 .505 
               
               
                 4477 
                 .022 
                 −.004 
                 .640 
                 .070 
                 .553 
               
               
                 4718 
                 .025 
                 −.005 
                 .681 
                 .072 
                 .590 
               
               
                 4977 
                 .026 
                 .001 
                 .767 
                 .078 
                 .622 
               
               
                 5209 
                 .027 
                 .007 
                 .850 
                 .081 
                 .736 
               
               
                 5494 
                 .029 
                 .012 
                 .928 
                 .084 
                 .804 
               
               
                 2,615 (P) 
                 .013 
                 −.001 
                 .314 
                 .045 
                 .256 
               
               
                   
               
               
                 Test Conditions: 70° F.; 38% Relative Humidity 
               
               
                 Diaphragm Width 143 inches; Diaphragm Length 144 inches; Load Time (min:sec): 5:28 
               
               
                 Ultimate Load (Pn) = 6,538 lbs.; P = 0.4(Pn) = 2,615 lbs. 
               
               
                 Shear Strength (Sn) = 544.8 plf; Shear Stiffness (G′) = 121,526 plf 
               
               
                 Failure: Row #3 butt-joint separation with SCP failure around the fasteners. Fastener shear and rotation into the SCP along Row #1-2 T&amp;G edge (typically limited to the fasteners at or within 12″ of the T&amp;G). SCP failure around fasteners on Row #2 at the compression side. SCP corner breaks along both T&amp;G edges. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 43 
               
             
            
               
                   
               
               
                 Test No. 6 Specimen: ¾″ SCP (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws spaced 6″ o.c. 
               
               
                 around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
            
               
                 Load in 
                   
               
            
           
           
               
               
               
            
               
                 Pounds 
                 Deflection in Inches-Indicator Number 
                 Net Shear 
               
            
           
           
               
               
               
               
               
               
            
               
                 (lbf) 
                 1 
                 2 
                 3 
                 4 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 0 
                 .000 
                 .000 
                 .000 
                 .000 
                 .000 
               
               
                 223 
                 .001 
                 .003 
                 .023 
                 .011 
                 .008 
               
               
                 482 
                 .003 
                 .011 
                 .066 
                 .011 
                 .042 
               
               
                 749 
                 .003 
                 .020 
                 .099 
                 .011 
                 .066 
               
               
                 999 
                 .004 
                 .027 
                 .135 
                 .011 
                 .094 
               
               
                 1240 
                 .005 
                 .037 
                 .180 
                 .011 
                 .128 
               
               
                 1499 
                 .007 
                 .045 
                 .220 
                 .011 
                 .157 
               
               
                 1749 
                 .009 
                 .053 
                 .263 
                 .011 
                 .190 
               
               
                 1972 
                 .010 
                 .062 
                 .298 
                 .011 
                 .216 
               
               
                 2239 
                 .012 
                 .072 
                 .339 
                 .011 
                 .244 
               
               
                 2480 
                 .013 
                 .079 
                 .375 
                 .011 
                 .272 
               
               
                 2748 
                 .014 
                 .087 
                 .411 
                 .011 
                 .299 
               
               
                 2988 
                 .017 
                 .096 
                 .453 
                 .011 
                 .330 
               
               
                 3203 
                 .018 
                 .103 
                 .489 
                 .011 
                 .357 
               
               
                 3479 
                 .019 
                 .111 
                 .532 
                 .011 
                 .391 
               
               
                 3702 
                 .021 
                 .117 
                 .563 
                 .011 
                 .414 
               
               
                 3997 
                 .022 
                 .125 
                 .608 
                 .011 
                 .451 
               
               
                 4237 
                 .023 
                 .131 
                 .650 
                 .011 
                 .486 
               
               
                 4469 
                 .025 
                 .135 
                 .685 
                 .011 
                 .514 
               
               
                 4701 
                 .026 
                 .142 
                 .724 
                 .011 
                 .546 
               
               
                 4951 
                 .027 
                 .148 
                 .778 
                 .011 
                 .593 
               
               
                 5236 
                 .029 
                 .154 
                 .837 
                 .011 
                 .643 
               
               
                 5477 
                 .030 
                 .158 
                 .885 
                 .011 
                 .687 
               
               
                 5700 
                 .032 
                 .164 
                 .941 
                 .011 
                 .735 
               
               
                 5941 
                 .033 
                 .167 
                 .985 
                 .011 
                 .775 
               
               
                 3,415 (P) 
                 .019 
                 .108 
                 .515 
                 .011 
                 .378 
               
               
                   
               
               
                 Test Conditions: 70° F.; 38% Relative Humidity 
               
               
                 Diaphragm Width 143 inches; Diaphragm Length 144 inches; Load Time (min:sec): 6:02 
               
               
                 Ultimate Load (Pn) = 8,537 lbs.; P = 0.4(Pn) = 3,415 lbs. 
               
