Note: Descriptions are shown in the official language in which they were submitted.
SHAFT WALL AND HORIZONTAL METAL ~TU~ THEREFOR
This invention relates to sheet metal studs for
supporting gypsum wallboard and to improved fire-resis-
tant hollow shaft walls.
BACKGROUND OF THE INVENTION
Several patents have disclosed hollow shaft
walls employing metal studs and gypsum wallboards; for
example, U.~. Patent Nos. 3,740,912 and 4,353,192. These
prior patents all employ metal studs between adjacent
gypsum core boards, which metal studs are vertical studs.
These prior patents also have one-inch-thick core boards
which have square edges abutting the webs of the vertical
studs. The core boards commonly employed in these
syste~s sometimes include slightly bevelled edges,
strictly for ease of insertion into the channels formed
between ~langes and tabs.
These prior structures have enjoyed consider-
able commercial success; however, a shaft wall which can
be more easily installed at lower cost and have improved
performance is clearly desirable. These prior structures
also required the studs to have greater flange-to-flange
dimensions as walls were made progressively higher,
resulting in increased steel usage and an increase in
cost and labor.
SUMMARY OF THE INVENTION
In the present invention~ novel sheet metal
studs are placed horizontally between adjacent, horizon-
tally extending gypsum core boards~ typically in the four
walls surrounding an elevator shaft and stairwells, and
.
in area separation walls and the like. The metal studs
include, essentially, an inner flange, an outer flange
and an adjoining web with a core board abutting each side
of the web. At least a narrow portion of the web which
is closely adjacent the inner flange is in a plane which
forms an acute angle with the inner flanqe creating a
channel-like means for holding an edge of one of the two
core boards against the inner ~lange. The web also
includes means for holding an edge of the second core
board aqainst the inner flange, on the opposite side of
the web.
Two-foot wide and up to ten-foot long,
one-inch-thick gypsum core boards are disposed, with
their widths extending vertically and their lengths
extending horizontally, between the horizontally extend-
ing studs, said boards having bevelled lateral edges
which abut the acutely angled webs of the studs.
The typical long side of a shaft enclosure is
ten-feet long and consists essentially of alternating
ten-foot long, horizontally extending core boards and
ten-foot long, hori~ontally extending metal studs. The
ends of the metal studs and the core boards are disposed
within a channel in a suitable vertically extending
corner stud or the like. Two layers of standard or
special fire-retardant~ typically 4-foot wide gypsum
wallboard (referred to herein as wide wallboard) are
screw attached to the outer f langes of the metal studs.
The corner stud has two outwardly opening
channels directed at right angles, and the core boards
~0
~&~>~s~
and horizontal studs of two perpendicular walls ext~nd
into the two respective channels.
It is an object of the present invention to
provide a novel hori~ontal stud and a novel and improved
wall construction utilizing such horizontal studs.
It is a further object of the invention to
provide an improved, more economical shaft wall, suitable
for erection from one side.
It is a still further object of the invention
to provide a method of erecting walls which result in
improved walls at a reduced cost.
It is a still further object of the invention
to provide a method of erecting shaft walls which
inherently includes the initial construction of a rela-
tively low safety wall around the shaft opening that also
provides ready access to the shaft for the installation
o~ cants and the like.
It is a still ~urther object of the invention
to provide a sha~t wall which is not substantially
weakened by omission or removal of a narrow top portion
for the installation of elevator rail supports/brackets.
It is still a further object of the invention
to provide a shaft wall system that requires th~ stocking
of fewer components for typical shaft wall installations.
. .
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages oE the
invention will be more readi'ly apparent when considered
in relation to the preferre,d embodiments as set forth in
the specification and shown in the drawings in which:
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~ ~ $ ~
Fig. 1 is a perspective view o~ a portion of
two perpendicular walls of an elevator shaft enclosure,
constructed in accordance with the inventîon.
~ Fig. 2 is a cross-sectional plan view of the
wall corner, taken on line 2-2 o~ Fig. 1.
Fig. 3 is a cross-sectional end view of the
left wall of Fig. 1.
Fig. 4 is an isometric view of a horizontal
stud of the walls of Fig. 1.
Fig. 5 is a cross-sectional end view of a
modified wall embodying the invention.
Fig. 6 is an isometric view of an extra-long
wall embodying the invention. '
Fig. 7 is an end view of a double-width board
for forming two core boards.
Fig. 8 is an end view of a double-width board
for forming two modified core boards.
