U.S. patent application number 10/890542 was filed with the patent office on 2005-01-13 for moisture barriers for building construction.
This patent application is currently assigned to Bondo Corporation. Invention is credited to Meister, Chris, Razzak, Abdul, Simonelli, Peter.
Application Number | 20050005567 10/890542 |
Document ID | / |
Family ID | 33567921 |
Filed Date | 2005-01-13 |
United States Patent
Application |
20050005567 |
Kind Code |
A1 |
Meister, Chris ; et
al. |
January 13, 2005 |
Moisture barriers for building construction
Abstract
Moisture and condensation barriers for protecting wood from
damage in building structures, particularly wood that is or may be
exposed to moisture from internal or external sources, wherein such
barriers comprise a non-vulcanized liquid rubberized coating
material coated on to one or more portions of wood members of
building structures.
Inventors: |
Meister, Chris; (Gypsum,
CO) ; Simonelli, Peter; (Northglenn, CO) ;
Razzak, Abdul; (Marietta, GA) |
Correspondence
Address: |
CALFEE HALTER & GRISWOLD, LLP
800 SUPERIOR AVENUE
SUITE 1400
CLEVELAND
OH
44114
US
|
Assignee: |
Bondo Corporation
Atlanta
GA
|
Family ID: |
33567921 |
Appl. No.: |
10/890542 |
Filed: |
July 12, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60486542 |
Jul 11, 2003 |
|
|
|
Current U.S.
Class: |
52/831 |
Current CPC
Class: |
E02D 31/02 20130101;
E04B 1/66 20130101; E04B 5/12 20130101 |
Class at
Publication: |
052/720.1 |
International
Class: |
E04C 003/30 |
Claims
We claim:
1. A building construction material comprising: a wood board; and a
moisture barrier having a non-tacky surface and comprising a
non-vulcanized, modified rubber, permanently attached to the board
and covering only part of the surfaces of the board.
2. A building construction material as recited in claim 1 wherein
the moisture barrier has a thickness in a range selected from the
group consisting of at least 6 to 8 mil, at least 8 to 12 mil, at
least 12 to 14 mil, at least 14 to 18 mil, and at least 18 to 20
mil
3. A building construction material as recited in claim 2 wherein
the moisture barrier entirely covers the surface of only one side
of the wood board.
4. A building construction material as recited in claim 2 wherein
the moisture barrier entirely covers the surfaces at least one but
not more than five sides of the wood board.
5. A building construction material as recited in any one of claims
1-4 wherein said wood board is selected from the group consisting
of solid wood board, plywood board, CDX plywood, oriented strand
board, tongue and groove board, composite board, chipboard and
particle board.
6. A building structure having a floor portion, a wall portion, and
a roof portion, wherein said roof portion comprises a building
construction material as recited in claim 1, said building
construction material having a moisture barrier that is at least 6
to 20 mil thick.
7. A building structure as recited in claim 6 wherein said floor
portion comprises a building construction material as recited in
claim 1, said building construction material having a moisture
barrier that is at least 6 to 12 mil thick.
8. A building structure as recited in claim 6 wherein said wall
portion comprises a building construction material as recited in
claim 1, said building construction material having a moisture
barrier that is at least 6 to 12 mil thick.
9. A building structure having a floor portion, a wall portion, and
a roof portion, wherein at least one portion of said building
structure comprises a plurality of wood boards which have a
moisture barrier permanently attached to only part of the surfaces,
and wherein said moisture barrier has a non-tacky surface and
comprises a non-vulcanized, modified rubber.
10. A building structure as recited in claim 9 wherein the roof
portion comprises a plurality of wood boards having a moisture
barrier that is at least 18 to 20 mil thick, and wherein the floor
portion comprises a plurality of boards having a moisture barrier
that is at least 8 to 10 mil thick, and wherein the wall portion
comprises a plurality of wood boards having a moisture barrier that
is at least 6 to 12 mil thick.
11. A building structure as recited in any one of claims 6-10,
wherein the moisture barrier is permanently attached to the wood
board prior to its installation in the building structure.
12. A building structure as recited in any one of claims 6-10
wherein said wood boards are selected from the group consisting of
solid wood board, plywood board, CDX plywood, oriented strand
board, tongue and groove board, composite board, chipboard and
particle board.