               
                 Shear Strength (Sn) = 711.4 plf; Shear Stiffness (G′) = 107,653 plf 
               
               
                 Failure: Row #2&amp;3 butt-joint separation with SCP failure around the fasteners. Fastener shear and rotation into the SCP along Row #2-3 T&amp;G edge 8′ in from compression and the remaining 4′ shifted along Row #1-2 T&amp;G edge (typically limited to the fasteners at or within 12″ of the T&amp;G). SCP failure around fasteners on Row #2&amp;3 at the compression side. SCP corner breaks along both T&amp;G edges. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 44 
               
             
            
               
                   
               
               
                 Test No. 7: Specimen: ¾″ SCP (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws spaced 4″ o.c. 
               
               
                 around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
            
               
                 Load in 
                   
               
            
           
           
               
               
               
            
               
                 Pounds 
                 Deflection in Inches-Indicator Number 
                 Net Shear 
               
            
           
           
               
               
               
               
               
               
            
               
                 (lbf) 
                 1 
                 2 
                 3 
                 4 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 0 
                 .000 
                 .000 
                 .000 
                 .000 
                 .000 
               
               
                 446 
                 .000 
                 .004 
                 .028 
                 .010 
                 .014 
               
               
                 981 
                 −.001 
                 .008 
                 .049 
                 .016 
                 .026 
               
               
                 1472 
                 −.002 
                 .014 
                 .068 
                 .019 
                 .037 
               
               
                 1980 
                 −.004 
                 .019 
                 .086 
                 .022 
                 .049 
               
               
                 2480 
                 −.002 
                 .025 
                 .103 
                 .024 
                 .057 
               
               
                 2962 
                 −.001 
                 .028 
                 .119 
                 .027 
                 .065 
               
               
                 3497 
                 .001 
                 .032 
                 .169 
                 .030 
                 .106 
               
               
                 3987 
                 .004 
                 .040 
                 .178 
                 .035 
                 .100 
               
               
                 4478 
                 .005 
                 .046 
                 .196 
                 .040 
                 .105 
               
               
                 4978 
                 .008 
                 .052 
                 .226 
                 .046 
                 .119 
               
               
                 5459 
                 .011 
                 .060 
                 .259 
                 .052 
                 .137 
               
               
                 5995 
                 .013 
                 .066 
                 .276 
                 .056 
                 .141 
               
               
                 6414 
                 .015 
                 .071 
                 .314 
                 .063 
                 .165 
               
               
                 6985 
                 .018 
                 .077 
                 .322 
                 .070 
                 .158 
               
               
                 7466 
                 .021 
                 .083 
                 .342 
                 .076 
                 .163 
               
               
                 7957 
                 .025 
                 .088 
                 .383 
                 .085 
                 .187 
               
               
                 8483 
                 .027 
                 .094 
                 .403 
                 .093 
                 .190 
               
               
                 8956 
                 .040 
                 .109 
                 .506 
                 .172 
                 .186 
               
               
                 9483 
                 .044 
                 .113 
                 .544 
                 .185 
                 .204 
               
               
                 9920 
                 .053 
                 .158 
                 .597 
                 .185 
                 .203 
               
               
                 10401 
                 .057 
                 .160 
                 .623 
                 .185 
                 .224 
               
               
                 10919 
                 .063 
                 .164 
                 .702 
                 .185 
                 .293 
               
               
                 11400 
                 .068 
                 .169 
                 .734 
                 .185 
                 .314 
               
               
                 11909 
                 .073 
                 .172 
                 .774 
                 .185 
                 .346 
               
               
                 9,053 (P) 
                 .040 
                 .109 
                 .507 
                 .174 
                 .185 
               
               
                   
               
               
                 Test Conditions: 69° F.; 44% Relative Humidity 
               
               
                 Diaphragm Width 143 inches; Diaphragm Length 144 inches; Load Time (min:sec): 10:14 
               
               
                 Ultimate Load (Pn) = 22,631 lbs.; P = 0.4(Pn) = 9,053 lbs. 
               
