U.S. patent application number 11/054423 was filed with the patent office on 2006-08-17 for method and apparatus for integral modular masonry flashing.
Invention is credited to Claude S. Creech.
Application Number | 20060179747 11/054423 |
Document ID | / |
Family ID | 36814197 |
Filed Date | 2006-08-17 |
United States Patent
Application |
20060179747 |
Kind Code |
A1 |
Creech; Claude S. |
August 17, 2006 |
Method and apparatus for integral modular masonry flashing
Abstract
A masonry wall includes a masonry foundation, a flashing unit
disposed on the masonry foundation, a masonry weep structure, a
mortar bed and at least one layer of masonry units disposed upon
the mortar bed. A gap defined between the back surface of the
masonry unit and the back edge is sufficient to allow water that
has seeped through a plurality of masonry units to downwardly
toward the platform. A mesh masonry weep structure is disposed on
the platform of the flashing unit to allow drainage of water that
has seeped behind the wall. A modular flashing unit and template
system facilitates building a masonry foundation and quick
application of flashing.
Inventors: |
Creech; Claude S.; (Cumming,
GA) |
Correspondence
Address: |
BRYAN W. BOCKHOP, ESQ.
2375 MOSSY BRANCH DR.
SNELLVILLE
GA
30078
US
|
Family ID: |
36814197 |
Appl. No.: |
11/054423 |
Filed: |
February 9, 2005 |
Current U.S.
Class: |
52/302.1 |
Current CPC
Class: |
E04D 13/1478
20130101 |
Class at
Publication: |
052/302.1 |
International
Class: |
E04B 1/70 20060101
E04B001/70 |
Claims
1. A masonry wall, comprising: a. a foundation; b. a flashing unit
disposed on the foundation, the masonry flashing unit comprising:
i. a platform having a front edge and an opposite back edge and
having a width between the front edge and the back edge so that
when a masonry unit is disposed on the platform with a front
surface substantially flush with the front edge, a gap is defined
between the back surface of the masonry unit and the back edge; ii.
a back vertical wall, having a top edge, extending upwardly from
the back edge of the platform, the back vertical wall having a
height so that the top edge extends by a predetermined amount
beyond the top surface of a masonry unit of a plurality of masonry
units placed on the platform; and iii. a front vertical wall
depending downwardly from the front edge of the platform; c. a
masonry weep structure placed on the platform of the flashing unit,
the masonry weep structure including: i. a first elongated mesh
strip; and ii. a first plurality of spaced-apart mesh fingers
extending from the elongated mesh strip, each finger extending from
the elongated mesh strip at a distance at least equal to a width of
a masonry unit, the mesh strip and the mesh fingers made of a mesh
material that allows water to pass therethrough and that is stable
in the presence of mortar, the mesh fingers terminating in a front
surface that is in alignment with the front edge of the platform;
d. a mortar bed disposed on the platform of the flashing unit so as
to fill in a space between the spaced-apart mesh fingers; and at
least one layer of masonry units disposed upon the mortar bed and
the spaced-apart mesh fingers, the layer having a back surface that
is spaced-apart from the back vertical wall of the flashing unit by
a predetermined distance sufficient to allow water that has seeped
through the masonry units to flow down to first elongated mesh
strip and through the spaced-apart mesh fingers.
2. A masonry flashing unit for use with a plurality masonry units,
each masonry unit having a front surface, an opposite back surface,
a bottom surface and an opposite top surface, the masonry flashing
unit comprising: a. a platform having a front edge and an opposite
back edge; b. a back vertical wall, having a top edge, extending
upwardly from the back edge of the platform, the back vertical wall
having a height so that the top edge extends by a predetermined
amount beyond the top surface of a masonry unit of the plurality of
masonry units placed on the platform; and c. a front vertical wall
depending downwardly from the front edge of the platform, the
platform having a width between the front edge and the back edge so
that when a masonry unit of the plurality of masonry units is
disposed on the platform with the front surface substantially flush
with the front edge, a gap of predetermined width is defined
between the back surface of the masonry unit and the back vertical
wall, the predetermined width being sufficient to allow water that
has seeped through the plurality of masonry units to flow
downwardly to the platform.
