U.S. patent application number 12/814360 was filed with the patent office on 2011-12-15 for mortar and debris collection system.
Invention is credited to Tom Sourlis.
Application Number | 20110302863 12/814360 |
Document ID | / |
Family ID | 45095062 |
Filed Date | 2011-12-15 |
United States Patent
Application |
20110302863 |
Kind Code |
A1 |
Sourlis; Tom |
December 15, 2011 |
MORTAR AND DEBRIS COLLECTION SYSTEM
Abstract
Mortar and debris collection systems for cavity wall
construction and/or walls constructed from concrete masonry units
(CMU), for example, include a mesh body made of a material that is
formed with circuitous paths therethrough making the body
water-permeable. The mesh body is formed of a material having
enhanced hydrophobic properties. The mesh body has a porosity
sufficient to permit water to pass therethrough but insufficient to
permit mortar and other debris to pass therethrough to weep holes
or other water channels covered by the collection debris.
Inventors: |
Sourlis; Tom; (Highland,
IN) |
Family ID: |
45095062 |
Appl. No.: |
12/814360 |
Filed: |
June 11, 2010 |
Current U.S.
Class: |
52/302.1 |
Current CPC
Class: |
E02D 19/00 20130101 |
Class at
Publication: |
52/302.1 |
International
Class: |
E02D 19/00 20060101
E02D019/00 |
Claims
1. A mortar and debris collection system for a wall having,
comprising: a water-permeable body positioned in alignment with at
least some channel openings formed through said wall, said body
having circuitous non-linear pathways therethrough which interrupt
the downward movement of free-falling material and extending from
an upper surface upon which water and debris can fall, and yielding
a porosity for said body sufficient to permit water to pass
therethrough, but mortar and other debris is substantial prevented
from passing therethrough, and said water-permeable body having
enhanced hydrophobic properties.
2. The mortar and debris collection device of claim 1, comprising a
flashing member.
3. The mortar and debris collection device of claim 2, wherein the
flashing member is formed of a material having enhanced hydrophobic
properties.
4. The mortar and debris collection device of claim 1, comprising a
tray member.
5. The mortar and debris collection device of claim 4, wherein the
tray member is formed of a material having enhanced hydrophobic
properties.
6. The mortar and debris collection device of claim 1, comprising a
pan member.
7. The mortar and debris collection device of claim 6, wherein the
pan member is formed of a material having enhanced hydrophobic
properties.
8. The mortar and debris collection device of claim 1, further
comprising a plurality of weep tabs.
9. The mortar and debris collection device of claim 8, wherein the
weep tabs are formed of a material having enhanced hydrophobic
properties.
10. The mortar and debris collection device of claim 1, further
comprising a plurality of weep hole bodies, each of the plurality
of weep hole bodies being sized and shaped to be received within a
channel opening of the wall.
11. The mortar and debris collection device of claim 10, wherein
the weep hole bodies are formed of a material having enhanced
hydrophobic properties.
Description
FIELD OF THE INVENTION
[0001] This invention generally relates to mortar and debris
collection devices, such as are used in association with cavity
wall and other types of wall construction. To illustrate, in the
course of construction of a masonry cavity wall for example, mortar
and other debris falls into the cavity, and may then block weep
holes or other water outlets necessary to prevent moisture build-up
within the wall cavity. This invention more specifically relates to
a device and system for collecting loose mortar and other debris in
order to prevent the same from blocking the weep holes that
ventilate such a cavity wall. The invention is also applicable to
other types of wall construction, such as, for example, walls made
of concrete masonry units (CMUs). Moreover, the invention is
directed to devices for managing water in various types of wall
construction having a mesh body and related structures being formed
of materials with enhanced hydrophobic properties.
BACKGROUND OF THE INVENTION
[0002] The present invention, in one application, finds its origin,
in some embodiments, in so-called masonry cavity wall construction.
Masonry cavity walls have inner and outer vertical walls. The inner
wall is typically constructed from wood with an inner surface of
drywall, structural clay tile, vertical stacks of mortared bricks,
or a shear concrete surface. The stacks of bricks that are held
together by mortar. A space, or cavity, exists between the two
walls, which may be partially filled with insulation. For purposes
of this application a "cavity wall" may have a space greater than
about 0.4 inches.
[0003] A crack in the wall can allow water to enter the cavity.
More often, however, moisture can condense on the inside of the
wall under changing temperatures. Either way, for various reasons,
it is well established that water may collect in the cavity between
the inner and outer wall and this is undesirable.
[0004] The presence of moisture in the space between the inner wall
and outer wall is undesirable for a number of reasons. First, the
trapped moisture can degrade the inner and outer wall, causing a
weakening of the structure. Second, the presence of water under
freezing temperatures may also cause cracks in the walls when the
water expands as it freezes. Trapped water in the cavity between
the inner and outer walls may cause the walls to become discolored,
and may even leak into the dwelling.
[0005] To overcome the problems associated with water trapped
within a masonry cavity wall, flashing systems and/or other devices
are used and weep holes are commonly placed along the base of the
outer wall. The flashing systems and weep holes allow water to pass
from the cavity to drain outside the wall structure.
[0006] During construction of a masonry cavity wall, excess mortar
and other debris can and often does fall between the inner and
outer wall. When the bricks are stacked during the erection of the
outer wall, for example, mortar droppings are squeezed into the
space between the walls. The excess mortar, as well as other
debris, drops to the base of the cavity, and can block the weep
holes.
[0007] Wicks have been used in weep holes. For instance a cotton
wick, such as a segment of cotton rope, has been used in weep
holes. Such wicks can be extended from the weep hole up within the
cavity to a height considered sufficient to exceed any build-up of
mortar droppings. Moisture within the cavity is absorbed by the
wick, and passed to the outside face of the wall. Wicks are
typically made from cotton, because nylon or hemp is considered
less efficient in transferring water. The cotton wick, however, may
become broken or squashed, and will rot with time. Furthermore,
wicks, being water absorbent, tend to retain water, which can be
undesirable for a number of reasons. Accordingly, the weep hole may
still become blocked during and after construction, thereby
preventing moisture in the cavity from passing to the outside of
the wall and can promote undesirably moist conditions.
[0008] Another attempt to overcome the problems associated with
obstructed weep holes is described in U.S. Pat. No. 4,852,320. The
'320 patent describes embodiments of a mortar collection device
located in the wall cavity. One embodiment is adapted to collect
mortar but deflect water. This mortar collection device has an
upper surface with sufficient inclination to cause moisture to
slide off, but is purportedly insufficiently inclined to prevent
mortar from falling off. A second embodiment has a plurality of
vertically aligned passageways of dimension sufficient to allow
moisture to pass therethrough, but of insufficient dimension to
allow mortar to pass therethrough. This honeycomb-like mortar
collection device of the '320 patent is made from plastic.
[0009] It can be seen, nonetheless, that mortar or other debris may
still roll down the surface of one or more of the collection
devices of the '320 patent and plug a weep hole. Also, the '320
patent mortar collection devices are specially adapted to be
carried on reinforcement rods extending between the inner and outer
wall. They are not shown adapted to simply rest on the base of the
wall, so as to completely cover the weep holes. Furthermore, in the
second embodiment of the '320 patent described above having the
vertical passageways, small pieces of mortar on other debris may
still pass through the holes extending through the unit, thereby
allowing the debris to reach the base of the wall and plug the weep
holes.
[0010] It would be desirable to have a mortar and debris collection
device capable of protecting the weep holes, as well as being
supportable at different heights on the wall, but allows water to
freely pass through. Furthermore, a collection device should
preferably prevent mortar droppings and other debris of any
appreciable size from reaching the weep holes, but not yield a dam
for water passage, in one example by breaking up clumps of mortar.
Moreover, the materials of the collection device should ideally not
have their function affected negatively by water.
SUMMARY OF THE INVENTION
[0011] Accordingly, it is an objective of this invention to provide
an improved mortar and debris collection device that can protect
one or more weep holes preventing mortar or debris of any
significant size from reaching a weep hole and thereby blocking the
holes, which is not negatively affected by water.
[0012] Another objective is to provide a surface configuration for
such a collection device which facilitates adequate dispersal of
debris thereon to assure a water path remains to the collection
device.
[0013] To the foregoing and other ends, the improved mortar and
debris collection device of this invention comprises, in one aspect
of the invention, a water-permeable body formed with circuitous
(non-linear) pathways therethrough, which body can be readily
placed within a cavity wall or other wall construction. The
inventive collection device can preferably be a non-absorbent
water-permeable fibrous or mesh block having a porosity sufficient
to permit water to pass therethrough, but insufficient to permit
mortar or other debris of appreciable size to pass therethrough.
Another embodiment contemplates laterally extending projections
formed on a supporting board which form the circuitous path.
Another embodiment contemplates that the weep hole is provided with
a weep hole body, composed of the same material as the mesh block.
A central aspect of the invention herein is that the
water-permeable body, and preferably related structures like the
weep hole body, is comprised of material provided with enhanced
hydrophobic properties compared to prior art devices.
[0014] One such collection device is intended to be placed on the
wall base within the cavity to cover up and block one or more weep
holes openings from the effects of mortar and debris. Water can
migrate through the porous mass to a drain outlet, such as the weep
holes, but mortar and debris cannot.