Figs. 9-12 are isometric views of four modified
horizontal studs wlth core boards in place, all in
2n accordance with the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Re~erring to Fig. 1, there is shown part of a
side wall 10 and part of a front wall 12 o~ a hollow
shaft wall structure 14 surrounding an elevator shaft 16.
Elevator shaft 16 extends verticallv through a plurality
of floor-ceillng platforms~ including the lower platform
18 and the upper plat~orm 20 of Fig. 1. The shaft wall
structure 14 extends vertically from the lower platform
18 to the upper platform 20 along the edges 22 of these
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floor-ceiling platforms which surround and form the
elevator shaft 16.
Side wall 10 consists of standard upwardly
opening, channel-shaped floor track 24 (Fig. 3), having
a horizontal we~ 26 and two vertical flanges 28, 30, a
downwa~dly opening, channel shaped, ceilin~ track 32,
having a horizontal web 34 and two vertical flanges 36,
38. Floor track 24 is mechanically a~fixed to t.he top of
lower platform 18 and ceilinq track 32 is mechanically
affixed to the bottom of upper platfGrm 20~ each adiacent
the edges 22 of these floor-ceiling plat~orms. Ceiling
track 32 preferably has a pluralit~ of spaced-apart vent
openinqs 39 alony the top edge of flange 38, to improve
the wall fire-resistance. Ceiling track 32 can also be
used as a floor track.
At the corner of side wall 10 and front wall
12, as seen in Figs. l and 2, a vertical corner post ~0
is mounted with a bottom end ~2 disposed in a floor track
24 and a top end 44 disposed in a ceiling track 32, where
the two floor tracks 24 and the two ceiling tracks 32
meet to form a 90~ corner 46 between side wall 10 and
fxont wall 12. The corner post 40, which could be made
by affixing two channels together back-to-side, is
preferably a sin~le, elongate~ roll-formed sheet of metal
having two outwardly opening channels 48, 50 fo~med of a
single piece of 0.020-inch-thick steel, with the two
channels 48 and 50 opening outwardly in directions at a
90~ angle ta one another and being directed toward,
respectively, the side wall 10 and the front wall l?.
.
Considering the side wall 10, Fig. 3 shows the
arrangement of core boards 52, horizontal studs 54, and
outwardly disposed gypsum wide wallboards 56, 58, which
combin~e to form the side wall 10.
Typically the core boards 52 are paper-covered
gypsum boards which are, in cross section, 2 feet by l
inch, and will normally have a length equal to the extent
of the wall 10. Of particular importance are the
bevelled edges 60, 62 along the two long edges of each
core board 52. Alternatively, non-bevelled board can be
used. Preferably, the bevelled edges 60, 62 on each core
board 52 have a bevel 64, 66 which is in a plane forming
an angle of 12Q~ with one of the core board faces and 60~
with the opposite core board face, and preferably, when
installed as shown in Fig. 3, the bevelled edges 60, 62
are parallel, one with the other, whereby the bevel 64 on
edge 60 is at an angle of 120~ with core board face 68
and an angle of 60~ with core board face 70, whereas
bevel 66 on edge 62 is at an angle of 120~ with core
board face 70 and an angle of 60~ with core board face
68.
Preferably, the bevelled edges 60, 62 have a
~1at portion 72, of a width of about 3~8 inch, however,
this could be varied considerably.
The first core board 52 to be installed in
constructing wall 10 has a flat portion 72 resting on web
26 of floor track 24 and face 70 is held against flange
30 by a plurality of screws 74. The two ends 76 (one
shown in Fig. 1) of core board 52 extend into corner
posts 40 (one shown) but are not affixed thereto. On top
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of the first core board 52 to be installed is the first
horizontal stud 54 to be installed, and progressively, in
constructing wall lO, additional core boards 52 and
horizo~tal studs 54 alternately are put into place, each
extending at each end thereof into the channel g8 of
corner posts 90 (one shown~ but, preferably, neither core
boards 52 nor studs 54 are affixed thereto.
The horizontal studs 54, shown in Figs. 3 and
4, are each a single, elongate, roll-formed sheet of
metal, preferably 0.020-inch-thick steel, and include,
essentially a Z-shaped cross section which includes an
inner flange 78, a web 80 extending outwardly from inner
flange 78 with an inwardly facing surface 84 which forms
an angle of 60~ with inner flange 78, an outer flange 82
which is parallel to and preferably about 2-1/2 inches
from inner flange 78 and a means 86 for holding a core
board edge 62 against outwardly facing surface 88 of web
80. The stud 54 will be seen to form two opposed pockets
for receiving the edges of two adjacent core boards 52.
