RELATED APPLICATION

[0001] The present application is a Non-Provisional of, and claims 35 U.S.C. 119 priority from, US Provisional application Serial No. 63/362,798 filed April 11 , 2022, and US application Serial No. 18/060,384 filed November 30, 2022, the contents of which are incorporated by reference.

BACKGROUND

[0002] The present disclosure relates generally to noncombustible exterior structural walls, and more specifically to buildings with noncombustible exterior structural walls that include lightweight structural cementitious panels.

[0003] Exterior walls of buildings serve a number of different functions. Specifically, exterior walls provide structural support and resist uniform, lateral, axial and concentrated loads applied to the building. Additionally, exterior walls act as a water, vapor and air barrier for the building. Further, exterior walls provide protection from flying debris during storms and are noncombustible. Beyond providing these functions, it is desired to reduce the overall thickness of the exterior walls.

[0004] Many modern buildings use a steel frame within the exterior structural walls. Typically, noncombustible paneling is attached to the steel frame members. This noncombustible paneling sometimes includes cement panels. For example, U.S. Pat. No. 8,079,198 to Tonyan et al., incorporated herein by reference, discloses a residential and commercial construction including a metal frame and lightweight cement panel shear wall. The shear wall is made from a mixture of inorganic binder and lightweight fillers. The combination of a metal frame with cement panels results in the noncombustible shear wall system. [0005] Additionally, U.S. Pat. No. 8,122,679 to Tonyan et al., incorporated herein by reference, discloses wall systems having cement panels employed on metal frames. In particular, the disclosed wall system includes structural cement panels which are mechanically and/or adhesively fastened to a fire wall or other fire resistive assembly light gauge cold formed metal framing system, which acts as a shear resistant diaphragm. Moreover, U.S. Pat. No. 8,061 ,108 to Tonyan et al., incorporated herein by reference, discloses a foundation system which includes metal framing members that support a reinforced, lightweight, dimensionally stable cementitious panel.

[0006] However, conventional buildings which utilize a steel frame with noncombustible panels also include sheet steel cross-strapping or complete sheets of steel, referred to as shear walls, to resist lateral loading. Moreover, the steel frame typically includes high gauge studs for accommodating axial loading. Further, special multi-layered, built-up facades are commonly used for providing protection from flying debris during storms. Additionally, these exterior wall structures require separate water, vapor and air barriers in order to achieve proper building seals. In particular, the noncombustible panels are unable to adequately repel water and vapor.

[0007] Accordingly, there is the need for a building with a noncombustible exterior wall structure which addresses the above-listed drawbacks.

SUMMARY

[0008] The above-listed need is met or exceeded by the present noncombustible exterior structural wall. In particular, the present noncombustible structural exterior wall includes a plurality of noncombustible panels which resist uniform, lateral, axial and concentrated loads, while acting as a water, vapor and air barrier for the building.

Accordingly, the presently disclosed noncombustible structural exterior wall does not include a separate water and vapor barrier such as TYVEK® (sheet membrane product), other membrane coverings, or a spray coating, as is used in conventional exterior wall structures. In this application, such coatings and membranes will be collectively referred to as an air/weather membrane. The noncombustible panels are inherently water resistant and noncombustible. Therefore, application of either caulk or tape to the joints of the noncombustible panels is sufficient to seal the building as required by building codes. [0009] Moreover, the present noncombustible structural exterior walls are noncombustible according to the International Building Code (IBC) based on tests performed according to ASTM E136. In addition, the present noncombustible structural exterior wall includes relatively thin support studs due to the load carrying capacity and lateral resistance of the noncombustible panels. Further, the noncombustible panels protect the building from windblown debris. Preferably, the noncombustible exterior structural walls also include an insulating material located between the support studs. Moreover, an exterior ornamental covering is preferably applied directly to the noncombustible panels.

[0010] More specifically, the present disclosure includes a noncombustible exterior structural wall of a building, where the noncombustible wall includes a steel frame with a plurality of vertically oriented support studs, a plurality of noncombustible panels attached directly to the steel frame, and an exterior ornamental covering attached directly to the plurality of noncombustible panels with an absence of an air/weather membrane. In preferred embodiments, the noncombustible panels are noncombustible fiber-cement-panels which include at least one of Portland cement and Magnesium Oxide cement with reinforcing.

[0011] In another embodiment, the noncombustible panels are resin or polymer- based reinforced panels. Preferably, the noncombustible exterior structural wall also includes an insulating material between the vertically oriented support studs.

[0012] In yet another embodiment, the noncombustible panels resist lateral loads applied to the noncombustible exterior structural wall, and the noncombustible panels have a thickness of approximately ¹ /2 inch (1 .25 cm).

[0013] A second embodiment of the present disclosure includes a building with a plurality of noncombustible exterior structural walls. The noncombustible exterior structural walls include a steel frame with a plurality of vertically oriented support studs, a plurality of noncombustible panels attached directly to the steel frame, and an exterior ornamental covering attached directly to the plurality of noncombustible panels.

BRIEF DESCRIPTION OF THE DRAWINGS

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

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

DETAILED DESCRIPTION

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

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

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

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

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

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

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

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

[0024] Preferably, the noncombustible panels 20 resist lateral loads applied to the noncombustible exterior structural wall 12, and function as shear walls. In this way, the noncombustible exterior structural walls 12 do not require an additional shear wall.

Moreover, the noncombustible panels 20 preferably have a thickness of approximately ¹ Z> inches or less.

[0025] An exemplary structural panel 20 at ¹ /2 inch thick has a shear wall capacity in excess of 1900 PLF (pounds per linear foot). Slightly thinner 7/16 inch panels 20 made of Oriented Strandboard (OSB) have shear wall capacity of between 458 and 1017 PLF depending on screw spacing. Vapor permeability of such panels 20 is approximately 2.84 permeability for 1/2 inch thick panel and 1.4 permeability for % inch panels.

[0026] Permeability is classified as: <0.1 is impermeable; 0.1 <x<1 is Class II semi- impermeable; and 1 <x<10 is Class III permeable, which is still considered semi-permeable.

Accordingly, the panels 20 are Class III are a suitable air and water barrier. Joints/seams and screw heads are taped or caulked. Nominal uniform load capacity on a face of the panel 20, representing wind resistance with a stud spacing of 24 inches is 270 lb.

Concentrated load capacity of the panel 20 is 764 lb. when the panel is dry.

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

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

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

[0030] While a particular embodiment of the present building with noncombustible exterior structural walls has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.