Note: Descriptions are shown in the official language in which they were submitted.
216910~
FIELD AND BACKGROUND OF THE INVENTION
This invention relates to sheet metal studs for
supporting gypsum wallboard and to improved fire-resistant
hollow shaft walls.
Several patents have disclosed hollow shaft walls
employing metal studs and gypsum wallboards; for example,
U.S. 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 systems sometimes
include slightly bevelled edges, strictly for ease of inser-
tion into the channels formed between flanges and tabs.
These prior structures have enjoyed considerable
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.
2169101
SUMMARY OF THE INVENTION
In the present invention, novel sheet metal studs
are placed horizontally between adjacent, horizontally
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 ad-
joining web connecting the flanges, with a core board abut-
ting 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 flange, creating
a channel-like means for holding an edge of one of the two
core boards against the inner flange. The web also includes
means for holding an edge of the second core board against
the inner flange, on the opposite side of the web.
As a specific example, two-foot wide and up to
ten-foot long, one-inch-thick gypsum core boards are dis-
posed, with their widths extending vertically and their
lengths extending horizontally, between the horizontally ex-
tending studs, said boards preferably having bevelled later-
al 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, horizontally extending metal studs. The ends
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21631 01
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 flanges
of the metal studs.
The corner stud has two outwardly opening channels
directed at right angles, and the core boards and horizontal
studs of two perpendicular walls extend into the two respec-
tive channels.
In an extra-long wall, an improved intermediate
vertical post may be provided.
It is an object of the present invention to pro-
vide a novel horizontal 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.
216~101
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 relatively low safety
wall around the shaft opening that also provides ready
access to the shaft for the installation of cants and the
like.
It is a still further object of the invention to
provide a shaft wall which is not substantially weakened by
omission or removal of a narrow top portion for the instal-
lation of elevator rail supports/brackets.
It is still a further object of the invention to
provide a shaft wall system that requires the stocking of
fewer components for typical shaft wall installations.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of the
invention will be more readily apparent when considered in
relation to the preferred embodiments as set forth in the
specification and shown in the drawings in which:
Fig. 1 is a perspective view of a portion of two
perpendicular walls of an elevator shaft enclosure, con-
structed in accordance with the invention.
2 1 6~
Fig. 2 is a cross-sectional plan view of the wall
corner, taken on line 2-2 of 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.
10Fig. 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
20forming two modified core boards.
Figs. 9-12 are isometric views of four modified
horizontal studs with core boards in place, all in accor-
dance with the invention.
Fig. 13 is a sectional view of an improved inter-
mediate vertical post in accordance with the invention.
9101
Figs. 14 and 15 are exploded views of parts of the
vertical post shown in Fig. 13.
Figs. 16 and 17 are views similar to Figs. 13 and
14 but showing an alternative construction.
Figs. 18 and 19 are views similar to Figs. 13 and
14 but showing another alternative construction.
Fig. 20 is a view similar to Fig. 2 but showing a
preferred construction of the corner post.
DESCRIPTION OF THE PREFERRED EM~30DIMENTS
Referring to Fig. 1, there is shown part of a side
wall 10 and part of a front wall 12 of a hollow shaft wall
structure 14 surrounding an elevator shaft 16. Elevator
shaft 16 extends vertically through a plurality of
floor-ceiling platforms, including the lower platform 18 and
the upper platform 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 floor-ceiling
platforms which surround and form the elevator shaft 16.
Side wall 10 consists of a standard upwardly
opening, channel-shaped floor track 24 (Fig. 3), having a
horizontal web 26 and two vertical flanges 28, 30, and a
downwardly opening, channel shaped, ceiling track 32, having
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2169101
a horizontal web 34 and two vertical flanges 36, 38. Floor
track 24 is mechanically affixed to the top of lower plat-
form 18 and ceiling track 32 is mechanically affixed to the
bottom of upper platform 20, each adjacent the edges 22 of
these floor-ceiling platforms. Ceiling track 32 preferably
has a plurality of spaced-apart vent openings 39 along 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. 1 and 2, a vertical corner
post 40 is mounted with a bottom end 42 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
front wall 12. The corner post 40, which could be made by
affixing two channels together back-to-side, is preferably a
single, elongate, roll-formed sheet of metal having two
outwardly opening channels 48, 50 formed 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 to one anoth-
er and being directed toward, respectively, the side wall 10
and the front wall 12. Fig. 20 illustrates a preferred
corner post design to be described in greater detail herein-
after.