[0015] It is furthermore contemplated that the collection device
may also be placed on existing supports, such as ties, along the
walls. No special fixation means for emplacement of the collection
device is therefore required, and the collection device need not be
specifically adapted for the particular application.
[0016] A preferred form of the collection device has upwardly
extending protrusions, such as protrusions defining overhangs as
well as steps, which serve to break up mortar and debris falling on
top of the collection device. This prevents ponding of the material
on the surface of the collection device.
[0017] In one embodiment of the invention, a plurality of screens
having a porosity sufficient to permit water to pass therethrough
but insufficient to permit mortar or other larger-size debris to
pass therethrough, are organized in an overlapping arrangement in a
collection device. The screens are overlapped such that a vertical
line perpendicular to the base of the wall must intersect at least
one screen in the device. Mortar and the like falling under the
influence of gravity within the cavity must thereby contact at
least one of the screens, and preferably two, preventing the mortar
and debris from reaching the wall base and blocking a weep
hole.
[0018] There are many and sundry ways to make the water-permeable
debris-catching body. However, according to a central feature of
the invention, one or all of the inventive collection device, mesh
block, porous mesh, screens and related structures, for example,
perhaps including weep hole bodies and flashing, pans, trays and so
on, are formed of, treated with, or coated by materials having
enhanced hydrophobic properties.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] While the drawings depict preferred embodiments of the
present invention, they are by way of example only and are not
intended to limit the scope of the invention. It is expected that
variations and further modifications as well as further
applications of the principles of the invention will occur to
others skilled in the art and while differing from the foregoing,
remain within the spirit and scope of the invention as
described.
[0020] FIG. 1 is a perspective view partly in section and partially
broken away of the invention located in a wall cavity;
[0021] FIG. 2 is an enlarged perspective view of a portion of the
embodiment of the collection device shown in FIG. 1;
[0022] FIG. 3 is a perspective view of another embodiment of the
inventive collection device;
[0023] FIG. 4 is a perspective view of yet another embodiment of
the inventive collection device;
[0024] FIG. 5 is a perspective view of still another embodiment of
the inventive collection device;
[0025] FIG. 6 is a perspective view of a further embodiment of the
invention;
[0026] FIG. 7 is a perspective view of an embodiment similar to
FIG. 2 having a fine porous layer therein;
[0027] FIG. 8 is a perspective view of an embodiment having a
stepped configuration across its horizontal thickness;
[0028] FIG. 9 is a front elevational view of a portion of the
fibrous mass.
[0029] FIG. 10 is a perspective view, partially in section and
partially broken away of an embodiment of a combination flashing
and collection device made according to the present invention
located in a cavity between an inner and an outer wall;
[0030] FIG. 11 is a perspective view of an embodiment of the
inventive combination flashing and collection device;
[0031] FIG. 12 is a perspective view of another embodiment of the
inventive combination flashing and collection device;
[0032] FIG. 13 is a perspective view of yet another embodiment of
the inventive combination flashing and collection device;
[0033] FIG. 14 is a perspective view of a still another embodiment
of the inventive combination flashing and collection device.
[0034] FIG. 15 is an exterior perspective view of a drainage system
in accordance with an embodiment of the invention used in a single
wythe masonry wall formed by courses of concrete masonry units
(CMUs);
[0035] FIG. 16 is a perspective view of a tray of the drainage
system of FIG. 15;
[0036] FIG. 17 is a sectional view taken along the line 17-17 of
FIG. 16;
[0037] FIG. 18 is a sectional view taken along the line 18-18 of
FIG. 16;
[0038] FIG. 19 is a sectional view, similar to FIG. 18, for a tray
according to the invention;
[0039] FIG. 20 is a perspective view, similar to FIG. 16,
illustrating a tray with a peel and stick adhesive layer;
[0040] FIG. 21 is an elevation view of a block of water permeable
material in a static state used in the drainage system of FIG.
15;
[0041] FIG. 22 is a perspective view of the block of FIG. 21 bent
to conform to walls of a CMU hollow core;
[0042] FIG. 23 is a perspective view, with a CMU removed for
clarity, illustrating relationship between the block and the tray
in accordance with the invention;
[0043] FIG. 24 is a plan view of a tray element in accordance with
the invention comprising a plurality of trays;
[0044] FIG. 25 is a perspective view of a tray in accordance with
the invention to accommodate a rebar;
[0045] FIG. 26 is a perspective view of an adapter used with the
trays in accordance with the invention to accommodate rebar;
[0046] FIG. 27 is an exterior perspective view of a drainage system
in accordance with the invention used in a single wythe masonry
wall formed by courses of concrete masonry units (CMUs);
[0047] FIG. 28 is a plan view of a flashing member with a layer of
water permeable material in accordance with the invention;
[0048] FIG. 29 is an exterior perspective view of an elongate bar
and the flashing material of FIG. 28 mounted to a wall
foundation;
[0049] FIG. 30 shows a perspective view of a flashing and drainage
assembly according to the invention;
[0050] FIG. 31 shows a perspective view of a flashing and drainage
assembly according to another aspect of the invention;
[0051] FIG. 32 shows alternate embodiments of a mesh body;
[0052] FIG. 33 shows a perspective view of yet another flashing and
drainage assembly;
[0053] FIG. 34 shows a partial perspective view of the flashing and
drainage device of FIG. 33 with a full end dam;
[0054] FIG. 35 shows a partial perspective view of another flashing
and drainage device;
[0055] FIG. 36 shows a top view of yet another flashing and
drainage device according to the invention;
[0056] FIG. 37 shows a partial perspective view of the flashing and
drainage device of FIG. 36; and
[0057] FIG. 38 shows another partial perspective view of the
flashing and drainage device according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE
INVENTION
[0058] Brick masonry cavity walls 10, as shown in FIG. 1 include
two wythes of masonry separated by an air space. The interior
masonry wythe (the inner wall) 12 may be brick, hollow brick,
structural clay tile, wood or hollow or solid concrete masonry
units, for example. The exterior masonry wythe 14 (the outer wall)
is brick. The cavity 16 between the two wythes may be either
insulated or left open as air space. The cavity may have, for
example, a width from about 0.4 to about 41/2 inches.
[0059] A common problem associated with a cavity wall construction,
as noted above, is how to allow moisture, as from seepage or
condensation or other sources, to pass from the cavity to outside
the wall. Weep holes 18 creating an unobstructed opening passing
from the cavity to the outside of the wall are provided to this
end. Generally, the weep holes 18 may be placed approximately two
feet apart at the base of the outer wall 14. Moisture collecting in
the cavity 16 is intended to run down the cavity wall and be
directed by flashing 20 toward the weep holes 18. The flashing 20
can be composed of materials such as sheet metals, bituminous
membranes, plastics or vinyls, for example.
[0060] A cotton wick 22 may be placed within the weep hole
extending into the cavity. The moisture from inside the cavity will
be absorbed and passed to the other end of the wick. The end of the
wick is left outside the wall to let the moisture evaporate outside
the wall. More preferably, the cotton wick 22 is replaced with a
plastic mesh weep hole body, having enhanced hydrophobic
properties, examples of such materials being discussed in more
detail hereinbelow.
[0061] In the course of construction of a cavity wall 10 as shown
in FIG. 1, mortar 24 and other debris will commonly fall into the
cavity 16 between the inner wall 12 and outer wall 14.
[0062] FIGS. 1 and 2 show one embodiment of an improved mortar and
debris collection device of the present invention. A fibrous or
mesh body 28 preferably having enhanced hydrophobic properties
according to the present invention rests on the base 26 of the
cavity between the inner wall 12 and the outer wall 14, covering at
least one weep hole 18. In this embodiment, the body has a
generally rectangular shape with a flat bottom edge that will rest
flush against the wall 14. The width of the body is roughly
determined by the width of the cavity 16.
[0063] The body 28 is preferably composed of plastic, such as, for
example, the filament-type plastic used to surface walk-off mats.
These materials are preferred because they are relatively
inexpensive and can be formed into cut-able blocks or sheets. A
quantity of one or more of these materials is formed in a mass of
random fibers with a density which is sufficient to catch and
support mortar and other debris thereon without significant
collapse, but allow water to pass freely therethrough. A preferred
embodiment of the plastic material is a polyethylene or polyester
fibrous mesh such as ENKADRAIN 9120 manufactured by Akzo Industries
in Asheville, N.C. or FIBERBOND EM 6645 manufactured by Fiberbond
in Michigan City, Ind.
[0064] Materials, such as those used in the invention, may be
modified to increase their hydrophobicity. For example, polymers
may be fluorinated by exposure to mixture of fluorine gas or
CF.sub.4 in an inert carrier gas under glow discharge or
radio-frequency discharge conditions which generate a fluorine or
CF.sub.4 plasma. Suitable carrier gases include helium, argon, and
mixtures thereof. See, for example, Handbook of Plastic Films,
Abdel-Bary, E. M., ed., pp. 215-217 (Rapra Tech. Ltd., Shawbury,
UK, 2003).
[0065] In another method, a surface coating of a hydrophobic
polymer (e.g., polytetrafluoroethylene) may be deposited as a
surface coating under vapor deposition conditions. See, for
example, Favia, P., "Plasma Deposition of Fluoropolymer Films in
Different Glow Discharge Regimes," in Plasma Polymer Films, pp.
