Evaluation of Drywall Resilient Sound Isolation Clips. Dr. Peter D Antonio RPG Diffusor Systems, Inc. January 2010

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1 Evaluation of Drywall Resilient Sound Isolation Clips by Dr. Peter D Antonio RPG Diffusor Systems, Inc. January 2010

2 TABLE OF CONTENTS 0 INTRODUCTION 1. THEORY 1.1 TRANSMISSIBILITY 1.2 Static stiffness Springs Elastomers 2. PERFORMANCE ISSUES 2.1 Separate wall and ceiling clips 2.2 Elastomer resonant frequency 2.3 Secure mechanical capture of hat channel 2.4 Optimal pre-compression 3. CONCLUSION 4. APPENDIX CDM TEST REPORTS 2

3 0 INTRODUCTION In creating a box-in-box construction, it is necessary to isolate the floor, walls and ceiling from the existing structure. In this white paper we will explore one way to isolate drywall walls and ceiling from the structure when attached to either steel or wooden studs. This is accomplished using what are called resilient isolation clips, which attach to wood or steel studs and capture a steel hat channel to which drywall is attached. While there are variations on the theme in the market place, the basic approach is to resiliently isolate the hat channel to which the drywall is attached in an elastomer, which is supported by an outer steel frame, and mechanically fasten the surrounding metal frame of the clip to the stud. The Isomax, offered by Kinetics (top) and the QRW offered by RPG (bottom) are shown below. The thesis of this white paper is that there are four issues which can be improved upon, using the new RPG CDM-ISO-QRC and CDM-ISO-QRW. These four topics will be discussed in detail in the body of the paper, but are briefly listed here: 1. All current approaches utilize the same clip for both walls and ceiling, despite the fact that walls and ceiling offer totally different loads. RPG developed a separate ceiling, CDM-ISO-QRC, and wall, CDM-ISO-QRW, resilient isolation clip to optimally handle the different loads. 2. All current approaches utilize neoprene as the resilient elastomer and lower resonant frequency elastomers in the CDM-ISO- QRC and CDM-ISO-QRW can offer higher isolation efficiency 3. No current approach mechanically captures the steel hat channel. It is simply inserted into a resilient holder. 4. None of the available clips guarantee that the elastomer is under optimal compression. This is guaranteed using the failsafe pre-compression technique used in the RPG clips. 1 THEORY 1.1 Transmissibility The key metric describing isolation is the Transmissibility, T, which is proportional to the ratio, beta, of the disturbing frequency, fd, and the resonant frequency of the isolator, fr. The resonant frequency of a system is the frequency at which resonance or amplification takes place (beta=1), meaning that the displacement and the force transmission are maximized. Frequencies above fr times the square root of 2 will be isolated, with isolation increasing as beta increases. The isolation efficiency, I in either % or dbv is related to the transmissibility as shown. When T is plotted versus beta three regions are illustrated. The SCR, which I(%) = 100 ( 1 T) IdBv ( ) = 20 LogT ( ) with 1 T = fd 2 ( ) 1 f r is the stiffness controlled region and the DCR, damping controlled regions both cause amplification, meaning the disturbing noise is actually made louder. This occurs below a beta of the square root of 2, as can be seen in the transmissibility equation, because at this ration T=1 and all of the sound is transmitted. Above this we have the mass controlled region in which isolation is achieved. The x values indicate different amounts of damping and it can be seen that as you increase damping transmissibility increases. Now the complete equation for transmissibility, including damping, is given below. A possibly more instructive way of looking at isolation would be to plot the Isolation Efficiency, I in % and I(%) = 100 ( 1 T) dbv. Using this view it can be seen where the rule of thumb that IdBv ( ) = 20 LogT ( ) the isolator resonant frequency with should be 1/4 or less of the disturbing frequency. At this ratio, 2 1+ ( 2ξβ ) one can achieve greater than 90% T = isolation. It is noted that the 2 2 ( 1 β ) + ( 2ξβ) 2 greater this ratio, the greater the isolation efficiency, and this is precisely the phenomenon we will β = f fd r employ in our isolation clips, i.e. we will use elastomers that have a lower resonant frequency than conventional neoprene elastomers 3

