U.S. patent application number 15/806202 was filed with the patent office on 2019-05-09 for foundation waterproofing system and method.
The applicant listed for this patent is JOHNS MANVILLE. Invention is credited to Ralph Michael Fay, Diana Fisler, William J. Fredericks, II, Dennis A. Kopp, ChangQing Shen, Zebonie Sukle, Guodong Zheng.
Application Number | 20190136515 15/806202 |
Document ID | / |
Family ID | 66326851 |
Filed Date | 2019-05-09 |
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United States Patent
Application |
20190136515 |
Kind Code |
A1 |
Fredericks, II; William J. ;
et al. |
May 9, 2019 |
FOUNDATION WATERPROOFING SYSTEM AND METHOD
Abstract
Systems and methods for making a waterproofed concrete wall
assembly, such as for a basement wall. A waterproof liner is
present at the pouring of the concrete of the wall assembly, and
has a fibrous layer into which concrete can infuse before
hardening. The waterproof liner may include one or more boards
including a polymer foam. The boards may line a form used to make
the wall assembly, or may make up part of the form.
Inventors: |
Fredericks, II; William J.;
(Highlands Ranch, CO) ; Fay; Ralph Michael;
(Lakewood, CO) ; Fisler; Diana; (Centennial,
CO) ; Shen; ChangQing; (Centennial, CO) ;
Zheng; Guodong; (Highlands Ranch, CO) ; Sukle;
Zebonie; (Denver, CO) ; Kopp; Dennis A.;
(Dublin, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JOHNS MANVILLE |
Denver |
CO |
US |
|
|
Family ID: |
66326851 |
Appl. No.: |
15/806202 |
Filed: |
November 7, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 1/0007 20130101;
E04B 2/8647 20130101; E04G 17/14 20130101; E04B 1/665 20130101;
E04B 2002/8682 20130101; E04G 9/10 20130101; E04B 1/80 20130101;
E04B 1/762 20130101; E04B 1/16 20130101; E04B 2103/04 20130101;
E02D 31/02 20130101 |
International
Class: |
E04B 1/76 20060101
E04B001/76; E04B 1/00 20060101 E04B001/00; E04B 1/16 20060101
E04B001/16; E04B 1/80 20060101 E04B001/80; E04B 1/66 20060101
E04B001/66; E04G 9/10 20060101 E04G009/10 |
Claims
1. A waterproofed concrete wall assembly, comprising: a vertical
wall of hardened concrete, the wall having a first side and a
second side; one or more boards forming a waterproof liner adjacent
the first side of the wall of hardened concrete, each of the boards
comprising a polymer foam and a fibrous facer joined to the polymer
foam, wherein some of the concrete is infused into the fibrous
facer, the fibrous facer having been present at an inner surface of
a form during pouring of the concrete.
2. The waterproofed concrete wall assembly of claim 1, wherein the
fibrous facer is a nonwoven facer.
3. The waterproofed concrete wall assembly of claim 2, wherein the
polymer foam is polyisocyanurate foam.
4. The waterproofed concrete wall assembly of claim 2, wherein the
polyisocyanurate foam has a density between 2.5 lb/ft3 and 25
lb/ft3.
5. The waterproofed concrete wall assembly of claim 2, wherein the
polyisocyanurate foam has a density between 4 lb/ft3 and 15
lb/ft3.
6. The waterproof concrete wall assembly of claim 1, wherein a
plurality of boards are present, and further comprising tape
sealing joints between the plurality of boards.
7. The waterproof concrete wall assembly of claim 6, wherein the
tape is on an inner side of the plurality of boards, in contact
with the concrete.
8. The waterproof concrete wall assembly of claim 6, wherein the
tape is on an outer side of the plurality of boards.
9. A method of making a waterproofed concrete wall assembly, the
method comprising: constructing a form, the form having a first
side and a second side, the first and second sides defining a gap
between the first and second sides for receiving poured concrete,
wherein the first side is made of one or more boards comprising a
polymer foam and a fibrous layer; pouring concrete in the gap
between the first and second sides of the form; allowing the
concrete to harden, some of the concrete having infused into the
fibrous layer; and leaving the boards of the first side of the form
in place adjacent the hardened concrete.
10. The method of claim 9, further comprising removing the second
side of the form.
