AU2003200746B2 - Wall system and wall including same - Google Patents

Description

Regulation 3.2 AUSTRALIA Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT (ORIGINAL) Name of Applicant: Boral Australian Gypsum Limited Actual Inventors: David Stephens; John Bajkai; Mark Debevc; Bernard Shalekoff; Bill Poynter and Andrew Close Address for Service: DAVIES COLLISON CAVE, Patent Attorneys, 1 Little Collins Street, Melbourne, Victoria 3000. Invention Title: WALL SYSTEM AND WALL INCLUDING SAME The following statement is a full description of this invention, including the best method of performing it known to me/us: - 1- WALL SYSTEM AND WALL INCLUDING SAME The present invention relates to a wall system and wall including such a system. In particular, the invention relates to a wall system that includes shaft liner material that 5 extends between a length of track secured to an upper support surface of the wall system and a length of angle secured to a lower support surface of the wall system. Various wall systems are known from the prior art. These include systems designed for separation of living areas or separate apartments in an apartment building. In many 10 instances such systems are required to provide sound insulation between adjoining properties and/or a so-called "fire-wall" that protects adjoining properties from fire. In cases where sound insulation or fire protection are required, insulating materials are employed. These may include a sound insulating material that is disposed between plaster 15 board surfaces of the walls, or fire resistant plaster board may be used. In many instances it is difficult to assemble and install such systems due to multi-layered structures within the system or due to the weight of components that require heavy lifting. 20 Advantageously the present invention provides an alternative system that is easy to install and avoids the need for heavy lifting. In particular, the invention advantageously provides a system that includes readily available components that are easy to handle and that can be easily installed by a plastering contractor. 25 According to the present invention there is provided a wall system when installed to form a wall supported between existing fixed upper and lower support surfaces, the wall system including: a length of track secured to the existing fixed upper support surface and extending along the length of the wall system; 30 a length of angle secured to the existing fixed lower support surface and extending along the length of the wall system such that a web of the length of angle extends vertically -2 from the lower support surface; first and second shaft liner means, each extending between the track and the angle such that lower edges of said first and second shaft liner means are located within said angle and upper edges of said first and second shaft liner means are located within said track; and 5 a separating member extending vertically between the first and second shaft liner means and including an I-section having two opposing flanges and a central web extending between the opposing flanges; wherein a vertical edge of the first shaft liner means is located between the flanges of the I-section on one side of the central web and an opposing vertical edge of the 10 second shaft liner means is located between the flanges of the I-section on the opposing side of the central web, In order to provide better acoustic properties, fire-seal material may be provided within the wall system. For example, in a preferred embodiment a length of fire-seal material is 15 provided along the length of the wall system between the upper edges of the first and second shaft liner means and the track. Preferably, the fire-seal material is a foamed sealing rod and provides not only fire resistance, but also provides for improved acoustic properties in the wall system. 20 Although the first and second shaft liner means may include a single sheet of shaft liner material, in order to make installation of the system easier, it is preferred that each of the first and second shaft liner means includes a pair of shaft liner panels. Preferably, the first and second shaft liner means include two 25 mm shaft liner panels, such as Boral Shaftliner panels or the like. This advantageously ensures that no heavy lifting is required 25 during assembly and installation of the wall system. The wall system may be of any suitable length or height, depending on the height and length of the area to be partitioned or walled off. In some instances, therefore, the wall system may only include the first and second shaft liner means, each respectively 30 extending from opposing walls and being separated by the separating member. That is, in one embodiment the first shaft liner means extends between a first wall surface and the separating member and the second shaft liner means is a final shaft liner means and P:\OPER\Axd\2614975 complete.doc-28/02/03 -3 extends between the separating member and a second wall surface. In other situations, there will be additional shaft liner means to the first and second shaft liner means. That is, in some instances the first shaft liner means extends between a first 5 wall surface and the separating member and the second shaft liner means extends from the separating member towards a second wall surface, and at least one additional separating member and associated additional shaft liner means is disposed between the second shaft liner means and the second wall surface, the additional separating member(s) and additional shaft liner means terminating with a final separating member and a final shaft 10 liner means that extends between the final separating member and the second wall surface. The above description provides some broad detail of positioning the first and second shaft liner means between a length of track secured to an upper support surface and a length of angle secured to a lower support surface. This arrangement, particularly the inclusion of a 15 length of angle at a lower support surface to which the shaft liner means are secured, provides for easy installation of the wall system according to the invention. It is also noted here that the term "track" as used herein includes within its scope not only an elongate member having two opposing flanges extending from a web, but also a pair of opposing angle lengths that may effectively provide the same function. In a preferred 20 embodiment, a similar arrangement is provided at the vertical edges of the shaft liner means where they respectively meet the wall surfaces between which the wall system extends. That is, in a preferred embodiment a vertical edge of the first shaft liner means is received by a track secured to the first wall surface and a vertical edge of the final shaft liner means, which may be the second shaft liner means or an additional shaft liner means, 25 is received by an angle secured to the second wall surface. As with the arrangement for the upper and lower support surfaces, in a preferred embodiment a fire-seal material is provided and extends between the vertical edge of the final shaft liner and the angle and/or the second wall surface. Again, the fire-seal material 30 is preferably a foamed sealing rod that improves not only the fire resistant properties of the wall system, but also the acoustic properties of the system.