In the form as shown in Fig. 4, the means 86,
for holding core board edge 62 against the outwardly
facing surface 88 of web 80, is a plurality of tabs 86
formed o~ ahout l-inch by about 3-inch sections o~ metal
cut and bent out of web ao, located about every 12
inches. The inner flange 78 has a narrow, outwardly-
turned hem 90. Inner flange 78 also has an outwardly
depressed, elongate rib 92 with depth equal to the
outward extent of hem 90. Rib 92 prevents twisting of
the stud 54 when a builder rests a core board on the top
of outer flange 82 during construction. Inner flange 78
~3~
has a short, downwardly extending, elongate lip 94 formed
by a reverse bend ~f the sheet metal and web 80 is
adjoined to inner flange 78 at the top of lip 94. The
inner flange 78 can be strengthened to some degree by
forming the flange with the double thickness extending
upwardly and the single thickness extending downwardly,
with a hem at the bottom, as illustrated in Figs. 9-12.
An elongate, outermost portion 96 of web 80 i5
perpendicular to the outer flange 82, and outer ~1ange 82
has a narrow, inwardly turned hem 98.
In the embodiment shown in Fig. 3, all the
horizontal studs 59 are disposed with the inner flange 78
extending primarily upwardly from web 80 and the outer
flange 82 and tabs 86 extending downwardly from web 80.
It will be readily understood how gravity assists in the
installation of the upper core board engaged in each stud
59. Two layers of gypsum wide wallboard 56, 58, prefera-
bly 4-~oot wide and 1/2-inch or 5/8-inch thick, are screw
attached to the outer flange 82 of each horizontal stud
2~ 54 and to corner posts 40.
In alternative embodiments, not shown, the
horizontal studs 54 could be reversed with inner flanges
78 extending downwardly and the outer flanges 82 and tabs
86 extending upwardly, necessitating a reversal of the
~aces of the core boards 52. In this embodiment, tabs
could interfere with the installation of the upper board,
making construction a little more difficult. In a still
further alternative embodiment, alternate horizontal
studs 54 could be reversed, necessitating the use of core
hoards with bevels on the s~me side on each core board
~ 3 ~ 2')
and with core board faces alternating on adjacent core
boards. This alternating embodiment will be clearly
understood from the alternative embodiment of Fig. 5.
In Fig. 5, a different embodiment of the
invention, employing modified horizontal studs 100, is
shown, with the horizontal studs 100 arranged to show an
alternating stud arrangement. The embodiment Gf Fig. 5
also has non-aligned core boards 102, which permit the
inclusion oE vent holes 104 in the webs 106.
The elongate hori~ontal studs 100 have inner
flanges 108 and outer flanges 110 which are parallel and
extend in the same direction from the web 106. The web
106 includes three elongate elements, a diagonal section
112 extending outwardly at 60~ from one edge of inner
flange 108, a mid-wall 11~ extending from the opposite
edge of diagonal section 112 in the opposite direction as
and parallel to the inner flange 108, and an outermost
portion 116 which is perpendicular to the outer flange
110 and to mid-wall 114.
In order to improve the fire-resistant charac-
ter of the wall 118, the mid-wall 114 is spaced outwardly
of the lnner ~lange 108, a distance greater than the
thickness of the core boards 102~ preferably a 1-1/4-inch
spacing with l-inch-thick core board 102. Core board 102
having a flat portion 123 and a bevelled portion 12~, has
edges 122, 122 with the bevel 124 o~ each edge adjacent
the same face 126. The core boards 102 and the studs 100
are both erected in an alternatiny manner, with adiacent
core boards 102 having faces 126 facing oppositely and
adjacent horizontal studs having upper and lower sides
g
reversed. Consequently, every othe~ core board 102 is
disposed outwardly l/9 inch, leaving an inner 1/4-inch
strip 128 of web 106 exposed. A plurality of vent
openings 104 are formed at spaced locations along this
inner 1/4-inch strip 128. When a wall 118 is exposed to
a fire, air is able to move through vent openings 104,
cooling the wall 118.
