Blast resistant structural building element

Abstract

One embodiment is directed to a blast resistant building element having a compressed polymeric foamed core, the element including an internal track having an internal track web integrally connected to a pair of spaced apart and outwardly extending internal track sidewalls so as to define a first generally U-shaped profile, a surrounding track having a surrounding track web integrally connected to a pair of spaced apart and outwardly extending surrounding track sidewalls so as to define a second generally U-shaped profile and a compressed polymeric foamed core disposed within the internal track, wherein the compressed polymeric foamed core exerts a force against a portion of internal surfaces of the internal track and surrounding track.

1 . A method of constructing a blast resistant building element having a compressed polymer foamed core, the method comprising:
 bending a first elongated sheet-metal piece to form a surrounding track, having a surrounding track web integrally connected to a pair of spaced apart and outwardly extending surrounding track sidewalls to thereby define a first generally U-shaped profile;   bending a second elongated sheet-metal piece to form an internal track having an internal track web integrally connected to a pair of spaced apart and outwardly extending internal track sidewalls to thereby define a second generally U-shaped profile;   applying an adhesive to at least one of the surfaces within the generally U-shaped internal track;   positioning a block of foamed polymer within the first generally U-shaped internal track, the block of foamed polymer being slightly larger than the space defined by the internal track web and its pair of spaced apart and outwardly extending internal track sidewalls;   positioning the surrounding track about the internal track, and compressing the tracks together to yield the blast resistant building element having the compressed polymer core.   
     
     
         2 . The method of  claim 1 , further comprising coupling the surrounding and internal track in a compressed position. 
     
     
         3 . The method of  claim 2 , wherein coupling the surrounding and internal track comprises applying a plurality of pins along a first face of the building element. 
     
     
         4 . The method of  claim 3 , wherein the pins extend through adjoining surrounding and internal track sidewalls and into the core. 
     
     
         5 . The method of  claim 3 , wherein coupling the surrounding and internal track comprises applying a plurality of pins along a second opposing face of the building element. 
     
     
         6 . The method of  claim 1 , wherein the core comprises polystyrene. 
     
     
         7 . The method of  claim 1 , wherein the surrounding track sidewalls extend past the internal track web in the formed building element. 
     
     
         8 . A blast resistant building element having a compressed polymeric foamed core, the element comprising:
 an internal track having an internal track web integrally connected to a pair of spaced apart and outwardly extending internal track sidewalls so as to define a first generally U-shaped profile;   a surrounding track having a surrounding track web integrally connected to a pair of spaced apart and outwardly extending surrounding track sidewalls so as to define a second generally U-shaped profile; and   a compressed polymeric foamed core disposed within the internal track, wherein the compressed polymeric foamed core exerts a force against a portion of internal surfaces of the internal track and surrounding track.   
     
     
         9 . The blast resistant building element of  claim 8  further comprising an adhesive layer surrounding a portion of the core and coupling a portion of the core to an internal portion of the internal and surrounding tracks. 
     
     
         10 . The blast resistant building element of  claim 8 , further comprising a plurality of pins on a first set of opposing faces extending through adjoining surrounding and internal track sidewalls and into the core. 
     
     
         11 . The blast resistant building element of  claim 8 , wherein the core comprises polystyrene. 
     
     
         12 . The blast resistant building element of  claim 8 , wherein the surrounding track sidewalls extend past the internal track web.