4 to provide a greater isolation efficiency. The isolation efficiency is shown in blue in %, solid is for no damping and dashed is for 10% typical damping. The isolation efficiency is shown in red for dbv. It is important to also indicate that the isolation efficiency or transmission loss, TL, is what we should be discussing and not the STC, which is a derivative single number that does not include data below 125 Hz! 1.2 Static Stiffness versus Dynamic Stiffness All mechanical systems, including springs and elastomers once set into motion will oscillate at their natural frequency. In noise and vibration isolation this is THE key parameter to consider. As we have seen, the lower the natural or resonant frequency of the isolator, the greater the transmission loss Springs There are two equations that explain the behavior of a spring. The first is Hooks Law which says the restoring force is equal to the spring constant (static stiffness) times the static deflection. We also know that force is equal to the mass on the spring times the acceleration due to gravity. The second is the harmonic oscillator equation, which says the resonant frequency of a spring is proportional to the square root of the dynamic stiffness divided by the mass. These two relations are shown below and algebraic Elastomers design deflection is 20% of their height, so that for a 2 pad, the maximum deflection is 0.4. Typical neoprene elastomers have an r value of about 2-2.5, whereas the best CDM pads have an r=1.5. Therefore, the lowest possible resonant frequency using a natural rubber or polyurethane elastomer is 5 Hz, which is very effective, as we will illustrate. It is important to understand that the resonant frequency of an elastomer cannot be determined from the static stiffness, because elastomers have hysteresis due to their damping and need to be tested with an oscillatory frequency, typically 5-15 Hz. This is carried out at CDM using an Instron Press. The sample is tested between two rigid steel plates 300 mm x 300 mm. The static stiffness is measured through a load cell in the upper part: in a span of 1 minute the load is increased from 0 to the desired maximum load and then decreased at the same rate. Two conditional hysteresis loops are run, before registering the official test on the third load cycle. The data are expressed in a load versus deflection graph (see test reports in Appendix). The dynamic stiffness is measured in a similar way, except in this case the increasing load varies +/- 10% at a certain frequency, typically 15 Hz. The data are plotted as the dynamic stiffness as a function of the load. manipulation reveals the well known equation that the resonant frequency, fr, is proportional to the square root of r divided by the static deflection, delta. The factor r is equal to the reciprocal of dynamic stiffness divided by the static stiffness. We will describe the dynamic stiffness later, but it is not important at this time because r=1 for a spring and hence it is typically not shown in this well known equation. For a practical compression spring, the maximum deflection is roughly 2. Therefore, the lowest possible resonant frequency is 2.2 Hz. For machinery, springs offer an optimal isolator, provided they have added damping. For box-in-box isolation of walls, floors and ceilings a less costly option with a somewhat higher resonant frequency may be acceptable, i.e. an elastomer Elastomers Elastomers have an r value greater than 1 and a reasonable amount of internal damping. The higher this r-ratio, the further away from the ideal spring behavior. Above a factor of 4, the material becomes uninteresting as an isolator. Therefore, the resonant frequency of an elastomer is higher than that for a spring, due to the fact that r is greater than 1; and we need to now determine the dynamic stiffness, as well as the static stiffness. In addition to the r factor, elastomers are also affected by their shape factor. The reason is that while springs can be compressed without change in size, elastomers compress by bulging. The shape factor is equal to the area on which the force is applied LW divided by the bulge area 2H(L+W), where L, W and H are the length, width and height of the elastomer, respectively. Hence a 2 x2 x2 pad will have a lower shape factor than a strip or a mat. 4