PAOPER\Axd\2614975 compitcdc-28M2)3 -4 The present invention also provides a wall that includes a wall system according to the invention and as described above, wherein a facing material is secured to one or both sides of the wall system. According to one embodiment the facing material is secured directly to 5 one or both sides of the wall system. In order to increase the acoustic and/or fire resistant properties of the wall, a fire and/or sound resistant material may be disposed between the facing material and the wall system on one or both sides of the wall system. Appropriate materials for this purpose would be 10 readily ascertained by those skilled in the art of fire resistant and sound acoustic wall construction. For example, the fire and/or sound resistant material may include a glass wool batt or polyester batt. Embodiments of the present invention will now be described in more detail with reference 15 to the accompanying drawings in which: Figure 1 illustrates a vertical section of the wall system; Figure 2 illustrates a horizontal section of the wall system; Figures 3-7 illustrate various walls that include the wall system of the invention as part of 20 their structure. Referring firstly to Figures 1 and 2, the wall system 10 includes a length of track 11 that is secured to an upper support surface 12. The length of track 11 may include, for example, a 0.55 mm BMT 25/40 mm flange GMS track. The track 11 is fastened to the upper support 25 surface 12 by bolts. For example, the track 11 may be fastened at 600 mm maximum centres with expanding masonry anchors, such as Dynabolts. A length of angle 13 extends along the length of the wall system 10 and is secured to a lower support surface 14 such as a reinforced concrete floor. Again, the angle 13 may be 30 secured to the lower support surface 14 by means of a bolt, such as by fastening at 600 mm maximum centres with expanding masonry anchors such as Dynabolts.

P:\OPER\Axd\2614975 completc.doc-28/02A)3 -5 As illustrated in Figure 1, a first shaft liner means 15 including a pair of shaft liner panels 15a and 15b extends between the track 11 and the angle 13. In this embodiment, the pair of shaft liners 15a, 15b are each 25 mm Boral shaft liners. The use of separate 25 mm 5 thick x 600 mm shaft liner panels reduces the loads installers are required to lift at one time. Also, the use of a pair of 25 mm shaft liner panels introduces sufficient mass into the wall to benefit its acoustic isolation properties. A foamed sealing rod 16, such as a continuous 22 mm IBS rod, is inserted above the shaft 10 liners 15a, 15b to provide a fire and acoustic seal whilst allowing for some deflection. Fire and/or sound grade sealant 17 may also be provided at upper and lower junctures where plasterboard 18 of a wall including the wall system 10 is secured to the shaft liners 15a, 15b. The plasterboard 18 may include, for example, 13 mm Boral FireStop plasterboard and may be secured to the shaft liner material 15a, 15b and/or a separating member 20 by 15 means of screws 19. The use of plasterboard sheets such as FireStop plasterboard sheets manufactured by Boral provide good thermal insulation of the wall during a fire event. The separating member 20 in the form of an I-stud extends between the track 11 and the length of angle 13 and separates shaft liner means 15 from further shaft liner means in the 20 wall system. This is best illustrated in Figure 2. It will, however, be appreciated that the support member may take other forms so long as it includes an I-stud section. Referring to Figure 2, the wall system 10 extends between a first wall surface 21 and a second wall surface 22. A vertical track 24 receives the first shaft liner means 15 25 constituted by the pair of shaft liners 15a, 15b. An opposing end of the shaft liners 15a, 15b is received by the separating member 20. The ends of the shaft liner 15b are secured to the track 24 and the separating member 20 by means of screws 25. The screws 25 also extend through a plasterboard sheet 18 applied to the wall system 10. 30 A second shaft liner means 26 including a pair of shaft liners 26a, 26b extends from the separating member 20. The shaft liners 26a, 26b may be the final shaft liner means in the P:\OPER\Axd\2614975 complcte.doc-28/02/03 -6 wall system 10 and may therefore extend to the second wall surface 22. Alternatively, the shaft liners 26a, 26b may extend to an additional separating member (not shown) and so on. 5 A final shaft liner means 27 including shaft liners 27a, 27b (which may be the second shaft liner means 26) extends to the second wall surface 22 and is received by a vertical length of angle 28. The shaft liners 27a, 27b are secured to each other, to the angle 28 and to the plasterboard 18 by means of screws 29. 10 A sealant, such as a fire/sound grade sealant 30 is applied in the gap between the plasterboard 18 and the second wall surface 22 to improve acoustic properties and/or fire resistant properties of the wall. Also, a foamed sealing rod 31 is also provided between the shaft liner 27b and the second wall surface 22. This allows closure of the wall and also improves the fire resistant and acoustic properties of the wall. 15 The construction of the wall system according to the invention will now be discussed in further detail with reference to Figures 1 and 2. This discussion will further illustrate the advantages provided by the system of the invention. 20 Installing the wall system according to the invention is relatively straight forward and may be carried out by a plastering contractor or the like. Firstly, the track 11 is installed at the head of the wall by fastening at maximum 600 mm centres. The length of angle 13 is then installed at the base of the wall, again fastening at maximum 600 mm centres. The vertical track 24 is then installed where the wall commences fastening at maximum 600 mm 25 centres. An acoustic sealant is then applied where the angles and tracks abut surfaces. For example, along the horizontal edges of the track 11 and angle 13 where they abut surfaces 12 and 14 respectively. Alternatively, an acoustic sealant or closed-cell acoustic foam may 30 be applied between the angles and tracks and their respective abutting surfaces.