3. The masonry flashing unit of claim 2, wherein the platform, the
front vertical wall and the back vertical wall are formed from a
single piece of a material.
4. The masonry flashing unit of claim 3, wherein the material is
selected from a group consisting essentially of: a metal and a
plastic.
5. The masonry flashing unit of claim 2, wherein the front vertical
wall defines a bottom edge, wherein the bottom edge is at an angle
that is transverse to the platform.
6. The masonry flashing unit of claim 5, wherein the platform has a
side edge, the masonry flashing unit further comprising a vertical
side wall, having a top edge, extending upwardly from the side
edge.
7. The masonry flashing unit of claim 6, further comprising a lip
extending outwardly from the top edge of the vertical side
wall.
8. The masonry flashing unit of claim 6, wherein the vertical side
wall has a height so that when a first masonry flashing unit is
placed on top of a second masonry flashing unit so that the
platform of the second masonry flashing unit rests on the top edge
of the vertical side wall of the first masonry flashing unit and so
that the platform of the second modular flashing unit overlaps the
vertical sidewall of the first modular flashing unit, the bottom
edge of the front vertical wall of the first modular flashing unit
is in substantial alignment with the bottom edge of the front
vertical wall of the second modular flashing unit.
9. A modular flashing unit for use with a plurality masonry units,
each masonry unit having a front surface, an opposite back surface,
a bottom surface and an opposite top surface, the modular flashing
unit comprising a. a stepped member including at least a first
latitudinal platform and a second latitudinal platform, the second
latitudinal platform being not coplanar with the first latitudinal
platform, each of the first latitudinal platform and the second
latitudinal platform having a front edge, an opposite back edge, a
first side edge and an opposite second side edge, the stepped
member also including at least one longitudinal wall connecting the
first side edge of the first latitudinal platform to the second
side edge of the second latitudinal platform, the longitudinal wall
including a front edge and an opposite back edge, the stepped
member having a width between the first latitudinal platform and
the second latitudinal platform that is wider than a masonry unit
of the plurality of masonry units by a predetermined amount; b. a
front vertical wall having a stepped edge connected to the front
edge of the first latitudinal platform, the front edge of the
second latitudinal platform and the front edge of the longitudinal
wall; and c. a back vertical wall having a stepped edge connected
to the back edge of the first latitudinal platform, the back edge
of the second latitudinal platform and the back edge of the
longitudinal wall.
10. The modular flashing unit of claim 9, further comprising a
planar template that has dimensions corresponding to a masonry
foundation upon which the modular flashing unit is to be installed,
so that when the masonry foundation is made according to the
template, the modular flashing unit will fit on the masonry
foundation.
11. The modular flashing unit of claim 9, wherein the stepped
member, the front vertical wall, and the back vertical wall are all
made from a unitary sheet of a material.
12. The modular flashing unit of claim 11, wherein the material
comprises a plastic.
13. The modular flashing unit of claim 12, wherein the plastic has
been vacuum-formed.
14. A masonry weep system, comprising: a. a mesh finger, having a
first side, an opposite second side, a front end and an opposite
back end, the mesh finger made of a mesh material that allows water
to pass therethrough and that is stable in the presence of mortar,
the mesh finger placed on a masonry foundation; and b. mortar
placed on the masonry foundation and disposed about the first side
and the second side of the mesh finger and not covering the back
end or the front end.
15. A masonry weep structure, comprising: a. a first elongated mesh
strip; and b. a first plurality of spaced-apart mesh fingers
extending from the elongated mesh strip, each finger extending from
the elongated mesh strip at a distance at least equal to a width of
a masonry unit, the mesh strip and the mesh fingers made of a mesh
material that allows water to pass therethrough and that is stable
in the presence of mortar.
