CA2493239A1 - Aboveground waterproofing boards, systems, and methods - Google Patents
Aboveground waterproofing boards, systems, and methods Download PDFInfo
- Publication number
- CA2493239A1 CA2493239A1 CA002493239A CA2493239A CA2493239A1 CA 2493239 A1 CA2493239 A1 CA 2493239A1 CA 002493239 A CA002493239 A CA 002493239A CA 2493239 A CA2493239 A CA 2493239A CA 2493239 A1 CA2493239 A1 CA 2493239A1
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- CA
- Canada
- Prior art keywords
- coating
- board
- foundation
- boards
- insulation
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 30
- 238000004078 waterproofing Methods 0.000 title claims description 8
- 238000000576 coating method Methods 0.000 claims abstract description 82
- 239000011248 coating agent Substances 0.000 claims abstract description 78
- 238000009413 insulation Methods 0.000 claims abstract description 53
- 239000011152 fibreglass Substances 0.000 claims abstract description 29
- 239000012528 membrane Substances 0.000 claims description 13
- 239000000835 fiber Substances 0.000 claims description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 7
- 239000005002 finish coating Substances 0.000 claims description 6
- 239000000945 filler Substances 0.000 claims description 5
- 239000011347 resin Substances 0.000 claims description 5
- 229920005989 resin Polymers 0.000 claims description 5
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 3
- 239000000654 additive Substances 0.000 claims description 3
- 238000004519 manufacturing process Methods 0.000 claims description 3
- 239000000049 pigment Substances 0.000 claims description 3
- 229920001909 styrene-acrylic polymer Polymers 0.000 claims description 3
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 3
- 229920002554 vinyl polymer Polymers 0.000 claims description 3
- -1 vinyl-acrylic Chemical group 0.000 claims description 3
- 239000000853 adhesive Substances 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- 239000007921 spray Substances 0.000 claims 1
- 238000009434 installation Methods 0.000 description 5
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 238000005299 abrasion Methods 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000010426 asphalt Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000001913 cellulose Substances 0.000 description 1
- 229920002678 cellulose Polymers 0.000 description 1
- 239000012765 fibrous filler Substances 0.000 description 1
- 239000010881 fly ash Substances 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000004005 microsphere Substances 0.000 description 1
- 230000001012 protector Effects 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D31/00—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution
- E02D31/02—Protective arrangements for foundations or foundation structures; Ground foundation measures for protecting the soil or the subsoil water, e.g. preventing or counteracting oil pollution against ground humidity or ground water
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/762—Exterior insulation of exterior walls
Abstract
Systems, methods, and boards for insulating building foundations are provided.
The boards can be fiberglass, and the boards may have a pre-applied scrim. At least one coating can be provided on at least one face of the insulation boards. The boards can be applied to a portion of the building foundation above the grade line.
The boards can be fiberglass, and the boards may have a pre-applied scrim. At least one coating can be provided on at least one face of the insulation boards. The boards can be applied to a portion of the building foundation above the grade line.
Description
ABOVEGROUND WATERPROOFING BOARDS, SYSTEMS, AND METHODS
RELATED APPLICATIONS
This application claims priority to and any other benefit of U.S. Provisional Patent Application No. 60/591,216 filed July 26, 2004, which is expressly incorporated by reference herein.
BACKGROUND
Waterproofing and insulation of building foundations can be one goal for new or existing construction, and existing systems can provide waterproofing and/or insulation to building foundations. However, such systems can be difficult to install, and such systems may not provide adequate protection to an above grade portion of the foundation. Thus, there remains a need in the art for systems and methods of providing insulation and/or waterproofing to building foundations.
SUMMARY
In accordance with embodiments of the present invention boards are provided.
The boards can comprise a fiberglass board having a first surface and a second surface and a scrim in contact with the first surface of the fiberglass board. The scrim is pre-applied to the fiberglass board by placing the scrim on a woolpack and curing the woolpack such that the fiberglass board with the scrim in contact with the first surface of the fiberglass board is formed.
In accordance with further embodiments of the present invention, methods for producing boards are provided. The methods comprise placing a scrim on at least a portion of a first surface of a fiberglass woolpack and curing the fiberglass woolpack in at least one fiberglass curing oven such that a fiberglass board having the scrim adhered to at least a portion of a first surface of the fiberglass board is formed.
In accordance with other embodiments of the present invention, systems for insulation of building foundations are provided. The systems comprise at least one insulation board having a scrim pre-applied to at least a portion of a first face of the at least one insulation board and a coating. The at least one insulation board is disposed to be installed on a building foundation 21363760.1 - 1 such that the at least one insulation board covers at least a portion of the building foundation above the grade line and such that a top edge of the at least one insulation board is proximate to the sill plate of the building foundation. The coating is disposed to be applied to the first face of the insulation board such that the coating provides waterproofing properties to the system.
In accordance with embodiments of the present invention, methods for providing aboveground insulation are provided. The methods comprise applying insulating boards to cover at least a portion of the aboveground portion of a building foundation and coating the insulating boards with an elastomeric coating after the insulating boards have been applied to the foundation.