Referring now to front wall 12 of Fig. 1, an
elevator doorway 132 is shown, formed by two vertical
roll-formed, sheet metal elongate door-frame posts 134
(one vertical post not shown), (similar door frame posts
are shown in Fig. 6). As shown in a broken-away portion
in Fig. 1, the door frame posts 134 include a web 136,
two perpendicular flanges 138 and an inwardly protruding
lip 140. A short section of re~ular formed sheet metal
elongate channel 135 is affixed back-to-back with the
portion of vertical door frame post 134 extending from
the top of doorway 132 to the ceiling track 32, and
anothsr section of channel 135 extends across the top of
doorway 132.
Front wall 12 has short sections of core board
52 alternating with short sections of horizontal stud 54
along the side of doorway 132, with boards 52 and studs
54 extending into the channel 50 o~ corner post 40 and
into the door frame post 134. Other short sections o~
horizontal studs 54 and core boards 52 extend horizon-
tally over doorway 132 and into the short sections of
channel 135. Two layers of gypsum wide wallboard 56, 58
are screw attached to the outer flanges of horizontal
30 studs 54 and to posts 40 and 139.
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Referrin~ now to Fig. 6, an extra-lony wall 142
is shown, constructed in accordance with the invention.
The horizontal studs 54 preferably will not be more than
10-feet long for most elevator shaft walls, particularly
with only 2-1/2-inch-wide studs. For walls having a
length greater than 10 feet, an intermediate vertical
post 144 is positioned at spacings o~ 10 feet or less. A
suitable intermediate vertical post 144 is shown formed
o~ two door frame posts 134, back-to-back, preferably
mechanically affixed together, however other configura-
tions can also be used. Core boards 52 and hori~ontal
studs 54 are shown extending from within corner posts 40
to within intermediate vertical post 144. Wide wall-
boards 56, 58 are affixed to the outer flanges 82 of the
horizontal studs 54.
Figs. 9 thru 12 show four additional modifica-
tions of the invention.
Fig. 9 shows horizontal stud 170 with two core
boards 172, in a manner similar to the structures of
~0 Figs. 1, 2 and 60 Horizontal studs 170 and core boards
172 are assembled into vertical corner posts 40,
intermediate posts 149 and door frame posts 134 similar
to core boards 102.
Horizontal stud 170 is an elongate, roll-formed
sheet of metal with a cross section which includes an
inner flange 174, a web 176 extending perpendicularly
outwardly from the middle of inner flange 174 for about
9J16 inch to a 30~ upward bend 178, then extends upwardly
and outwardly to a 30~ downward bend 180 and then extends
outwardly to downwardly extending outer flanqe 18~.
'3
Bends 178 and 180 thus divide web 176 into an inner flat
portion 184, a central diagonal portion 186 and an outer
flat portion 188. In the several disclosed embodiments
of this invention it is important that a portion of the
web be at an acute angle to the inner flange at a portion
which is spaced outwardly from the inner flange. This
angled portion may extend inwardly and be ad~oined to the
inner flange or the angled portion may be adioined to the
inner ~lange by a narrow portion perpendicular to the
inner flange.
Horizontal stud 170 also includes a plurality
of downwardly extending tabs 190 formed of l-inch by
~-inch seGtions of metal cut and bent out of central
diagonal portion 186. Tabs 190 are adjoined to central
diagonal portion 186 adjacent to bend 178, and include a
downwardly and outwardly extending angled portion 192 and
a downwardly extending portion 194 terminating in a
downwardly and outwardly angled lip 196 for ease of
insertion of a core board 17~.
Inner ~lange 174 includes an upper double-
thickness portion 198 and a lower single-thickness
portion 200 which includes a lower hem 202 and a midway
rib 204. Hem 202 and rib 204 both extend outwardly from
the balance of lower port1on 200.
Horizontal stud 170 is mounted ~top an upper
edge portion 206 of one of the two core boards 172 in
Fig. 9, and a lower edge portion 207 of the other core
board 172 is disposed atop stud 170.
The upper edge portion 206 of the one core
30 board 172 is held firmly between tabs 190 and the hem 202
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and Lib ~04 of single-thickne~s portion 200 of inner
flange 174. Upper edge portion 206 has a flat top
portion 208 and a bevelled portion 210. Flat portion 208
abuts inner flat portion 184 of web 176 and bevelled
portion 210 is parallel to and closely spaced from angled
portion 192 of tab 190.
The lower edge portion 207 of the other core
board 172 has a flat bottom portion 212, similar to flat
top portion 208~ and a bevelled portion 214, similar to
bevelled portion 210. Bevelled portion 214 rests on
central diagonal portion 186 of web 176 and flat bottom
portion ~12 is parallel to and closely spaced from inner
flat portion 184 of web 176.