16. The masonry weep structure of claim 15, wherein the mesh strip
and the mesh fingers comprise a non-woven plastic mesh.
17. The masonry weep structure of claim 15, further comprising: a.
a second elongated mesh strip; and b. a second plurality of
spaced-apart mesh fingers extending from the elongated mesh strip,
each finger extending from the elongated mesh strip at a distance
at least equal to a width of a masonry unit, the second elongated
strip and the second plurality of spaced-apart mesh fingers in
opposed engagement with the first elongated mesh strip and the
first plurality of spaced-apart mesh fingers, so as to form a
single belt of mesh with division to facilitate separation of the
first elongated mesh strip and the first plurality of spaced apart
mesh fingers from the second elongated mesh strip and the second
plurality of spaced-apart mesh fingers.
18. A method of making a modular flashing system for a user to
employ with a masonry foundation, comprising the steps of: a.
receiving dimensions corresponding to the masonry foundation; b.
making a modular flashing system that is sized to fit the masonry
foundation, based on the dimensions; c. making a template that has
an edge that corresponds to an edge of the masonry foundation; and
d. delivering the template to the user so that when the user builds
the masonry foundation according to the template, the modular
flashing system will fit the masonry foundation.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to masonry and, more
specifically, to a thru-wall masonry flashing system.
[0003] 2. Description of the Prior Art
[0004] Typical masonry veneer walls are made by laying a plurality
of bricks (or other masonry units, such as stones) in an ordered
arrangement. With a veneer wall, the structural support for the
wall is typically a wood or steel frame and the masonry veneer
functions aesthetically.
[0005] Typically, rainwater is absorbed through masonry veneer in a
very short amount of time. In such a case, a mechanism must be in
place to prevent the structural components of the wall and other
building assemblies and components from becoming wet. This is
typically done by employing thru wall flashing and weep structures.
Thru wall flashing is a sheet structure placed at the bottom
regions of a masonry veneer, at intersections and terminations,
providing moisture barrier protection that allows water to collect
and travel in a gap between a vertical portion of the thru wall
flashing and the rear surface of the veneer. Water is allowed to
drain out of the veneer through the weep structure, which is
typically a plastic tube, wicking rope or other type of weep,
embedded in the mortar at the bottom of the veneer and on top of
the thru wall flashing platform.
[0006] Frequently, the masonry veneer must interface with a
structure. For example, an angled roof may intersect with the
masonry veneer of a wall. In such an intersection, a stair-stepped
structure of masonry and thru wall flashing is built up by the
mason. Once the veneer is complete, a roofer applies counter
flashing to the part of the thru wall flashing extending beyond the
outer surface of the veneer. The counter flashing interfaces the
veneer with the roof line.
[0007] Existing thru wall flashing units are typically made at the
job site from sheet metal by masons or sheet metal fabricators.
Doing so can be time consuming and costly. The additional step of
applying counter flashing adds to the time consumed and the
cost.
[0008] Also, existing weep structures tend to get clogged with
mortar droppings generated by masons. If the weep structures get
clogged, then drainage through the veneer and cavity wall
ventilation is hampered, thereby increasing the likelihood of
moisture-related problems in the frame structure of the wall
assemblies and components.
[0009] Therefore, there is a need for a flashing system that is
relatively inexpensive, reliable and easy to use.
[0010] There is also a need for a flashing system that incorporates
both thru wall flashing and counter flashing in a single unit.
[0011] There is also a need for a weep structure that resists
clogging.