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2169101
As seen in Figs. 1 and 2, the vertical corner post
40, comprises a formed single-piece sheet metal member
including two channels 48, 50 each of which consists solely
of a bottom wall and parallel, spaced, inner and outer side
walls extending perpendicularly from the bottom wall. The
bottom wall of a first one of said channels (opening down-
wardly and to the right in Fig. 2) is also the inner side
wall of a second one of said channels (opening downwardly
and to the left in Fig. 2). Also, the bottom wall of the
second one of said channels will be seen to be coplanar with
the outer side wall of the first one of said channels.
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
combine to form the side wall 10.
Typically the core boards 52 are paper-
covered gypsum boards which are, in cross section, 2
feet by 1 inch, and will normally have a length equal to the
horizontal extent of the wall 10 (except in the instance of
an extra long wall in which case a vertical post 144, shown
in Fig. 6, is provided). 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
1 0 1
120 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 flat
portion 72, of a width of about 3/8 inch, however, this
could be varied considerably.
After the floor track and the ceiling track are in
place, the first core board 52 to be installed in construct-
ing the 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 of the first core board
52 to be installed is the first horizontal stud 54 to be in-
stalled, and progressively, in constructing wall 10, addi-
tional core boards 52 and horizontal studs 54 alternately
are put into place, each extending at each end thereof into
the channel 48 of corner posts 40 (one shown) but, prefera-
bly, neither core boards 52 nor studs 54 are affixed there-
to.
21S9101
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 of
about 1-inch high by about 3-inch long sections of metal cut
and bent out of web 80, 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 construc-
tion. Inner flange 78 has a short, downwardly extending,
elongate lip 94 formed by a reverse bend of 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
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2163101
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 is
perpendicular to the outer flange 82, and outer flange 82
has a narrow, inwardly turned hem 98.
In the embodiment shown in Fig. 3, all the hori-
zontal studs 54 are disposed with the inner flange 78 ex-
tending 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 54. Two
layers of gypsum wide wallboard 56, 58, preferably 4-foot
wide and 1/2-inch or 5/8-inch thick, are screw attached to
the outer flange 82 of each horizontal stud 54 and to corner
posts 40.
In alternative embodiments, not shown, the hori-
zontal 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 faces of
the core boards 52. In this embodiment, tabs could inter-
fere with the installation of the upper board, making con-
struction a little more difficult. In a still further
alternative embodiment, alternate horizontal studs 54 could
be reversed, necessitating the use of core boards with
bevels on the same side on each core board and with core
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21~91 01
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 inven-
tion, employing modified horizontal studs 100, is shown,
with the horizontal studs 100 arranged to show an alternat-
ing stud arrangement. The embodiment of Fig. 5 also has
non-aligned core boards 102, which permit the inclusion of
vent holes 104 in the webs 106.
The elongate horizontal 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 114 extending from the opposite edge of
diagonal section 112 in the opposite direction as and paral-
lel 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 character
of the wall 118, the mid-wall 114 is spaced outwardly of the
inner flange 108, a distance greater than the thickness of
the core boards 102, preferably a 1-1/4-inch spacing with
1-inch-thick core board 102. Core board 102 having a flat
portion 123 and a bevelled portion 124, has edges 122, 122
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2~9101
with the bevel 124 of each edge adjacent the same face 126.
The core boards 102 and the studs 100 are both erected in an
alternating manner, with adjacent core boards 102 having
faces 126 facing oppositely and adjacent horizontal studs
having upper and lower sides reversed. Consequently, every
other core board 102 is disposed outwardly 1/4 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 perpen-
dicular flanges 138 and an inwardly protruding lip 140. A
short section of regular 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 another 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
- 13 -
- 2~6slal
54 extending into the channel 50 of corner post 40 and into
the door frame post 134. Other short sections of horizontal
studs 54 and core boards 52 extend horizontally 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 studs 54 and to posts 40 and
134.
Referring now to Fig. 6, an extra-long 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 posi-
tioned at spacings of 10 feet or less. A suitable interme-
diate vertical post 144 is shown formed of two door frame
posts 134, back-to-back, preferably mechanically affixed
together, however other configurations can also be used,
including posts shown in Figs. 13 to 19. Core boards 52
and horizontal studs 54 are shown extending from within
corner posts 40 to within intermediate vertical post 144.