5 2 PERFORMANCE ISSUES 2.1 Separate Wall and Ceiling Clip Problem: All current approaches utilize the same clip for both walls and ceiling, despite the fact that walls and ceiling offer totally different loads. Solution: RPG developed a separate wall, CDM-ISO-QRW, and ceiling, CDM-ISO-QRC, resilient isolation clip to optimally handle the different loads imposed on walls and ceilings. Let s look at a typical load on a wall clip. It is important to note at this point that none of the isolation clips on the market are designed to handle a load in shear. This means that drywall is attached to the hat channel and allowed to hang vertically applying a shear load on the elastomer. The proper way to isolate a wall is to support the wall load on an isolation strip (CDM-ISO- STRIP) on the floor, the wall isolation clip merely acts like a sway brace. Therefore, the load on the wall isolation clip is minor and it s resonant frequency can be made very low to provide optimal isolation efficiency in compression due to lateral forces. The CDM-93 polyurethane elastomer chosen for the wall clip has a resonant frequency of roughly 12.2 Hz, under ideal loading, which will be discussed in 2.2. Separate wall and ceiling clips with optimal low resonant frequencies for each different loading requirement offer better performance than one clip with a higher resonant frequency. 2.2 Elastomer Resonant Frequency Problem: All current approaches utilize neoprene as the resilient elastomer with a relatively high resonant frequency. Solution: RPG has chosen a polyurethane elastomer to replace the conventional neoprene elastomer, because we can design resilient isolation clips that have a lower resonant frequency and hence a higher isolation efficiency. In the appendix, we have provided the experimental static and dynamic testing on the elastomers used by Kinetics, PAC International and RPG. In the following table we compare various properties of the RPG CDM-ISO-QRW wall and CDM-ISO- QRC isolation clip with neoprene. It can be seen that the CDM lower resonant frequencies offer higher isolation efficiency. We will discuss other items in the table in subsequent sections. If we examine the Isolation Efficiency chart we can see that the QRW, which has a resonant frequency of 12.2 Hz at 22.4 lbf, offers 95% isolation efficiency, whereas neoprene, with a resonant frequency of 23 Hz at 22.4 lbf (Wall) offers 79%, for an example disturbing frequency, fd, of 60 Hz. Now ceiling loads, typically 2-3 layers of 5/8 drywall, offer a much higher load than walls, where the primary load is handled by the floor elastomer (ISO-STRIP). For ceiling applications, RPG developed the CDM-ISO-QRC, in which we use a stiffer CDM 96 polyurethane elastomer with an optimally loaded resonant frequency of 17.2 Hz at 33.7 lbf. It can be see in the Isolation efficiency chart that the neoprene offers roughly 82% isolation (25.5 Hz at 33.7 lbf (Ceiling)), however, the CDM- ISO-QRC offers 91% isolation. 2.3 Secure mechanical capture of hat channel Problem: No current approach mechanically and safely captures the steel hat channel. It is simply inserted into a resilient holder. Solution: Both the wall and ceiling isolation clips are designed to physically capture the hat channel, in stead of having it be held 5