SUMMARY OF THE INVENTION
[0012] The disadvantages of the prior art are overcome by the
present invention which, in one aspect, is a masonry wall that
includes a masonry foundation, a flashing unit disposed on the
masonry foundation, a masonry weep structure, a mortar bed and at
least one layer of masonry units disposed upon the mortar bed. The
masonry flashing unit includes a platform having a front edge and
an opposite back edge. The masonry flashing unit has a width
between the front edge and the back edge so that when a masonry
unit is disposed on the platform with the front surface
substantially flush with the front edge, a gap of predetermined
width is defined between the back surface of the masonry unit and
the back edge. The predetermined width is sufficient to allow water
that has seeped through a plurality of masonry units to downwardly
toward the platform. A back vertical wall, having a top edge,
extends upwardly from the back edge of the platform The back
vertical wall has a height so that the top edge extends by a
predetermined amount beyond the top surface of a brick of a
plurality of masonry units placed on the platform. A front vertical
wall depends downwardly from the front edge of the platform. A
masonry weep structure is disposed on the platform of the flashing
unit. The masonry weep structure includes a first elongated mesh
strip and a first plurality of spaced-apart mesh fingers extending
from the elongated mesh strip. Each finger extends from the
elongated mesh strip at a distance at least equal to a width of a
masonry unit. The mesh strip and the mesh fingers are made of a
mesh material that allows water to pass therethrough and that is
stable in the presence of mortar. The mesh fingers terminate in a
front surface that is in alignment with the front edge of the
platform. The mortar bed is disposed on the platform of the
flashing unit so as to fill in a space between the spaced-apart
mesh fingers. The masonry units are disposed upon the mortar bed
and the spaced-apart mesh fingers. The layer of masonry units has a
back surface that is spaced-apart from the back vertical wall of
the flashing unit by a predetermined distance sufficient to allow
water that has seeped through the masonry units to flow downwardly
to the first elongated mesh strip and through the spaced-apart mesh
fingers.
[0013] In another aspect, the invention is a masonry flashing unit
for use with a plurality masonry units wherein each masonry unit
has a front surface, an opposite back surface, a bottom surface and
an opposite top surface. The masonry flashing unit includes a
platform, a back vertical wall and a front vertical wall. The
platform has a front edge and an opposite back edge. The back
vertical wall has a top edge and extends upwardly from the back
edge of the platform. The back vertical wall has a height so that
the top edge extends by a predetermined amount beyond the top
surface of a masonry unit of the plurality of masonry units placed
on the platform. The front vertical wall depends downwardly from
the front edge of the platform. The platform has a width between
the front edge and the back edge so that when a masonry unit of the
plurality of masonry units is disposed on the platform with the
front surface substantially flush with the front edge, a gap of
predetermined width is defined between the back surface of the
masonry unit and the back vertical wall. The predetermined width is
sufficient to allow water that has seeped through the plurality of
masonry units to run down the back vertical wall.
[0014] In another aspect, the invention is a modular flashing unit
for use with a plurality masonry units in which each masonry unit
has a front surface, an opposite back surface, a bottom surface and
an opposite top surface. The modular flashing unit includes a
stepped member, a front vertical wall and a back vertical wall. The
stepped member includes at least a first latitudinal platform and a
second latitudinal platform. The second latitudinal platform is not
coplanar with the first latitudinal platform. Each of the first
latitudinal platform and the second latitudinal platform has a
front edge, an opposite back edge, a first side edge and an
opposite second side edge. The stepped member also includes at
least one longitudinal wall connecting the first side edge of the
first latitudinal platform to the second side edge of the second
latitudinal platform. The longitudinal wall includes a front edge
and an opposite back edge. The stepped member has a width between
the first latitudinal platform and the second latitudinal platform
that is wider than a masonry unit of the plurality of masonry units
by a predetermined amount. The front vertical wall has a stepped
edge connected to the front edge of the first latitudinal platform,
the front edge of the second latitudinal platform and the front
edge of the longitudinal wall. The back vertical wall has a stepped
edge that is connected to the back edge of the first latitudinal
platform, the back edge of the second latitudinal platform and the
back edge of the longitudinal wall.