Wide wallboards 56, 58 are affixed to the outer flanges 82
of the horizontal studs 54.
Figs. 9 through 12 show four additional modified
studs in accordance with this invention.
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2169~1
,
Fig. 9 shows horizontal stud 170 with two core
boards 172, in a manner similar to the structures of Figs.
1, 2 and 6. Horizontal studs 170 and core boards 172 are
assembled into vertical corner posts 40, intermediate posts
144 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 9/16 inch to a
30 upward bend 178, then extends upwardly and outwardly to
a 30 downward bend 180 and then extends outwardly to down-
wardly extending outer flange 182. 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 impor-
tant 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 adjoined to the inner flange or the angled portion may be
adjoined to the inner flange by a narrow portion perpendicu-
lar to the inner flange.
Horizontal stud 170 also includes a plurality of
downwardly extending tabs 190 formed of 1-inch by 3-inch
sections 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
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21 69101
-
and outwardly extending angled portion 192 and a downwardly
extending portion 194 terminating in a downwardly and out-
wardly angled lip 196 for ease of insertion of a core board
172.
Inner flange 174 includes an upper double-thick-
ness 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 portion 200.
Horizontal stud 170 is mounted atop 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 board
172 is held firmly between tabs 190 and the hem 202 and rib
204 of single-thickness 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
- 16 -
216.~101
_
portion 186 of web 176 and flat bottom portion 212 is paral-
lel 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 previ-
ously 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 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 wall-
board (not shown) is screw attached against the outer sur-
faces 216 of the outer flanges 182 and to posts 40, 134 and
144.
Fig. 10 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
21~9101
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 of inner flange 224 to a downward bend 228
and then extends outwardly to downwardly 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 adjoined 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 angled lip 242 for ease of insertion of core
board 222.
Inner flange 224 includes an upper double-thick-
ness portion 244 and a lower single-thickness portion 246
which includes a lower hem 248 and a midway rib 249, both
extending outwardly.
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21fi910~
Horizontal stud 220 is mounted atop an upper edge
portion 250 of one of the two core boards 222 in Fig. 10,
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 flange 224.
Upper edge portion 250 has a flat top portion 254 and a
bevelled portion 256 with an elongate corner 258 therebe-
tween of about 150.
The lower edge portion 252 of the other core board
222 has a flat bottom portion 260, similar to flat 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 forms 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-thick-
ness portion 244. Consequently, the upper edge portion 250
and the lower edge portion 252 of the core boards 222 both
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2~ ~9~01
abut the web diagonal portion 232 at the corners 258 and
264.
The core boards 222 are easily inserted onto each
previously mounted horizontal stud 220, and the lower edge
portion 252 is held firmly between inner flange 224 and web
diagonal portion 232 by the weight of the core board 222,
plus the weight of all core boards 222 and horizontal studs
220 which are thereabove a part of the wall. Horizontal
studs 220, being much lighter than the core boards 222, can
be reasonably easily forced down onto the upper edge por-
tions 250 of 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 frame 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 up-
wardly extending outer flange 282. Bend 280 thus divides
web 278 into an inner flat portion 284, and an outer diago-
nal portion 286.
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216910~
Horizontal stud 272 also includes, at spaced apart
locations along web 278, a plurality of upwardly extending
tabs 288 and a plurality of downwardly extending tabs 290,
each formed of, respectively, 1-inch by 3-inch sections and
1/2-inch by 3-inch sections of metal cut and bent out of
outer diagonal portion 286. Tabs 288 are adjoined to outer
diagonal portion 286 adjacent to bend 280, and include an
upwardly and outwardly extending angled portion 292 and an
upwardly extending portion 294 terminating in an upwardly
and outwardly angled lip 296, for ease of insertion of a
core board 274. Tabs 290 are adjoined to outer diagonal
portion 286 about 1/2 inch outwardly from bend 280, and
include a downwardly extending portion 298 and a downwardly
and outwardly extending lip 300.
Inner flange 276 includes an upper double-thick-
ness 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.
Horizontal 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 is
disposed atop stud 272.
The upper edge portion 310 of the one core board
274 is held firmly between tabs 290 and the hem 306 and rib
- 21 -
2 ~ 69101
308 of single-thickness portion 304 of inner flange 276.