In accordance with other embodiments of the present invention, methods for providing aboveground insulation are provided. The methods comprise applying a plurality of insulating boards each having a first face, a second face, a top edge, a bottom edge, and a pre-applied scrim on said first face to a building foundation such that the second face of each of the plurality of insulating boards is proximate to the building foundation and such that tje plurality of insulating boards covers the foundation from at least proximate to a grade line of the foundation to proximate a sill plate of said building foundation. The methods further comprise fastening the insulating board proximate to the bottom edge to the foundation with a plurality of fasteners and applying mesh tape to the top edge of the insulating boards such that at least a portion of the mesh tape at the top edge of the boards contact one of the sill plate and a band board installed to the sill plate. The methods further comprise fastening the mesh tape to the sill plate or the band board with a plurality of fasteners and applying a coating over the insulating boards and the mesh tape.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The following detailed description of embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
Fig. 1 is an illustration of a board in accordance with embodiments of the present invention; and 21363760.1 - 2 -Fig. 2 is an illustration of a system in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
The present invention will now be described with occasional reference to specific exemplary embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein.
Rather, these embodiments are provided so that this disclosure will be thorough and complete.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms "a,"
"an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety.
The present invention provides boards that may be used in aboveground insulation or covering of foundations. The present invention provides systems and methods of insulating, finishing, or covering at least the aboveground portion of a foundation. The present invention provides kits for insulating, finishing, or covering at least the above ground portion of a foundation.
In accordance with embodiments of the present invention, insulation boards are provided and methods of making insulation boards are provided. The insulation boards comprise an insulation board having a scrim that is applied to the board during the manufacture of the board.
For purposes of defining and describing the present invention, the term "scrim" shall be understood as refernng to any suitable woven, non-woven, polymeric, or other suitable structure that may be applied to a board in order to enhance application of coatings to the board. For example, as shown in Fig. 1, an insulation board 10 may comprise a board 12 having a first surface 14 and a second surface 16. The first surface 14 can have a scrim 18 applied to the first surface 14 during the manufacture of the insulation board 10. The insulation board 10 may be 21363760.1 - 3 -any suitable type of insulation board. For example, the insulation board may be a dense fiberglass similar to the Owens Corning WARM-N-DRI~ Foundation Board. The insulation board 10 may have any suitable dimensions or thickness. The scrim 18 can be any suitable scrim that is open enough to allow coating to flow through the scrim 18. For example, the scrim 18 can have between about 30x30 to about 3x3 threads per inch. In another example, the scrim 18 can have about l Ox 10 threads per inch. In another example, the scrim 18 can be a glass scrim having G37, G75, or 6150 yarns and a temperature resistant binder.
The scrim 18 can be applied to the board 10 in any suitable manner. In one example, the board 10 can be a fiberglass board, and the scrim 18 can be placed on top of the woolpack prior to curing the woolpack in a fiberglass drying and curing oven. The scrim 18 is adhered to the board 10 during curing in the fiberglass drying oven. No other adhesives are necessary to adhere the scrim 18 to the board 10. The pre-applied scrim 18 allows the board 10 to be easily installed on a structure and to have a coating immediately applied to the board 10.
Thus, the additional step of installing a scrim over installed board is not required.
In accordance with other embodiments of the present invention, systems, kits, and methods for providing above ground insulation to foundations are provided.
Referring to Fig. 2, a system 21 on a foundation 20 is illustrated. The exemplary foundation 20 has a wall portion 22, a sill plate 24, and a band board 26. It will be understood that any suitable foundation structure may be insulated in accordance with the present invention. The foundation has a portion 28 below the grade line 30 and a portion 32 above the grade line 30.
During the construction of a structure, both the below grade portion 28 and the above grade portion 32 can be exposed. In order to waterproof and insulate the above grade portion 32, a waterproof membrane 34 is applied to the wall portion 22 of the foundation 20 to within about
RELATED APPLICATIONS
This application claims priority to and any other benefit of U.S. Provisional Patent Application No. 60/591,216 filed July 26, 2004, which is expressly incorporated by reference herein.
BACKGROUND
Waterproofing and insulation of building foundations can be one goal for new or existing construction, and existing systems can provide waterproofing and/or insulation to building foundations. However, such systems can be difficult to install, and such systems may not provide adequate protection to an above grade portion of the foundation. Thus, there remains a need in the art for systems and methods of providing insulation and/or waterproofing to building foundations.
SUMMARY
In accordance with embodiments of the present invention boards are provided.
The boards can comprise a fiberglass board having a first surface and a second surface and a scrim in contact with the first surface of the fiberglass board. The scrim is pre-applied to the fiberglass board by placing the scrim on a woolpack and curing the woolpack such that the fiberglass board with the scrim in contact with the first surface of the fiberglass board is formed.
In accordance with further embodiments of the present invention, methods for producing boards are provided. The methods comprise placing a scrim on at least a portion of a first surface of a fiberglass woolpack and curing the fiberglass woolpack in at least one fiberglass curing oven such that a fiberglass board having the scrim adhered to at least a portion of a first surface of the fiberglass board is formed.
In accordance with other embodiments of the present invention, systems for insulation of building foundations are provided. The systems comprise at least one insulation board having a scrim pre-applied to at least a portion of a first face of the at least one insulation board and a coating. The at least one insulation board is disposed to be installed on a building foundation 21363760.1 - 1 such that the at least one insulation board covers at least a portion of the building foundation above the grade line and such that a top edge of the at least one insulation board is proximate to the sill plate of the building foundation. The coating is disposed to be applied to the first face of the insulation board such that the coating provides waterproofing properties to the system.