13. A method of protecting a framed building structure from the
damaging effects of moisture, comprising: providing a building
structure frame comprising a floor portion, a wall portion, and a
roof portion, and having an interior space defined by the floor,
wall and roof portions; providing a building construction material
comprising a board, and a moisture barrier having a non-tacky
surface and comprising a non-vulcanized, cured liquid rubberized
material, wherein said material is permanently attached to the
board and covers only part of the surfaces of the board; and
combining said building construction material with said building
structure frame to form an intermediate building structure, wherein
the building construction material is installed on the building
structure frame to form part of one or more of the roof, floor or
wall portions of the building structure.
14. A method as recited in claim 13 wherein the building
construction material is installed to form part of the roof
portion, with the moisture barrier facing away from the interior
space.
15. A method as recited in claim 13 wherein the building
construction material is installed to form part of the wall portion
with the moisture barrier facing away from the interior space.
16. A method as recited in claim 13 wherein the building
construction material is installed to form part of the floor
portion, with the moisture barrier facing toward the interior
space.
17. A method as recited in claim 13 wherein the building
construction material is installed to form part of the wall
portion, with the moisture barrier facing toward the interior
space.
18. A method as recited in claim 13 wherein the building
construction material is installed to form part of the floor
portion, with the moisture barrier facing away from the interior
space.
19. A building structure having an interior portion which is
exposed to moisture conditions, wherein at said interior portion of
said building structure comprises a plurality of wood boards which
have a moisture barrier permanently attached to only part of the
surfaces, and wherein said moisture barrier has a non-tacky surface
and comprises a non-vulcanized, modified rubber.
20. A building structure according to claim 19, wherein the
plurality of wood boards are installed to form part of one or more
of the roof, floor, or wall portions of the building structure.
21. A building structure according to claim 20, wherein the
plurality of wood boards are installed to form part of the floor
portion of the building structure.
22. A building structure according to claim 20, wherein the
plurality of wood boards are installed to facing away from the
interior space.
23. A building structure according to claim 20, wherein the
plurality of wood boards are installed to facing toward the
interior space.
24. A building structure according to claim 20, wherein the
moisture barrier attached to the plurality of wood boards is at
least 8 to 10 mil thick.
25. A building structure according to claim 20, wherein the
plurality of wood boards are selected from the group consisting of
solid wood board, plywood board, CDX plywood, oriented strand
board, tongue and groove board, composite board, chipboard and
particle board.
26. A building structure according to claim 20, wherein the
moisture barrier is attached to the plurality of wood boards either
before or after installation in the building structure.
27. A building structure according to claim 20, wherein the
moisture barrier is attached to the plurality of wood boards after
installation in the building structure.
Description
PRIORITY CLAIM
[0001] This application claims priority to U.S. patent application
Ser. No. 09/874,801, filed Jun. 5, 2001, and U.S. Provisional
Patent Application 60/486,542, filed Jul. 11, 2003, each of which
is incorporated by reference herein in its entirety.
FIELD
[0002] The subject matter herein relates to building construction
materials having moisture barriers for use in building
structures.
BACKGROUND
[0003] Moisture is known to cause warping, cracking, buckling,
rotting and other damage to wood building materials in building
structures and can create an environment for the growth of mold,
mildew and termites in or on the wood. Moisture in the form of
precipitation or condensation may enter a building structure by
penetrating the sides (walls) or the roof; moisture and moisture
vapor from ground water and other sources may enter a building
structure by penetrating the floor of the structure through
concrete slabs or unfinished crawl spaces. Newly fabricated
building structures are particularly vulnerable to the entry of
moisture since it is not usually possible or practical to install
complete roofing or exterior wall protection systems immediately
after the basic building structure is erected. The potentially
damaging effects of moisture is a particular impediment to the
progress of building, since interior building work cannot proceed
prior to the installation of appropriate moisture barriers on the
roof and other portions of a framed building structure. Moisture
and condensation are also a problem in building structures having
radiant heating systems. Condensation that forms as a result of
frequent cycling of the systems and moisture released through leaks
or ruptures in the systems can cause serious damage to the floor
and other portions of a building structure.