               
                 Shear Strength (Sn) = 1,886.0 plf; Shear Stiffness (G′) = 581,716 plf 
               
               
                 Failure: Adhesion failure to SCP along bearing side of the floor (Row #3) near the tension side. Fastener pull-through along the same edge. The tension joist was severely deformed around the Simpson Strong-Tie connection. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 45 
               
             
            
               
                   
               
               
                 Test No. 8: Specimen: ¾″ SCP (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws spaced 6″ o.c. 
               
               
                 around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
            
               
                 Load in 
                   
               
            
           
           
               
               
               
            
               
                 Pounds 
                 Deflection in Inches-Indicator Number 
                 Net Shear 
               
            
           
           
               
               
               
               
               
               
            
               
                 (lbf) 
                 1 
                 2 
                 3 
                 4 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 0 
                 .000 
                 .000 
                 .000 
                 .000 
                 .000 
               
               
                 421 
                 .010 
                 .013 
                 .074 
                 .008 
                 .043 
               
               
                 992 
                 .016 
                 .025 
                 .118 
                 .020 
                 .057 
               
               
                 1483 
                 .024 
                 .040 
                 .156 
                 .024 
                 .068 
               
               
                 1964 
                 .029 
                 .054 
                 .179 
                 .023 
                 .073 
               
               
                 2446 
                 .033 
                 .064 
                 .192 
                 .021 
                 .074 
               
               
                 2892 
                 .038 
                 .074 
                 .205 
                 .020 
                 .073 
               
               
                 3463 
                 .042 
                 .085 
                 .220 
                 .019 
                 .074 
               
               
                 3963 
                 .046 
                 .092 
                 .232 
                 .019 
                 .075 
               
               
                 4444 
                 .050 
                 .101 
                 .251 
                 .019 
                 .080 
               
               
                 4962 
                 .056 
                 .111 
                 .269 
                 .020 
                 .083 
               
               
                 5452 
                 .061 
                 .121 
                 .286 
                 .020 
                 .085 
               
               
                 5916 
                 .067 
                 .130 
                 .310 
                 .021 
                 .093 
               
               
                 6478 
                 .072 
                 .141 
                 .333 
                 .021 
                 .099 
               
               
                 6978 
                 .076 
                 .149 
                 .350 
                 .021 
                 .104 
               
               
                 7477 
                 .081 
                 .157 
                 .371 
                 .021 
                 .113 
               
               
                 7879 
                 .085 
                 .164 
                 .386 
                 .021 
                 .116 
               
               
                 8485 
                 .091 
                 .173 
                 .411 
                 .021 
                 .126 
               
               
                 8985 
                 .095 
                 .181 
                 .429 
                 .021 
                 .133 
               
               
                 9413 
                 .100 
                 .191 
                 .447 
                 .021 
                 .135 
               
               
                 9913 
                 .106 
                 .201 
                 .472 
                 .021 
                 .146 
               
               
                 10394 
                 .111 
                 .210 
                 .496 
                 .021 
                 .155 
               
               
                 10903 
                 .115 
                 .218 
                 .519 
                 .021 
                 .166 
               
               
                 11438 
                 .119 
                 .227 
                 .544 
                 .021 
                 .178 
               
               
                 11946 
                 .126 
                 .242 
                 .578 
                 .021 
                 .191 
               
               
                 7,740 (P) 
                 .084 
                 .161 
                 .380 
                 .021 
                 .115 
               
               
                   
               
               
                 Test Conditions: 73° F.; 45% Relative Humidity 
               
               
                 Diaphragm Width 143 inches; Diaphragm Length 144 inches; Load Time (min:sec): 5:45 
               
               
                 Ultimate Load (Pn) = 19,351 lbs.; P = 0.4(Pn) = 7,740 lbs. 
               