In accordance with embodiments of the present invention, methods for providing aboveground insulation are provided. The methods comprise applying insulating boards to cover at least a portion of the aboveground portion of a building foundation and coating the insulating boards with an elastomeric coating after the insulating boards have been applied to the foundation.
In accordance with other embodiments of the present invention, methods for providing aboveground insulation are provided. The methods comprise applying a plurality of insulating boards each having a first face, a second face, a top edge, a bottom edge, and a pre-applied scrim on said first face to a building foundation such that the second face of each of the plurality of insulating boards is proximate to the building foundation and such that tje plurality of insulating boards covers the foundation from at least proximate to a grade line of the foundation to proximate a sill plate of said building foundation. The methods further comprise fastening the insulating board proximate to the bottom edge to the foundation with a plurality of fasteners and applying mesh tape to the top edge of the insulating boards such that at least a portion of the mesh tape at the top edge of the boards contact one of the sill plate and a band board installed to the sill plate. The methods further comprise fastening the mesh tape to the sill plate or the band board with a plurality of fasteners and applying a coating over the insulating boards and the mesh tape.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
The following detailed description of embodiments of the present invention can be best understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
Fig. 1 is an illustration of a board in accordance with embodiments of the present invention; and 21363760.1 - 2 -Fig. 2 is an illustration of a system in accordance with embodiments of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
The present invention will now be described with occasional reference to specific exemplary embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein.
Rather, these embodiments are provided so that this disclosure will be thorough and complete.
Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms "a,"
"an," and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety.
The present invention provides boards that may be used in aboveground insulation or covering of foundations. The present invention provides systems and methods of insulating, finishing, or covering at least the aboveground portion of a foundation. The present invention provides kits for insulating, finishing, or covering at least the above ground portion of a foundation.
In accordance with embodiments of the present invention, insulation boards are provided and methods of making insulation boards are provided. The insulation boards comprise an insulation board having a scrim that is applied to the board during the manufacture of the board.
For purposes of defining and describing the present invention, the term "scrim" shall be understood as refernng to any suitable woven, non-woven, polymeric, or other suitable structure that may be applied to a board in order to enhance application of coatings to the board. For example, as shown in Fig. 1, an insulation board 10 may comprise a board 12 having a first surface 14 and a second surface 16. The first surface 14 can have a scrim 18 applied to the first surface 14 during the manufacture of the insulation board 10. The insulation board 10 may be 21363760.1 - 3 -any suitable type of insulation board. For example, the insulation board may be a dense fiberglass similar to the Owens Corning WARM-N-DRI~ Foundation Board. The insulation board 10 may have any suitable dimensions or thickness. The scrim 18 can be any suitable scrim that is open enough to allow coating to flow through the scrim 18. For example, the scrim 18 can have between about 30x30 to about 3x3 threads per inch. In another example, the scrim 18 can have about l Ox 10 threads per inch. In another example, the scrim 18 can be a glass scrim having G37, G75, or 6150 yarns and a temperature resistant binder.
The scrim 18 can be applied to the board 10 in any suitable manner. In one example, the board 10 can be a fiberglass board, and the scrim 18 can be placed on top of the woolpack prior to curing the woolpack in a fiberglass drying and curing oven. The scrim 18 is adhered to the board 10 during curing in the fiberglass drying oven. No other adhesives are necessary to adhere the scrim 18 to the board 10. The pre-applied scrim 18 allows the board 10 to be easily installed on a structure and to have a coating immediately applied to the board 10.
Thus, the additional step of installing a scrim over installed board is not required.
In accordance with other embodiments of the present invention, systems, kits, and methods for providing above ground insulation to foundations are provided.
Referring to Fig. 2, a system 21 on a foundation 20 is illustrated. The exemplary foundation 20 has a wall portion 22, a sill plate 24, and a band board 26. It will be understood that any suitable foundation structure may be insulated in accordance with the present invention. The foundation has a portion 28 below the grade line 30 and a portion 32 above the grade line 30.
During the construction of a structure, both the below grade portion 28 and the above grade portion 32 can be exposed. In order to waterproof and insulate the above grade portion 32, a waterproof membrane 34 is applied to the wall portion 22 of the foundation 20 to within about
2 inches of the sill plate 24 or any openings 36. The waterproof membrane 34 can be any suitable membrane. For example, the waterproof membrane 34 can be an elastomeric spray-on polymer modified asphalt membrane such as a TUFF-N-DRI~ membrane available from Tremco Barner Solutions. The below grade portion 28 of the foundation 20 may be further insulated with an insulation board such as a WARM-N-DRI~ Foundation Board (not shown). If the below grade portion 28 of the foundation 20 is insulated with an insulation board, the board will terminate below the grade line 30.
