Exterior finishing system and building wall containing a corrosion-resistant enhanced thickness fabric and method of constructing same

• US 20050144901A1
• Filed: 12/19/2003
• Published: 07/07/2005
• Est. Priority Date: 12/19/2003
• Status: Active Grant

• Current Assignee: BASF Corporation (BASF SE)
• Original Assignee: Construction Research & Technology GmbH (BASF SE)
• Inventors: Egan, William F., Tucker, Mark W., Newton, Mark J.
• Granted Patent: US 7,625,827 B2
• Time in Patent Office: Days
• US Class Current: 52/782.100
• CPC Class Codes: D03D 1/00 Woven fabrics designed to make specified articles
• CPC Class Codes: D03D 19/00 Gauze or leno-woven fabrics
• CPC Class Codes: D10B 2503/04 Floor or wall coverings; Carpets
• CPC Class Codes: E04F 13/04 Bases for plaster sub-ceilings with plaster-carrying means E04B9/06
• CPC Class Codes: E04F 13/047 Plaster carrying meshes
• CPC Class Codes: Y10T 428/249925 Fiber-containing wood product [e.g., hardboard, lumber, or wood board, etc.]
• CPC Class Codes: Y10T 428/249932 Fiber embedded in a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 442/102 Woven scrim
• CPC Class Codes: Y10T 442/133 Inorganic fiber-containing scrim
• CPC Class Codes: Y10T 442/171 Including a layer derived from a water-settable material [e.g., cement, gypsum, etc.]
• CPC Class Codes: Y10T 442/172 Coated or impregnated
• CPC Class Codes: Y10T 442/176 Three or more layers
• CPC Class Codes: Y10T 442/178 Synthetic polymeric fiber
• CPC Class Codes: Y10T 442/181 Bitumen coating or impregnation
• CPC Class Codes: Y10T 442/184 Nonwoven scrim
• CPC Class Codes: Y10T 442/191 Inorganic fiber-containing scrim
• CPC Class Codes: Y10T 442/198 Coated or impregnated
• CPC Class Codes: Y10T 442/3179 Woven fabric is characterized by a particular or differential weave other than fabric in which the strand denier or warp/weft pick count is specified
• CPC Class Codes: Y10T 442/3195 Three-dimensional weave [e.g., x-y-z planes, multi-planar warps and/or wefts, etc.]
• CPC Class Codes: Y10T 442/322 Warp differs from weft

Abstract

A corrosion-resistant lath is provided for use in exterior finishing systems, such as stucco systems and exterior insulation and finish systems (“EIFS”). The lath includes in a first embodiment an open, woven fabric comprising weft and warp yarns containing non-metallic fibers, such as glass fibers. A portion of the weft yarns are undulated, resulting in an increased thickness for the fabric. The fabric is coated with a polymeric resin for substantially binding the weft yarns in the undulated condition. This invention also includes methods for making an exterior finish system and building wall including an exterior finish system using such a lath.

Claims

1. A stucco system comprising:

a corrosion-resistant lath including a porous layer containing non-metallic fibers;

a coating disposed over at least a portion of said non-metallic fibers; and

a stucco matrix applied to said lath;

said lath having a thickness of at least about 0.125 inches (3.175 mm) and being capable of retaining and supporting the weight of a wet stucco matrix applied thereto, without sloughing or sagging.

2. The system of claim 1 wherein said porous containing layer comprises a woven or non- woven fabric, scrim, mesh, or a combination thereof.

3. The system of claim 1 wherein said porous layer comprises an open woven fabric comprising high strength, weft and warp yarns containing glass fibers.

4. The system of claim 1 wherein said at least a portion of said fibers are mechanically manipulated to increase the layer'"'"'s thickness by at least 50%.

5. The system of claim 1 further comprising a polymeric resin for substantially binding said fibers.

6. The system of claim 1 further comprising a polymeric resin disposed over said fibers, said polymeric resin being substantially non-soluble in wet stucco.

7. The system of claim 1 wherein the non-metallic fibers are selected from the group consisting of polymeric fibers, glass fibers or both.

8. The system of claim 7 wherein the non-metallic fibers are glass fibers.

9. The system of claim 8, wherein the glass fibers are selected from the group consisting of E-glass fibers, A-glass fibers, ECR-glass fibers, S-glass fibers, and AR-glass fibers.

10. A stucco system comprising:

a corrosion-resistant lath including an open, woven fabric comprising high strength, non-metallic weft and warp yarns, whereby a portion of said yarns are mechanically manipulated to increase the fabric'"'"'s thickness by at least about 50%;

said lath being applied to a building wall substrate, said lath capable of retaining and supporting the weight of a wet stucco matrix applied thereto; and

a stucco matrix applied over said lath.

11. The system of claim 10 wherein said fabric comprises a leno weave.

12. The system of claim 11 wherein said weft and warp yarns are spaced apart to provide openings of about 0.02-4.0 square inches (0.5-102 mm²).

13. The system of claim 11 further comprising a polymeric resin for substantially binding said yarns.

14. The system of claim 11 wherein said warp yarns are subjected to a tensile force which causes said weft yarns to become undulated.

15. The system of claim 11 wherein said warp yarns have a combined weight which is greater than the combined weight of the weft yarns.

16. The system of claim 11 wherein a portion of said warp yarns are heavier than a portion of said weft yarns and said warp yarns are fewer in number than said weft yarns.

17. The system of claim 10 wherein the non-metallic fibers are selected from the group consisting of polymeric fibers, glass fibers or both.