Upper edge portion 310 has a flat top portion 314 and a
bevelled portion 316. Flat portion 314 abuts inner flat
portion 284 of web 278 and bevelled portion 316 is parallel
to and closely spaced from outer diagonal portion 286 of web
278.
The lower edge portion 312 of the other core board
274 has a flat bottom portion 318, similar to flat top
portion 314, and a bevelled portion 320, similar to bevelled
portion 316. Flat bottom portion 318 is parallel to and
closely spaced from inner flat portion 284 of web 278 and
bevelled portion 320 rests on angled portion 292 of tabs
288.
The core boards 274 are relatively easily inserted
between the tabs 288 and 290 and the inner flange 276 be-
cause 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
surfaces 322 of outer flanges 282 and to posts 40, 134 and
144.
In a preferred embodiment, Fig. 12 shows horizon-
tal studs 324 with two core boards 326, similar to core
boards 52. Horizontal studs 324 and core boards 326 are
assembled into corner posts 40, intermediate posts 144 and
door frame channels 134 in a manner similar to the struc-
- 22 -
2 1~910~
tures of Figs. 1, 2 and 6. Horizontal stud 324 is an elon-
gate roll-formed sheet of metal with a cross section which
includes an inner flange 328, a web 330 extending perpendic-
ularly outwardly from the middle of inner flange 328 about
5/8 inch, forming a flat portion 332, whereat a major por-
tion 334 of web 330 extends upwardly and outwardly about 5/8
inch to bend 336 and thence downwardly and outwardly 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
downwardly and outwardly about 5/8 inch to bend 342, thence
downwardly to bend 344 and thence outwardly to upwardly
extending outer flange 338. Slits 346 were cut 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 ~lm~nsion 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 346,
heat transfer through the stud, from one flange 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 con-
necting portion 358.
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2 16910~
Both ends of web major portion 334 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-thick-
ness 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 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 368 of the one core
board 326 is held firmly between board holding portion 356
of web minor portion 340 and the hem 364 and rib 366 of
single-thickness portion 362 of inner flange 328. Upper
edge portion 368 has a flat top portion 372 and a bevelled
portion 374 with an elongate corner therebetween of about
150. Flat portion 372 abuts flat portion 332 of web 330.
Bevelled portion 374 is parallel to and closely spaced from
minor portion, bevel portion 354.
- 24 -
21~1Gl
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 from 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 previ-
ously mounted horizontal 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 flange 328. The
lower edge portion 370 is held between the ramp portion 350
and inner flange 328 by the weight of 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 of each core board 326, with the core board bev-
elled portion 374 guiding the stud web minor portion 340
into the space between the inner flange 328 and the board
holding portion 356.
Gypsum wide wallboard (not shown) is screw at-
tached against the outer surfaces 380 of the outer
flanges 338 and to posts 40, 134 and 144.
2169101
-
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, typically about 3
inches by 1/2 inch, spaced an inch apart, for reducing the
5 heat conductivity through a wall, in case of fire on one or
the other sides of 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 104 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 verti-
cal or with one layer horizontal and one layer vertical.
All-vertical application is normally preferred, 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 preferred construction, the walls could be constructed
with tabs 86, 190 and 236 extending upward; that is, by
reversing the horizontal 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-foot-wide, 1-inch-thick, paper-covered gypsum board 146
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21691~1
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
of the back face 156, the wide board 146 can be broken in
half to form two core boards 52 or 222.
In Fig. 8, a 4-foot-wide, 1-inch-thick,
paper-covered gypsum board 158 is shown with a jagged break
line 160 in the center of board 158. By forming board 158
with two bevelled edges 162 adjacent 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 form 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, 100 or 220 where the jagged edges pres-
ent no problem.
Figs. 13 to 19 illustrate preferred constructions
of the intermediate vertical post 401, which are alterna-
tives to the post 144 shown in Fig. 6. With reference first
to Fig. 14, the post 401 comprises three roll-formed sheet
metal parts 402, 403 and 404. The parts 402 and 404 are J-
shaped structures including webs 402A and 404A, long flanges
402B and 404B, and short flanges 402C and 404C, respective-
ly. The part 403 is hat shaped and includes a web 406, two
long flanges 408 and 409, and two short flanges 410 and 411.