               
                 Shear Strength (Sn) = 1,612.5 plf; Shear Stiffness (G′) = 803,716 plf 
               
               
                 Failure: Adhesion failure to SCP along bearing side of the floor (Row #3) near the tension side. Fastener pull-through and SCP failure around the fasteners along the same edge. The tension joist was severely deformed around the Simpson Strong-Tie connection. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 46 
               
             
            
               
                   
               
               
                 Test No. 9: Specimen: ¾″ SCP (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws spaced 12″ o.c. 
               
               
                 around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
            
               
                 Load in 
                   
               
            
           
           
               
               
               
            
               
                 Pounds 
                 Deflection in Inches-Indicator Number 
                 Net Shear 
               
            
           
           
               
               
               
               
               
               
            
               
                 (lbf) 
                 1 
                 2 
                 3 
                 4 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 0 
                 .000 
                 .000 
                 .000 
                 .000 
                 .000 
               
               
                 170 
                 .002 
                 .002 
                 .035 
                 −.002 
                 .033 
               
               
                 455 
                 .007 
                 .006 
                 .068 
                 −.008 
                 .063 
               
               
                 750 
                 .013 
                 .009 
                 .084 
                 −.011 
                 .074 
               
               
                 901 
                 .017 
                 .015 
                 .097 
                 −.013 
                 .078 
               
               
                 1214 
                 .024 
                 .022 
                 .116 
                 −.017 
                 .086 
               
               
                 1499 
                 .035 
                 .032 
                 .145 
                 −.021 
                 .099 
               
               
                 1722 
                 .041 
                 .038 
                 .166 
                 −.023 
                 .109 
               
               
                 1972 
                 .051 
                 .050 
                 .191 
                 −.024 
                 .115 
               
               
                 2159 
                 .056 
                 .056 
                 .209 
                 −.023 
                 .119 
               
               
                 2471 
                 .065 
                 .065 
                 .231 
                 −.020 
                 .121 
               
               
                 2685 
                 .071 
                 .071 
                 .248 
                 −.018 
                 .123 
               
               
                 2953 
                 .077 
                 .081 
                 .267 
                 −.014 
                 .124 
               
               
                 3212 
                 .081 
                 .087 
                 .286 
                 −.010 
                 .129 
               
               
                 3497 
                 .084 
                 .093 
                 .298 
                 −.008 
                 .130 
               
               
                 3729 
                 .088 
                 .099 
                 .317 
                 −.003 
                 .134 
               
               
                 3934 
                 .090 
                 .105 
                 .330 
                 .000 
                 .135 
               
               
                 4113 
                 .091 
                 .109 
                 .337 
                 .002 
                 .136 
               
               
                 4416 
                 .095 
                 .117 
                 .361 
                 .009 
                 .142 
               
               
                 4719 
                 .098 
                 .124 
                 .380 
                 .014 
                 .145 
               
               
                 4925 
                 .100 
                 .129 
                 .393 
                 .018 
                 .147 
               
               
                 5246 
                 .103 
                 .136 
                 .409 
                 .024 
                 .147 
               
               
                 5495 
                 .106 
                 .145 
                 .425 
                 .031 
                 .145 
               
               
                 5736 
                 .110 
                 .150 
                 .460 
                 .036 
                 .165 
               
               
                 5995 
                 .113 
                 .156 
                 .477 
                 .041 
                 .169 
               
               
                 6,369 (P) 
                 .116 
                 .161 
                 .496 
                 .045 
                 .176 
               
               
                   
               
               
                 Test Conditions: 73° F.; 45% Relative Humidity 
               
               
                 Diaphragm Width 143 inches; Diaphragm Length 144 inches; Load Time (min:sec): 4:19 
               
               
                 Ultimate Load (Pn) = 15,924 lbs.; P = 0.4(Pn) = 6,369 lbs. 
               
               
                 Shear Strength (Sn) = 1,327.0 plf; Shear Stiffness (G′) = 432,444 plf 
               
               
                 Failure: Adhesion failure to SCP along bearing side of the floor (Row #3). Fastener pull-through and shear along the same edge. The tension joist was severely deformed around the Simpson Strong-Tie connection. The fastener shear near the compression side of the floor. 
               