[0015] In another aspect, the invention is a masonry weep system
that includes a mesh finger, having a first side, an opposite
second side, a front end and an opposite back end. The mesh finger
is made of a mesh material that allows water to pass therethrough
and that is stable in the presence of mortar. The mesh finger
placed on a masonry foundation. Mortar is placed on the masonry
foundation and is disposed about the first side and the second side
of the mesh finger and does not cover the back end or the front
end.
[0016] In another aspect, the invention is a masonry weep structure
that includes a first elongated mesh strip and a first plurality of
spaced-apart mesh fingers that extend from the elongated mesh
strip. Each finger extends from the elongated mesh strip at a
distance at least equal to a width of a masonry unit. The mesh
strip and the mesh fingers are made of a mesh material that allows
water to pass therethrough and that is stable in the presence of
mortar.
[0017] In yet another aspect, the invention is a method of making a
modular flashing system for a user to employ with a masonry
foundation. Dimensions corresponding to the masonry foundation are
received. A modular flashing system that is sized to fit the
masonry foundation is made based on the dimensions. A template that
has an edge that corresponds to an edge of the masonry foundation
is made. The template is delivered to the user so that when the
user builds the masonry foundation according to the template, the
modular flashing system will fit the masonry foundation.
[0018] These and other aspects of the invention will become
apparent from the following description of the preferred
embodiments taken in conjunction with the following drawings. As
would be obvious to one skilled in the art, many variations and
modifications of the invention may be effected without departing
from the spirit and scope of the novel concepts of the
disclosure.
BRIEF DESCRIPTION OF THE FIGURES OF THE DRAWINGS
[0019] FIG. 1A is a top perspective view of one embodiment of a
flashing unit.
[0020] FIG. 1B is a front elevational view of the embodiment shown
in FIG. 1A.
[0021] FIG. 1C is a cross sectional view of the embodiment shown in
FIG. 1B, taken along line 1C-1C.
[0022] FIG. 2A is a top perspective view of a second embodiment of
a flashing unit.
[0023] FIG. 2B is a front elevational view of the embodiment shown
in FIG. 1B.
[0024] FIG. 2C is a front elevational view of a third embodiment of
a flashing unit.
[0025] FIG. 2D is a front elevational view of several flashing
units, as shown in FIG. 2C, used together.
[0026] FIG. 3A is a plan view of one embodiment of a weep
structure.
[0027] FIG. 3B is a cross-sectional view of mesh used in a weep
structure.
[0028] FIG. 3C is a plan view of a weep structure, as shown in FIG.
3A, used with mortar.
[0029] FIG. 3D is a plan view of a weep structure strip.
[0030] FIG. 4A is a cross-sectional view of a flashing unit, a weep
structure and masonry units used together to form a masonry
wall.
[0031] FIG. 4B is a front elevational view of the wall shown in
FIG. 4A.
[0032] FIG. 5 is a plan view of a second embodiment of a weep
structure.
[0033] FIG. 6A is a top perspective view of a modular flashing
system.
[0034] FIG. 6B is a front elevational view of a stepped member of a
modular flashing unit.
[0035] FIG. 6C is a front elevational view of a flashing
template.
[0036] FIG. 6D is a front elevational view of a flashing template
applied to a masonry foundation.
[0037] FIG. 6E is a front elevational view of a masonry foundation
made according to the template shown in FIG. 6D.
[0038] FIG. 6F is a front elevational view of the masonry
foundation shown in FIG. 6E, with the stepped member shown in FIG.
6B applied thereto.
DETAILED DESCRIPTION OF THE INVENTION
[0039] A preferred embodiment of the invention is now described in
detail. Referring to the drawings, like numbers indicate like parts
throughout the views. As used in the description herein and
throughout the claims, the following terms take the meanings
explicitly associated herein, unless the context clearly dictates
otherwise: the meaning of "a," "an," and "the" includes plural
reference, the meaning of "in" includes "in" and "on." "Masonry
unit" includes any unit of solid masonry material, including a
brick, a concrete block, a ceramic block, a glass block, a piece of
stone, or any unit of any other type of material that is used to
make a masonry wall. "Mortar" includes cement, grout and any
substance used to bind masonry units.
