BUILDING WITH NONCOMBUSTIBLE EXTERIOR STRUCTURAL WALL

Abstract

A noncombustible exterior structural wall of a building, where the noncombustible wall includes a steel frame with a plurality of vertically oriented support studs, a plurality of noncombustible panels attached directly to the steel frame, and an exterior ornamental covering attached directly to the plurality of noncombustible panels with an absence of an air/weather membrane.

Claims

1. A noncombustible exterior structural wall of a building, the noncombustible wall comprising: a steel frame comprising a plurality of vertically oriented support studs; a plurality of noncombustible panels attached directly to said steel frame; and an exterior ornamental covering attached directly to said plurality of noncombustible panels with an absence of an air/weather membrane.

2. The noncombustible exterior structural wall of claim 1, wherein said noncombustible panels are noncombustible fiber-cement-panels.

3. The noncombustible exterior structural wall of claim 2, wherein said noncombustible fiber-cement-panels comprise at least one of Portland cement and Magnesium Oxide cement with glass-fiber reinforcing.

4. The noncombustible exterior structural wall of claim 1, wherein said noncombustible panels are resin or polymer-based reinforced panels.

5. The noncombustible exterior structural wall of claim 1, further comprising an insulating material between said vertically oriented support studs or continuously around an exterior of the building.

6. The noncombustible exterior structural wall of claim 1, wherein said noncombustible panels resist lateral loads applied to said noncombustible exterior structural wall.

7. The noncombustible exterior structural wall of claim 1, wherein said noncombustible panels have a thickness of approximately ½ inches.

8. A building, comprising: a plurality of noncombustible exterior structural walls, comprising: a steel frame comprising a plurality of vertically oriented support studs; a plurality of noncombustible panels attached directly to said steel frame; and an exterior ornamental covering attached directly to said plurality of noncombustible panels with an absence of an air/weather membrane.

9. The building of claim 8, wherein said noncombustible panels are noncombustible fiber-cement-panels.

10. The building of claim 8, wherein said noncombustible fiber-cement-panels comprise at least one of Portland cement and Magnesium Oxide cement with glass-fiber reinforcing.

12. The building of claim 8, wherein said noncombustible panels are resin or polymer-based reinforced panels.

13. The building of claim 8, further comprising an insulating material between said vertically oriented support studs or continuously around an exterior of the building.

14. The building of claim 8, wherein said noncombustible panels resist lateral loads applied to said noncombustible exterior structural wall.

15. The building of claim 8, wherein said noncombustible panels have a thickness of approximately ½ inches.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a top fragmentary perspective view of the present building with noncombustible exterior structural walls; and

[0015] FIG. 2 is an enlarged fragmentary perspective view of the present building with noncombustible exterior structural walls.

DETAILED DESCRIPTION

[0016] Referring now to FIGS. 1 and 2, the present building with noncombustible exterior structural walls is generally designated 10 and includes a plurality of noncombustible exterior structural walls 12. Each of the noncombustible exterior structural walls 12 includes a steel frame 14, with a plurality of vertically oriented support studs 16. The support studs 16 are secured to upper and lower horizontal frame members using fasteners as is known in the art. In a preferred embodiment, the vertically oriented support studs 16 are spaced an equal distance apart. Preferably, an insulating material 18 is provided between the vertically oriented support studs 16 or continuously around the exterior of the building. One example of the latter is an incorporation of the insulating material 18 into an external ornamental covering (described below).

[0017] Example insulating materials 18 include, but are not limited to, fiberglass, cellulose, foam, mineral wool, polystyrene, polyisocyanurate, polyurethane, and natural fibers as is known in the art. Moreover, the insulating material 18 is optionally provided in the form of loose-fill, batts, rolls, foam board, and spray foam.

[0018] Additionally, noncombustible panels 20 are attached to the vertically oriented studs 16 by way of mechanical fasteners, adhesive, or other attachment method as is known in the art. In a preferred embodiment, the noncombustible panels 20 are attached directly to the vertically oriented studs 16. Preferably, the noncombustible panels 20 are fiberglass-impregnated cement board panels.

[0019] Various types of cement panels are optionally used as the noncombustible panels 20. For example, U.S. Pat. No. 8,038,790 to Dubey et al., incorporated herein by reference, discloses cement panels able to resist lateral forces imposed by high wind and earthquake. The principal starting materials used to make the cement panels are inorganic binder, e.g., calcium sulfate alpha hemihydrate, hydraulic cement, and pozzolanic materials, lightweight filler coated expanded perlite and optional additional, ceramic microspheres or glass microspheres, as well as superplasticizer, e.g., polynapthalene sulphonates and/or polyacrylates, water, and optional additives.

