Firestop block and thermal barrier system for fluted metal decks

Abstract

The invention provides methods, systems and devices for installing thermal barriers in openings or gaps in or between structures such as walls, ceilings and floors. At least one firestop block is positioned in the holes or gaps formed by the wall and a fluted metal deck of the ceiling or floor. The walls can be gypsum walls, which may have a metal track at the top or bottom, or could be block walls made of concrete or similar material. The firestop blocks are made of fire resistant material such as hydratable cement or intumescent materials. A flexible or flowable firestop material that is operative to cure or harden, such as elastomeric sealant or silicone, or hydratable cementitious slurry, is introduced into the space between the firestop block and the hole or gap, as a sealant or filler.

1 . A building joint structure, comprising: a thermal barrier in a joint gap between a first structure comprising a wall and a second structure comprising a ceiling or floor, said thermal barrier comprising at least one firestop block, the firestop block comprising an acceptable fire resistant material that is configured to conform to the dimensions of the join gap. 
   
   
       2 . The joint structure of  claim 1 , wherein the structure comprising the ceiling or floor is a fluted metal deck. 
   
   
       3 . The joint structure of  claim 1 , wherein the acceptable fire resistant material of the firestop block comprises a cementitious material, a hydratable cementitious material or an intumescent material. 
   
   
       4 . The joint structure of  claim 1 , further comprising a flexible or flowable fire resistant filler material contained within spaces between the joint gap and the firestop block, thereby sealing the joint gap. 
   
   
       5 . The joint structure of  claim 4 , wherein the flexible of flowable fire resistant filler material is an intumescent material. 
   
   
       6 . The joint structure of  claim 1 , wherein said firestop block is located in a head-of-wall joint. 
   
   
       7 . A firestop block made of acceptable fire resistant material having a top surface, a bottom surface, side surfaces and end surfaces, and wherein said firestop block is configured to conform to the dimensions of a joint gap between a first structure comprising a wall and a second structure comprising a ceiling or floor. 
   
   
       8 . The firestop block of  claim 7 , wherein the ceiling or floor is a fluted metal deck. 
   
   
       9 . The firestop block of  claim 7 , wherein the fire resistant material comprises a cementitious material, a hydratable cementitious material or an intumescent material. 
   
   
       10 . The firestop block of  claim 9 , wherein the firestop block is configured in the shape of an elongated trapezoid. 
   
   
       11 . The firestop block of  claim 10 , further comprising at least one scoring mark on the top surface for breaking the firestop block at the location of the scoring marks. 
   
   
       12 . A method of creating a thermal barrier in a building joint gap between a first structure comprising a wall and a second structure comprising a ceiling or floor, comprising the step of:
 inserting into said joint gap at least one firestop block comprising an acceptable fire resistant material that is configured to conform to the dimensions of the join gap.   
   
   
       13 . The method of  claim 12 , further comprising the step of filling or sealing the space between the joint gap and the firestop block with a flexible fire resistant material. 
   
   
       14 . The method of  claim 13 , wherein the structure comprising the ceiling or floor is a fluted metal deck. 
   
   
       15 . The method of  claim 12 , wherein the firestop block comprises a cementitious material, a hydratable cementitious material or an intumescent material. 
   
   
       16 . The method of  claim 13 , wherein the flexible fire resistant material is an intumescent material. 
   
   
       17 . The method of  claim 12 , wherein the firestop block is configured in the shape of an elongated trapezoid.