[0004] Various types of moisture barriers have been developed to
prevent damage to building structures. However, conventional
moisture barriers suffer from lack of durability in that they
degrade upon exposure to moisture, heat, and other conditions that
are present in the environment or are created by systems such as
radiant heating systems. Additionally, conventional moisture
barriers have proven unsatisfactory for use in new construction in
that they do not provide adequate protection to enable accelerated
building of structural and other systems inside a newly framed
building structure. Accordingly, an non-conventional moisture
barrier is required that does not degrade over time or with
repeated heating and cooling or with exposure to moisture, heat or
other environmental factors.
SUMMARY
[0005] In accordance with the present disclosure, building
construction materials are provided that comprise a moisture
barrier comprising non-vulcanized, modified rubber. The moisture
barrier does not degrade over time, especially when exposed to
moisture or heating/cooling or freeze/thaw cycles. The building
construction materials comprise a board to which is permanently
adhered a non-vulcanized cured, modified rubber comprising a
non-tacky surface.
[0006] Also provided are building structures which comprise several
discrete structural portions, including a roof portion, a floor
portion and a wall portion, in which one or more of each of the
said portions comprise the building construction materials
comprising a moisture barrier as described above.
[0007] Also provided are methods for constructing building
structures wherein one or more portions of the structures are
constructed with a building construction material that comprises a
moisture barrier as described above.
[0008] Additional features and advantages of the invention will be
set forth in part in the description which follows, and in part
will be obvious from the description, or may be learned by practice
of the invention. The features and advantages of the invention will
be realized and attained by means of the elements and combinations
particularly pointed out in the appended claims.
[0009] It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the invention, as
claimed.
[0010] The accompanying drawings, which are incorporated in and
constitute a part of this specification, illustrate several
embodiments of the invention, and together with the description,
serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a cross sectional view of a floor portion of a
building structure comprising a moisture barrier coated onto the
bottom side and at least two edge sides of subfloor boards. The
boards are installed directly over a concrete slab having installed
a radiant heating system, and the moisture barrier is oriented
towards the concrete slab.
[0012] FIG. 2 is a cross sectional view of a floor portion of a
building structure comprising a moisture barrier coated onto the
bottom side and at least two edge sides of subfloor boards. The
boards are installed directly over an in floor radiant heating
system and the moisture barrier is oriented towards the radiant
heating system. The radiant heating system is installed over lower
subfloor which is installed over a crawl space.
[0013] FIG. 3 is a cross sectional view of a floor portion of a
building structure comprising a moisture barrier coated onto the
bottom side and at least two edge sides of subfloor boards. The
boards are installed directly over a crawl space and the moisture
barrier is oriented towards the crawl space.
DETAILED DESCRIPTION
[0014] Moisture Barriers made with Liquid Rubberized Coating
Materials
[0015] The moisture barrier is made of a rubberized material that
is initially in a liquid formulation. Generically, such
formulations have rubber polymers in solution along with solvents
such as methylene chloride and petroleum distillates, and other
additive. These materials include polymeric rubber, adhesion
promoters (agents that enhance binding to the substrate surface),
and diluents and thinners (agents that enhance miscibility and
reduce viscosity of the liquid solution). Preferably, liquid
rubberized coating material formulations include surface acting
agents that stabilize the mixture, inert reinforcement powders, and
UV (ultraviolet light) protection agents. Examples of polymeric
rubber include: poly-butadiene, poly-isoprene,
poly-ethylene-butylene, and polystyrene ethylene-butylene. Examples
of surface acting agents include: suspending agents, deaerating
agents, fume silica, clays, castor oil-based materials,
surfactants. Examples of adhesion promoters include: silane
coupling agents, modified polymeric coupling agents, titinates.
Examples of inert reinforcement powders include: talc powder,
clays, calcium carbonates. Examples of plasticizers include: DOP
and DIBP. Examples of diluents and thinners include: organic
solvents (aromatic or aliphatic); xylene; kerosene. An example of a
UV protection additive is tinuvin, made by Ciba Geigy.
[0016] Examples of commercially available liquid rubberized
coatings include "Dynatron Dyna-Pro Rubberized Undercoat" and
"Mar-Hyde Paintable Rubber Undercoating," which are commonly used
as undercoatings in the automotive and marine industries.