[0020] Moreover, U.S. Pat. No. 8,030,377 to Dubey et al., incorporated herein by reference, discloses a self-leveling cementitious mixture with excellent flow properties and which hardens with a controlled rate of strength development to an ultra-high compressive strength composite composition for use in making articles such as cementitious armor panel with ballistic and blast resistant properties. Such panels are also considered suitable for the noncombustible panels 20.

[0021] Further, U.S. Pat. No. 6,620,487 to Tonyan et al., incorporated herein by reference, discloses a reinforced, lightweight, dimensionally stable panel capable of resisting shear loads when fastened to framing equal to or exceeding shear loads provided by plywood or oriented strand board panels. It is contemplated that the noncombustible panels 20 optionally include cement panels made according to each of the preceding patents incorporated by reference.

[0022] It is also contemplated that the noncombustible panels 20 are fiber-cement-panels which include at least one of Portland cement and Magnesium Oxide cement with glass-fiber reinforcing. Alternatively, the noncombustible panels 20 are resin or polymer-based reinforced panels.

[0023] Various methods are optionally employed to make the noncombustible panels 20. For example, U.S. Pat. No. 7,670,520 to Dubey et al., incorporated by reference, discloses a process for producing fiber-reinforced structural cementitious panels made of at least one layer of fiber reinforced cementitious slurry, the process for each such layer of slurry including providing a moving web; depositing a first layer of individual, loose fibers upon the web; depositing a layer of settable slurry upon the deposited first layer of individual, loose fibers; depositing a second layer of individual, loose fibers upon the deposited layer of settable slurry; and actively embedding both layers of individual, loose fibers into the layer of slurry to distribute the fibers throughout the slurry.

[0024] Preferably, the noncombustible panels 20 resist lateral loads applied to the noncombustible exterior structural wall 12, and function as shear walls. In this way, the noncombustible exterior structural walls 12 do not require an additional shear wall. Moreover, the noncombustible panels 20 preferably have a thickness of approximately % inches or less.

[0025] An exemplary structural panel 20 at ½ inch thick has a shear wall capacity in excess of 1900 PLF (pounds per linear foot). Slightly thinner 7/16 inch panels 20 made of Oriented Strandboard (OSB) have shear wall capacity of between 458 and 1017 PLF depending on screw spacing. Vapor permeability of such panels 20 is approximately 2.84 permeability for ½ inch thick panel and 1.4 permeability for ¾ inch panels.

[0026] Permeability is classified as: <0.1 is impermeable; 0.1<x<1 is Class II semi-impermeable; and 1<x<10 is Class III permeable, which is still considered semi-permeable. Accordingly, the panels 20 are Class III are a suitable air and water barrier. Joints/seams and screw heads are taped or caulked. Nominal uniform load capacity on a face of the panel 20, representing wind resistance with a stud spacing of 24 inches is 270 lb. Concentrated load capacity of the panel 20 is 764 lb. when the panel is dry.

[0027] In view of the above data, an important feature of the noncombustible panels 20 is their low water and vapor permeability. In particular, the noncombustible panels 20 act as a water, water-vapor and air barrier for the building 10. Accordingly, a feature of the building 10 is that it does not require application of a liquid applied exterior membrane (sprayed or rolled on over the entire exterior surface of the building) or a sheet membrane product (such as TYVEK®). In other words, the building 10 does not require an air/weather membrane. Rather, use of either caulk or tape on the joints or seams 22 as well as screw heads of the noncombustible panels 20 is sufficient to seal the building 10 as required by local building ordinances.

[0028] As a result of not needing the liquid applied exterior membrane or sheet membrane product, an ornamental covering 24 of the building 10 is preferably applied directly to the noncombustible panels 20. Suitable attachment methods, such as with adhesive or mechanical fasteners, are appropriate for directly attaching the ornamental covering 24 to the noncombustible panels 20 as is known in the art.

[0029] Further, the noncombustible panels 20 are noncombustible according to International Building Code (IBC) as the noncombustible panels 20 pass an un-modified ASTM E136 test for noncombustibility (per the IBC). Additionally, the noncombustible panels 20 resist lateral forces applied to the building 10, such that the noncombustible panels 20 act as an exterior shear wall for the building 10.

[0030] While a particular embodiment of the present building with noncombustible exterior structural walls has been described herein, 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.