21363760.1 - 4 -Insulation boards 10 having a pre-applied scrim 18 are prepared for installation by beveling the top edge 38 of the board at an angle of about 10° to about 60°. For example, the boards 10 are beveled at a 45° angle as shown. The beveled edge 38 provides a continuous water drainage plane once the board 10 is coated as discussed herein. The boards 10 are installed to cover the above grade portion 32 of the foundation to within about 1 inch above or about 1 inch below the sill plate 24. The boards 10 may also be installed to be at least about 6 inches below the grade line 30. The boards 10 may extend below the grade line 30 any suitable distance up to the frost line if desired. The boards 10 may have any suitable dimensions. For example, the boards 10 may be 4x8 foot boards. The boards 10 can be 1 3/16 inches thick, 2
21363760.1 - 4 -Insulation boards 10 having a pre-applied scrim 18 are prepared for installation by beveling the top edge 38 of the board at an angle of about 10° to about 60°. For example, the boards 10 are beveled at a 45° angle as shown. The beveled edge 38 provides a continuous water drainage plane once the board 10 is coated as discussed herein. The boards 10 are installed to cover the above grade portion 32 of the foundation to within about 1 inch above or about 1 inch below the sill plate 24. The boards 10 may also be installed to be at least about 6 inches below the grade line 30. The boards 10 may extend below the grade line 30 any suitable distance up to the frost line if desired. The boards 10 may have any suitable dimensions. For example, the boards 10 may be 4x8 foot boards. The boards 10 can be 1 3/16 inches thick, 2
3/8 inches thick, or be of any other suitable thickness. In some applications, more than one run of boards 10 will be required to provide suitable coverage to the above grade portion 32 of the foundation 20 when the distance from the sill plate 24 to 6 inches below the grade line 30 exceeds the maximum height of the boards 10.
As an aid to installation, the boards 10 rnay be temporarily fixed to the foundation 20 during installation by using clips 40. In addition, one or more clips 40 can be installed on the sill plate 24 or the band board 26 prior to the installation of the boards 10 at any suitable interval.
The clips 40 can be angled with an angle that matches the beveled edge 38 angle of the boards 10 and set to meet the board 10 at the proper top edge height, and the top 38 of the board 10 can be seated against the junction between the foundation 20 and the clip 40 to aid in installation. The board 10 is fastened near the bottom 42 of the board 10 with a suitable number of mechanical fasteners 44. For example, one fastener 44 can be installed every two feet.
When only one run of boards 10 is necessary, the fasteners 44 can be hidden below the grade line 30. If more than one run of boards 10 is necessary, the fasteners 44 above the grade line 30 need to be spackled prior to coating as described hereinafter. Any suitable type of fasteners such as pneumatic or hand driven fasteners may be used.
Seams 46 between the boards 10 can be taped with a mesh tape 48. Additionally, openings 36 in the foundation can be taped with a mesh tape 48. Corner protectors can be applied. The top beveled edge 38 of the board 10 is also taped with a run of mesh tape 50 along the beveled edge 38 and onto the sill plate 24 or the band board 26. The mesh tape 50 on the sill plate 24 or the band board 26 is fastened with fasteners 52 to the sill plate 24 or the band board 21363760.1 - 5 -26. This attachment of the mesh tape 50 to the sill plate 24 or the band board 26 obviates the need fasteners to fasten the top of the board 10 to the foundation 20 when coated as discussed herein.
Once the boards 10 have been installed, a coating (not shown) can be applied to cover the boards 10 and mesh tape 48, 50. Tt will be understood that the present invention is also directed to boards having a coating in accordance with the present invention whether or not the coating is applied in place as described herein. The coating can provide waterproofing properties to the insulation system. The coating can have a dry thickness of between about 10 to about 60 mils.
For example, the coating may have a thickness of about 40 mils dry. This high thickness coating allows the surface to have a dimensional texture if desired. Additionally, the coating can provide a board 10 surface having enhanced damage resistance.
The coating may be any suitable high quality elastomeric coating. For example, the coating could be an acrylic, styrene-acrylic, vinyl-acrylic, vinyl, or other suitable polymer type coating. For example, Horizons coatings from Tremco Barrier Solutions may be used. In another example, the coating can be an elastomeric coating having cellulosic fibers as filler. For example, the coating can comprise about 25% to about 55% resin, about 25% to about 75%
fillers and pigments, about 0% to about 40% water, and about 0% to about 6%
additives. In another example, the coating can comprise 40% resin, 52% fillers and pigments, 5% water, and 3% additives. The resin can comprise an acrylic, styrene-acrylic, vinyl-acrylic, vinyl, or other suitable resin. The filler can comprise a particulate and/or fibrous filler, such as calcium carbonate, fly ash, and cellulose or other polymeric fibers or microspheres.
The coating can be a matte finish coating or an aggregate finish coating. For purposes of defining and describing the present invention, the term "matte finish coating"
shall be understood as referring to a coating that does not contain a substantial amount of coarse aggregate material.
For purposes of defining and describing the present invention, the term "aggregate finish coating" shall be understood as referring to a coating that contains coarse aggregate. For purposes of defining and describing the present invention, the term "coarse aggregate" shall be understood as referring to an aggregate that can produce a surface feature in the finish of the coating. Any suitable type of coarse aggregate may be used. For example, calcium carbonate aggregate may be used in the coating. In another example, an aggregate that has 0% passing 21363760.1 - 6 -through a 16 mesh sieve, 2% passing through an 18 mesh sieve, 64% passing through a 30 mesh sieve, 33% passing through a 40 mesh sieve, and 2% passing through a greater than 40 mesh sieve can be used.
When an elastomeric coating containing cellulosic fibers is used in conjunction with a fiberglass board 10, the coated surface displays a surprising degree of damage resistance to abrasion and puncture impacts and other types of damage. Without wishing to bound to any particular theory, it is believed that the fibers in the fiberglass board 10 reinforce the coating. It is also believed that the coating fibers may interact synergistically with the fiberglass fibers of the board 10 to produce a more damage-resistant coated board. This enhanced damage resistance is desirable because the boards 10 and coating may experience impacts from people, yard equipment, etc., during the life of the building.