11. The method of claim 9, wherein the boards comprise
polyisocyanurate foam.
12. The method of claim 9, wherein each of the boards comprises a
fibrous facer on at least one side of the board.
13. The method of claim 9, further comprising sealing joints
between the boards using a tape, a sealant, or a combination of
tape and sealant.
14. The method of claim 9, further comprising sealing joints
between the boards using a tape before the concrete is poured.
15. The method of claim 9, wherein the joints between the boards
are sealed with a tape initially having a split release liner.
16. The method of claim 9, wherein the joints between the boards
are sealed at an inside surface of the boards, adjacent the
gap.
17. The method of claim 9, wherein the joints between the boards
are sealed at an outside surface of the boards.
18. The method of claim 9, further comprising: installing form ties
between the first and second form sides before pouring the
concrete, to prevent expansion of the gap due to hydrostatic
pressure of the poured concrete, wherein the form ties protrude
from both sides of the form; removing the protruding portions of
the form ties once the concrete is hardened; and sealing the points
at which the form ties formerly protruded through the boards using
a tape, a sealant, or a combination of tape and sealant.
19. The method of claim 9, wherein the boards form an outside
surface of the wall.
20. The method of claim 9, wherein the second side of the form is
made of one or more boards comprising a polymer foam.
Description
BACKGROUND OF THE INVENTION
[0001] Poured concrete walls are widely used for foundations,
basements, tunnels, and other underground structures. Concrete
walls have many advantages, including high strength and durability.
Concrete walls can be made to suit nearly any floor plan.
[0002] However, concrete is not inherently waterproof, and is not a
good thermal insulator. Because backfilled earth may be in direct
contact with a basement wall for decades or more, measures are
typically taken to prevent seepage of water from the surrounding
soil through the concrete wall and into the interior of the
structure. Additional thermal insulation may also be provided below
ground level, either outside the concrete wall or inside.
BRIEF SUMMARY OF THE INVENTION
[0003] According to one aspect, a waterproofed concrete wall
assembly comprises a vertical wall of hardened concrete, the wall
having a first side and a second side. The assembly further
comprises one or more boards forming a waterproof liner adjacent
the first side of the wall of hardened concrete. Each of the boards
comprises a polymer foam and a fibrous facer joined to the polymer
foam. Some of the concrete is infused into the fibrous facer, the
fibrous facer having been present at an inner surface of a form
during pouring of the concrete. In some embodiments, the fibrous
facer is a nonwoven facer. In some embodiments, the polymer foam is
polyisocyanurate foam. In some embodiments, the polyisocyanurate
foam has a density between 2.5 lb/ft.sup.3 and 25 lb/ft.sup.3. In
some embodiments, the polyisocyanurate foam has a density between 4
lb/ft.sup.3 and 15 lb/ft.sup.3. In some embodiments, a plurality of
boards are present, and the waterproofed concrete wall assembly
further comprises tape sealing joints between the plurality of
boards. In some embodiments, the tape is on an inner side of the
plurality of boards, in contact with the concrete. In some
embodiments, the tape is on an outer side of the plurality of
boards.
[0004] According to another aspect, a method of making a
waterproofed concrete wall assembly comprises constructing a form,
the form having a first side and a second side. The first and
second sides define a gap between the first and second sides for
receiving poured concrete, and the first side is made of one or
more boards comprising a polymer foam and a fibrous layer. The
method further comprises pouring concrete in the gap between the
first and second sides of the form, and allowing the concrete to
harden, some of the concrete having infused into the fibrous layer.
The method further comprises leaving the boards of the first side
of the form in place adjacent the hardened concrete. In some
embodiments, the method further comprises removing the second side
of the form. In some embodiments, the boards comprise
polyisocyanurate foam. In some embodiments, each of the boards
comprises a fibrous facer on at least one side of the board. In
some embodiments, the method further comprises sealing joints
between the boards using a tape, a sealant, or a combination of
tape and sealant. In some embodiments, the method further comprises
sealing joints between the boards using a tape before the concrete
is poured. In some embodiments, the joints between the boards are
sealed with a tape initially having a split release liner. In some
embodiments, the joints between the boards are sealed at an inside
surface of the boards, adjacent the gap. In some embodiments, the
joints between the boards are sealed at an outside surface of the
boards. In some embodiments, the method further comprises
installing form ties between the first and second form sides before
pouring the concrete, to prevent expansion of the gap due to
hydrostatic pressure of the poured concrete, wherein the form ties
protrude from both sides of the form; removing the protruding
portions of the form ties once the concrete is hardened; and
sealing the points at which the form ties formerly protruded
through the boards using a tape, a sealant, or a combination of
tape and sealant. In some embodiments, the boards form an outside
surface of the wall. In some embodiments, the second side of the
form is made of one or more boards comprising a polymer foam.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1 illustrates a typical prior art poured concrete
foundation wall installation.