The very heavy, normally about ten-foot-long
core boards 172 are relatively easily inserted onto each
previously mounted horizontal stud 170 by merely sliding
the bevelled portion 214 down the central diagonal
portion 186 until the lower edge 207 abuts the double-
thick portion 198 of inner flange 174. Lower edge
20 portion 207 is held firmly between inner flange 174 and
diagonal portion 186 by the weight of the core board 172,
plus the weight of all core boards 172 and horizontal
studs 170 which are thereabove a part of the wall.
The horizontal studs 170 fit tightly onto the
upper edge 206 of core boards 172~ but being much lighter
and easier to manipulate than the core boards 172, very
little problem is involved in this step. Gypsum wide
wallboard (not shown) is screw attached against the outer
surfaces 216 of the outer flanges 182 and to posts 40,
30 134 and 144.
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Fig. lO shows horizontal stud 220 with two core
boards 222, similar to core boards 52. Horizontal studs
220 and core boards 222 are assembled into vertical
corner posts 40, intermediate posts 144 and door frame
channels 134 in a manner similar to the structures of
Figs. 1, 2 and 6.
Horizontal stud 220 is an elongate, roll-formed
sheet of metal with a cross section which includes an
inner flange 224, a web 226 extending outwardly and
upwardly from the middle o~ inner ~lange 224 to a
downward bend 22B and then extends outwardly to down-
wardly extending outer flange 230. Bend 228 thus divides
web 226 into an inner diagonal portion 232 and an outer
flat portion 234.
Horizontal stud 220 also includes a plurality
of downwardly extending tabs 236 formed of 1-inch by
3-inch sections of metal cut and bent out of inner
diagonal portion 232~ Tabs 236 are adioined to the inner
diagonal portion 232 of web 226 at about the middle of
diagonal portion 232 and includes a downwardly and
outwardly extending portion 238, a downwardly extending
portion 240, and a downwardly and outwardly anqled lip
242 for ease of insertion of a core board 222.
Inner flange 224 includes an upper double-
thickness portion 244 and a lower single-thickness
portion 246 which includes a lower hem 248 and a midway
rib 249, both extending outwardly.
Horizontal stud 220 is mounted atop an upper
edge portion 250 of one of the two core boards 222 in
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Fig. lO, and a lower edge portion 252 of the other core
board 222 is disposed atop stud 220.
The upper edge portion 250 of the one core
board 222 is held firmly between tabs 236 and the hem 248
and rib 249 of single-thickness portion 246 of inner
~lange 224. Upper edge portion 250 has a flat top
portion 254 and a bevelled portion 256 with an elongate
corner 258 therebetween of about 150~.
The lower edge portion 252 of the other core
board 222 has a flat bottom portion 260, similar to ~lat
top portion 254 with the exception that it is on the
opposite side of the core board 222, a bevelled portion
262, similar to bevelled portion 256 but also on the
opposite side of core board 222, and an elongate corner
264 therebetween of about 150~.
The inner diagonal portion 232 of web 226 ~orms
an angle 266 of 70~ with upper double-thickness portion
244 of inner flange 224. Since the corners 258 and 264
are both about 150~, the bevelled portions 256 and 262
extend at an angle 268 of about 60~ relative to the upper
double-thickness portion 244. Conseguently, the upper
edge portion 250 and the lower edge portion 252 of the
core boards 222 both abut the web diagonal portion 232 at
the corners 258 and 264.
The core boards 222 are easily lnserted onto
each previously mounted horizontal stud 220, and the
lower edge portion 252 is held ~irmly between înner
flange 224 and web diagonal portion 232 by the ~eight o~
the core board 222, plu~ the weight oE all core boards
222 and horizontal studs 220 which are thereabove a part
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of the wall. Ho~izontal studs 220, being much lighter
than the core boards 222, can be reasonably easily forced
down onto the upper edge portions ~50 o~ the core boards
222. Gypsum wide wallboard (not shown) is screw attached
against the outer surfaces 270 of the outer flanges 230
and to posts 40, 134 and 144.