The coating can be applied in any suitable manner. In one example, the coating is applied by spraying coating, such as a matte and/or aggregate coating, onto the insulation boards and the mesh tape 48, 50. In another example, a two-step wet on wet process may be used.
In the first step, a high-output airless sprayer may be used to apply a matte coating. In the second step, an air-atomized sprayer may be used to apply an aggregate coating on top of the wet matte coating. This two-step application procedure provides a fast wet-on-wet application of the coating. Additionally, the use of an aggregate coating provides increased damage resistance and aesthetic improvement to the insulation system 21. In one example, about 75%
of the dry thickness of the coating may be a matte coating and about 25% of the dry thickness of the coating may be an aggregate coating. In another example, the ratio of the matte coating to the aggregate coating may be between about 1:4 to 4:1.
The coated boards 10 provide aboveground insulation. Additionally, the coated boards 10 provide a continuous water shedding plane on the foundation of a building.
The coated boards 10 can also serve as a sill sealer because the seam between the sill plate 24 and the foundation 20 can be covered by mesh 50 and a coating. The insulation system 21 does not require the use of cementicious products. The coated boards 10 stop water from reaching the foundation 20, but the coated boards 10 are vapor permeable. Therefore, the insulation system 21 offers vapor permeable insulation of the foundation of buildings. It will be understood that 21363760.1 - 7 -the boards 10 and coatings of the present invention can be configured and installed to cover any building foundation.
It will be readily apparent to those skilled in the art that various changes may be made without departing from the scope of the invention, which is not to be considered limited to what is described in the specification.
21363760.1 - 8 -
As an aid to installation, the boards 10 rnay be temporarily fixed to the foundation 20 during installation by using clips 40. In addition, one or more clips 40 can be installed on the sill plate 24 or the band board 26 prior to the installation of the boards 10 at any suitable interval.
The clips 40 can be angled with an angle that matches the beveled edge 38 angle of the boards 10 and set to meet the board 10 at the proper top edge height, and the top 38 of the board 10 can be seated against the junction between the foundation 20 and the clip 40 to aid in installation. The board 10 is fastened near the bottom 42 of the board 10 with a suitable number of mechanical fasteners 44. For example, one fastener 44 can be installed every two feet.
When only one run of boards 10 is necessary, the fasteners 44 can be hidden below the grade line 30. If more than one run of boards 10 is necessary, the fasteners 44 above the grade line 30 need to be spackled prior to coating as described hereinafter. Any suitable type of fasteners such as pneumatic or hand driven fasteners may be used.
Seams 46 between the boards 10 can be taped with a mesh tape 48. Additionally, openings 36 in the foundation can be taped with a mesh tape 48. Corner protectors can be applied. The top beveled edge 38 of the board 10 is also taped with a run of mesh tape 50 along the beveled edge 38 and onto the sill plate 24 or the band board 26. The mesh tape 50 on the sill plate 24 or the band board 26 is fastened with fasteners 52 to the sill plate 24 or the band board 21363760.1 - 5 -26. This attachment of the mesh tape 50 to the sill plate 24 or the band board 26 obviates the need fasteners to fasten the top of the board 10 to the foundation 20 when coated as discussed herein.
Once the boards 10 have been installed, a coating (not shown) can be applied to cover the boards 10 and mesh tape 48, 50. Tt will be understood that the present invention is also directed to boards having a coating in accordance with the present invention whether or not the coating is applied in place as described herein. The coating can provide waterproofing properties to the insulation system. The coating can have a dry thickness of between about 10 to about 60 mils.
For example, the coating may have a thickness of about 40 mils dry. This high thickness coating allows the surface to have a dimensional texture if desired. Additionally, the coating can provide a board 10 surface having enhanced damage resistance.
The coating may be any suitable high quality elastomeric coating. For example, the coating could be an acrylic, styrene-acrylic, vinyl-acrylic, vinyl, or other suitable polymer type coating. For example, Horizons coatings from Tremco Barrier Solutions may be used. In another example, the coating can be an elastomeric coating having cellulosic fibers as filler. For example, the coating can comprise about 25% to about 55% resin, about 25% to about 75%
fillers and pigments, about 0% to about 40% water, and about 0% to about 6%
additives. In another example, the coating can comprise 40% resin, 52% fillers and pigments, 5% water, and 3% additives. The resin can comprise an acrylic, styrene-acrylic, vinyl-acrylic, vinyl, or other suitable resin. The filler can comprise a particulate and/or fibrous filler, such as calcium carbonate, fly ash, and cellulose or other polymeric fibers or microspheres.
The coating can be a matte finish coating or an aggregate finish coating. For purposes of defining and describing the present invention, the term "matte finish coating"
shall be understood as referring to a coating that does not contain a substantial amount of coarse aggregate material.
For purposes of defining and describing the present invention, the term "aggregate finish coating" shall be understood as referring to a coating that contains coarse aggregate. For purposes of defining and describing the present invention, the term "coarse aggregate" shall be understood as referring to an aggregate that can produce a surface feature in the finish of the coating. Any suitable type of coarse aggregate may be used. For example, calcium carbonate aggregate may be used in the coating. In another example, an aggregate that has 0% passing 21363760.1 - 6 -through a 16 mesh sieve, 2% passing through an 18 mesh sieve, 64% passing through a 30 mesh sieve, 33% passing through a 40 mesh sieve, and 2% passing through a greater than 40 mesh sieve can be used.