25-56. (Imperial College Press, London, 2004).
[0066] It will be understood that other methods may be used to
deposit a surface coating of a hydrophobic polymer onto the base
polymer or material of the invention such as spraying, dipping, and
so on. See, for example, Chanda, M. and Roy, S. K., Plastic
Technology Handbook (CRC Press, Boca Raton, Fla., 2007); in
particular, see sections 2.19.1.1-2.19.1.3. In another method, a
surface coating of a hydrophobic polymer may be deposited from a
polymerizable composition comprising a fluorinated monomer (e.g.,
perfluoroalkyl acrylates) and suitable crosslinker in the presence
of a free-radical initiator (e.g., a chemical initiator, heat, or
UV radiation). See, for example, Matyjaszewski, K. and Davis, T.
P., Handbook of Radial Polymerization (John Wiley & Sons,
2002).
[0067] In another method, the polymer surface may be activated to
increase its chemical reactivity by, for example, treatment with an
Ar plasma or other ionizing radiation. The activated surface can be
subsequently treated with one or more chemicals suitable to
increase the hydrophobicity of the polymer surface. For example,
the activated surface can be subsequently treated with a
substituted silane (e.g., perfluoroalkylsiloxanes or
polymethylsilsesquioxane) or a polymerizable monomer which either
forms a hydrophobic polymer layer or may be used to attach
hydrophobic molecules to the surface. In one example, the activated
surface may be treated with glycidyl methacrylate to form a
chemically reactive surface and subsequently treated to graft a
hydrophobic polymer (e.g., carboxy-terminated
polypentafluorostyrene) or other fluorinated molecules
(perfluoroalkylamines) onto the polymer surface. See, for example,
U.S. Pat. No. 4,954,256. See also, Ikada, Y., Neoh, K. G., Kang, E.
T., "Polymer Surfaces, Grafting of in Encyclopedia of Surface and
Colloid Science, Somasundaran, P., ed., vol. 6, pages 4936-4957 (2d
ed., CRC Press, Boca Raton, Fla. 2006).
[0068] In another example, polymers may be formulated, formed,
coextruded or laminated with a second polymer having enhanced
hydrophobic properties. See, for example, Rauwendaal, C. Polymer
Extrusion (4.sup.th ed., Carl Hanser Verlag, 2001) In this example,
the base polymer of the mesh material may be considered to form a
matrix or mixture with the material having enhanced hydrophobic
properties.
[0069] In another method, hydrophobic filler materials may be
introduced into polyethylene or polyesters to generate a blend
which has increased hydrophobicity. Suitable fillers include, but
are not limited to, fluorinated fused silicas, such as
Cab-o-Sil.TM. fumed silicas or Aerosil.TM. R972, R7200, and R812.
See, for example, Function Fillers for Plastics, Xanthos, M., ed.
(2d ed., Wiley-VCH, 2010); in particular, see, Patel, S. H.,
"Surface Property Modifiers", Chapter 19, pp 373-406, therein.
[0070] It is a central feature of this invention that the porous
mesh body, porous wick or weep hole material (mesh weep hole body),
is comprised of material preferably having enhanced hydrophobic
properties compared to prior art cotton and other materials, such
as plastics, used for mortar catching bodies and inserts for weep
holes, some examples thereof being detailed herein.
[0071] Another feature of the invention provides a mortar and
debris collection system, wherein the base portion of the system,
comprising one or more flashing member, pan member or tray member,
or the like being formed of material(s) having enhanced hydrophobic
properties. It will be understood that the method of manufacturing
or forming the material is not critical as the invention
contemplates any method of making one or more of the structural
components of the system of material having enhanced hydrophobic
properties, some illustrative examples of which are detailed
herein.
[0072] Returning to FIG. 1, a mesh weep hole body 22 may be
attached to, or formed with, the body 28 to aid in the passage of
water from the wall. The mesh weep hole body 22 can serve to hold
the body 28 in place. When used with such an integral mesh weep
hole body 22, the body 28 would be emplaced when the wick holes
were formed. Otherwise, it is contemplated that the mortar
collection device of this invention will simply be set at the base
26 of the wall foundation covering respective weep holes 18,
without the need of any fixation device. Flashing 20 can
furthermore be directly attached to the bottom and/or back of the
body 28.
[0073] The porosity of the body 28 made from the fibrous material
can be quite varied, so long as it effectively serves to strain out
the mortar and debris before it reaches the weep holes. Most mortar
and debris will be quite large, i.e., greater than 1/8 or 1/16 of
an inch or clearly visible to the naked eye, so a porosity
sufficient to catch such relatively large particulate matter will
suffice to prevent plugging of the weep holes. The body 28 may also
function to break up clumps of mortar, which also facilitates
penetration and egress of water.
[0074] Besides being positionable on the base of the cavity 16,
fibrous bodies 28 may be placed on wall tie rods 32 above the base
26 of the cavity. The tie rods 32 are often part of the cavity wall
structure, tying the inner wall 12 and the outer wall 14
together.
[0075] As particularly shown in FIG. 1, the body 28 may include
reinforcing rods 30 extending along the bottom of the body to
support and better distribute weight on the body 28 when not simply
resting on the base 26 of the cavity 16. The reinforcing rods 30
will better enable a collection device to span adjacent tie rods 32
and still work effectively.
[0076] A system using the collection device of FIGS. 1 and 2, for
example, would include bodies 28 placed on the base 26 in
sufficient number to cover and block some or all of the weep holes
18 in the cavity 16. It could further include bodies 28, having the
reinforcing rods 30, placed on tie rods 32.
[0077] The body 28 of the device shown in FIG. 2 has
trapezoidal-like cutouts 36. Two slanted edges 38 of the body and a
bottom edge 40 of the body (the latter running roughly parallel to
the longitudinal axis of the body) define the cutout 36. The
dove-tailed cutouts 36 thereby formed in the body 28 yield
protrusions which help break up the mortar and other debris falling
thereon to prevent ponding of moisture in the mortar and debris
that collect on the collection device surface. The overhangs formed
by the slanted sides 38 are intended to assure that gaps remain in
fallen mortar and debris for water to progress to the body 28.
[0078] FIG. 3 illustrates another embodiment of this invention
having a fibrous mass 41, preferably having enhanced hydrophobic
properties, with a stepped configuration along its length created
by a series of slanted edges 44. The top step 48 may have a length
of approximately 6 to 8 inches, for example. The height of each
step may be approximately 4 inches. Again, the stepped cutout 42 is
intended to break up mortar and debris falling thereon to thereby
prevent the ponding of moisture.
[0079] FIG. 4 illustrates another embodiment of this invention with
the fibrous mass 50 preferably having enhanced hydrophobic
properties and having rectangular cutouts formed by a series of
perpendicular edges 54. In a presently contemplated embodiment, the
steps would have a height of approximately 4 inches and a length of
approximately 8 inches.
[0080] FIG. 5 illustrates yet a further embodiment of this
invention. The debris collecting fibrous body 58 preferably having
enhanced hydrophobic properties has dove-tailed cutouts formed from
non-planar curved steps 60. This is another shape for the upper
surface of the collection device designed to break up the mortar
and other debris falling thereon, to thereby prevent the ponding of
moisture on the surface of the body 58.
[0081] FIG. 6 illustrates another embodiment of this invention.
Three series of planar screens 62, 64 and 66 preferably having
enhanced hydrophobic properties and having a porosity sufficient to
permit water to pass therethrough but at least collectively
insufficient to permit mortar and other debris to pass therethrough
are arranged to form the collection device. A first plurality of
screens 62 extend on one horizontal plane. On a second and lower
horizontal plane, a plurality of screens 64 are arranged in spaced
apart relation. On a third and still lower horizontal plane, a
plurality of screens 66 are arranged in spaced apart relation, but
with portions overlapping with screens 64 of the second horizontal
plane. A vertical line extending substantially perpendicular
through the collection device of FIG. 6 must therefore pass through
at least one and move often two screens in this embodiment.
[0082] Generally, the screens should have a width determined by the
width of the cavity 16 (FIG. 1). The screens can be formed of a
sufficiently rigid screen material to maintain their shape when
attached to vertical rods 68 or like supporting structure, or may
each be provided with a rigid frame. Screen 62 may have a large
mesh size to catch only the larger particles, with screens 64 and
66 having a smaller mesh. Wicks 22 may be attached to the base of
the rods 68. Screen 62 might also be omitted entirely, if desired.
Whether present or not, however, mortar droppings and other debris
falling into the cavity 16 above the screen collection device of
FIG. 6 must contact at least one screen to thereby become trapped
and isolated from the weep holes.
[0083] FIG. 7 illustrates a modified embodiment similar to that of
FIG. 2, except that a thin layer of material 70 is provided above
the bottom of the fibrous body, which material has the ability to
pass water but substantially no visible solids. Such a material
could be the type of landscaping material used to control weeds.
The layer could be located 1 to 2 inches above the bottom, for
example.
[0084] FIG. 8 illustrates an embodiment having a stepped upper
surface extending across its horizontal thickness, i.e.,
perpendicular to its long axis. Steps 72a, 72b and 73a, 73b of the
fibrous mass serve to prevent "bridging" of material across the
space of the wall cavity (i.e., extending between the inner wall 12
and outer wall 14).