The flanges 408 and 409 are spaced apart and parallel, and
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2l~310~
they are perpendicular to the web 406 and to the short
flanges 410 and 411. The three parts 402, 403 and 404 are
firmly secured together, as by spot welding, with the webs
402A and 404A against the outer sides of the flanges 408 and
409, and with the flanges 402C and 404C against the outer
sides of the flanges 410 and 411. Fig. 13 shows the assem-
bled parts 402, 403 and 404. The flanges 402C, 404C, 410
and 411 have essentially the same length.
The long flanges 408 and 409 are substantially
longer (in this example, about twice as long) as the webs
402A and 404A. The width of the space 412 between the two
flanges 408 and 409 is determined by the length of the web
406 and it is sized to receive a double thickness of the
core boards. Two strips 413 (Figs. 13 and 15) of core board
are snugly inserted into the space 412 as shown in Fig. 13.
With reference to Fig. 13, a relatively long wall
415 requires a vertical center post between the corner posts
as illustrated by the post 144 in Fig. 6, the center post
serving to support the adjacent ends of the horizontal studs
and the horizontally elongated core boards. Long horizontal
core boards 416 and 417 are positioned against the interior
surfaces of the flanges 402B and 404B and additional strips
of core boards 418 and 419 are positioned against the outer
sides of the boards 416 and 417 within the openings of the
J-channels 402 and 404. The flanges 402B and 404B overlie
the inner flanges 78 of the horizontal studs 54, and compa-
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21fi91 01
rable flanges in the other center post constructions de-
scribed herein similarly overlie the inner flanges of the
studs. Fasteners 421 secure the boards 416-419 to the long
flanges 402B and 404B and to the horizontal studs. Thereaf-
ter, one or more layers of boards 422 are positioned against
the flanges 410 and 411 and secured thereto by fasteners
423.
The vertical center post 401 is highly advanta-
geous because it forms a sturdy support in the center area
of the wall and it is relatively fire-resistant. The rela-
tively wide flanges 408 and 409 plus the J-channels 402 and
404 form a relatively rigid support, particularly when
secured to the boards 416-419, the horizontal studs, and the
boards 422. The strips 413 add further rigidity, and the
strips 413, 418 and 419 of core board enhance the fire-
resistant structure.
Figs. 16 and 17 illustrate an alternative con-
struction of a vertical center post for a wall 431. The
wall 431 includes core boards 432 to 435 corresponding to
core boards 416 to 419, and it includes boards 437 corre-
sponding to boards 422. The center post 440 is formed by
two C-channels 441 and 442 and by two J-channels 443 and
444. The webs and the short flanges of the channels 443 and
444 are secured to the webs and inner flanges of the chan-
nels 441 and 442 with the flanges extending parallel to each
other, and the webs of the channels 441 and 442 are secured
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- 21~910~
together in back-to-back relation. The channels 441 and 442
are preferably formed integrally (by a roll forming opera-
tion) with the channels 443 and 444, respectively.
In the assembled wall 431, the core boards 432 to
435 are mounted between the J-channels 443 and 444 and the
outer flanges of the C-channels 441 and 442, and the boards
are secured by fasteners 446. The boards 437 are secured by
fasteners 447 to the outside surfaces of the outer flanges
of the C-channels 441 and 442.
It will be apparent from Fig. 16 that the webs of
the C-channels 441 and 442 are extra long and project from
the boards 432 and 433, and they hold the boards 437 sepa-
rated from the boards 432 to 435, thereby forming an
air space 448 (such an air space is also formed by the other
center posts described herein).
Figs. 18 and 19 show another vertical center post
450 in a wall 451 which again includes core boards 452 to
455 and gypsum boards 456. The post 450 is formed by two J-
channels 458 and 459 which have their webs positioned in
back-to-back relation and secured together. The boards 452
to 455 are positioned within the openings of the J-channels
and are secured by fasteners 460 to the interior sides of
the longer flanges. The boards 456 are spaced from the
boards 452 to 455 and are secured by fasteners 461 to the
exterior sides of the shorter flanges. To increase the
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21691~1
strength of the post 450, the flanges of the J-channels 458
and 459 may be made longer and/or thicker than is customary.
Fig. 20 illustrates an improved vertical corner
post 470 at the juncture of two walls 471 and 472. The wall
471 includes a core board 473 and a double thickness of two
gypsum boards 474 and 475. Similarly, the wall 472 includes
a core board 476 and two boards 477 and 478. It will be
apparent from a comparison of Figs. 2 and 20 that the walls
are generally similar. While not shown in Fig. 20 (but
shown in Fig. 2) the two walls 471 and 472 also include
horizontal studs, a lower floor track and an upper ceiling
track, as disclosed herein.