6 by friction. Inspection of the QRW/QRC clips reveals that they are constructed from a continuous steel frame with a hinged left and right side containing screw openings. Both the back and hinged sides contain elastomer pads. The isolation clips are shipped with the hinged wings open and double sided tape on the rear surface. Installation is simple. Peel the tape and attach temporarily to the stud, then insert the hat channel into the open sides and then close them. When the screws are inserted and secured to the stud, the hinged sides apply positive pressure on the hat channel safely securing it. Another benefit of this is that the QRC can support a heavier ceiling load than the Isomax clip. The test reports reveal that the maximum load when the QRC separated from the hat channel, without any prior metal-to-metal contact, was 157 lbf, whereas the Isomax failed at 101 lbf. 2.4 Optimal pre-compression When pressure, p, is applied and a spring is compressed, the dynamic stiffness, kd, is constant and the resonant frequency, fr, monotonically decreases as shown in the graph. However, an elastomer is different. Under increasing load the dynamic stiffness increases and the resonant frequency will decrease initially, 3 CONCLUSION We have proven that conventional isolation clips suffer from several design limitations, which are corrected in the RPG CDM- ISO-QRW and CDM-ISO-QRC wall and ceiling clips. Our research supports the following conclusions: 1. All conventional isolation clips use the same clip for wall and ceiling application, even though the loads are very different. RPG offers a different isolation clip for walls and ceiling with different elastomers to optimize the isolation efficiency for these very different loading conditions. 2. All conventional isolation clips use neoprene as the elastomer which has a relatively high resonant frequency of roughly 24 Hz offering roughly 80% isolation efficiency. RPG offers a wall isolation clip with a 12 Hz resonant frequency offering 95% isolation efficiency and a separate ceiling isolation clip with a 17 Hz resonant frequency offering 91% isolation efficiency. 3 All conventional isolation clips support the hat channel through friction and do not have a positive mechanical fastening. RPG offers a novel design which positively captures the hat channel, when secured to the stud. 4. None of the conventional isolation clips insure that the elastomer is under optimal compression, which does not insure the lowest resonant frequency. RPG offers a novel design which has a fail-safe securing mechanism which insures optimal pre-compression and guarantees the elastomer is operating in its optimal design range offering the lowest resonant frequency and optimal isolation efficiency. but at some pressure the stiffness of the elastomer will increase and cause the resonant frequency to increase. Hence, for elastomers there is an optimal loading zone (arrow line), indicated by the minimum in the red parabola in the graph. To insure that the QRW and QRC isolation clips operate in this optimal pressure zone, they are designed with a fail-safe mechanism to insure optimal precompression. Examination of the lower portion of the hinged sides, it can be seen that the metal is cut at an angle, which is not parallel to the back of the clip. When the wings are screwed into the stud, there will be a pressure at which the hinged sides touch the stud and can go no further. At this pressure the elastomer is at its optimal load and thus the low resonance frequency is assured. It cannot be higher or lower. This is seen in the photo with the QRW installed on a wood stud. 6

7 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 1 Total pages: 7 Handled by: Veelhaver Bram Approved by: Michael Vanstraelen TEST SUBJECT: CONTENTS: CDM-ISO-QRW 7 pages TEST PERIOD: June INTRODUCTION page 2 2. TEST SAMPLES page 2 3. TEST DEVICES page 2 4. DESCRIPTION OF TEST PROCEDURE page 3 5. TEST RESULTS page 4 6. APPENDICES page 6

8 TEST REPORT CDM Lab report n : Issued on: , Page n : 2 Total pages: form: QS-lab01ap05 FOR DISTRIBUTION 7 1. INTRODUCTION The CDM lab has been provided with 10 resilient wall ties, named CDM-ISO-QRW, together with hat channel profiles. These clips enable drywall to be mechanically fastened to existing wall surfaces or steel studs, without transmission of audible energy. The objective of these tests is to determine the following properties of these materials: Stiffness via a static and dynamic test Creep properties Maximum load at failure 2. TEST SAMPLES CDM tested the following samples: 3. TEST DEVICES for static and dynamic tests: Type (brand): Instron 8802 Year manufactured: 2000 Last Calibration: November 2008 Steel plate dimensions: 300 mm x 300 mm [11.81 x ] Max. capacity: 250 kn [56.2 klbf] Tests carried out according to: DIN 53513, specific project requirements and own experience. for creep tests: CTS (Cantilever testing system) Tests carried out according to: UNI (1997) and ISO-8013 (1998)