[0085] FIG. 9 is a front elevational view of a portion of the
fibrous mass. It is a central aspect of the invention that the
material of the fibrous mass, whether it is used positioned within
or adjacent the weep hole, in place of the wick material, or mortar
catching material in the form of bodies or screens as will be
detailed herein, attached to the surface of a flashing device, tray
or the like, is provided with enhanced hydrophobic properties. A
preferred embodiment of the material is a polyethylene or polyester
fibrous mesh such as ENKADRAIN 9120 manufactured by Akzo Industries
in Asheville, N.C. or FIBERBOND EM 6645 manufactured by Fiberbond
in Michigan City, Ind. The material 132 may be of two or more
different materials or layers. As seen in FIG. 11, the material 132
is attached to the flashing member in multiple spaced apart
longitudinal strips. Preferably, the fibrous mass is further
coated, treated or formed of or with materials preferably having
enhanced hydrophobic properties as detailed above.
[0086] Brick masonry cavity walls 110, as shown in FIG. 10 consists
of two wythes of masonry separated by an air space. The interior
masonry wythe (the inner wall) 112 may be brick, hollow brick,
structural clay tile, wood or hollow or solid concrete masonry
units, for example. The exterior masonry wythe 114 (the outer wall)
is brick. The cavity 116 between the two wythes may be either
insulated or left open as air space. The cavity has a typical width
of about 0.4 to 41/2 inches, but could be outside this range,
although non-standard.
[0087] A common problem associated with a cavity wall construction
is how to allow moisture, as from seepage or condensation, to pass
from the cavity to outside the wall. Weep holes 118 creating a
passageway from the cavity to the outside of the wall are provided
to this end. Generally, the weep holes 118 will be placed
approximately 16 to 24 inches apart at the base of the outer wall
114. Moisture collecting in the cavity is intended to run down the
cavity wall and be directed by the combination flashing and mortar
and debris collection device 120 of the present invention toward
the weep holes 118.
[0088] In the course of construction of a cavity wall 110 as shown
in FIG. 10, mortar and other debris will commonly fall into the
cavity 116 between the inner wall 112 and outer wall 114. The
falling mortar is collected on the surface of the combination
flashing and mortar and debris collection device 120 of the present
invention.
[0089] FIGS. 10 and 11 show one embodiment of a combination
flashing and debris collection device 120 of the present invention.
Device 120 comprises a flashing member 130 having a mortar and
debris collection material 132 applied to at least a portion of the
surface thereof. Flashing member 130 includes an upper portion 134,
an inclined central portion 136 and a lower portion 138. Referring
to FIG. 10, the upper portion 134 is preferably received within the
inner wall 112 at an elevation above the floor 140 of the cavity
116. The central portion 136 is inclined and extends from the
elevated portion of the inner wall 112 through the cavity 116 to a
base portion of the outer wall at the floor 140. The lower portion
138 is preferably received at the base of the outer wall 118. The
flashing member 130 functions to direct moisture collected in the
cavity toward weep holes that are formed at the base of the outer
wall 118 in a manner which will be further discussed below. The
flashing member may be made from various materials such as sheet
metals, bituminous membranes, plastics, vinyls or the like.
[0090] A mortar and debris collection material 132 is suitably
positioned along at least a portion of the outer surface of the
central portion 136 of the flashing member 130. The material 132
functions to permit water to pass therethrough and to substantially
prevent mortar and other debris from passing therethrough. The
material is preferably a non-absorbent, water-permeable, fibrous
mesh material formed with circuitous (non-linear) pathways
therethrough. The material preferably having enhanced hydrophobic
properties is preferably a mass of random filament-type plastic
fibers with a density which is sufficient to catch and support
mortar and other debris thereon without significant collapse, but
allow water to pass freely therethrough. The overall thickness of
the material 132 is preferably between one-eighth inch and one-half
inch.
[0091] Referring to FIG. 11, in accordance with the invention, the
lower portion 138 of the flashing member 130 may be provided with
spaced apart strips 142 of the above described mesh materials,
which serve to create, reinforce and permit drainage through the
weep holes 18 within the mortar joint. The strips 142 may be
provided with suitable reinforcement such as solid plastic rods or
the like to accommodate the load of the bricks. The outer edge of
the lower portion 138 may be provided with an overhang or lip 144.
The lip 144 may be a colored strip to make the device invisible on
the face of the building.
[0092] Referring to FIG. 12, there is shown another embodiment of
the invention wherein the same referenced numerals from the
embodiment of FIGS. 10 and 11 followed by a prime sign are used to
identify common elements. Flashing member 130' of device 120'
includes an upper portion 134', an inclined central portion 136'
and a lower portion 138'. Device 120' includes a plurality of
spaced apart structural bars or dowels 145 positioned between the
strips 142' atop flashing member 130'. The bar or dowels 145 serve
as further reinforcement to accommodate the load of the bricks.
[0093] Device 120' includes a strip of material 132' adjacent the
intersection of the central portion 136' and the lower portion
138'. The outer edge of the lower portion 138' may be provided with
an overhang or lip 144'.
[0094] Referring to FIG. 13 there is shown yet another embodiment
of the invention wherein the same reference numerals from the first
embodiment followed by a double prime sign are used to identify
common elements. Device 120'' includes a strip of material 132''
adjacent the intersection of the central portion 136'' and the
lower portion 138''. A plurality of spaced apart tubes or channels
146 are formed in the upper surface of lower portion 138''
extending about to lip 144'' to create the weep holes within the
mortar joint. The tubes or channels 146 alternatively may be
integrally formed as a separate member or members positioned
immediately adjacent the upper surface of portion 138''. The tubes
or channels 146 may be positioned over mesh strips 142 as shown in
FIG. 11.
[0095] Referring to FIG. 14, there is shown still another
embodiment of the invention wherein the same reference numerals
from the first embodiment followed by a triple prime sign are used
to identify common elements. Device 120''' may take the form of the
embodiments shown in FIGS. 11, 12 and 13 with the addition of a
fabric material 150 positioned on top of the mesh material 132'''
to assist in keeping mortar and debris from blocking the passage of
water therethrough.
[0096] Referring to FIG. 15, a drainage system 220 is illustrated
in connection with concrete masonry unit (CMU) wall construction.
In the illustrated embodiment of the invention, the drainage system
220 is used in a single wythe masonry wall construction 222 formed
by courses 224 of CMUs 226. The wall construction 222 is used on a
building structure including a foundation wall 228. In the
illustrated embodiment of the invention, the foundation wall 228
comprises a concrete wall. The foundation wall could be of block
construction, as will be apparent to those skilled in the art.
Referring also to FIG. 23, the drainage system 220 comprises a tray
230 and a pair of blocks 232 of water permeable material.
[0097] CMUs 226 most typically have a nominal height of eight
inches, a nominal length of sixteen inches and come in nominal
widths of eight, ten or twelve inches. Actual sizes are about 3/8
inches less to allow for a 3/8 inch mortar joint. The CMU 226
comprises a hollow concrete block 234 having a web 235 to provide a
pair of vertically extending hollow cores or cavities 236
therethrough. The hollow cores or cavities 236 are typically about
five inches square. In conventional single wythe masonry wall
construction, a first course 224-1 of CMUs 226 is secured to the
foundation wall 228 with a layer of mortar. Mortar is also provided
between adjacent CMUs 226. A layer of mortar is then placed upon
the first course 224-1 and the second course 224-2 is laid on the
first course 224-1. Again, mortar is provided between each CMU 226.
The CMUs 226 in each course are typically offset from one another
as illustrated. As a result, the vertical cores 236 in any course
224 are aligned with the vertical cores 236 in other courses 224 to
provide a continuous channel from the top of the wall down to the
foundation wall 228, as is well known.
[0098] Referring to FIGS. 16-18, the tray 230 comprises a tray unit
238 and a pair of strips 240 (see also FIG. 15) of water permeable
material preferably having enhanced hydrophobic properties. The
tray unit 238 is of one piece molded plastic construction and has a
length and a width less than that of a CMU so that it can be set in
mortar and the mortar will set up and secure the tray unit 238 in
position. For example, the length of the tray unit 238 may be on
the order of twelve inches and the width of the tray unit 238 may
be on the order of six inches for an eight inch wide CMU.
[0099] The tray unit 238 comprises a peripheral flange 242 formed
by a front flange 244, a rear flange 246, a right side flange 248
and an opposite left side flange 250. A web flange 252 is connected
transversely, centrally within the perimeter flange 242 and in
particular extends from a center of the rear flange 246 to a center
of the front flange 244. The perimeter flange 242 and the web
flange 252 are U-shaped in cross section, as shown in FIGS. 17 and
18, and open downwardly. A pair of pans 256 and 258 is supported
between the perimeter flange 242 and the web flange 252 each on
opposite sides of the web flange 252. Particularly, the first pan
256 is supported in an area bound by the left side flange 250, the
front flange 244, the web flange 252 and the rear flange 246.
Similarly, the right pan 248 is supported in an area bound by the
web flange 252, the front flange 244, the right side flange 248,
and the rear flange 246. The pans 256 and 258 are generally
rectangular in shape and of a size at least as large a shape of the
hollow cores 236 (see FIG. 15). The perimeter flange 242 and web
flange 252 define an upper surface 260. In the embodiment of FIGS.
