IMPROVED SYSTEM AND METHODS FOR FIRE RESISTANT PANELS

SYSTEMES ET METHODES AMELIORES DESTINES A DES PANNEAUX IGNIFUGES

English Abstract

A method of applying fire resistant panel assembly to a wall is described. A
first layer of fire resistant panels are applied to a wall. Each panel
comprises a first
planar surface, a second planar surface substantially parallel to the first
planar surface,
and an edge between the first and second planar surfaces. Each of the panels
is
attached to the wall such that the first planar surface is substantially
parallel to the
wall. A second layer of the fire resistant panels is applied to the first
layer of fire
resistant panels. Each of the panels of the second layer is attached to the
first layer
such that the first planar surface is substantially parallel to the second
planar surface
of panels in the first layer. The edges of panels in the first layer are
substantially
covered by panels in the second layer and edges of the panels in the second
layer are
substantially over panels of the first layer.

Claims

WE CLAIM:
1. A method of applying fire resistant panel assembly to a wall comprising:
applying a first layer of fire resistant panels to a wall, wherein each panel
comprises a first planar surface, a second planar surface substantially
parallel to the
first planar surface, an edge between the first and second planar surfaces,
wherein
each of the panels is attached to the wall such that the first planar surface
is
substantially parallel to the wall;
applying a second layer of the fire resistant panels to the first layer of
fire
resistant panels, where in each of the panels of the second layer is attached
to the first
layer such that the first planar surface is substantially parallel to the
second planar
surface of panels in the first layer;
wherein the edges of panels in the first layer are substantially covered by
panels in the second layer and edges of the panels in the second layer are
substantially
over panels of the first layer.
2. The method of claim 1 wherein the fire resistant panels further comprise
an
orientation, wherein the method of applying a first layer further comprises
aligning
one or more of the panels of the first layer in a first orientation, and the
method of
applying a second layer further comprises aligning one or more panels of the
second
lawyer in a second orientation, wherein the second orientation is
substantially
perpendicular to the first orientation.
3. The method of claims 1 or 2 wherein the fire resistant panels comprise
woven
rock wool.
4. The method of any one of claims 1 to 3 further comprising applying a
cladding
to the second layer of fire resistant panels.
5. The method of any one of claims 1 to 4 wherein applying a first layer of
fire
resistant panels to a wall further comprises using one or more first fasteners
to attach
the panels of the first layer to the wall; and
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wherein applying a second layer of the fire resistant panels to the first
layer
further comprises using one or more second fasteners to attach the panels of
the
second layer to the panels of the first layer such that there is low thermal
conductivity
between the first fasteners and the second fasteners.
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Description