[0040] As shown in FIGS. 1A-1C, one embodiment of the invention is
a thru-wall masonry flashing unit 100 that includes a platform 110
having a front edge 112, an opposite back edge 114 and a first side
edge 116. A back vertical wall 120, having a top edge 122, extends
upwardly from the back edge 114 of the platform 110. The back
vertical wall 120 has a height so that the top edge 122 extends by
a predetermined amount (typically two inches) beyond the top
surface 154 of a masonry unit 150 (such as a brick) of the
plurality of masonry units 150 placed on the platform 110. A front
vertical wall 130 depends downwardly from the front edge 112 of the
platform 110. The width of the platform 110 between the front edge
112 and the back edge 114 is sufficient so that a gap 126 is
defined between the back vertical wall 120 and the back surface 152
of masonry units 150 placed on the platform 110 so that the front
surface 156 of the masonry units 150 are aligned with the front
vertical wall 130. The gap 126 is wide enough (typically one inch)
to allow water that has seeped through the plurality of masonry
units 150 to run down the back vertical wall 120 to the platform
110. The front vertical wall 130 has a bottom edge 132 that may be
either flat or at an angle a, depending on the location where the
masonry flashing unit 100 is being used. The platform 110, the
front vertical wall 130 and the back vertical wall 120 may be
formed from a single piece of a material, such as sheet metal
(e.g., copper, aluminum, or galvanized steel) or plastic (e.g.,
PVC, HDPE, composites, laminates). If a sheet thermoplastic is
used, the embodiments of the flashing units shown herein can be
made through vacuum forming.
[0041] As shown in FIGS. 2A-2B, a vertical side wall 210, having a
top edge 212, can extend upwardly from the first side edge 116. As
shown in FIG. 2C, a lip 214 can be formed in the vertical side wall
210. The lip 214 can be manufactured at a manufacturing facility,
or it can be formed at the job site using a pair of metal shears
and a pair of pliers. As shown in FIG. 2D, if the height of the
vertical side wall 210 of masonry flashing units 100 is chosen
correctly, they can be stacked so that their bottom edges 132 are
in substantial alignment. This is a useful feature when it is
desirable for the bottom edges 132 are to follow a roof line. By
having the platforms 110 overlap the vertical side walls 210, water
flowing through the masonry units into the flashing units 100 will
not leak out of the flashing units 100 into the frame structure
about which the masonry is being applied.
[0042] A weep structure may be used with the flashing units 100
disclosed herein. While a conventional weep structure, such as a
plastic tube, may be used to drain water from the gap 126, a
mesh-type weep structure 300, as shown in FIG. 3A, offers several
advantages. Such a weep structure 300 includes a first elongated
mesh strip 310 and a first plurality of spaced apart mesh fingers
320, each extending from the elongated mesh strip 310. Each finger
320 is at least as long as a masonry unit is wide. As shown in FIG.
3B, the mesh strip 310 and the mesh fingers 320 are made of a mesh
material 302, shown in FIG. 3B, that allows water to pass
therethrough and that is stable in the presence of mortar. The mesh
fingers 320 terminate in a front surface 322. Examples of a
suitable mesh material 302 include a nonwoven thermoplastic mesh
(such as a polyester fiber mesh). One example of a suitable mesh is
COBRA.RTM. RIDGE VENT, available from Cobra Ventilation Co., Inc.,
1361 Alps Road, Wayne, N.J. 07470-3689. As shown in FIG. 3C, the
weep structure 300 may be used with a mortar bed 312, to allow
water to drain out of a masonry structure. As shown in FIG. 3D, the
mesh-type weep structure 300, may be sold as a mesh strip that
includes tear lines 318 that allow the contractor to separate two
cross-positioned weep structures 300 by tearing them apart.
Additional pieces 330 of mesh may also be included in the strip.