[0017] The liquid rubberized coating material is cured to form a
non-tacky surface when it is applied to the wood board. For curing,
the liquid rubberized coating material does not require additional
treatment, pressurizing, heating, vulcanizing or other processing
steps. The moisture barriers are described as having thicknesses
that are described in units of "mil." A mil refers to a unit of
length equal to one thousandth of an inch or 0.0254 millimeter. The
non-vulcanized, cured liquid rubberized materials have been used
effectively to prepare moisture barriers having thicknesses from 2
to 22 mil. For use in floors lacking radiant heating systems,
thickness of 6 to 8 mil is acceptable. For use with in-floor
radiant heating systems, application of these rubberized materials
to thicknesses of about 10 to 12 mils provided optimal results. For
roofing systems exposed to normal conditions (wind speed from 10 to
60 mph, sun exposure, moisture, temperature from about -10.degree.
F. to 110.degree. F.), thicknesses ranging from 8 to 12 mil are
acceptable. For extreme weather conditions (wind speed at or above
60 mph, sun exposure, moisture, temperature from about -40.degree.
F. to 180.degree. F.), or for extended exposure to normal
conditions (i.e., up to about 90 days), thicknesses from 15 to 20
mil is desirable.
[0018] Preparing Construction Materials having Rubberized Moisture
Barriers
[0019] Rubberized coating materials are applied to boards to
provide building construction materials, building structures, and
roofing, wall, flooring and deck systems with moisture barriers.
The materials may be applied in liquid form, by coating dipping or
by using brushes, sprayers, squeegees and other means for applying
liquids and allowed to dry or cure in ambient environment into a
flexible non-tacky solid state permanently attached to the wood
board. The rubberized materials may also be applied in the form of
pre-cured membranes that are permanently affixed to the boards
using heat, glue or other bonding methods or agents. In either
case, the moisture barriers are contacted permanently with the
surface of the board substrate; optionally, the moisture barriers
may be contacted with the surface of the board at least in part
through covalent chemical bonds between components of the moisture
barrier and components of the board.
[0020] The term "wood board" as used herein refers to boards used
as construction materials that are made of or comprise wood; wood
boards may also comprise other materials. Boards have six sides;
typically, two sides of a board comprise a large percentage of the
overall surface area of the board, and are most alternately
referred to as sides or faces; the remaining four sides of a board
each comprise a small percentage of the overall surface area of the
board, and are alternately referred to as the edges.
[0021] Wood boards that may be used according to the present
disclosure include solid wood board, plywood board, CDX plywood,
oriented strand board, tongue and groove board, composite board,
chipboard and particle board, and the like. The wood boards may
optionally have a tongue and groove construction or other similar
inter-fitting construction for fitting one or more wood boards
tightly together. The wood boards may be provided in any length or
width, and likewise have any of a variety of thickness dimensions.
For example, wood boards may have thicknesses of 1/2", 3/8", 5/8",
3/4" or 11/8".
[0022] The moisture barrier is permanently attached to and entirely
covers at least one side of a wood board. Optionally, the moisture
barrier entirely covers from one to five sides of the wood board
and does not cover any part of one or more of the remaining six
sides of the wood board. Optionally, the moisture barrier entirely
covers from one to five sides of the wood board, and partially
covers one or more of the remaining six sides of the wood board.
Preferably, the moisture barrier entirely covers five sides of the
wood board and covers only part of the surface of the remaining
side of the wood board.
[0023] The terms "partially covers" and "partially covered," as
used herein to describe the extent of coverage of the surfaces of a
wood board with a moisture barrier, means that only part of the
total surface area of a wood board, or only part of a discrete side
of a wood board, is covered with the moisture barrier.
[0024] The term "entirely covers," as used herein to describe the
extent of coverage of a discrete side of a wood board with a
moisture barrier, means that substantially 100% of the surface area
of a discrete side of a wood board is covered with the moisture
barrier.
[0025] The term "only part of the surfaces," as used herein to
describe the extent of coverage of the surfaces of a wood board
with a moisture barrier, means that less than substantially 100% of
the total surface of the board is covered with the moisture
barrier, however, 100% of any one side may be covered (i.e.,
entirely covered) so long as at least one side is only partially
covered.