Attorney Docket: 17901-21
IMPROVED SYSTEM AND METHODS FOR FIRE RESISTANT PANELS
TECHNICAL FIELD
100011 This invention relates to the use of panels on the surfaces of walls
and roofs. In
particular, this invention relates to use of a double layer of woven rock wool
panels to
improve fire resistance of walls.
BACKGROUND
[0002] Walls and roofs, in addition to providing structural supporting,
provide barriers to
the passage of elements into the building. Various coverings, cladding or
layers added
can block or slow water and wind.
[0003] Some wall coverings also improve the heat insulation properties of the
wall,
which can improve the energy efficiency of the building. Some wall coverings
are
susceptible to fire.
[0004] It is desirable to have a wall covering that is easy to install,
provides heat
insulation and is resistant to fire.
SUMMARY
100051 A method of applying fire resistant panel assembly to a wall is
described. A first
layer of fire resistant panels are applied to a wall. Each panel comprises a
first planar
surface, a second planar surface substantially parallel to the first planar
surface, and an
edge between the first and second planar surfaces. Each of the panels is
attached to the
wall such that the first planar surface is substantially parallel to the wall.
A second layer
of the fire resistant panels is applied to the first layer of fire resistant
panels. Each of the
panels of the second layer is attached to the first layer such that the first
planar surface is
substantially parallel to the second planar surface of panels in the first
layer. The edges of
panels in the first layer are substantially covered by panels in the second
layer and edges
of the panels in the second layer are substantially over panels of the first
layer.
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BRIEF DESCRIPTION OF THE DRAWINGS
10006] In drawings which illustrate by way of example only various embodiments
of the
disclosure,
[0007] Figure 1 is a perspective view of a wall system.
DETAILED DESCRIPTION
[0008] A wall generally typically is framed using studs 10, either steel or
wood. The
studs are typically oriented vertically with a fix spacing between the studs,
typically 12",
16" or 24" and may be mounted in steel track 20
[0009] On the surface of the studs 10 facing the exterior of the building,
sheathing,
barriers or panels may be attached to provide protection from the elements.
These may
include vapour barrier 50, insulated panels 60 or other panels. The wall
system, is the
combination of the wall and the barriers and panels that are affixed to the
wall.
100101 As will be described below, it is desirable that the wall and the
barriers and panels
attached provide sufficient heat insulation to provide energy efficiency and
that the wall
system meet or exceed pertinent fire code requirements.
100111 In an embodiment, the wall system includes a fiberglass mat gypsum
sheathing 40
secured to the exterior of the studs 10. The gypsum sheathing may be DensGlass
or
similar material that provides a solid surface with a fire rating based on
thickness and
may also provide moisture protection.
[00121 A vapour barrier 50 made of plastic, such as polyethylene film may be
attached to
the sheathing 40. The film may be adhered using glue or other means to reduce
or
eliminate the use of staples, nails or other modes of attachment that cause
holes in the
film. The vapour barrier 50 preferably blocks the transmission of air and
water vapour
through the wall system. The polyethylene film may comprise tri-woven layers.
100131 Foam panels 60 may be mounted to the wall using mounting tracks, such
as using
z-channels 70, as described in the applicants application 62/441,158 which is
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incorporated by reference. The foam panels 60 may provide insulation, both to
heat
transfer and sound. The foam panels may be made from polyurethane.
[0014] To the wall, fire resistant panels 80, 90 are mounted. The panels are
preferably
made of woven rock wool, such as sold by Roxul. In an embodiment, the panels
are four
feet by eight feed. The panels may be one and half inches thick. The material
preferably
has an R-value of approximately 4.2 hr ft2/Btu. The two layers of the woven
rock wool
panels may be mounted to the wall. If the panels are thinner, or have lower
fire ratings,
additional layers of the panels may attached.
[0015] A first layer 80 may be mounted such that the panels are oriented in a
first
orientation with the flat surface of the panels of the first layer mounted to
the wall. For
example, the first orientation may have the long dimension of the panels in
the
substantially horizontal.
[0016] A second layer 90 of the panels may be mounted to the first panel in a
second
orientation, with the flat surface of the panel parallel with the first layer.
The second
orientation differs from the first orientation such that the seams 85 or
joints between
panels of the first layer are substantially covered by panels of the second
layer.
Preferably, the panels of the second layer are mounted substantially
perpendicular to the
panels of the first layer. Similarly, the seams 95 of the second layer of
panels 90 are
substantially covered by panels of the first layer 80.
100171 If more than two layers of panels are used, the additional layers may
be similar
cross-laminated to cover seams of underlying layers. By having joints and
seams covered,
the layered panels reduce the transfer of flame and heat exposure to other
parts of the
wall system, including the foam panels.
100181 If, in an embodiment, the panels are square such that a first dimension
is
substantially the same as a second dimension, the panels of the second layer
may be
mounted offset from the panel from the panels of the first layer. Preferably,
the panels of
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the second layer are offset from the panels of the first layer by
approximately half the
length of the dimension of the square panels.
100191 To the second layer 90, additional protective layers may be attached
such as
siding or other rain and weather resistant layer, which may also be referred
to as wall
cladding. The weather resistant layer may be affixed to the wall, and to the
second layer
of the fire resistant panel using a hat track 100 or other attachment means.
[00201 The first and second layers of the fire resistant panels may be mounted
to the wall
using a system of interlocking panels and support members as described in
Application
No. 62/441,158. Preferably the panels are mounted such that fasteners do not
provide a
thermal bridge through both the first and second layers. By reducing the
thermal
conductivity of the panels and the fasteners, the panel layers provide
additional insulation
and improve the fire resistance of the panels.
100211 Various embodiments of the present invention having been thus described
in
detail by way of example, it will be apparent to those skilled in the art that
variations and
modifications may be made without departing from the invention. The invention
includes
all such variations and modifications as fall within the scope of the appended
claims.
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Representative Drawing