            
           
         
       
     
     
       
         
           
               
             
               
                 TABLE 47 
               
             
            
               
                   
               
               
                 Test No. 10 Specimen: ¾″ Plywood (T&amp;G) fastened to 16 ga. Steel 
               
               
                 Joists, set 24″ o.c., with #8 × 1⅝″ screws spaced 6″ o.c. 
               
               
                 around the perimeter and 12″ o.c. in the field. 
               
            
           
           
               
               
               
            
               
                 Load in 
                   
                   
               
               
                 Pounds 
                 Deflection in Inches-Indicator Number 
                 Net Shear 
               
            
           
           
               
               
               
               
               
               
            
               
                 (lbf) 
                 1 
                 2 
                 3 
                 4 
                 Deflection 
               
               
                   
               
            
           
           
               
               
               
               
               
               
            
               
                 0 
                 .000 
                 .000 
                 .000 
                 .000 
                 .000 
               
               
                 223 
                 .008 
                 −.003 
                 .058 
                 .061 
                 −.008 
               
               
                 491 
                 .010 
                 .003 
                 .109 
                 .081 
                 .016 
               
               
                 723 
                 .011 
                 .007 
                 .152 
                 .083 
                 .051 
               
               
                 973 
                 .012 
                 .013 
                 .219 
                 .087 
                 .107 
               
               
                 1222 
                 .013 
                 .017 
                 .276 
                 .089 
                 .158 
               
               
                 1481 
                 .015 
                 .023 
                 .335 
                 .092 
                 .206 
               
               
                 1722 
                 .016 
                 .027 
                 .392 
                 .095 
                 .255 
               
               
                 1990 
                 .018 
                 .034 
                 .455 
                 .098 
                 .307 
               
               
                 2231 
                 .020 
                 .039 
                 .498 
                 .100 
                 .340 
               
               
                 2489 
                 .021 
                 .046 
                 .552 
                 .104 
                 .383 
               
               
                 2713 
                 .023 
                 .052 
                 .593 
                 .106 
                 .413 
               
               
                 2971 
                 .025 
                 .058 
                 .634 
                 .110 
                 .442 
               
               
                 3203 
                 .026 
                 .063 
                 .669 
                 .112 
                 .470 
               
               
                 3498 
                 .027 
                 .069 
                 .709 
                 .115 
                 .498 
               
               
                 3748 
                 .028 
                 .074 
                 .737 
                 .117 
                 .519 
               
               
                 3971 
                 .030 
                 .079 
                 .769 
                 .120 
                 .542 
               
               
                 4238 
                 .031 
                 .086 
                 .810 
                 .124 
                 .569 
               
               
                 4444 
                 .033 
                 .091 
                 .836 
                 .127 
                 .586 
               
               
                 4658 
                 .033 
                 .095 
                 .860 
                 .130 
                 .602 
               
               
                 4988 
                 .035 
                 .102 
                 .903 
                 .134 
                 .633 
               
               
                 5220 
                 .035 
                 .107 
                 .933 
                 .137 
                 .655 
               
               
                 5479 
                 .038 
                 .112 
                 .971 
                 .139 
                 .683 
               
               
                 5711 
                 .038 
                 .116 
                 1.018 
                 .143 
                 .722 
               
               
                 5960 
                 .039 
                 .121 
                 1.156 
                 .146 
                 .850 
               
               
                 2,534 (P) 
                 .021 
                 .046 
                 .552 
                 .104 
                 .383 
               
               
                   
               
               
                 Test Conditions: 68° F.; 43% Relative Humidity 
               
               
                 Diaphragm Width 143 inches; Diaphragm Length 144 inches; Load Time (min:sec): 6:43 
               
               
                 Ultimate Load (Pn) = 6,335 lbs.; P = 0.4(Pn) = 2,534 lbs. 
               
               
                 Shear Strength (Sn) = 527.9 plf; Shear Stiffness (G′) = 78,880 plf 
               
               
                 Failure: Fastener shear and rotation into the Plywood along Row #1-2 T&amp;G edge, on row #2 side 6 feet in from compression and the remaining 6 feet shifted on Row #1 T&amp;G edge (typically limited to the fasteners at or within 12″ of the T&amp;G). Plywood failure around fasteners on Row #2 at the compression side. 
               
            
           
         
       
     
     While a particular embodiment of the foundation system employing a diaphragm of fiber-reinforced structural cement panels on a metal frame has been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.