[0006] FIG. 2 shows typical forms having two parallel vertical
sides separated by a space for receiving poured concrete.
[0007] FIG. 3 shows a hardened wall with the forms removed.
[0008] FIG. 4 illustrates a step in making a waterproofed concrete
wall assembly, in accordance with embodiments of the invention.
[0009] FIG. 5 illustrates the process of pouring concrete into the
form shown in FIG. 4, in accordance with embodiments of the
invention.
[0010] FIG. 6 shows the wall assembly as poured in FIG. 5, in
accordance with embodiments of the invention.
[0011] FIG. 7 shows the wall of FIG. 6 in an oblique view,
including a waterproofing layer.
[0012] FIG. 8 illustrates the sealing of openings in the
waterproofing layer of FIG. 7.
[0013] FIG. 9 illustrates a step in making a concrete wall assembly
in accordance with another embodiment of the invention.
[0014] FIG. 10 shows another step in making a concrete wall
assembly in accordance with embodiments of the invention.
[0015] FIG. 11 shows the resulting wall, including a membrane and a
flap, in accordance with embodiments of the invention.
[0016] FIG. 12 shows openings and a seam in the membrane of FIG.
11.
[0017] FIG. 13 illustrates sealing of the openings and seam shown
in FIG. 12.
[0018] FIG. 14 illustrates a step in making a concrete wall
assembly in accordance with another embodiment.
[0019] FIG. 15 shows another step in making a concrete wall
assembly in accordance with embodiments of the invention.
[0020] FIG. 16 shows the wall resulting from the steps of FIG. 14
and FIG. 15, in accordance with embodiments of the invention.
[0021] FIG. 17 illustrates the sealing of openings and a seam in a
waterproof layer of the wall assembly of FIG. 16.
[0022] FIG. 18 illustrates a stage in forming a concrete wall in
accordance with other embodiments.
[0023] FIG. 19 illustrates a pre-taped board, in accordance with
embodiments of the invention.
[0024] FIG. 20 illustrates a tape with a split release liner, in
accordance with embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 illustrates a typical prior art poured concrete
foundation wall installation 100. A footer 101 preferably rests on
undisturbed soil 102. Foundation wall 103 is poured on top of
footer 101. Fill 104, for example gravel, is placed on the interior
side of footer 101, and a slab floor 105 may be poured on top of
fill 104. Anchor bolts 106 may be set in wall 103 at the time of
pouring, for attachment of framed walls.
[0026] Waterproofing 107 may be applied to the exterior surface of
wall 103. Waterproofing may be, for example, a liquid coating
applied to foundation wall 103, or may be in the form of a membrane
as shown. Additional insulation 108, such as polystyrene foam, may
be applied outside of waterproofing 107, for providing thermal
insulation and protecting waterproofing layer 107 during
backfilling of wall 103.
[0027] Various reinforcing bars and meshes may be placed in footer
101, wall 103, and floor 105.
[0028] For pouring of foundation wall 103, forms are typically
assembled. FIG. 2 shows typical forms having two parallel vertical
sides 201 and 202 separated by a space 203 for receiving the poured
concrete. Vertical sides 201 and 202 are often made of plywood, but
can also be made of more durable and rigid materials such as
aluminum, steel, or other metals. Bracing 204 may be provided for
holding sides 201 and 202 against the hydrostatic pressure of the
poured concrete. In addition, form ties 205 may be provided. Form
ties 205 hold sides 201 and 202 together against the pressure of
the concrete, and the concrete is poured around them. Form ties 205
may include weakened points 206. After the wall is poured and
hardened, the forms are removed, leaving a bare concrete wall. The
protruding ends of form ties 205 are preferably broken off, with
the ties snapping apart at weakened points 206, to leave an
unobstructed face. The resulting hardened wall is shown in FIG. 3.