Fig. 11 shows horizontal stud 272 with two core
boards 274, similar to core boards 102. Horizontal studs
272 and core boards 274 are assembled into vertical
corner posts 40, intermediate posts 144 and door fra~e
channels 134 in a manner similar to the structures of
Figs. 1, 2 and 6. Horizontal stud 272 is an elongate
roll-formed sheet of metal with a cross section which
includes an inner flange 276, a web 278 extending
perpendicularly outwardly from the middle of inner flange
276 about 5/8 inch to 30~ downward bend 280, then extends
downwardly and outwardly to an upwardly extending outer
flange 282. Bend 280 thus divides web 278 into an inner
flat portion 284~ and an outer diagonal portion 286.
Horizontal stud 272 also includes, at spaced
apart locations along web 278, a plurality of upwardly
extending tabs 288 and a plurality of downwardly extend-
ing tabs 290, each forrned of, respectivel.y, l-inch by
3-inch sections and 1/2-inch by 3-inch sections o~ metal
cut and bent out o~ outer diagonal portion 286. Tabs 288
are adjoined to outer diagonal portion 286 adjacent to
bend 280~ and inc].ude an upwardly and outwardly extending
angled portion 292 and an upwardly extending portion 294
terminating in an upwardly and outwardly angled lip 2967
30 for ease of insertion of a core board 274. Tabs 290 are
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adjoined to outer diagonal portion 286 about 1/2 inch
outwardly ~rom bend 2~0, and include a downwardly extend-
ing portion 298 and a downwardly and outwardly extending
lip 300.
Inner flange 276 includes an upper double-
thickness portion 302 and a lower single-thickness
portion 304 which includes a lower hem 306 and a midway
rib 308, both extending outwardly from the other parts of
lower portion 304.
Hori~ontal stud 272 is mounted atop an upper
edge portion 310 of one of the two core boards 274 in
Fig. 11, and a lower edge portion 312 of the other core
board 274 i5 disposed atop stud 272.
The upper edge portion 310 o~ the one core
board 274 is held Eirmly between tabs 290 and the hem 306
and rib 308 of single-thickness portion 304 of inner
flange 276. Upper edge portion 310 has a ~lat top
portion 314 and a bevelled portion 316. Flat portion 319
abuts inner flat portion 284 of web 278 and bevelled
portion 316 is parallel to and closely spaced from outer
diagonal portion 286 o~ web 278.
The lower edge portion 312 of the other core
board 274 has a ~lat bottom portion 318, similar to flat
top portion 314, and a bevelled portion 320, similar to
bevelled portion 316. Flat bottom portion 31B is
parallel to and closel~ spaced from inner flat portion
284 of web 278 and bevelled portion 320 rests on a~gled
por~ion 292 of tabs 288.
The core boards 274 are relatively easily
inserted between the tabs 288 and 290 and the inner
flange ~76 because of the bevelled portions 316 and 320,
which engage and slide on the respective tab lips 296 and
300. Gypsum wide wallboard (not shown) is screw attached
against the outer surface~ 322 of outer flanges 282 and
to posts 40, 134 and 194.
In a preferred embodiment, Fi~ shows
horizontal studs 324 with two core boards 326, similar to
core boards 52. Horizontal studs 324 and core ~oards 326
are assembled into corner posts 40, intermediate posts
144 and door frame channels 134 in a manner similar to
the structures of Figs. 1, 2 and 6. Horizontal stud 324
is an elongate roll-formed sheet of metal with a cross
section which includes an inner flange 328; a web 330
extending perpendicularly outwardly from the middle of
inner flange 328 about 5/8 inch, forming a flat portion
332, whereat a major portion 334 of web 330 extends
upwardly and outwardly about 5/8 inch to bend 336 and
thence downwardly and outward]y to an upwardly extending
outer flange 338. A minor portion 340 of web 330, about
a 3-inch length of each foot of web, extends down~ardly
and outwardly about 5/8 inch to bend 342, thence down-
wardly to bend 394 and thence outwardly to upwardly
extending outer flange 338. Slits 34G were ~ut crosswise
of web 330, during forming of horizontal stud 324, from
the flat portion 332 to the outer flange 338. The slits
346 are preferably angled slightly to form minor portions
340 which have a shorter dimension along the outer flange
bend 348 than along the bend 349, whereat the minor
portion 340 is adjoined to the flat portion 332. By
angling the slits 3469 heat trans~er through the stud,
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~fi~
from one Elange to the opposite flange is reduced, and,
also, the studs are more easily stacked for warehousing
and shipping.
The bend 336 divides the major portion 334 of
web 330 into a ramp portion 350 and a connecting portion
352. The bends 342 and 344 divide the minor portion 340
into a bevel portion 354, a board holding portion 356 and
a connecting portion 358.