9 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 3 Total pages: 7 4. DESCRIPTION OF TEST PROCEDURE 4.1 Static and dynamic tests Each test (with 10 ties measured simultaneously) is carried out according a classic test method (CDM-LTS-10: internal CDM-norm according to DIN 53513, specific project requirements or own experience): Static test: consists of 3 loading and unloading cycles from 0,05 kn [1.124 lbf] up to the maximum static load of the material e.g. 150N/min [ lbf/min], only the 3 rd load-deflection curve is recorded. Dynamic test: mean load in 9 steps from 10 to 90% of the maximum total load. Dynamic load in each of 9 steps fluctuates 20% around the mean load at 15 Hz. e.g. the maximum total load is 150N [33.7 lbf], first test is at 20%, so at kn [3.37 lbf] with an amplitude varying from kn [2.27 lbf] up to kn [4.044 lbf], second test is at kn [6.74 lbf], with amplitude varying from kn [5.39 lbf] up to kn [8.09 lbf] 4.2 Creep test A load is put on the test sample for 7 days by means of the CTS. Additional deflection due to creep is measured during this period. After removing the sample, recovery of the height was measured after 30 min and 8 h. 4.3 Maximum load at failure The samples were tested in the Instron press. The maximum load at failure was determined by increasing the load manually until there was contact between the metal of the clip and the hat channel profile (metal-metal contact) and until the profile separated from the clip. This test was carried out in the horizontal direction as well as in the vertical direction.

10 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 4 Total pages: 7 5. TEST RESULTS 5.1 Static and dynamic tests The static and dynamic tests on the CDM-ISO-QRW clips are shown in appendix 1. The clips have a load range from 0 to 100 N [0 to 22.5 lbf] with a design load of 100 N [22.5 lbf]. The static test shows the load-deflection curve from the 3 rd cycle. at 100 N [22.5 lbf] the static deflection is limited to approx. 3,1 mm [0.12 ]. The dynamic test shows the dynamic stiffness and the resonance frequency in function of the mean load. at 100 N [22.5 lbf] the resonance frequency is 12.2 Hz. 5.2 Creep test The creep test on 1 CDM-ISO-QRW clip is shown in appendix 2. A clip has been put under a force of 100 N [22.5 lbf] for 7 days. The graphs on the creep test report show the relative creep deflection as a function of time. The table shows 3 values: Creep rate (CR) in % free height / decade minutes 0,84% Elastic recovery (R) after 30 min of unloading 97,6% Creep criterion (CC) after 30 min of unloading 2,86% 5.3 Maximum load at failure Vertically: Metal-metal contact occurred at approx. 150 N [33.8 lbf] and the separation from the clip at approx. 500 N [112.4 lbf].

11 TEST REPORT, CDM Lab report n : Issued on: Page n : 5 Total pages: form: QS-lab01ap05 FOR DISTRIBUTION 7 Horizontally: the hat channel separation of the clip occurred at approx. 254 N [57.1 lbf].

12 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 6 Total pages: 7 6. APPENDICES Appendix 1: CDM-ISO-QRW static and dynamic test report

13 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 7 Total pages: 7 Appendix 2: CDM-ISO-QRW creep report

14 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 1 Total pages: 6 Handled by: Veelhaver Bram Approved by: Michael Vanstraelen TEST SUBJECT: CONTENTS: CDM-ISO-QRC 6 pages TEST PERIOD: June INTRODUCTION page 2 2. TEST SAMPLES page 2 3. TEST DEVICES page 2 4. DESCRIPTION OF TEST PROCEDURE page 3 5. TEST RESULTS page 4 6. APPENDICES page 5

15 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 2 Total pages: 6 1. INTRODUCTION The CDM lab has been provided with 10 resilient ceiling clips, named CDM-ISO-QRC together with hat channel profiles. These clips enable plasterboard ceiling to be mechanically fixed without transmission of audible energy. The objective of these tests is to determine the following properties of these materials: Stiffness via a static and dynamic test Creep properties Maximal load at failure 2. TEST SAMPLES CDM tested the following samples: 3. TEST DEVICES for static and dynamic tests: Type (brand): Instron 8802 Manufacturing year: 2000 Last Calibration: November 2008 Steel plate dimensions: 300mm x 300mm [11.8 x11.8 ] Max. capacity: 250kN [56.2 klbf] Tests carried out according to: DIN 53513, specific project requirements and own experience. for creep tests: CTS (Cantilever testing system) Tests carried out according to: UNI (1997) and ISO-8013 (1998)