PAOPER\Ax\2614975 cmplete.doc-2802/f3 -7 The I-studs and shaft liner sheets are then cut in lengths, such as a length 15 mm shorter than the height of the floor 14 to the sealing 12. The shaft liner sheet 15a is then fitted into the head track 11 and the vertical wall track 24 (or previous I-stud 20). The shaft liner sheet 15a is fitted hard against the base angle 13. 5 A 22 mm diameter IBS rod 16 is then pushed into the gap above shaft liner sheet 15a. This ensures that there are no gaps between the shaft liner means 15 and the track 11. The second shaft liner sheet 15b is then fitted into the head and wall tracks 11 and 24 respectively and flush against the previous shaft liner sheet 15a. 10 Once the first shaft liner means 15a is fitted into the head and wall tracks 11 and 24 respectively, an I-stud is fitted into the head track 11 and against the end of the two shaft liner sheets 15a, 15b so that they fit snugly in between the flanges of the I-stud 20 and hard against its web. The base angle 13 is then secured to the I-stud 20, for example with a 15 single screw. Additional shaft liner sheets (such as sheets 26a, 26b) and additional I-studs are then fitted until the remaining wall length is 600 mm or less. Following this, the vertical angle 28 is fastened at maximum 600 mm centres to the face of the wall 22 that the wall system is 20 being terminated on. In fastening the vertical angle 28, it should be ensured that the free leg of the vertical angle 28 lines up with the upright angle of the angle 13 at the base of the wall. A shaft liner sheet 27a is then cut to fit snugly between the final stud web and the angle 28 25 on the terminating wall 22. This shaft liner sheet is then cut horizontally in half. The bottom half of the shaft liner sheet 27a is installed between the stud flanges and screwed to the angle 28 on the terminating wall 22 at 400 mm centres. The top half of the shaft liner sheet 27a is then installed between the stud flanges and against the face of the bottom sheet. The top half of the shaft liner sheet 27a is then slid upwards until it is within the 30 head track 11 and positioned so that it sits directly over the edge of the bottom half of the shaft liner sheet 27a. The top half of the sheet is then secured to the angle 28 on the P:\OPER\Axd\614975 compiete.doc-2802A)3 -8 terminating wall 22 at 400 mm centres. Once the shaft liner sheet 27, in its two halves, has been secured in place a 22 mm diameter IBS rod is pushed into the gap above the shaft liner sheet 27a ensuring that there 5 are no gaps. A second shaft liner sheet 27b is then cut to a width 17 mm narrower than the previous shaft liner sheet 27a. The second sheet 27b is then fitted into the head track 11 and slid home between the stud flanges leaving the 17 mm gap between the end of the shaft liner 10 sheet 27b and the terminating wall 22. The front sheet 27b is then secured to the back sheet 27a using screws at 200 mm centres along both sides of the horizontal cut and at 400 mm centres along the vertical edge. A continuous 22 mm diameter IBS rod 31 is then fitted in to the gap between the edge of 15 the last shaft liner sheet 27b and the terminating wall 22. This completes the construction of the wall system 10 according to a preferred embodiment of the invention. The wall may be finalised by constructing and sealing adjacent lining, furred or free standing walls, as required and discussed hereafter. 20 Figures 3 through 7 illustrate various embodiments of walls that include the wall system according to the invention. These embodiments include situations where a sheet of 13 mm Boral Plasterboard standard core is secured to the wall system (Figure 3) and where a 13 mm Boral FireStop board is secured to the wall system (Figure 4). These embodiments 25 also provide illustrations where a 75 mm glass wall blanket or batt, or a 75 mm polyester blanket or batt is provided on one or both sides of the wall system to provide for improved acoustic and fire insulation (Figures 5-7). An embodiment is also provided that illustrates a furring channel provided between the wall system and a sheet of Boral FireStop (Figure 7). 30 It will be appreciated that various other forms of walls including the wall system of the PAOPER\Axd\2614975 complcec.d-2/02/03 -9 invention may be devised and that Figures 3-7 only provide examples of such walls. The reference to any prior art in this specification is not, and should not be taken as, an acknowledgment or any form of suggestion that that prior art forms part of the common 5 general knowledge in Australia. The invention has been described by way of non-limiting example only and many modifications and variations may be made thereto without departing from the spirit and scope of the invention described. 10