Waterproofing 107 may typically not be applied for up to 30 days
after pouring of wall 103, to allow wall 103 to cure before
waterproofing 107 is applied.
[0029] According to embodiments of the invention, waterproofing is
provided for a concrete wall as part of the process of fabrication
of the wall.
[0030] FIG. 4 illustrates a step in making a waterproofed concrete
wall assembly, in accordance with embodiments of the invention. A
form is constructed, having a first side 401 and a second side 402,
defining a space 403 between them for receiving poured concrete.
First side 401 is made of one or more boards comprising a polymer
foam. In other embodiments, both sides 401 and 402 may be made of
such boards. Preferably, at least the outer side (the side of the
form defining the outdoor face of the wall) of the form is made of
one or boards comprising polymer form.
[0031] Any foam-containing boards may be used, but boards that may
be particularly suitable include Invinsa.RTM. and GoBoard.RTM.
boards available from Johns Manville of Denver, Colo., USA.
[0032] Invinsa.RTM. boards include a polyisocyanurate core and
mineral-coated fiberglass-reinforced facers 407 on both sides.
These boards are readily available in 4 ft..times.4 ft. and 4 ft.
by 8 ft. sizes, and are typically 1/4 in. thick, although other
sizes and thicknesses may be used if desired. The density of the
polyisocyanurate core may be about 2.5 to 8 lb/ft.sup.3, and
typically about 3.5 to 4.5 lb/ft.sup.3, although other densities
may be used. In other embodiments, boards having facers on only one
side may be used. In that case, the facer is preferably placed
adjacent space 403, so that the poured concreted will directly
contact the facer.
[0033] GoBoard.RTM. boards also include a polyisocyanurate core and
a fiberglass facer. GoBoard boards are readily available in 3 ft.
by 5 ft. and 4 ft. by 8 ft. sizes, in thicknesses ranging from 1/4
in. to 2 in., although other sizes and thicknesses may be used if
desired. The density of the polyisocyanurate core is typically
about 10 lb/ft.sup.3, although other densities may be used.
[0034] In some embodiments, the thickness or density (or both) of
the boards may be selected to meet the flexural and other
requirements of the concrete forms. For example, densities of
between 2.5 lb/ft.sup.3 and 25 lb/ft.sup.3 may be used, and
thicknesses between 1 and 6 inches. In other embodiments, densities
and thicknesses outside these ranges may be used. In addition,
longer boards may be used, for example 4 ft. by 12 ft. or 4 ft. by
16 ft., to reduce the number of seams in an installation.
[0035] The polyisocyanurate core of these boards makes the boards
waterproof, and the fibrous facer bonds well to concrete, because
the uncured concrete can infuse into the fibrous facer to some
degree. In other embodiments, different kinds of foam may be used,
for example polyurethane foam. In embodiments with facers on both
sides of the boards, one of the facers contacts the concrete, and
the other facer is at least initially exposed to the air. This
second facer may provide a second waterproofing layer, a smooth
surface that is easier to clean, tape, and seal, or a more durable
and abuse-resistant surface than a foam surface without a
facer.
[0036] As is shown if FIG. 4, bracing 404 and form ties 405 may be
provided for holding sides 401 and 402 against the hydrostatic
pressure of the poured concrete. Weakened points 406 of form ties
405 may be in the conventional location just inside space 403, or
may be positioned as shown in FIG. 4, just inside the outer surface
of side 401. In other embodiments, form ties may not be used,
relying on bracing 404 and the rigidity of the forms to hold form
sides 401 and 402 in the correct spacing. The use of metal forms
may help avoid the need for form ties.
[0037] With form sides 401 and 402, bracing 404, any form ties 405,
and any reinforcing bars or mesh (not shown) in place, concrete is
poured in space 403 as shown in FIG. 5. Once the concrete has
hardened, form side 402 and bracing 404 are removed and the
breakaway ends of any form ties 405 are broken off, leaving the
wall assembly 601 as shown in FIG. 6. Form side 401 is left in
place, and provides a naturally waterproof layer on the side of
wall assembly 601. Inner facer 407 naturally adheres to the
concrete of wall assembly 601, so that side 401 is securely joined
to the concrete.