Both ends of web maior portion 33~ and of web
minor portion 340 are integrally connected to the stud;
they have no free or dangling ends. Thus, as shown in
Fig. 12, web 330 has no tabs or any other part with a
dangling or free end, all of which enhances the
structural integrity of the web.
Inner flange 328 includes an upper double-
thickness portion 360 and a lower single-thickness
portion 362 which includes a lower hem 364 and a midway
rib 366, both extending outwardly.
Horizontal stud 324 is mounted atop an upper
20 edge portion 368 of one of the two core boards 326 in
Fig. 12, and a lower edge portion 370 of the other core
board 326 is disposed atop stud 324.
The upper edge portion 363 of the one core
board 326 is held firmly between board holding portion
356 o~ web minor portion 3~0 and the hem 36~ and rib 366
of single-thickness portion 362 of inner flange 328.
Upper edge portion 368 has a Elat top portion 372 and a
bevelled portion 374 with an elongate corner therebetween
of about 150~. Flat portion 372 abuts flat portion 332
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2 ~
of web 330. Bevelled portion 374 is parallel to and
closely spaced from minor portion, bevel portion 354.
The lower edge portion 370 of the other core
board 326 has a flat bottom portion 376, similar to flat
top portion 372, and a bevelled portion 378 similar to
bevelled portion 374. Flat bottom portion 376 is
parallel to and closely spaced Erom flat portion 332 of
web 330, and the junction of flat bottom portion 376 and
bevelled portion 378 rests on ramp portion 350.
The core boards 326 are inserted onto each
previously mounted hori~ontal stud 324 by merely sliding
the bevelled portion 378 of lower edge portion 370 down
the ramp portion 350 of the web 330 until the lower edge
portion 370 abuts the double-thick portion 360 of inner
~lange 328. The lower edge portion 370 is held between
the ramp portion 350 and inner flange 328 by the weight
o~ the core board 326, plus the weight of all core boards
326 and horizontal studs 324 which are thereabove a part
of the wall.
The horizontal studs 324 are forced onto the
upper edge 368 o~ each core board 326, with the core
board bevelled portion 374 guiding the stud web minor
portion 340 into the space between the inner ~lange 328
and the board holding portion 356.
Gypsum wide wallboard ~not shown) is screw
attached against the outer surfaces 380 of the outer
flanges 338 and to posts 40, 134 and 144.
In the preferred forms of the invention,
narrow, elongate slots 382 are arranged at spaced
locations along the webs 80, 106, 176, 226, 278 and 330,
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typically about 3 inches by l/2 inch, spaced an inch
apart, for reducing the heat conductivity through a walI,
in case of fire on one or the other sides o~ the wall.
Also, horizontal studs 54, 170, 220, 272 and 324 could
have 3/16-inch by 2-1~4-inch vent holes 384 added, with
3/4-inch spacing, similar to the vent holes 109 in stud
100 .
With regard to the application of two layers of
gypsum wide wallboard 56, 58, on any of the horizontal
stud embodiments, these 1/2-inch or 5/8-inch wallboards
may be screw applied with their long dimension horizontal
or vertical or with one layex horizontal and one layer
vertical. All-vertical application is normally pre-
ferred, with joint locations staggered. With regard to
the installation of all-horizontal studs 54, 170 and 220
in side wall 10 with tabs 86, 190 and 236 extending
downward, although this is the pre~erred construction,
the walls could be constructed with tabs 86, 190 and 236
extending upward; that is, by reversing the horizontal
20 studs 54, 170 and 220 and reversing the core boards 52
and 222.
Figs. 7 and 8 show how two 2-foot-wide core
boards 52 and 222 or 102 can be manufactured as a
substitute for the more common standard 2-foot-wide core
board. In Fig. 7, a 4-fGot wide~ l-inch~thick, paper-
covered gypsum board 146 is shown with a jagged break
line 148 in the center of board 146. By forming board
146 with two bevelled edges 150 adjacent the top face 152
and a V-groove 154 in the center o~ the back face 155,
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the wide board 146 can be broken in half to form two core
boards 52 or 222.
In Fi~. 8, a 4-fnot-wide, 1-inch-thick, payer-
covered gypsum board 158 is shown with a jagged break
line 160 in the center of board 158. By ~orming board
158 with two bevelled edges 162 adiacent the top face 164
and V-groove 166 in the center of the top face 164, the
wide core board 158 can be broken in half to for~ two
core boards 102. The present invention has an added
advantage in that the rough, jagged edges formed by
breaking wide gypsum boards 146, 158, extend into a 60~
channel in either of the horizontal studs 5, lO0 or 220
where the jagged edges present no problem.