16-18, the upper surface 260 is planar and the pans 256 and 258 are
likewise planar and parallel to the upper surface 260.
[0100] The front flange 244 includes a pair of notches 264 and 266.
The notch 264 is associated with the left pan 256 and is centered
between the left side flange 250 and the web flange 252. Similarly,
the right notch 266 is associated with the right pan 258 and is
centered between the web flange 252 and the right side flange
248.
[0101] FIG. 19 illustrates a tray unit 238' in accordance with an
alternative embodiment of the invention shown, for example, in
FIGS. 17 and 18. This embodiment differs in that the pans,
including a left pan 256', are sloped from the rear flange 246
toward the front flange 244. Indeed, depending on the slope, the
rear flange 246 may even be eliminated. The sloped pans enhance
drainage toward a front edge 262 of the pan 256' and thus the front
flange 244 to enhance drainage. The pan 256' could also be sloped
from the sides toward the strip 240. In the illustrated embodiments
of the invention, the tray unit 238 has a uniform wall thickness on
the order of 1/16 inch. Alternatively, the flanges could be solid
plastic.
[0102] The strips 240 are of a water permeable material having a
thickness in the range of about 1/8 inch to 1/2 inch with 1/4 inch
being typical. The strips 240 are adhered in any known manner to
the pans 256 and 258 and extend transversely beyond the front edge
262 of the pans 256 and 258 and also beyond front flange 244. The
strips 240 function to permit water to pass therethrough and to
substantially prevent mortar and other debris from passing
therethrough. The material is preferably a non-absorbent
water-permeable, fibrous mesh material formed with circuitous
(non-linear) pathways. The material is preferably a mass of random
filament-type plastic fibers. The material is provided with
enhanced hydrophobic properties, for example, with a coating of
materials having enhanced hydrophobic properties or formed within a
matrix including materials having enhanced hydrophobic properties.
The strip may also include an outer layer of backing material. The
backing material may be a finely woven paper like material which
will pass water but not fine debris, such as vermiculite or the
like. Overall, the material is sufficient to catch and support
mortar and debris without significant collapse, but allow water to
pass freely therethrough. The strips 240 may be secured with a
suitable adhesive or molded in situ with the tray unit 238.
[0103] Referring to FIG. 20, the tray unit 238, similar to that
shown in FIG. 16, for example, includes an adhesive layer 268 on
the upper surface 260. The adhesive layer 268 is initially covered
by a removable film 270 to provide a peel and stick configuration.
In the illustrated embodiment of the invention, the adhesive layer
268 covers the entire upper surface 260 and incidentally functions
also to protect the pan surfaces, one of which is shown at 258.
Alternatively, the adhesive layer could be provided only on the
side flanges 248 and 250 and the web flange 252, as necessary or
desired (see FIG. 16). Likewise, the adhesive layer could be
provided on a bottom surface (not shown), particularly when used
with solid flanges. As illustrated, the strips 240 are of a length
to extend forwardly of the CMU 226 and then optionally be cut off
after the mortar sets or be provided with a score line to be broken
off.
[0104] Referring to FIG. 21 and FIG. 22, the block 232 comprises a
T-shaped body or sheet 272 of water permeable material, having
enhanced hydrophobic properties, similar to material of the strips
240. The sheet 272 has a thickness in the range of about 1/8 inch
to 1/2 inch with 1/4 inch being typical. The sheet 272 has a top
part 274 wider than a CMU core 236 (FIG. 16) and a bottom part 276
narrower than a CMU core 236. For example, with a CMU having a
5.times.5 inch core, the top part 274 might be about six to eight
inches across and about seven inches tall, while the bottom part
276 might be on the order of four inches across and four inches
tall. The block 232 is then inserted into a core 236 of the first
course 224-1 by bending the bottom part 276 so that it extends
horizontally and thus perpendicular to the top part 274 and then
curving opposite ends 278 and 280 of the top part 274 to conform to
the walls of the core 236. As a result, the curve of the top part
274 gives stability to the mesh material to withstand impact of
falling mortar. The proper type of mesh, as described above, will
provide a prickly adhesion to the porous walls of the CMUs 226. The
horizontal bottom part 276 covers the drainage strip 240 to protect
it from being plugged by mortar droppings or granular or foam
insulation.
[0105] FIG. 23 illustrates a tray unit 230 with one block 232
installed over the left pan 256. For clarity, the CMU 226 (FIG. 15)
is not shown in FIG. 23. As is apparent, the block top portion 274
will be supported above or by the tray unit upper surface 260. The
bottom portion 276 could be resting directly atop the strip 240 or
be supported slightly above the strip 240, as necessary or desired.
As shown, the tray 230 is particularly adapted to function with a
dual core CMU, such as a CMU 226. The tray unit 238 could be
provided with a single pan with two strips 240 as by eliminating
the web flange 252 for use with dual cores, or could be provided in
half the size with only a single pan for use with a smaller CMU
having only a single core.
[0106] Referring to FIG. 24 and FIG. 15, a tray element 290
according to an alternative embodiment of the invention is
illustrated. The tray unit 290 comprises a plurality of trays 230
formed together of one piece construction to be received beneath a
plurality of CMUs 226 in a course. In the illustrated embodiment of
the invention, the tray element 290 comprises six trays 230
integrally joined together so that at least one side flange of each
tray 230 adjoins a side flange of an adjacent tray. A score line
292 could be provided between adjacent trays 230 for separability
in the field if fewer than six trays 230 are required. Also, a
score line 292 could be provided between pans 256 and 258 of each
tray 230 in the event that an odd number of cores are present. In
all other respects, the trays 230 are as described above. As is
apparent, the tray element 290 could have more or less than six
trays 230. After installation, a block 232, (see FIG. 23) of water
permeable material will be positioned above the tray element 290 at
each core 236, as described above.
[0107] Referring to FIG. 25, a tray 300 is adapted to accommodate
rebar in a reinforced wall. The tray unit 300 comprises a pan 302
connected to a left side sloped end wall 304. The end wall 304
includes a semicircular notch 306 to receive a rebar. The notch 306
should be sized larger than the rebar to allow field placement of
the tray 300. Front and rear flanges 308 and 310, respectively,
extend across the pan 302 and the end wall 304 and are connected by
a right side flange 312. A notch 314 in the front flange 314
receives a strip 240 of water permeable material, having enhanced
hydrophobic material, as above. As is apparent, the end wall 304
and side flange 312 could be reversed for installation on the
opposite side of the rebar.
[0108] FIG. 26 illustrates an adapter 320 for use with the tray 230
of FIG. 16 to accommodate rebar. The adapter 320 comprises a plate
322 having a notch 324 on one side edge 326 and a downwardly
depending lip 328 on an edge 330 opposite edge 326. The lip 328 can
hook over a side flange 248 or 250 of tray 230 so that the notched
edge 326 is away form the pan 258 or 256.
[0109] Turning back to FIG. 23, though the block 232 is described
as a T-shaped sheet element, other configurations for the block 232
could also be used. These blocks include triangular elements,
cylindrical elements, as well as other shapes.
[0110] Turning to FIG. 27, a drainage system 410 is illustrated in
connection with a concrete masonry unit (CMU) wall construction. In
the illustrated embodiment of the invention, the drainage system
410 is used in a single wythe masonry wall construction 412 formed
by courses 414 of CMUs 416. The wall construction 412 is preferably
used on a building structure including a foundation wall 418 with
an interior floor 420 inside the foundation wall 418 and exterior
grade 422 outside the foundation wall 418. In the illustrated
embodiment of the invention, the foundation wall 418 comprises a
concrete wall. The foundation wall could be of block r other
construction, as will be apparent to those skilled in the art.
[0111] Referring to FIGS. 27 and 28, the drainage system 410
includes a flashing member 424, a layer 428 of water permeable
material and a plurality of blocks 430 of water permeable material.
CMUs 416 are typically about 16'' long wide and come in nominal
widths of eight, ten and twelve inches. The CMU 416 comprises a
concrete block 432 having a pair of vertically extending cavities
434 therethrough. In conventional single wythe masonry wall
construction, a first course 414-1 of CMUs 416 is secured to the
foundation wall 418 with a layer of mortar. Mortar is also provided
between adjacent CMUs 416. A layer of mortar is then placed upon
the first course 414-1 and the second course 414-2 is laid on the
first course 414-1. Again, mortar is provided between each CMU 416.
The CMUs 416 in each course are typically offset from one another
as illustrated in FIG. 27. As a result, the vertical cavities 434
in any one course 414 are aligned with the vertical cavities 434 in
other courses to provide a continuous channel from the top of the
wall down to the foundation wall, as is well known.
[0112] Referring to FIG. 28, the flashing member 424 comprises an
elongate body 436 of flashing material. The body may be formed of
plastic or sheet metal or the like. In the illustrated embodiment
of the invention, the flashing member 424 may comprise a peel and
stick material to protect, before and during installation of an
adhesive layer provided on an underside of the body 436. The body
436 is defined by an inner or rear edge 438, an outer or front edge
440 and opposite longitudinal ends 442 and 444. Width of the body
436 (front to back) is similar to, or less than, the width of the
CMUs. The body 436 has a length sufficient to extend at least
across a single cavity 434 or advantageously to extend the entire
length of the foundation wall 418.