[0026] Installation of Building Construction Materials having
Rubberized Moisture Barriers Roofing Installation
[0027] Roofing systems may be constructed with the moisture barrier
facing the exterior of the building structure so as to limit the
entry of moisture into the structure. The gaps between the
construction materials may be sealed with tape, such as flashing
membrane, or other appropriate sealing materials. The roofing
systems may also comprise other layers such as styrofoam insulation
or thermal blanket materials. The final, surface layer of the
roofing system may comprise wood, asphalt shingles, slate, tile,
metal, or other finishing materials.
[0028] Walls and Siding Installation
[0029] Wall systems may be constructed with the moisture barrier
facing the exterior of the building structure. The gaps between the
construction materials may be sealed with tape, such as flashing
membrane, or other appropriate sealing materials. The wall system
may also comprise other layers such as styrofoam or blown
insulation. The final, surface layer of the wall system may
comprise wood, metal, or vinyl siding, shakes or shingles, stone,
or brick veneer, lathe and stucco siding, or other finishing
materials.
[0030] Flooring Installation
[0031] Flooring systems may be supported by structural joists, or
floor trusses, which in turn may be installed over either a
concrete slab or a crawl space, and supported by some type of
concrete slab so as to elevate the structural joists and flooring
system above the ground. A flooring system may further include a
"finished" hardwood stone, carpet, tile, vinyl, or cork floor above
a first wood subfloor. The finished floor may overlay an optional
radiant heating system above a second wood subfloor, which is
supported by the structural joists. There are many types of radiant
heating systems for flooring; one example is a radiant heating
system that includes lightweight concrete or Gypcrete sections
having heat pipes displaced throughout the length of the
lightweight concrete or Gypcrete sections. The radiant heating
system keeps the flooring system, and consequently the building
structure, warm during cold temperature seasons.
[0032] Flooring systems may be installed with the moisture barrier
facing either towards or away from the source of moisture. The
construction material with the moisture barrier is installed below
a hardwood floor, either directly over a slab, crawl space or in a
floor heating system. In some cases, the moisture barrier is
installed in two layers. In such flooring systems, a lower sub
floor is installed over a concrete or Gypcrete slab or crawl pace
with the moisture barrier facing away from the slab or crawl space.
An in floor radiant heating system is then installed over this
lower sub floor using lightweight concrete to encase the heating
system. Above the encased heating system an upper sub floor is
installed, with the moisture barrier facing toward the heating
system. The hardwood flooring is installed above this upper sub
floor.
[0033] Foundation Installation
[0034] Foundation (below grade): Plywood foundations may be
installed with the moisture barrier facing the exterior of the
building structure. Seams between the wood boards must be sealed
with tape or a flashing membrane, and the wood boards are nailed to
studs, such as 2.times.6 studs, which are anchored to the structure
footing using anchor bolts.
[0035] Waterproof Deck Installation
[0036] Deck systems may be constructed with 3/4" or 11/8" tongue
and groove plywood or OSB boards with moisture barriers and
installed to form the deck subfloor, with the moisture barrier
facing the elements. Seams between the edges of the boards are
sealed with tape or flashing membrane. Preferably, membrane is
applied along all vertical surfaces and extending from 12" to 18"
on to the deck surface. After coated plywood is installed and taped
to prevent leaking an additional layer (membrane) is optionally
applied to overlap all seams by at least 6". A 1/4" thick
protection mat is installed over optional second membrane. Sleeper
system, 11/2".times.11/2", is installed on top of protection mat.
Wood decking is attached to sleeper system using attachment means
to avoid penetrating the moisture barriers below. If stone or other
material is used for the finished deck surface, the sleeper system
is replaced with a setting bed (made, for example, with mortar mix)
to set the stone or other material.
[0037] Interior Water Exposed Spaces
[0038] Interior water exposed spaces such as showers, whirlpools,
tubs and the like may be constructed using building construction
materials with moisture barriers. The materials are installed with
the moisture barriers facing toward the moisture conditions.
[0039] Constructing Dried-In, Intermediate Building Structures
[0040] The building construction materials comprising moisture
barriers as provided herein can be used to effectively "dry-in"
framed structures so as to shorten the time from framing to
roughing-in. Traditionally, building structures are constructed by
first building a frame ("framing") then by further build up of the
various portions of the structure, such as the floors, roof, walls,
facia and soffets. After framing, the next layer of the structure,
which usually comprises wood boards that are unfinished and are not
intended for exposure to the environmental elements for extended
periods of time, as well as other components such as, for example,
the exterior windows and doors and brick, stone or concrete, are
installed. Thereafter, weatherproofed roofing and siding materials
are installed. After installation of weatherproofed roofing
materials (and optionally, siding materials), the interior work is
begun with installation of plumbing, electrical and HVAC systems
("roughing-in").