[0038] FIG. 7 shows wall assembly 601 in an oblique view. (Anchor
bolts and the like have been omitted for clarity, but may be
present.) Side 401 may include joints 701 between the
foam-containing boards that make up side 401, and may include
partial-thickness openings 702 where form ties 405 were broken off.
While the boards are shown as being oriented horizontally, the
boards may alternatively be oriented vertically, which may minimize
the number of joints between the boards.
[0039] FIG. 8 shows the joints 701 and openings 702 covered with a
sealant 801, for example, a sealant such as GoBoard.RTM. Sealant
available from Johns Manville. The portion of the outer surface of
side 401 that requires a secondary sealant may be exaggerated in
FIG. 8. Typically, joints 701 and openings 702 are small in
relation to the area of wall assembly 601. A bead of caulk 802 may
also be applied to the joint between footer 803 and side 401. Caulk
802 may be, for example, Tremco Dymonic.RTM. 100 sealant also
available from Tremco Incorporated, or another suitable kind of
caulk or sealant.
[0040] In other embodiments, joints 701 and openings 702 may be
sealed using an adhesive tape, for example ZIP System.TM. tape
available from Huber Engineered Woods of Charlotte, N.C., USA, or
another suitable kind of tape. A combination of a sealant and an
adhesive tape may be used if desired.
[0041] Concrete wall assemblies made according to the above
description may have one or more advantages over conventional
concrete walls. For example, a polymer foam board may be made
thicker, stronger, more flex resistant than plywood, so fewer
braces may be required in the forms for the wall, reducing the
labor required to make the wall. The boards also provide thermal
insulation to the wall. For example, a two-inch thick Invinsa.RTM.
panel may have an insulating value of about R 10, while a one-inch
thick panel of GoBoard.RTM. may have an insulating value of about R
5.
[0042] FIG. 9 illustrates a step in making a concrete wall assembly
in accordance with another embodiment. In this embodiment, one side
901 of a form is first erected. Side 901 may be mainly
conventional, for example being made of plywood and braced by
bracing 902.
[0043] Inside surface 903 of side 901 (the surface that will
eventually be in contact with concrete) is lined with a waterproof
membrane 904. Membrane 904 may be, for example, JM TPO FB 115.TM.,
TPO FB 135.TM., or TPO FB 150.TM. Fleece Backed Roofing Membrane
available from Johns Manville, or another suitable kind of
membrane. Each of the JM TPO FB products includes a thermoplastic
polyolefin (TPO) membrane reinforced with a polyester fabric, and
an integral polyester fleece backing. The membrane in the JM TPO FB
products is nominally 0.060 or 0.080 inches thick, but other
thicknesses may be used, for example thicknesses between about 1/32
inch to about 3/16 inch. In other embodiments, membrane 904 may be
another kind of membrane having an exposed fibrous layer, or may be
a board material as is described in more detail below. In some
embodiments, membrane 904 may comprise styrene butadiene styrene
(SBS) or ethylene propylene diene monomer (EPDM).
[0044] Waterproof membrane 904 may extend under form side 901 as
shown by flap 905, which may lap over footer 906 to provide a
continuous waterproof layer beyond the foundation. Any seams such
as seam 907 should preferably be arranged so that lower course 908
of membrane material laps over upper course 909 of membrane
material, when viewed from the lined side of form side 901. This
ensures that upper course 909 of membrane material will overlap
lower course 908 when viewed from the outside of the eventual wall,
so that membrane 904 will shed water rather than providing a path
of ingress toward the foundation.
[0045] Waterproof membrane material 904 may be available in rolls
of material up to 10 feet wide and 100 feet long. Thus, very few
seams may be required, assuming that equipment capable of carrying
and handling the large rolls is available.
[0046] Clips or clamps 910 may be used to temporarily hold membrane
904 in place on form side 901, and may be removed once the concrete
is poured. Intermittent lengths of tape (not shown) may be used
along seam 907 to hold lower course 908 of membrane 904 in place,
if desired. The weight of form side 901 holds membrane 904 against
footer 906.