When an elastomeric coating containing cellulosic fibers is used in conjunction with a fiberglass board 10, the coated surface displays a surprising degree of damage resistance to abrasion and puncture impacts and other types of damage. Without wishing to bound to any particular theory, it is believed that the fibers in the fiberglass board 10 reinforce the coating. It is also believed that the coating fibers may interact synergistically with the fiberglass fibers of the board 10 to produce a more damage-resistant coated board. This enhanced damage resistance is desirable because the boards 10 and coating may experience impacts from people, yard equipment, etc., during the life of the building.
The coating can be applied in any suitable manner. In one example, the coating is applied by spraying coating, such as a matte and/or aggregate coating, onto the insulation boards and the mesh tape 48, 50. In another example, a two-step wet on wet process may be used.
In the first step, a high-output airless sprayer may be used to apply a matte coating. In the second step, an air-atomized sprayer may be used to apply an aggregate coating on top of the wet matte coating. This two-step application procedure provides a fast wet-on-wet application of the coating. Additionally, the use of an aggregate coating provides increased damage resistance and aesthetic improvement to the insulation system 21. In one example, about 75%
of the dry thickness of the coating may be a matte coating and about 25% of the dry thickness of the coating may be an aggregate coating. In another example, the ratio of the matte coating to the aggregate coating may be between about 1:4 to 4:1.
The coated boards 10 provide aboveground insulation. Additionally, the coated boards 10 provide a continuous water shedding plane on the foundation of a building.
The coated boards 10 can also serve as a sill sealer because the seam between the sill plate 24 and the foundation 20 can be covered by mesh 50 and a coating. The insulation system 21 does not require the use of cementicious products. The coated boards 10 stop water from reaching the foundation 20, but the coated boards 10 are vapor permeable. Therefore, the insulation system 21 offers vapor permeable insulation of the foundation of buildings. It will be understood that 21363760.1 - 7 -the boards 10 and coatings of the present invention can be configured and installed to cover any building foundation.
It will be readily apparent to those skilled in the art that various changes may be made without departing from the scope of the invention, which is not to be considered limited to what is described in the specification.
21363760.1 - 8 -
Claims (36)
1. A board, comprising:
a fiberglass board having a first surface and a second surface; and a scrim in contact with said first surface of said fiberglass board, wherein said scrim is pre-applied to said fiberglass board by placing said scrim on a woolpack and curing said woolpack such that said fiberglass board with said scrim in contact with said first surface of said fiberglass board is formed.
a fiberglass board having a first surface and a second surface; and a scrim in contact with said first surface of said fiberglass board, wherein said scrim is pre-applied to said fiberglass board by placing said scrim on a woolpack and curing said woolpack such that said fiberglass board with said scrim in contact with said first surface of said fiberglass board is formed.
2. The board as claimed in claim 1 wherein said scrim has between about 3 × 3 to about 30 × 30 threads per square inch.
3. The board as claimed in claim 1 wherein at least one edge of said fiberglass board is beveled.
4. A method for producing a board, comprising:
placing a scrim on at least a portion of a first surface of a fiberglass woolpack;
curing said fiberglass woolpack in at least one fiberglass curing oven such that a fiberglass board having said scrim adhered to at least a portion of a first surface of said fiberglass board is formed.
placing a scrim on at least a portion of a first surface of a fiberglass woolpack;
curing said fiberglass woolpack in at least one fiberglass curing oven such that a fiberglass board having said scrim adhered to at least a portion of a first surface of said fiberglass board is formed.
5. A system for insulation of building foundations, comprising:~
at least one insulation board having a scrim pre-applied to at least a portion of a first face of said at least one insulation board; and a coating, wherein:
said at least one insulation board is disposed to be installed on a building foundation such that said at least one insulation board covers at least a portion of the building foundation above a grade line and such that a top edge of said at least one insulation board is proximate to the sill plate of said building foundation;
said coating is disposed to be applied to said first face of said insulation board such that said coating provides waterproofing properties to said system.
at least one insulation board having a scrim pre-applied to at least a portion of a first face of said at least one insulation board; and a coating, wherein:
said at least one insulation board is disposed to be installed on a building foundation such that said at least one insulation board covers at least a portion of the building foundation above a grade line and such that a top edge of said at least one insulation board is proximate to the sill plate of said building foundation;
said coating is disposed to be applied to said first face of said insulation board such that said coating provides waterproofing properties to said system.
6. The system as claimed in claim 5 further comprising at least one clip, wherein said at least one clip is disposed to be installed on the sill plate of the foundation in order to hold said at least one insulation board in place.
7. The system as claimed in claim 5 wherein said system comprises a plurality of said insulation boards, and said system further comprising mesh tape that is disposed to be provided over a joint between adjacent insulation boards on the foundation.
8. The system as claimed in claim 7 wherein said mesh tape is further disposed to be provided over a top edge of said plurality of insulation boards and proximate to said sill plate.