[0041] The period of time that elapses from framing to roughing-in
ranges from about 2 weeks to about 6 weeks for a two-story,
wood-based building structure of 4,000 to 10,000 square feet or
more. The long delay between framing and interior work is almost
exclusively due to the need to avoid the damaging effects of the
environmental elements, including wind, precipitation and sunlight,
on interior systems, such as electrical wiring. A dried-in
structure may be achieved much earlier in the construction process
by use of construction materials protected with moisture barriers,
as described herein. These construction materials may be installed
immediately during framing of the structure. When used in
conjunction with appropriate flashing and tape materials (for
example, Ultra-Shield EPDM flashing membrane or similar products),
the installed construction materials will effectively bar the
penetration of the elements, particularly moisture, into the
structure, thus permitting roughing-in to occur much sooner after
framing, or approximately 2-4 weeks earlier than usual.
[0042] A suitably dried-in structure will have the construction
materials with the moisture barrier installed to form at least the
roof portion. Either or both the wall and floor portions may also
have the construction materials installed. These dried-in
structures are "intermediate building structures" in that
additional layers such as siding, roofing materials, and flooring
components remain to be installed. Dried-in structures, and the
methods for making them, permit acceleration of the building
schedule by permitting rough-in to commence early.
EXAMPLES
Example 1
Installation of a Moisture Barrier above an In-Floor Radiant
Heating System Installed on Grade in a Concrete Slab
[0043] A building structure 234 having a flooring system 202
including an adequate moisture barrier is shown in FIG. 1. In this
embodiment, the moisture and condensation barrier 236 is coated
onto the undersides and the edges of a plurality of wood boards
(such as plywood, chipboard, particle board, etc.) that form a wood
subfloor 238 under the hardwood floor 206. The moisture and
condensation barrier 236 generally comprises a rubberized material
that can be sprayed, painted or otherwise coated onto the wood
board for the subfloor 238, with application occurring either in
the field before or after installation, or elsewhere before
installation. The moisture and condensation barrier 236 can then be
allowed to dry or cure to form a flexible non-tacky solid that is
permanently attached to the wood board, is resistant to penetration
by water, is durable and not subject to degradation when exposed to
water and/or to heating/cooling cycles (e.g. freeze/thaw cycles)
and can allow nails and staples to pass through in order to affix
the wood board for the subfloor 238 to other components of the
building structure 234, if needed. That product commonly referenced
by the trade name "Dynatron (.TM.) Dyna-Pro Rubberized Undercoat"
(.TM.) available from Bondo Corporation of Atlanta, Ga., is an
acceptable example of such a rubberized material. Additionally,
that product commonly referenced by the trade name "Mar-Hyde
Paintable Rubber Undercoating" (.TM.) available from Bondo/Mar-Hyde
Corporation of Atlanta, Ga. is also an acceptable example of such a
rubberized material. Additionally, the product Bondo formulation
9706 can be used. The flooring system 202 is shown placed between
the walls 210 above the concrete slab 230 supported above the
ground 216. The concrete slab 230 also serves as an optional
radiant heating system having the heat pipes 218 displaced
throughout the concrete slab 213. In the embodiment shown in FIG.
1, the moisture and condensation barrier 236 is installed in the
flooring system 202 oriented away from the interior of the building
structure 234. In alternate embodiments (not shown), the moisture
and condensation barrier 236 may be installed in the flooring
system 202 oriented toward the interior of the building structure
234. In further embodiments (not shown), the moisture and
condensation barrier 236 may be installed on two levels of wood
subfloor 238 with one level being oriented toward and one level
being oriented away from the interior of the building structure
234. The same flooring system 202 with the moisture and
condensation barrier 236 coated onto the wood boards of the wood
subfloor 238 may also be incorporated into a building structure
(not shown) not having the radiant heating system. Likewise, the
flooring system 202 may be installed into a building structure (not
shown) having a concrete slab on grade that is positioned directly
on the ground 216.