While Fig. 20 shows the parts slightly spaced from
each other, this is done merely to better illustrate the
construction. Normally the parts are mounted close togeth-
er. Where the ends of the boards 474-475 meet the ends of
the boards 477-478, the cut ends are staggered as indicated
at 479 to improve the seal at the corner.
The post 470 is a single piece roll-formed sheet
metal member. It includes a web 481, a short flange 482 and
a long flange 483 connected in the shape of a J-track; and a
short flange 484 and a long flange 485 connected in the
shape of an L-track. The ends of the flanges 482 and 485
are integrally formed, and the flange 482 closely overlies a
portion of the flange 485. The board 476 is secured by a
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21691Bl
fastener 487 to the interior surface of the flange 483, the
board 473 is secured by a fastener 488 to the exterior
surface of the web 481, the boards 474 and 475 are secured
by a fastener 489 to the exterior surface of the flange 484,
and the boards 477 and 478 are secured by a fastener 490 to
the exterior surface of the flange 485.
A comparison of Figs. 2 and 20 will reveal that
the post 470 is similar to the post 40 except that the
flange 483 is substantially longer than the corresponding
flange of the post 40. The longer length of the flange 483
enables the fastener 487 to be installed from the outside of
the wall before the boards 477 and 478 are installed because
the fastener 487 is located to the left (as seen in Fig. 20)
of the left edge of the flange 482. Further, the fastener
487 is able to penetrate the board 476 at a location sub-
stantially spaced from the edge 491, so that the edge por-
tion of the board 476 does not fracture. The longer length
of the flange also increases the strength of the post 470.
It should be kept in mind that a hollow wall as
disclosed herein is particularly suited to enclose or sur-
round a hollow shaft (such as an elevator shaft) of a build-
ing. The inner side of the wall is close to the shaft as
shown in Fig. 1 and therefore the wall must be assembled
entirely from the outside. With reference to Fig. 20, the
fasteners 487 and 488 may be installed from the outside of
the wall using a suitable power tool, because these fasten-
- 32 -
21fi9~ 0~
_
ers 487 and 488 are clear of the edges of the flanges 482
and 484. Thereafter, the outer boards 474, 475, 477 and 478
are installed from the outside of the wall.
Another very important 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, in-
volves 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 complete elevator shaft wall is
desired, leaving access to the shaft, over the four-foot
wall, during early phases of construction, for easy instal-
lation of cants or the like. Also, accordingly, core boards
can be omitted or removed from between the top horizontal
stud and the ceiling track without weakening substantially
the resultant wall, as occurs in prior vertical stud struc-
tures, 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 made stronger proportional
to the weight on them, which is not true of vertical studs,
- 33 -
216910~
which obviously do not carry the weight of core boards
between them. With core board edges bevelled and horizontal
stud webs or tabs at corresponding acute angles, a substan-
tial 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 guiding 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
diagonal portion 186; in Fig. 10, it comprises web diagonal
portion 232; in Fig. 11, it comprises upwardly and outwardly
extending lip portion 296 and angled portion 292; and in
Fig. 12, the guide structure comprises web ramp portion 350.
This type of guide structure facilitates positioning of the
core board at the desired location on the stud by an assem-
bler 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
- 34 -
21fi~1Ql
which is engageable with the lower edge of the core board
and which is inclined downwardly and inwardly toward the
inner flange of the stud which, in the preferred embodi-
ments, includes an upper portion having a double 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 location.
Still additional advantages of the invention
reside in the strong vertical corner posts and vertical
center post, which support the core boards and the horizon-
tal studs. The center post further enables a very long wall
to be assembled.
Although the invention has been described as a
shaft wall for construction around elevator shafts, its
advantages will be equally available when the wall is con-
structed 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
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2 1 691Ql
would be no reasonable height limitation. Conversely, prior
shaft walls required vertical studs with ~lmensions of more
than 2-1/2 inches flange-to-flange when the wall exceeded
the normal heights. For example, 4-inch and 6-inch
flange-to-flange vertical studs were required for construc-
tions when heights increased above about 14 feet. The
present invention provides a system wherein the 2-1/2-inch
flange-to-flange dimension is adequate regardless of wall
height. Still further, 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 configu-
ration built in accordance with the present invention will
also provide a number of benefits of the preferred embodi-
ments 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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