9. The system as claimed in claim 7 wherein said mesh tape is self-adhesive.
10. The system as claimed in claim 5 wherein said coating comprises an elastomeric coating.
11. The system as claimed in claim 10 wherein said elastomeric coating is selected from acrylic, styrene-acrylic, vinyl-acrylic, and vinyl type coatings.
12. The system as claimed in claim 10 wherein said elastomeric coating comprises about 25% to about 55% resin, about 25% to about 75% fillers and pigments, about 0% to about 40% water, and about 0% to about 6% additives.
13. The system as claimed in claim 10 wherein said elastomeric coating comprises a matte finish coating.
14. The system as claimed in claim 10 wherein said elastomeric coating comprises an aggregate finish coating.
-10-~~
-10-~~
15. The system as claimed in claim 10 wherein said elastomeric coating comprises Horizon .TM.
coating.
coating.
16. The system as claimed in claim 10 wherein said elastomeric coating contains cellulosic fibers.
17. The system as claimed in claim 5 wherein said at least one insulation board has a bottom edge, and wherein said bottom edge is disposed to be installed at least six inches below said grade line.
18. The system as claimed in claim 5 wherein said top edge comprises a beveled edge.
19. The system as claimed in claim 18 wherein said beveled edge comprises a bevel angle of between about 10° to about 60°.
20. The system as claimed in claim 5 further comprising a waterproof membrane disposed to be provided between said foundation and said at least one insulation board.
21. The system as claimed in claim 20 wherein said waterproof membrane comprises a spray on membrane.
22. The system as claimed in claim 5 said system further comprising fasteners to attach said at least one insulation board to said foundation.
23. The system as claimed in claim 5 wherein said at least one insulation board and said coating are vapor permeable.
24. A method for providing aboveground insulation, comprising:
applying insulating boards to cover at least a portion of the aboveground portion of a building foundation; and coating said insulating boards with an elastomeric coating after said insulating boards have been applied to said foundation.
applying insulating boards to cover at least a portion of the aboveground portion of a building foundation; and coating said insulating boards with an elastomeric coating after said insulating boards have been applied to said foundation.
25. A method for providing aboveground insulation, comprising:
applying a plurality of insulating boards each having a first face, a second face, a top edge, a bottom edge, and a pre-applied scrim on said first face to a building foundation such that said second face of each of said plurality of insulating boards is proximate to said building foundation, and such that said plurality of insulating boards covers said foundation from at least proximate to a grade line of said foundation to proximate a sill plate of said building foundation;
fastening said insulating board proximate to said bottom edge to said foundation with a plurality of fasteners;
applying mesh tape to said top edge of said insulating boards such that at least a portion of said mesh tape at said top edge of said boards contact one of said sill plate and a band board installed to said sill plate;
fastening said mesh tape to said sill plate or said band board with a plurality of fasteners;
and applying a coating over said insulating boards and said mesh tape.
applying a plurality of insulating boards each having a first face, a second face, a top edge, a bottom edge, and a pre-applied scrim on said first face to a building foundation such that said second face of each of said plurality of insulating boards is proximate to said building foundation, and such that said plurality of insulating boards covers said foundation from at least proximate to a grade line of said foundation to proximate a sill plate of said building foundation;
fastening said insulating board proximate to said bottom edge to said foundation with a plurality of fasteners;
applying mesh tape to said top edge of said insulating boards such that at least a portion of said mesh tape at said top edge of said boards contact one of said sill plate and a band board installed to said sill plate;
fastening said mesh tape to said sill plate or said band board with a plurality of fasteners;
and applying a coating over said insulating boards and said mesh tape.
26. The method as claimed in claim 25 applying mesh tape to joints between adjacent insulating boards.
27. The method as claimed in claim 25 further comprising applying a waterproof membrane to at least a portion of said foundation prior to said step of applying a plurality of insulating boards.
28. The method as claimed in claim 27 wherein said waterproof membrane is applied between said foundation and said insulating board.
29. The method as claimed in claim 27 wherein said waterproof membrane is applied by spraying said membrane on said foundation.
30. The method as claimed in claim 25 wherein said step of applying said coating to said insulating boards comprises applying said coating such that said coating has a thickness of between about 10 mils to about 60 mils when said coating is dry.
31. The method as claimed in claim 25 wherein said step of applying said coating to said insulating boards comprises applying said coating over said mesh tape at said top edge of said insulating boards such that a continuous water shedding plane on said foundation is formed.
32. The method as claimed in claim 25 wherein said step of applying said coating to said insulating board comprises applying a matte coating to said insulating boards and said mesh tape and subsequently applying an aggregate coating on said matte coating while said matte coating is wet.
33. The method as claimed in claim 25 wherein said step of fastening said insulating board comprises fastening said insulating boards to said foundation with a plurality of mechanical fasteners below said grade line.
34. The method as claimed in claim 25 further comprising beveling said top edge of said insulating boards before said step of applying said boards.
35. The method as claimed in claim 34 wherein said step of beveling said top edges of said insulating boards comprises beveling said top edge at an angle of between about 10° to about 60°.