[0113] The layer 428 of water permeable material includes an
elongate rectangular longitudinal portion 446 and a plurality of
longitudinally spaced shorter, rectangular transverse channel
portions 448 extending outwardly therefrom. As used herein, the
relative term inner refers to the inner side of the foundation
wall, i.e. the rear edge 438 of the flashing member 424, and outer
refers to the outer side of the foundation wall, or the front edge
440 of the flashing member 424.
[0114] The layer 428 is adhered to a top surface 450 of the
flashing member 424, such as by using a suitable adhesive. The
longitudinal portion 446 is disposed outwardly adjacent the rear
edge 438 at least one inch frontwardly of the rear edge 438. The
transverse channel portions 448 extend transversely from the
longitudinal portion 446 to the front edge 440 of the flashing
member 424. The transverse channel portions 448 are approximately
one inch across and are spaced apart in the range of two inches to
eight inches, as necessary or desired. The layer 428 has a
thickness in the range of about 1/8 inch to 1/2 inch with 1/4 inch
being typical. The longitudinal portion 446 serves to interconnect
the transverse channel portions 448. In accordance with the
invention, the layer 428 could be provided without the longitudinal
portion 446 and use only individual transverse channel portions 448
extending to the front edge 440.
[0115] In the illustrated embodiment of the invention, the water
permeable material used in the layer 428 functions to permit water
to pass therethrough and to substantially prevent mortar and other
debris from passing therethrough. The material is preferably a
non-absorbent water-permeable, fibrous mesh material formed with
circuitous (non-linear) pathways. The material is preferably a
massive random filament-type plastic fibers with a density which is
sufficient to catch and support mortar and other debris thereon
without significant collapse, but allow water to pass freely
therethrough. A preferred embodiment of the material is a
polyethylene or polyester fibrous mesh preferably having enhanced
hydrophobic properties. The layer 428 may be provided as one piece
or the transverse channel portions 448 may be provided separate
from the longitudinal portion 446, as desired. The layer 428 may
also be formed of a perforated tubular or cylindrical material. As
described herein, the material of the mesh includes an enhanced
hydrophobic coating or formed in a matrix of enhanced hydrophobic
material(s).
[0116] Alternatively, the water permeable material could be made by
a partial-fusion process which fuses closed-cell propylene or
polyethylene beads together at the tangents of the beads. In this
case water would flow between the beads in noncontacting areas. The
fused material are formulated of an enhanced hydrophobic material
and/or treated and/or coated with materials and/or processes that
yield a product having an enhanced hydrophobicity relative to
unmodified polyethylene or polyester as in the other examples
described herein.
[0117] Referring also to FIGS. 29 and 27, the elongate bar 426
consists of 1/4 inch high bar stock of plastic placed along the
foundation wall 418 near an interior side 452. The flashing member
424, a portion of which is shown, is adhered to the foundation wall
418, preferably with the rear edge 438 raised and overlying the
elongate bar 426 to define a dam at the interior side 452 of a
single wythe masonry wall. Due to the self adhering nature of the
underside of the flashing member 424, the flashing member 424
adheres to the top of the foundation 418 and to the bar 426.
[0118] In the illustrated embodiment to the invention, the elevated
ridge or elongate bar 426 is used in combination with the flashing
member 424 to define a dam, as described. Alternatively, other
devices could be used to raise the rear edge to define a dam.
Additionally, the foundation wall could be "L" shaped as by having
a continuous ridge proximate its rear edge. The flashing member 424
can then be formed or is placed on the foundation to adapt to the
foundation shape and thus similarly provide a dam at the interior
side of the masonry wall.
[0119] Thereafter, and referring back to FIG. 27, the first course
414-1 is constructed in the conventional manner applying mortar
between the first course 414-1 and the flashing member 424. As
such, the first course 414-1 is constructed on top of the flashing
member 424 and layer 428. At least some of the transverse channel
portions 448 are generally centered in the cavities 434 and serve
to create weep holes within the mortar joint. Enhanced hydrophobic
mesh material is used, and furthermore, the transverse channel
portions 448 may be provided with suitable reinforcement such as
solid plastic rods or the like to accommodate the load of the CMUs
416.
[0120] Referring to FIGS. 30 and 31, a drainage system 530 is
illustrated for use in connection with cavity wall construction.
The drainage system 530 includes three main parts, which will be
described in detail below, with a number of additional elements
optionally associated therewith and forming various embodiments of
the invention. The system 530 includes flashing member 532. The
flashing member 532 is provided with one or more weep tabs 534
preferably of enhanced hydrophobic material. The flashing member
532 also includes one or more vertical mesh members 536 preferably
of enhanced hydrophobic material.
[0121] The flashing member 532 may be any conventional flashing
material, for example stainless steel, cold-rolled copper, lead
coated copper, galvanized steel, copper laminates and other metals,
for example, aluminum, EPDM (man-made rubber), rubberized asphalt,
polyvinyl chloride (PVC) and other plastics and composite
materials. Preferably, the flashing member 532 is formed of
modified bitumen and more preferably, includes a "peel-and-stick"
type adhesive and protective backing sheet (not shown) on a
backside 538 thereof. The flashing member may be made of enhanced
hydrophobic material.
[0122] The flashing member 532 shown is rectangular and may
advantageously be about 5-7 feet in length and includes a lower
flashing portion 540 and a more upright upper flashing portion 542.
The flashing member 532 may be other lengths as needed or desired.
The lower flashing portion 540 is positioned over the top of a
foundation of a building or the like, or a lower course of bricks,
or blocks and so on.
[0123] The upper flashing portion 542 is positioned generally
vertically in a wall cavity as in FIGS. 1 and 10. The weep tabs 534
are positioned atop the lower flashing portion and are sized,
shaped and spaced to extend through the weep holes 18 (FIG. 1) of
wall 10. The tabs 534 are formed of a porous and/or draining
material, like an open mesh plastic, cotton, wool or hemp material
capable of functioning to transmit water from atop the flashing 532
and out the weep holes 18 (FIG. 1). In the illustrated embodiment
of FIG. 30, the weep tabs 534 are separate strips preferably of
enhanced hydrophobic material.
[0124] The vertical mesh bodies 536 preferably of enhanced
hydrophobic material are positioned on the upper flashing portions
542 and spaced in a manner to deflect and/or prevent debris and
mortar from occluding the tabs 534. Furthermore, the depth of the
vertical bodies 536 are provided so as to space the vertical
flashing portion 542 from the inner face 20 of the outer wall 14
and generally adjacent the inner face of the inner wall 12. In one
example, the vertical bodies 536 are about 1 inch thick.
[0125] The vertical bodies 536 may be formed of any suitable
fibroid water permeable material preferably of enhanced hydrophobic
material. The material of the vertical bodies 536 should resist
compression when under the weight of debris and mortar and continue
to permit water to pass through. In this embodiment, each body 536
has a generally rectangular shape that preferably will rest flush
against the wall 14. The width of the body 536 may roughly
determined by or correspond to the width of the cavity 16.
[0126] The body 536 is preferably composed of non-absorbent
plastic, such as, for example, the filament-type plastic used to
surface walk-off mats. These materials are preferred because they
are water-impervious, relatively inexpensive preferably of enhanced
hydrophobic material and can be formed into dividable blocks or
sheets. A quantity of one or more of these materials can be formed
into a mass of random fibers with a density which is sufficient to
catch and support mortar and other debris thereon without
significant collapse, but allow water to pass freely therethrough.
An objective of the vertical mesh bodies 536 is to separate clumps
of mortar and debris and direct the mortar and debris away from the
weep tabs 534 and ultimately prevent mortar and debris from
preventing the egress of water from within the cavity 16.
[0127] The porosity of the body 536 made from the fibrous material
can be quite varied, so long as it effectively serves to strain out
the mortar and debris before it reaches the weep holes 18. Most
mortar and debris will be quite large, i.e., greater than 1/8 or
1/16 of an inch or clearly visible to the naked eye, so an amount
of porosity sufficient to catch such relatively large particulate
matter will suffice to prevent plugging of the weep holes 18.
[0128] The drainage system 530 of this invention may simply be
positioned on the wall foundation in cavity 16 without the need of
any fixation device. In the alternate, the device 530 may be
caulked in place. In yet another embodiment, the flashing backside
538 may be supplied with a pressure sensitive adhesive, which is
protected by a backing sheet (not shown). Pressure sensitive
adhesives are well known.
[0129] The drainage system 530 illustrated includes other features.
The lower flashing portion 540 may include a drip edge 544 at a
leading edge thereof. The drip edge 544 is preferably stainless
steel, although other suitable materials are contemplated by the
invention, such as copper, aluminum, plastic, elastomeric
materials, and so on. The drip edge 544 may be a strip of material,
such as stainless steel bonded or otherwise connected to the bottom
of the lower flashing portion 540 or may be an extended lip formed
from the flashing portion itself. The lower edge 546 of the drip
edge 544 is turned down vertically, preferably about 75 degrees,
and may be plain or rolled back to provide a finished edge.
[0130] The drainage system 530 may include a base 548, which may
function as a pan or the like, underneath the flashing 532, which
includes a horizontal base portion 550 and a back leg portion 552.