Such pieces 330 of mesh may be used for individual weeps. As shown
in FIG. 6, a shaped mesh weep structure 600 may be made in which
the fingers 620 are shaped for esthetic or branding purposes.
[0043] As shown in FIGS. 4A and 4B, a masonry wall 400 may be made
according to one embodiment of the invention. The wall 400 includes
a foundation 410, typically made of several layers masonry units
150 topped with a mortar bed 412. Before hardening of the mortar
bed 412, a flashing unit 100 is placed on the mortar bed 412. The
weep structure 300 is then placed on the platform 110 of the
flashing unit 100 and a layer of mortar 312 is applied between the
fingers 320. Upon this combination of the weep structure 300 and
the mortar 312 is placed the masonry units 150 that make up the
wall 400. A bead of calk 402 may be applied to the bottom edge 132
of the front vertical wall 130 to provide a more esthetic
appearance.
[0044] One embodiment of a modular flashing system 700 is shown in
FIGS. 6A-6C. The modular flashing system 700 includes a modular
flashing unit 710 and a corresponding planar template 760. The
modular flashing unit 710 includes a stepped member 711, a front
vertical wall 740, and a back vertical wall 750. The stepped member
711 includes a plurality of latitudinal platforms 712 connected by
longitudinal walls 730 to form a stepped shape. The stepped member
711 has a front edge 732, an opposite back edge 734, a first side
edge 716 and an opposite second side edge 718. The front vertical
wall 740 has a stepped edge 742 connected to the front edge 714 of
the stepped member 711. The front vertical wall 740 also includes a
bottom edge 742. The back vertical wall 750 has a stepped edge 752
connected to the back edge 720 of the stepped member 711.
[0045] As shown in FIGS. 7A and 7C, the planar template 760 has
dimensions that correspond to the front vertical wall 740 of the
modular flashing unit 710. The planar template 760 has a top
stepped edge 764 and a bottom angled edge 762. As shown in FIG. 7D,
the planar template 760 is used as a template to build a masonry
foundation 770. The masonry foundation 770 is the foundation upon
which the modular flashing unit 710 will be installed.
[0046] As shown in FIGS. 7E and 7F, once the masonry foundation 770
is complete, a mortar bed 772 is placed on the masonry foundation
770 and the modular flashing unit 710 is placed on the mortar bed
772 before it sets. This ensures a good fit for the modular
flashing unit 710 and ensures that it is well supported by the
masonry foundation 770.
[0047] The modular flashing unit 710 could be made in one of
several ways. For example, it could be made from sheet metal using
conventional metalworking techniques. Similarly, it could be made
from sheet plastic using conventional plastic fabrication
techniques, including vacuum forming The planar template 760 could
be made from one of many sheet materials, including metal, plastic
or even sturdy cardboard.
[0048] In one method of making the modular flashing unit 710, a
builder or architect sends the dimensions for the masonry
foundation 770 to a fabrication facility. The fabrication facility
would employ a conventional computer-aided design and manufacturing
(CAD/CAM) system to design the modular flashing unit 710 and the
planar template 760, using predefined criteria, based on the
dimensions. The CAD/CAM system would control the necessary cutting
tools (such as a LASER cutting tool) to cut out the necessary
parts.
[0049] In one embodiment, a sheet cutting facility or a stair
manufacturer, could make two copies of the planar template 760,
each of which is marked with a unique identifier that corresponds
to the specific use specified by the builder. One of the dual twin
templates is sent to the mason; thereby allowing the building of
the masonry foundation 770 to commence, and the other is sent to a
fabrication facility for use in the fabrication of the modular
flashing unit 710. Making the masonry foundation 770 in tandem with
the planar template 760 allows for efficient workflow.
[0050] The above described embodiments are given as illustrative
examples only. It will be readily appreciated that many deviations
may be made from the specific embodiments disclosed in this
specification without departing from the invention. Accordingly,
the scope of the invention is to be determined by the claims below
rather than being limited to the specifically described embodiments
above.
* * * * *