Claims (13)

1. A wall system when installed to form a wall supported between existing fixed upper and lower support surfaces, the wall system including: 5 a length of track secured to the existing fixed upper support surface and extending along the length of the wall system; a length of angle secured to the existing fixed lower support surface and extending along the length of the wall system such that a web of the length of angle extends vertically from the lower support surface; 10 first and second shaft liner means, each extending between the track and the angle such that lower edges of said first and second shaft liner means are located within said angle and upper edges of said first and second shaft liner means are located within said track; and a separating member extending vertically between the first and second shaft liner means and including an I-section having two opposing flanges and a central web extending 15 between the opposing flanges; wherein a vertical edge of the first shaft liner means is located between the flanges of the I-section on one side of the central web and an opposing vertical edge of the second shaft liner means is located between the flanges of the I-section on the opposing side of the central web. 20

2, A wall system according to claim 1, wherein a length of fire-seal material is provided along the length of the wall system between the upper edges of the first and second shaft liner means and the track. 25

3. A wall system according to claim 2, wherein the fire-seal material is a foamed sealing rod.

4. A wall system according to claim 1, wherein each of the first and second shaft liner means includes a pair of shaft liner panels. 30

5. A wall system according to claim 1, wherein the first shaft liner means extends P:\OPER\Axd\2614975 completc.doc-2M2A3 -11 between a first wall surface and the separating member and the second shaft liner means is a final shaft liner means and extends between the separating member and a second wall surface. 5

6. A wall system according to claim 1, wherein the first shaft liner means extends between a first wall surface and the separating member and the second shaft liner means extends from the separating member towards a second wall surface, and wherein at least one additional separating member and associated additional shaft liner means is disposed between the second shaft liner means and the second wall surface, the additional separating 10 member(s) and additional shaft liner means terminating with a final separating member and a final shaft liner means that extends between the final separating member and the second wall surface.

7. A wall system according to claim 5 or 6, wherein a vertical edge of the first shaft 15 liner means is received by a track secured to the first wall surface and a vertical edge of the final shaft liner means is received by an angle secured to the second wall surface.

8. A wall system according to claim 7, wherein a fire-seal material is provided and extends between the vertical edge of the final shaft liner and the angle and/or the second 20 wall surface.

9. A wall system according to claim 8, wherein the fire-seal material is a foamed sealing rod. 25

10. A wall including a wall system according to any one of the preceding claims, wherein facing material is secured to one or both sides of the wall system.

11. A wall according to claim 10, wherein said facing material is secured directly to one or both sides of the wall system. 30

12. A wall according to claim 10, wherein a fire and/or sound resistant material is PAOPER\Axd\2614975 compctedoc-2A)23 - 12 disposed between said facing material and said wall system on one or both sides of said wall system.

13. A wall according to claim 12, wherein said fire and/or sound resistant material is a 5 glass wool batt or polyester batt. DATED: 28 February, 2003 10 by DAVIES COLLISON CAVE Patent Attorneys for the Applicant(s): BORAL PLASTERBOARD