[0044] Commercially available Bondo formulation 9706 was used to
form the moisture barrier 236. Bondo formulation 9706 is only one
example of a non-vulcanized rubber material that may be used
according to this invention. This liquid rubberized coating
material was coated onto solid wood boards to a thickness of
approximately 6-8 mil. The coating was applied using a roller and
approximately 3 coats were applied. The moisture barrier was then
allowed to dry under ambient conditions to form a flexible
non-tacky solid that was permanently attached to the wood board,
was resistant to penetration by water, was durable and not subject
to degradation when exposed to water and/or to heating/cooling
cycles (e.g. freeze/thaw cycles). The coated boards were installed
to form a wood subfloor 238 under the hardwood floor 206.
Example 2
Installation of a Moisture Barrier above an In-Floor Radiant
Heating System Installed over a Crawl Space
[0045] In another embodiment, a building structure 240 having a
flooring system 202 including an adequate moisture barrier 236 is
shown in FIG. 2. In this flooring system 202 the moisture and
condensation barrier 236 is coated onto the wood boards that form
the wood subfloor 238 under the hardwood floor 206. The flooring
system 202 is shown placed between the walls 210 and the flooring
system 202 is elevated above the ground 216 by the concrete or
Gypcrete slab 230 and the structural joists 228. The embodiment
also includes the radiant heating system 224 (having the heat pipes
218 and sleeper system 229) supported on the second wood subfloor
226 in the flooring system 202.
[0046] Bondo formulation 9706 was used to form the moisture
barrier, and was coated onto the wood boards that form the wood
subfloor under the hardwood floor. This liquid rubberized coating
material was coated onto solid wood boards to a thickness of
approximately 6-8 mil. The coating was applied using a roller and
approx 3 coats were applied. The moisture barrier was then allowed
to dry under ambient conditions to form a flexible non-tacky solid
that was permanently attached to the wood board, was resistant to
penetration by water, was durable and not subject to degradation
when exposed to water and/or to heating/cooling cycles (e.g.
freeze/thaw cycles). The coated boards were installed to form a
wood subfloor under the hardwood floor, with the moisture barrier
facing towards the heating system.
Example 3
Retro-Installation of a Moisture Barrier over a Crawl Space
[0047] A building structure 242 flooring system 202 including an
adequate moisture barrier 236 is shown in FIG. 3. In this flooring
system 202 the moisture and condensation barrier 236 is coated onto
the plurality of wood boards that form the wood subfloor 238 under
the hardwood floor 206. The flooring system 202 is shown placed
between the walls 210 and the flooring system 202 is elevated above
the ground 216 by the concrete slab 230 and the structural joists
228. The embodiment does not include a radiant heating system, so
the wood subfloor 238 having the coated-on moisture and
condensation barrier 236 is supported directly on the structural
joists 228.
[0048] Previously-installed hardwood flooring was removed to reveal
the sub-floor 238, which was installed on structural joists 228
over an earthen crawl space (ground 216). Bondo formulation 9706
was used to form the moisture barrier, and was coated directly on
to the upper surface of the wood boards of the installed sub floor.
The liquid rubberized coating material was coated onto to a
thickness of approximately 6-8 mil using a roller and approximately
3 coats were applied. The moisture barrier was then allowed to dry
under ambient conditions to form a flexible non-tacky solid. A hard
wood floor 206 was installed over the coated sub floor 238
boards.
[0049] It should be understood that every maximum numerical
limitation given throughout this specification will include every
lower numerical limitation, as if such lower numerical limitations
were expressly written herein. Every minimum numerical limitation
given throughout this specification will include every higher
numerical limitation, as if such higher numerical limitations were
expressly written herein. Every numerical range given throughout
this specification will include every narrower numerical range that
falls within such broader numerical range, as if such narrower
numerical ranges were all expressly written herein.
[0050] While particular embodiments of the subject invention have
been described, it will be obvious to those skilled in the art that
various changes and modifications of the subject invention can be
made without departing from the spirit and scope of the invention.
In addition, while the present invention has been described in
connection with certain specific embodiments thereof, it is to be
understood that this is by way of illustration and not by way of
limitation and the scope of the invention is defined by the
appended claims which should be construed as broadly as the prior
art will permit.
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