The horizontal base portion 548 is rectangular and is positioned
underneath the lower flashing portion 540 and may extend to a
position adjacent the drip edge 544. The back leg 552, which
preferably is inclined about 30 degrees, forms a dam at the back
edge thereof and also causes the flashing member 532 to be inclined
at the juncture of the lower and upper portions 540, 542, so as to
encourage the egress of water from the flashing and out weep holes
18. The back leg 552 prevents water that infiltrates past the
flashing 532 to enter the foundation. As will be shown in more
detail below, the back leg 552 may be an angled piece, a separate
piece or a triangular piece to produce a dam effect in the base 548
and alternately in the base and flashing 532. In a preferred
embodiment, the base 546 and drip edge 544 are formed from a single
sheet of material, but also may be separate.
[0131] At a top edge 554 of the upper portion 542 of flashing 532
one or more rigid horizontal bars 556 may be optionally provided to
enhance the rigidity of the flashing upper portion. The horizontal
bars 556 function to prevent the upper portion 542 of the flashing
532 from drooping or being dislodged from against the inner surface
22 of inner wall 12. The bar 556 may be cylindrical or rectangular,
for example, and affixed to the upper portion 542 by adhesives or
fasteners, like screws. The bar 556 may be provided in a pocket or
hem of the flashing material and also may be affixed to the inside
surface 22 of the inner wall 12 by screws, anchors, or other
fasteners, for example.
[0132] A pair of end dams 558 is formed at opposite ends of the
lower portion 540 of the flashing 532 to raise the end sections of
the flashing. Like the back leg 552, the end dams 558 function to
direct water off the flashing and away from the foundation. The end
dams 558 may be formed by turning edges of the flashing material
540 upwardly or inserting some thickness of material underneath the
flashing. The end dams 558 may also be one or more layer, bead,
structure or the like of caulk, glue, water resistant material or
the like to form a water resistant or waterproof structure.
[0133] An extension 560 of the base 548 is provided for joining
together in an end-to-end fashion multiple units 530. The extension
560 is preferably about 4 inches long, but may be anywhere from
about 1 inch to 6 inches or more. When adjacent units 530 are
joined, the ends of the flashing 532 can be covered with a
waterproof tape-like material, like a 4-inch strip of modified
bitumen to provide a seal over the joint. The base extension 560
ensures that any water coming through the joint will be directed
away from the wall.
[0134] The device 530 shown in FIG. 31 is similar to that shown in
FIG. 30 except that the weep tabs 534 are all formed and extend
from a common body portion 5162A formed of the same material as the
weep tabs. The common body portion 5162A is positioned on the
flashing 532 on the lower panel 540 thereof so as to align the tabs
534 with vertical mesh towers 536, which themselves are positioned
in a spaced configuration on the vertical or upper panel of the
flashing. Similarly, the vertical mesh bodies 536 may be joined at
lower edges thereof from a common body portion 5162B.
[0135] FIG. 32 illustrates several embodiments of the mesh bodies
536. In particular, the mesh bodies may be an inverted wedge shape
(inverted trapezoidal) 580, a wedge shape (trapezoidal) 582, wine
glass shape 584 and triangular 586, for example.
[0136] Referring to FIGS. 33-34, a drainage system 630 is
illustrated for use in connection with cavity wall construction.
The drainage system 630 includes three main parts, which will be
described in detail below, with a number of additional elements
optionally associated therewith and forming various embodiments of
the invention. The system 630 includes flashing member 632. The
flashing member 632 is provided with a single-piece water permeable
body 633 preferably of enhanced hydrophobic material and one or
more spaced weep tab portions 634 preferably of enhanced
hydrophobic material. The water permeable body 633 also includes
one or more vertical mesh portions 636 preferably of enhanced
hydrophobic material.
[0137] The flashing member 632 may be any conventional flashing
material, as described above. Preferably, the flashing member 632
includes a "peel-and-stick" type adhesive and protective backing
sheet (not shown) on a backside 638 thereof.
[0138] Referring also to FIG. 1, the flashing member 632 shown is
advantageously be about 5-7 feet in length and includes a lower
flashing portion 640 hingeably attached to a more upright upper
flashing portion 642. The aspect of the flashing member 632 which
functions as a hinge, namely hinge section 643 may be a flexible
section of waterproof flashing material, like modified bitumen
attached between upper and lower sections 640, 642 of flashing
member 632. When folded, the flashing assembly 630 can be packaged
in a relatively thin package and unfolded for installation. The
flashing member 632 may be other lengths as needed or desired.
[0139] The lower flashing portion 640 is positioned over the top of
a foundation of a building or the like, or a lower course of
bricks, or blocks and so on. The upper flashing portion 642 is
positioned generally vertically in a wall cavity 16 and spaced from
an inside face of the outer wythe 14 and in contact with an inner
face of the inner wythe 12 and keep spaced from the inside face of
the outer wythe 14 by pressure between the brick of the outer wythe
and the material of the vertical mesh portion 636 preferably of
enhanced hydrophobic material.
[0140] The water permeable body 633 is preferably formed as a
single unitary element including weep tab portions 634 and vertical
mesh body portions 636 extending therefrom. The weep tabs 634 are
positioned atop the lower flashing portion and are sized, shaped
and spaced to extend through the weep holes 18 of a wall 10. The
tabs 634 are formed of a porous and/or draining material,
preferably like open mesh plastic preferably of enhanced
hydrophobic material, or cotton, wool or a hemp material capable of
functioning to transmit water from atop the flashing 632 and out
the weep holes 18. In the illustrated embodiment, the weep tabs 634
are spaced strips of material extending from body 633 in alignment
with the vertical mesh portions 636.
[0141] The vertical mesh bodies 636 are positioned on the upper
flashing portion 642 and spaced in a manner to deflect and/or
prevent debris and mortar from occluding the tabs 634. Furthermore,
the depth of the vertical bodies 636 are provided so as to space
the vertical flashing portion 642 from the inner face of the outer
wall 14 and generally adjacent the inner face of the inner wall 12.
In one example, the vertical bodies 636 are about 1 inch thick.
[0142] The vertical portions 636 may be formed of any suitable
water permeable material as discussed above. The material of the
vertical portions 636 should resist compression when under the
weight of debris and mortar and continue to permit water to pass
through. In this embodiment, each portion 636 has a generally
triangular shape that will rest flush against the wall 14. The
width of the mesh portion 636 may roughly determined by or
correspond to the width of the cavity 16.
[0143] The vertical mesh portion 636 may be composed of
non-absorbent plastic, such as, for example, the filament-type
plastic used to surface walk-off mats. These materials are
preferred because they are water-impervious, relatively inexpensive
and can be formed into dividable blocks or sheets. A quantity of
one or more of these materials can be formed into a mass of random
fibers with a density which is sufficient to catch and support
mortar and other debris thereon without significant collapse, but
allow water to pass freely therethrough. A function of the vertical
mesh portion 636 is to separate clumps of mortar and debris and
direct the mortar and debris away from the weep tab portions 634
and ultimately keep mortar and debris from preventing the egress of
water from within the cavity 16.
[0144] The porosity of the mesh portions 636 made from the fibrous
material can be any of a wide range of values, so long as it
effectively serves to strain out the mortar and debris before the
weep holes 18 are occluded. Most mortar and debris will be quite
large, i.e., greater than 1/8 or 1/16 of an inch or clearly visible
to the naked eye, so an amount of porosity sufficient to catch such
relatively large particulate matter should suffice to prevent
plugging of the weep holes 18.
[0145] The drainage system 630 of this invention may simply be
positioned on the wall foundation in cavity 16 without the need of
any fixation device. In the alternate, the device 630 may be
caulked in place. In yet another embodiment, the flashing backside
638 may be supplied with a pressure sensitive adhesive, which is
protected by a backing sheet (not shown). Pressure sensitive
adhesives are well known.
[0146] The drainage system 630 illustrated includes other features.
The lower flashing portion 640 may include a drip edge 644 at a
leading edge thereof. The drip edge 644 is preferably stainless
steel, although other suitable materials are contemplated by the
invention, such as copper, aluminum, plastic, elastomeric
materials, and so on. The drip edge 644 may be a strip of material,
such as stainless steel bonded or otherwise connected to the bottom
of the lower flashing portion 640 or may be an extended lip formed
from the flashing portion itself. The lower edge 646 of the drip
edge 644 is turned down vertically, preferably about 75 degrees,
and may be plain or rolled back to provide a finished edge.
[0147] The drainage system 630 may operate alone or may include a
base, as discussed above. At a top edge 654 of the upper portion
642 of flashing part 632 one or more rigid horizontal bars 656,
also referred to as a termination bar may be optionally provided to
enhance the rigidity of the flashing upper portion. The termination
bar 656 functions to prevent the upper portion 642 of the flashing
632 from drooping or being dislodged from the desired position
against the inner surface of inner wall 12. The termination bar 656
shown in most detail in FIG. 134, may be rectangular, for example,
and affixed to the upper portion 642 by adhesives or fasteners,
like screws 659. The bar 656 may be provided in a pocket or hem
(not shown) of the flashing material and also may be affixed to the
inside surface of the inner wall 12 by screws, anchors, or other
fasteners, for example. The screws 659 are inserted through screw
holes, formed near the upper edge 654 of flashing upper portion 642
to affix the flashing assembly 630 to wall 12. The termination bar
656 may also be provided without screw holes as well.