16 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 3 Total pages: 6 4. DESCRIPTION OF TEST PROCEDURE 4.1 Static and dynamic tests Each test (with 10 clips simultaneously) is carried out according to a classic test method (CDM-LTS-10: internal CDM-norm according to DIN 53513, specific project requirements and own experience): Static test: consists of 3 loading and unloading cycles from 0,05 kn [11.24 lbf] up to the maximum static load of the material e.g. 300N/min [ lbf/min], only the 3 rd load-deflection curve is recorded. Dynamic test: mean load in 9 steps from 10 to 90% of the maximum total load. Dynamic load in each of 9 steps fluctuates 20% around the mean load at 15 Hz. e.g. the maximum total load is 300N [67.4 lbf], first test is at 10%, so at kn [6.74 lbf] with an amplitude varying from kn [5.40 lbf] up to kn [8.09 lbf], second test is at kn [13.5 lbf], with amplitude varying from kn [10.79 lbf] up to kn [16.19 lbf] 4.2 Creep test A load is put on the test sample for 7 days by means of the CTS. Additional deflection due to creep is measured during 7 days. After removing the sample recovery of the height was measured after 30min and 8h. 4.3 Maximal load until break The samples were tested in the Instron press. The maximal load at failure was determined by increasing the load manually until there was contact between the metal of the clip and the profile (metal-metal contact) and until the profile separated from the clip.

17 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 4 Total pages: 6 5. TEST RESULTS 5.1 Static and dynamic tests The static and dynamic test on the CDM-ISO-QRC clips is shown in appendix 1. The clips have a load range from 0 to 150N [0 to 33.7 lbf] with a design load of 150N [33.7 lbf]. The static test shows the load-deflection curve from the 3 rd 150N [33.7 lbf] the static deflection is limited to +/- 1,49mm [0.059 ]. The dynamic test shows the dynamic stiffness and the resonance frequency in function of the mean 150N [33.7 lbf] the resonance frequency is 17,2Hz. 5.2 Creep test The creep test on 1 CDM-ISO-QRC clip is shown in appendix 2. A clip has been put under a force of 150N [33.7 lbf] for 7 days. The graphs on the creep test show the relative creep deflection in function of the time. The table shows mainly 3 values: Creep rate (CR) in % free height / decade minutes 0,48% Elastic recuperation (R) after 30 min of unloading 96% Creep criterion (CC) after 30 min of unloading 5,71% 5.3 Maximal load at failure There was no metal-metal contact and the separation from the clip occurred at 650N [146.1 lbf].

18 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 5 Total pages: 6 6. APPENDICES Appendix 1: 652- CDM-ISO-QRC static and dynamic test report

19 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 6 Total pages: 6 Appendix 2: CDM-ISO-QRC creep report

20 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 1 Total pages: 4 Handled by: Veelhaver Bram Approved by: Michael Vanstraelen TEST SUBJECT: CONTENTS: Different tests on ISOMAX (Kinetics) 4 pages TEST PERIOD: June

21 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 2 Total pages: 4! "# $% % $%# & $ ' % ( $ ) ' % ' %! "'**+, $ $% ',+++ - ',++. '/++(/++ (# %',0+)1 2$'10/03/ &4$ (#

22 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 3 Total pages: 4!""#!$ %% 5!3+$ $%" $!6-63+' 6 $10/03/&4$ ("' '/%++0)1$ ##+7+8 9(0+(0+(0+9)1:9)1"%/ 6$# % '93+9+; ( <63+; :30=> &$''(")!'*+, # ($ $ )% $ %$! 6 " $ # $ > #!""#!$ %% % (3# +/+),+)# 6$/ %# :,+) <6,0# % % 4$%$ # :,+) 4$%,/*=># &$)$'(")!'*+, 1 6 $ <670)#

23 CDM Lab report n : form: QS-lab01ap05, Issued on: FOR DISTRIBUTION Page n : 4 Total pages: 4 (3'0/9,6 %

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