Another very lmportant advantage of the present
invention is in the fact that the construction of a wall
in accordance with the invention, such as side wall 10,
involves constructing, essentially, a two-foot wall with
the lowest core board 52, then a four-foot wall with the
second lowest core board 52~ etc. Construction of these
walls can be stopped at any two-foot multiple height.
Accordingly, a desired four-foot wall can be erected with
no extra trouble for use as a temporary safety wall
around an elevator shaft prior to the time when a com-
plete elevator shaft wall is desired, leaving access to
the shaft, over the four-foot wall, during early phases
of construction, ~or easy installation of cants or the
like. Also, accordingly, core boards can be omitted or
removed from ~etween the top horizontal stud and the
ceiling track without weakening substantially the resul-
tant wall, as occurs in prior vertical stud structures,
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~ 3
wherein portions of vertical studs must be cut away.
This omission is sometimes necessary to install elevator
rail supports~brackets.
Of greatest significance, is the fact that with
horizontal studs carrying the weight of core boards, the
horizontal studs are effectively rnade stronger propor-
tional to the weight on them, which is not true of
vertical studs, which o~viously do not carry the weight
of core boards between them. With core board edges
bevelled and horizontal stud webs or tabs at correspond-
ing acute angles, a substantial increase in strength and
stiffness is provided in the resultant wall. As a
result, horizontal studs which are only about 2-1/2
inches, flange-to-flange, are adequate regardless of the
height of the wall.
It should also be noted that the construction
of walls in accordance with the invention is easier and
faster than prior shaft walls, and is suitable for
construction from one side, the side opposite the shaft.
Contributing most to the ease of erection is the use of
the horizontal stud with a wide, angled-bottom channel
into which the bottom edge of each core board is fed.
More particularly, the web of the stud includes structure
for g~liding the bottom edge of the core board laterally
toward the stud's inner flange, under the urging of
gravity. For example, in the embodiment of Fig. 9, the
guide structure comprises web diayonal portion 186; in
Fig. 10, it comprises web diagonal portion 232; in Fig.
11, it comprises upwardly and outwardly extending lip
30 portion 296 and angled portion 292~ and in Fig. 12~ the
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': '
~ ~3 ~
guide structure comprises web ramp portion 350. This
type of guide structure facilitates positio~ing of the
core board at the desired location on the stud by an
assembler whose vision of that location can be impeded by
the core board during assembly. In all such embodiments
the guiding function results from the presence of web
structure which is engageable with the lower edge of the
core board and which is inclined downwardly and inwardly
toward the innex flange oE the stud which, in the pre-
ferred embodiments, includes an upper portion having adouble thickness of sheet metal. That part of the core
board adjacent its lower edge is positioned adjacent the
double thickness of sheet metal on the inner flange, and
that feature functions to retain the core board in place,
during a fire, for a relatively long period of time
compared to an inner flange having a single thickness of
sheet metal at that ]ocation.
Although the invention has been described as a
shaft wall for construction around elevator shafts, its
advantages will be egually available when the wall is
constructed anywhere else~ such as around stairwells or
as area separation walls of the type commonly constructed
between adjoining condominiums and townhouses. It is
presently contemplated that the walls of the present
invention can be successfully constructed with heights of
up to about 36 feet, compared to about 12 feet for a
similar sized vertical stud of prior shaft walls. If
core boards can be made with greater resistance to
crushing than presently normal, there would be no reason-
able height limitation. Conversely, prior shaft walls
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. .
~3 ~ fi ~
required vertical studs with dimensions oE more than
2-1/2 inches Elange-to-flange when the wall exceeded the
normal hei~hts. For example, 4-inch and 6-inch flange-
to-flange vertical studs were required for constructions
when heights increased above about 14 ~eet. The present
invention provides a system wherein the 2-1/2-inch
flange-to-flange dimension is adequate regardless of wall
height. Still ~urther, the horizontal stud of the
present invention requires the same or less metal than
any prior shaft wall stud.
It will be appreciated that a solid wall
configuration built in accordance with the present
invention will also provide a number of benefits of the
preferred embodiments of the invention.
Having completed a detailed description of the
preferred embodiments of my invention so that those
skilled in the art may practice the same, I contemplate
that variations may be made without departing from the
essence of the invention.
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