Static structures (e.g. – buildings) – With synthetic resinous component – With nonresinous component
Reexamination Certificate
1999-06-22
2001-11-13
Safavi, Michael (Department: 3635)
Static structures (e.g., buildings)
With synthetic resinous component
With nonresinous component
C052S364000, C052S446000, C052S454000, C052S741410, C427S294000, C427S351000, C427S403000
Reexamination Certificate
active
06314695
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to methods and apparatus of building construction, and more particularly to the application of stucco to the wall ofa building.
2. Prior Art
Stucco is a building finish that is applied to walls of those buildings, to make them weather proof and have a finished appearance. Stucco has been used primarily in the Southwest and South of the United States prior to the introduction of improved insulating techniques. Those insulating techniques typically include the use of elongated blocks of a pre-formed rigid open cell polystyrene. These polystyrene blocks are held on to a wall surface by mechanical fasteners, or by being adhered to the wall substrate with an adhesive. In this prior art practice, once those polystyrene foam insulation blocks are fixably attached to the wall, they are roughened by a rasp to permit a base coat of polymer paste reinforced with a fiberglass fabric mesh, to help bind subsequent material to that foam, and to unify those blocks together. That mesh in the prior art method, would be placed over the roughened outer surfaces of those blocks of foam on a base coat of cementitious material while still wet, to embed that mesh in the base coat. The base coat of cementitious material and mesh are trowelled smooth and made generally planer, to be parallel with the surface of the original wall. A finish coat of synthetic stucco would then be applied to the base coat of the cementitious material.
The problem of the prior art, however, remains that the polystyrene boards are used as discrete, separate gap-maintaining blocks, and may supported by array of channels or grids or adhesive to attach them to a wall. Any gap or crack between the adjacent blocks or gap between the blocks and the wall substrate permits the infiltration/migration of water, which then seeps into the existing walls surface and causes mildew, moisture build-up, rot and wall deterioration. Joints between the adjacent boards may induce cracking in the outer surface layers of material if those boards are not installed tightly against one another and the wall.
It is an object of the present invention, to provide a stucco wall construction arrangement which prevents water intrusion and migration into the wall structure, and which will overcome those typical problems of the prior art.
It is a further object of the present invention, to provide a stucco wall construction which will prevent the infiltration of water into the existing wall surface.
It is still yet a further object of the present invention, to provide a stucco construction arrangement which is easily applied, readily modified to accommodate variations in base wall surface characteristics, and permit an even outer surface for subsequent coat applications.
It is yet still a further object of the present invention to provide a stucco construction arrangement that is fast, easily applied, energy efficient, strong and which will outlast the prior art stucco construction by many years.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to a method and apparatus for the application of multiple layers of material to an existing wall, so as to produce a water impenetrable MASTERBOND™ stucco structure.
In the application of the present method of constructing such a stucco wall structure, the pre-existing wall may be pressure washed if dirty, cleaned, rinsed and air dried. The pre-existing wall may be any type of structure such as wood, brick, or cement. After the wall has been properly washed and dried, an arrangement of orientation screeds is applied to the vertical margins of the wall, as well as to the periphery of any windows or doors. A screed is a border support for the insulation to be sprayed against. A screed, in one embodiment, may be an elongated member which is attached to the peripheral margins of the wall, to define the area in which a foam urethane is to be sprayed. The screed in this embodiment, has a “ship-lap” shape, or a cross-section of generally “L” shape having a shoulder on its spray foam adjacent edge, so as to provide a “key” or “locking effect” onto the foam, which is to be subsequently sprayed onto the wall surface. The screed, of course, is attached to the wall by an adhesive and/or mechanical fasteners. A further embodiment of screeds, is the use of an extruded generally “J”-shaped channel arrangement having one side edge which is attached by adhesives and or mechanical fasteners, to the margins of the wall and to the periphery of any door or window openings thereon. The U-shaped channel member screed has its open edge directed toward the area of the wall to be subsequently foam sprayed. The use of such a channel screed also provides a method of determining the thickness of subsequent application of foam urethane.
The next step in the construction of a stucco wall, is to cover any openings with plastic, prior to the application of the foam spray so as to prevent any inadvertent overspray into undesired areas.
The foam urethane is spray-applied in a thickness of approximately ¼ inch over the final specified insulation thickness, applied to the wall in preferably one pass, so as to provide a secure and continuous bonding between the foam spray and that entire wall substrate. This continuous application of a single monolithic layer of foam to an entire wall surface enhances the bonding to that wall and eliminates the subsequent water migration between the wall and the urethane spray foam layer of a MASTERBOND™ stucco structure.
After the spray has been applied to the entire wall surface, a skin outer surface is developed thereon. After the spray foam has been applied to one entire wall, that foam spray outer layer is vacuum planed, to remove surface irregularities and expose the cell structure of that foam spray, for secure adhesive gripping of a bond coat of stucco and mesh. The vacuum planing is accomplished by a hand-guidable elongated rotary blade device which planes off the irregularities of polyurethane foam spray material to the desired thickness, as initially guided by the orientation screeds. The vacuum plane typically has one end which may ride on the screeds to provide initial control of the planing operation. The elongated vacuum plane is also flexibly connected, via an elongated, flexible hose, to a suction source, in which to permit the removal of foam spray particulate matter swept off by the rotary blades thereof, and into a holding container.
Once the spray foam layer has been properly vacuumed planed and flattened to the desired thickness, an application of polymer base bond coat of cementitious material and a thin mesh is applied adhesively thereto, in a thickness of about {fraction (1/16)} of an inch as a first coat. The mesh and base coat are allowed to dry over a period of about twelve hours. A second coat of polymer based base coat with no mesh therewith, is applied as thin (i.e. {fraction (1/16)} inch) an outer coat over the base coat in preparation for the final coat. The outermost coat of stucco is then applied to a minimum thickness of about {fraction (1/16)} of an inch thick.
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Halgren Don
Safavi Michael
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