[0047] FIG. 10 shows another step in making a concrete wall
assembly in accordance with embodiments of the invention. Second
side 1001 of a form is erected, and may be braced using bracing
1002. Form ties 1003 may be put in place. Anchor bolts and other
reinforcing such as rebar or wire mesh may be put in place, but are
not shown. In other embodiments, form ties may not be used, relying
on bracing 902 and 1002 to hold form sides 901 and 1001 in the
proper spacing.
[0048] Concrete is then poured between form sides 901 and 1002, as
described above. After the concrete has hardened, the forms are
removed, and the protruding portions of any form ties 1003 are
snapped off. FIG. 11 shows the resulting wall assembly 1101, having
membrane 904 on one face and extending down over footer 906 at flap
905. If multiple courses of waterproof membrane are used, the top
course preferably overlaps the bottom as shown at 1102. The secure
attachment of waterproof membrane 904 to the concrete wall is due
at least in part to the infusion of concrete into the fibrous
fleece layer of waterproof membrane 904.
[0049] As in the previous embodiments, form ties 1003 may leave
openings 1201 in waterproof membrane 904, as shown in FIG. 12. In
addition, a seam 1202 may exist if more than one course of membrane
904 is used. Other seams may be present where ends of sections of
membrane 904 meet. Openings 1201 and seam 1202 may be covered with
a sealant 1301, as shown in FIG. 13. Sealant 1301 may be any
suitable kind of sealant, for example GoBoard.RTM. sealant
available from Johns Manville, or ZIP System.TM. tape available
from Huber Engineered Woods.
[0050] During backfilling, flap 905 may be placed against footer
906, or may form a downwardly sloping wing that carries water even
further away from the wall before allowing it to seep into the
ground.
[0051] FIG. 14 illustrates a step in making a concrete wall
assembly in accordance with another embodiment. In this embodiment,
one side 1401 of a form is first erected. Side 1401 may be mainly
conventional, for example being made of plywood and braced by
bracing 1402.
[0052] The inside surface of side 1401 (the surface that will
eventually be in contact with concrete) is lined with a waterproof
layer in the form of waterproof boards 1403. Boards 1403 may be,
for example, Invinsa.RTM. or GoBoard.RTM. boards available from
Johns Manville as described above, or another suitable kind of
board. Each of boards 1403 includes a fibrous facer 1404, for
example a facer including a nonwoven fiberglass mat, or another
kind of fibrous facer.
[0053] FIG. 15 shows another step in making a concrete wall
assembly in accordance with embodiments of the invention. Second
side 1501 of the form is erected, and may be braced using bracing
1502. Form ties 1503 may be put in place. Anchor bolts and other
reinforcing such as rebar or wire mesh may be put in place, but are
not shown. In other embodiments, form ties may not be used, relying
on bracing 1402 and 1502 to hold form sides 1401 and 1501 in the
proper spacing.
[0054] Concrete is then poured between form sides 1401 and 1501, as
described above. After the concrete has hardened, the forms are
removed, and the protruding portions of any form ties 1503 are
snapped off. FIG. 16 shows the resulting wall assembly 1601, having
boards 1403 on one face. The secure attachment of boards 1403 to
the concrete wall is due at least in part to the infusion of
concrete into the fibrous facer 1404 of boards 1403.
[0055] As in the previous embodiments, the waterproof layer on wall
assembly 1601 may include joints 1602 between the foam-containing
boards 1403, and may include partial-thickness openings 1603 where
form ties 1503 were broken off.
[0056] Joints 1602 and openings 1603 may be covered with a sealant
1701, as shown in FIG. 17. Sealant 1701 may be any suitable kind of
sealant, for example GoBoard.RTM. sealant available from Johns
Manville, or ZIP System.TM. tape available from Huber Engineered
Woods.
[0057] FIG. 18 illustrates a stage in forming a concrete wall in
accordance with other embodiments. In this embodiment, one side
1801 of a form is first erected. Side 1801 may be mainly
conventional, for example being made of plywood or metal and braced
by bracing 1802.
[0058] Inside surface 1803 of side 1801 (the surface that will
eventually be in contact with concrete) is lined with boards 1804.
Boards 1804 may be, for example Invinsa.RTM. or GoBoard.RTM. boards
available from Johns Manville, or another kind of boards including
a polymeric foam and at least one facer, as described above. Each
of boards 1804 includes a fibrous facer on its inner side (the side
that will eventually be in contact with poured concrete). Boards
1804 may be temporarily held in place using clips or clamps 1805.