[0148] A pair of end dams 658 (one of which is best seen in FIG.
34) is formed across both the lower portion 640 and upper portion
642 at opposite ends of the flashing 632. The end dams 658 function
to direct water off the flashing 632 and away from the foundation.
The end dams 658 may be formed by turning edges of the flashing
material 640 upwardly, inserting some thickness of material
underneath the flashing or building up a berm or raised area on the
flashing. When adjacent units 630 are joined, the ends of the
flashing 632 are preferably covered with a waterproof tape-like
material, like a 4-inch strip of modified bitumen to provide a seal
over the joint.
[0149] FIG. 35 shows yet another embodiment of a flashing and
drainage system 730 according to the invention. The main parts of
the flashing and drawings system 730 include the flashing member
732. The flashing member 732 is provided with members 734, 736,
which may be separate or combined as detailed above, preferably of
enhanced hydrophobic material.
[0150] The flashing member 732 is a sheet of material which is
structurally capable of being used in a building joint, such as at
the bottom or elsewhere of a wall, atop a foundation without
destabilizing the wall or joint in which it is used. The flashing
member 732 is also made of a material which prevents water from
penetrating through the joint. These materials may include
conventional materials like metal (steel, copper and aluminum, for
example) or elastomeric or membranous materials, modified bitumen
and other suitable flashing materials, some of which are detailed
above. The flashing member 732 may be of enhanced hydrophobic
material.
[0151] The flashing member 732 includes a lower flashing portion
740, which is intended to be positioned horizontally or nearly
horizontally in the wall. The flashing member includes an upper
flashing portion 742 which is angled in a more upright fashion with
respect to the lower flashing portion 740.
[0152] An optional drip edge 744 is shown depending from a front
edge of the lower flashing portion 740. The drip edge 744 may be an
angled section of the flashing member 732 or may be a separate
sheet of material. Preferably, the drip edge 744 may be a unitary
formed segment of the flashing member 732 with a lower edge 746
being lower than the lower flashing portion 740.
[0153] The mesh members include weep tabs 734 preferably of
enhanced hydrophobic material. The weep tabs 734 are positioned
atop the lower flashing portion 740 and are sized, shaped and
spaced to correspond and extend through the weep holes 18 (FIG. 1)
of wall 10. The tabs 734 are formed of a porous and/or draining
material, like an open mesh plastic preferably of enhanced
hydrophobic material, or, in the alternate, cotton, wool or hemp
material capable of functioning to transmit water from atop the
flashing 732 and out the weep holes 18. In the illustrated
embodiment, the weep tabs 734 are separate strips preferably of
enhanced hydrophobic material. Alternately, the tabs 734 may be
joined at rear edge thereof.
[0154] The mesh members include vertical mesh bodies 736, which are
positioned on the upper flashing portion 742 and spaced in a manner
to correspond to the spacing of the weep tabs 734 and deflect
and/or prevent debris and mortar from occluding the tabs.
Furthermore, the thickness or depth of the vertical bodies 736 may
be provided so as to space the vertical flashing portion 742 from
the inner face of the outer wall 14 and generally adjacent the
inner face of the inner wall 12. In one example, the vertical
bodies 736 are about 1 inch thick.
[0155] The horizontal and vertical bodies 734, 736 may be formed of
any suitable water-permeable material as discussed above and should
resist compression to the point of being ineffective when under the
weight of debris and mortar and continue to permit water to pass
through. In this embodiment, each body 736 has a generally
triangular shape that will rest flush against the wall 14. Other
shapes are contemplated.
[0156] One feature of the illustrated embodiment 730 is that the
drip edge 744 extends to a point 745 less than the terminus or end
747 of the flashing lower portion 740. This creates an overlapping
portion or tab 749, preferably having a length of about 2 to 4
inches to overlap with an adjacent flashing member and the overlap
may include a mesh drainage strip 717 preferably of enhanced
hydrophobic material. Preferably, the vertical body 736 adjacent
the end 747 is aligned with the end 745 of the drip edge 744. The
vertical body 736 also preferably has a termination bar 756 along
an upper edge thereof as in an above-detailed embodiment.
[0157] FIG. 36 shows yet another embodiment of the flashing and
drainage system 830 according to the invention. The generally
top-down view shows the system 830 flashing member 832. The
flashing member 832 is a flattened sheet-like material sized and
shaped to be used, for example, within a cavity wall 10 and more
particularly in a building joint, such as over a foundation and
under an outer wall built thereon 14 (see FIG. 1). The flashing
member 832 includes lower flashing portion 840 and includes a drip
edge 844 at a front edge thereof. The drip edge 844 includes a
lower drip edge 846 depending therefrom and preferably angled
downwardly.
[0158] The drip edge 844 stops at a point 845 short of the terminal
end 847 of the lower flashing portion 840 a distance D to form an
overlap section between point 845 and end 847. The drip edge 844
extends a distance equal to D at an end of the lower flashing
portion 840 opposite terminal end 847 to form a overlap tab 841
which when positioned adjacent a second one of device 830 functions
to assist in the alignment and fixing in place of adjacent devices
830.
[0159] Atop of the lower flashing portion is a mesh body 833
preferably of enhanced hydrophobic material and includes a
plurality of weep tabs 834 extending toward the drip edge 844 and
spaced to correspond to weep holes formed in outer wall 14 (see
FIG. 1). The mesh body 833 extends from terminal end 847 to a point
short of the opposite end 853. Between the mesh body 833 and the
opposite end 853 of the flashing member 832 is first and second
beads of caulk 890C, 890B, a mesh drainage strip 892, and a third
bead of caulk 890A on a dam feature 858. The dam feature 858 may
be, in the alternate, made by the caulk material, the flashing,
flashing material or any suitable material or structure. The
opposite end 853 is formed upwardly as part of or on top of the
lower flashing member 840 so as to provide the dam feature 858
which causes the flashing to be elevated and sealed at that
point.
[0160] As in the above examples, the flashing member 832 preferably
includes a termination bar 856 to secure the upper portion 842 of
the flashing member 832 in place. The flashing upper portion 842
could be extended to provide a through wall flashing feature which
is known in the art. The termination bar 856 may be removed or left
in place for the through wall feature.
[0161] In a preferred embodiment, the total length of a flashing
device may be about 7 feet long from end to end, with a usable
(non-overlapped) length of about 6 feet. In this embodiment,
adjacent flashing units may be overlapped about 6 inches at each
end. Of course, other lengths are contemplated by the
invention.
[0162] FIG. 37 shows a portion of a lower flashing member 940
including a different arrangement of an opposite end 953. The
opposite end includes mesh body weep tabs 934 preferably of
enhanced hydrophobic material positioned on lower flashing member
940. Next to the weep tab 934 and atop the lower flashing member is
an upper gasket forming a first or primary dam 994 including a bead
of material 990E on top. Although the drawing shows only one dam
994, there may be multiples thereof. Next to the upper gasket
primary dam 994 is a mesh drainage strip 992 preferably of enhanced
hydrophobic material. At the extreme opposite end 953 is a raised
section of the lower flashing member 940 or a raised amount of
material atop the flashing member to form a flashing dam 958. Under
the flashing dam 958 and functioning at least as a support therefor
may be a second or lower gasket 996. Atop the flashing dam 958 or
forming the dam may be a bead of caulk material 990D. Under normal
operating conditions, the primary dam 994 will stop all water
traveling laterally. If water does pass the primary dam 994, under,
for example, sudden water accumulations the emergency drainage
strip 992 will exit the water before it flows over the end dam 958.
The caulking 990E, 990D also acts as a water tight seal to keep
water from reaching a seam between adjacent flashing devices. In
the above embodiments, other seals e.g., gaskets or other material,
may be substituted for the caulking to provide a seal or dam along
the flashing member and/or to adhere adjacent flashing units to
each other when installed.
[0163] FIG. 38 shows a lower flashing member 1040 similar to that
shown in FIG. 37 including a different arrangement of an opposite
end 1053. The opposite end 1053 includes mesh body preferably of
enhanced hydrophobic material with a plurality of weep tabs 1034 on
lower flashing member 1040. Next to the weep tabs 1034 and below
the lower flashing member 1040 is a first under gasket 1094 forming
a first or primary dam 1058B including a bead of material 1090E on
top. Next to the primary dam 1058B is a mesh drainage strip 1092.
At the extreme opposite end 1053 is a raised section of the lower
flashing member 1040 to form a second or flashing dam 1058A. Under
the flashing dam 1058A and functioning at least as a support
therefor is a second under gasket 1096. Atop the flashing dam 1058A
is a bead of caulk material 1090D. Under normal operating
conditions, the primary dam 1058B will stop all water traveling
laterally on the flashing member 1040. If water does pass the
primary dam 1058B, the emergency drainage strip 1092 will exit the
water before it flows over the end dam 1058A. The caulking 1090E,
1090D also acts as a water tight seal to keep water from reaching a
seam between adjacent flashing devices. In the above embodiments,
other seals e.g., gaskets or other material, may be substituted for
the caulking to provide a seal or dam along the flashing member
and/or to adhere adjacent flashing units to each other when
installed.
[0164] While the invention has been described in conjunction with
preferred embodiments, it will be obvious to one skilled in the art
that other objects and refinements of the present invention may be
made with the present invention within the purview and scope of the
present invention.
* * * * *