36. The method as claimed in claim 25 further comprising providing insulation to said portion of said foundation below said grade line of said foundation.~
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US59121604P | 2004-07-26 | 2004-07-26 | |
| US60/591,216 | 2004-07-26 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2493239A1 true CA2493239A1 (en) | 2006-01-26 |
Family
ID=35696176
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002493239A Abandoned CA2493239A1 (en) | 2004-07-26 | 2005-01-19 | Aboveground waterproofing boards, systems, and methods |
Country Status (2)
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|---|---|
| US (2) | US20060032164A1 (en) |
| CA (1) | CA2493239A1 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US9267285B2 (en) | 2013-11-08 | 2016-02-23 | Piotr Robert Tauferner | Reinforced water-resistant board with traffic coat |
| US10344469B2 (en) | 2013-11-08 | 2019-07-09 | Piotr Robert Tauferner | Reinforced water-resistant board with traffic coat |
| US10769191B2 (en) * | 2013-12-20 | 2020-09-08 | Google Llc | Classifying data objects |
| US10689851B2 (en) * | 2018-10-01 | 2020-06-23 | Durabond Products Limited | Insulation board assembly |
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| US3914495A (en) * | 1972-07-24 | 1975-10-21 | Chase Corp | Fire retardant insulating tape wrap |
| US4386136A (en) * | 1976-05-11 | 1983-05-31 | Global Coatings Limited | Roof coating composition and construction |
| US4141187A (en) * | 1977-01-28 | 1979-02-27 | Graves Robert J | Roofing and surfacing material and method |
| US4646498A (en) * | 1985-05-28 | 1987-03-03 | National Gypsum Company | Curtain wall panel and method |
| US5763043A (en) * | 1990-07-05 | 1998-06-09 | Bay Mills Limited | Open grid fabric for reinforcing wall systems, wall segment product and methods of making same |
| US5296288A (en) * | 1992-04-09 | 1994-03-22 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Protective coating for ceramic materials |
| US5836715A (en) * | 1995-11-19 | 1998-11-17 | Clark-Schwebel, Inc. | Structural reinforcement member and method of utilizing the same to reinforce a product |
| US5966885A (en) * | 1997-12-01 | 1999-10-19 | Chatelain; Paul J. | Foam panels for wall construction |
| US6357504B1 (en) * | 1999-07-29 | 2002-03-19 | Owens Corning Fiberglas Technology, Inc. | Technology for attaching facing system to insulation product |
| US6122874A (en) * | 1999-08-19 | 2000-09-26 | Smerilli; Philip | Dry 90 |
| US6536176B1 (en) * | 1999-10-20 | 2003-03-25 | Pactiv Corporation | Polymeric foam and scrim sheathings |
| US7100337B1 (en) * | 1999-10-20 | 2006-09-05 | Pactiv Corporation | Polymeric foam and scrim sheathings |
| MXPA03002948A (en) * | 2000-10-10 | 2004-12-13 | James Hardie Int Finance Bv | Composite building material. |
| US6539176B2 (en) * | 2000-11-16 | 2003-03-25 | Fuji Photo Film Co., Ltd. | Photometry device for camera |
| US6869901B2 (en) * | 2001-02-20 | 2005-03-22 | Pactiv Corporation | Protective drainage wraps |
| WO2002077382A1 (en) * | 2001-03-27 | 2002-10-03 | Owens Corning | Structural insulated sheathing and related sheathing methods |
| US6854166B2 (en) * | 2002-05-08 | 2005-02-15 | Atlantic Integrated Technologies | Insulative non-woven fabric and method for forming same |
| US6584746B1 (en) * | 2002-05-10 | 2003-07-01 | Hohmann & Barnard, Inc. | Masonry flashing system |
| US7393799B2 (en) * | 2002-12-10 | 2008-07-01 | Saint-Gobain Technical Fabrics Canada, Ltd | Breathable, waterproofing, tear-resistant fabric |
| US7223455B2 (en) * | 2003-01-14 | 2007-05-29 | Certainteed Corporation | Duct board with water repellant mat |
| US7049251B2 (en) * | 2003-01-21 | 2006-05-23 | Saint-Gobain Technical Fabrics Canada Ltd | Facing material with controlled porosity for construction boards |
| US7354876B2 (en) * | 2003-07-09 | 2008-04-08 | Saint-Gobain Technical Fabrics Canada Ltd. | Fabric reinforcement and cementitious boards faced with same |
| US7317051B2 (en) * | 2003-11-14 | 2008-01-08 | Chem Link | Moisture curable sealer and adhesive composition |
| US7625827B2 (en) * | 2003-12-19 | 2009-12-01 | Basf Construction Chemicals, Llc | Exterior finishing system and building wall containing a corrosion-resistant enhanced thickness fabric and method of constructing same |
| US7544267B2 (en) * | 2004-01-08 | 2009-06-09 | Certainteed Corporation | Method of making insulation product having nonwoven facing |
| US6960394B2 (en) * | 2004-02-25 | 2005-11-01 | Milliken & Company | Fabric reinforced cement |
| US7168561B2 (en) * | 2004-12-10 | 2007-01-30 | Saint-Gobain Technical Fabrics Canada, Ltd. | Packaged roll of textile fabric and method of packaging same |
-
2005
- 2005-01-19 CA CA002493239A patent/CA2493239A1/en not_active Abandoned
- 2005-07-26 US US11/190,067 patent/US20060032164A1/en not_active Abandoned
- 2005-07-26 US US11/189,567 patent/US20060016142A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| US20060032164A1 (en) | 2006-02-16 |
| US20060016142A1 (en) | 2006-01-26 |
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| Date | Code | Title | Description |
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| EEER | Examination request | ||
| FZDE | Discontinued |