Boards 1804 may be pre-taped using a tape 1806, to waterproof seams
between the boards. An example of tape 1806 is described in more
detail below. The pre-taping may be performed on either side of
boards 1804, or on both sides.
[0059] Boards 1804 may also have a facer 1807 on their outer sides
(away from the concrete). In some embodiments, outer facer 1807 may
extend beyond the lower edge of the board, so that a flap 1808 can
be passed under form side 1801 and over footer 1809. FIG. 19 shows
a partial view of one of boards 1804, showing tape 1806 already
installed, and showing flap 1808.
[0060] FIG. 20 illustrates tape 1806 in more detail, in accordance
with embodiments of the invention. Tape 1806 has a body 2001
including an adhesive surface 2002, and preferably includes a split
release liner 2003 over adhesive surface 2002. Split release liner
2003 may facilitate handling of tape 1806. For example, one side of
split release liner 2003 may be removed from tape 1806, and tape
1806 may be installed along the edge of one of boards 1804, as
shown in FIG. 19. Board 1804 can then be stood up against form 1801
and held in place using clips or clamps 1805. Because part of
release liner 2003 is in place through this step, no adhesive is
exposed and tape 1806 is not damaged while board 1804 is placed
against form side 1801.
[0061] The remaining side of release liner 2003 can then be
removed, and another board 1804 placed against form side 1801,
adjoining the first board 1804 and adhering to the exposed portion
of tape 1806. In the example of FIG. 18, boards 1804 are placed
vertically on form side 1801, but they could be placed horizontally
if desired.
[0062] Once form side 1801 and boards 1804 are in place, the second
side of the form can be constructed and concrete poured as
described above. Form ties may be used, or the forms may be braced
sufficiently to avoid the need for form ties. If form ties are
used, any penetrations of boards 1804 are preferably sealed using a
sealant or tape, as described above. The resulting wall assembly
may be similar to the wall assembly shown in FIGS. 16 and 17, with
the possible addition of flap 1808.
[0063] Embodiments of the invention may provide one or more
advantages as compared with prior art methods of waterproofing a
concrete wall. For example, foam boards, membranes, and sealing
materials as described are weather resistant, and are not harmed by
being left exposed to the elements while other construction
proceeds. Because the waterproofing layer is formed integrally with
the concrete wall, there is no need to wait for the concrete to
cure before waterproofing can be installed. Similarly, these
materials are not damaged by backfilling, and can remain in contact
with backfill soil indefinitely. In addition, the waterproofing
systems and methods may not require any volatile organic compounds
(VOCs) as may be present in spray-applied waterproofing coatings,
and no personal protective equipment may be needed during
installation.
[0064] Having described several embodiments, it will be recognized
by those of skill in the art that various modifications,
alternative constructions, and equivalents may be used without
departing from the spirit of the invention. Additionally, a number
of well-known processes and elements have not been described in
order to avoid unnecessarily obscuring the present invention.
Accordingly, the above description should not be taken as limiting
the scope of the invention.
[0065] Where a range of values is provided, it is understood that
each intervening value, to the tenth of the unit of the lower limit
unless the context clearly dictates otherwise, between the upper
and lower limits of that range is also specifically disclosed. Each
smaller range between any stated value or intervening value in a
stated range and any other stated or intervening value in that
stated range is encompassed. The upper and lower limits of these
smaller ranges may independently be included or excluded in the
range, and each range where either, neither or both limits are
included in the smaller ranges is also encompassed within the
invention, subject to any specifically excluded limit in the stated
range. Where the stated range includes one or both of the limits,
ranges excluding either or both of those included limits are also
included.
[0066] As used herein and in the appended claims, the singular
forms "a", "an", and "the" include plural referents unless the
context clearly dictates otherwise. Thus, for example, reference to
"a process" includes a plurality of such processes and reference to
"the device" includes reference to one or more devices and
equivalents thereof known to those skilled in the art, and so
forth.
[0067] Also, the words "comprise," "comprising," "include,"
"including," and "includes" when used in this specification and in
the following claims are intended to specify the presence of stated
features, integers, components, or steps, but they do not preclude
the presence or addition of one or more other features, integers,
components, steps, acts, or groups.
* * * * *