18. The system of claim 17 wherein the non-metallic fibers are glass fibers.

19. The system of claim 18, wherein the glass fibers are selected from the group consisting of E-glass fibers, A-glass fibers, ECR-glass fibers, S-glass fibers, and AR-glass fibers.

20. A stucco system comprising:

a corrosion-resistant lath including an open woven fabric comprising weft and warp yarns containing non-metallic fibers, whereby a portion of said weft yarns are undulated, resulting in a thickness for said fabric of at least about 0.125 in (3.175 mm);

a polymeric coating disposed over at least a portion of said yarns for substantially fixing said weft yarns in said undulated condition, said polymeric resin being substantially non- soluble in a wet composition of said stucco;

said coated fabric being capable of retaining and supporting the weight of a wet stucco matrix applied thereto; and

a stucco matrix applied to said lath.

21. The system of claim 20 wherein said polymeric coating is an alkaline resistant coating.

22. The system of claim 20 wherein the non-metallic fibers are selected from the group consisting of polymeric fibers, glass fibers or both.

23. The system of claim 22 wherein the non-metallic fibers are glass fibers.

24. The system of claim 23 wherein the glass fibers are selected from the group consisting of E-glass fibers, A-glass fibers, ECR-glass fibers, S-glass fibers, and AR-glass fibers.

25. An exterior insulation and finish system comprising:

a substrate;

a layer of insulation attached over said substrate;

a base coat applied over said insulation;

a corrosion-resistant reinforcing mesh substantially embedded within said base coat, said corrosion-resistant reinforcing mesh including a porous layer containing non- metallic fibers and a coating disposed over at least a portion of said non-metallic fibers, said reinforcing mesh having a thickness of at least about 0.125 inches (3.175 mm) and being capable of retaining and supporting the weight of a wet base coat applied thereto, without sloughing or sagging; and

a finish coat applied over said base coat and said reinforcing mesh.

26. The system of claim 25, including a weather barrier attached over said substrate.

27. The system of claim 25 wherein said reinforcing mesh comprises undulated weft yarns fixed by said coating.

28. The system of claim 27 wherein said coating is a polymeric coating.

29. The system of claim 28, wherein said polymeric coating is alkaline resistant.

30. The system of claim 25 wherein the non-metallic fibers are selected from the group consisting of polymeric fibers, glass fibers or both.

31. The system of claim 30 wherein the non-metallic fibers are glass fibers.

32. The system of claim 31 wherein the glass fibers are selected from the group consisting of E-glass fibers, A-glass fibers, ECR-glass fibers, S-glass fibers, and AR-glass fibers.

33. An exterior insulation and finish system comprising:

a substrate;

a layer of insulation attached over said substrate;

a base coat applied over said insulation;

a corrosion-resistant reinforcing mesh substantially embedded within said base coat, said reinforcing mesh including an open, woven fabric comprising high strength, non-metallic weft and warp yarns, whereby a portion of said yarns are mechanically manipulated to increase the fabric'"'"'s thickness by at least about 50%, said lath being applied to said substrate , said reinforcing mesh capable of retaining and supporting the weight of wet base coat applied thereto; and

a finish coat applied over said base coat and said reinforcing mesh.

34. The system of claim 33 wherein said non metallic fibers are coated with a polymeric coating.

35. The system of claim 34, wherein said polymeric coating is alkaline resistant.

36. The system of claim 33 wherein the non-metallic fibers are selected from the group consisting of polymeric fibers, glass fibers or both.

37. The system of claim 36 wherein the non-metallic fibers are glass fibers.

38. The system of claim 37 wherein the glass fibers are selected from the group consisting of E-glass fibers, A-glass fibers, ECR-glass fibers, S-glass fibers, and AR-glass fibers.

39. An exterior insulation and finish system comprising:

a substrate;

insulation attached over said substrate;

a base coat applied over said insulation;

a corrosion-resistant reinforcing mesh including an open woven fabric comprising weft and warp yarns containing non-metallic fibers, whereby a portion of said weft yarns are undulated, resulting in a thickness for said reinforcing mesh of at least about 0.125 in (3.175 mm);

a polymeric coating disposed over at least a portion of said yarns for substantially fixing said weft yarns in said undulated condition, said polymeric resin being substantially non-soluble in a wet composition of said base coat;

said coated reinforcing mesh being capable of retaining and supporting the weight of a wet base coat applied thereto; and

a finish coat applied over said base coat and said reinforcing mesh.

40. The system of claim 39 wherein said coating is a polymeric coating.

41. The system of claim 40 wherein said polymeric coating is alkaline resistant.

42. The system of claim 39 wherein the non-metallic fibers are selected from the group consisting of polymeric fibers, glass fibers or both.

43. The system of claim 42 wherein the non-metallic fibers are glass fibers.

44. The system of claim 43 wherein the glass fibers are selected from the group consisting of E-glass fibers, A-glass fibers, ECR-glass fibers, S-glass fibers, and AR-glass fibers.

45. A method of constructing a stucco system comprising:

(a) affixing a substrate to a frame;

(b) optionally disposing a secondary weather barrier over said substrate;

(c) optionally disposing a layer of insulation over said weather barrier or said substrate;

(d) affixing a corrosion resistant lath over said substrate, or secondary weather barrier, if present, or said insulation layer, if present, said lath comprising a porous layer containing non-metallic fibers and a coating disposed over at least a portion of said fibers, said lath having a thickness of at least about 0.125 inches (3.175 mm) and being capable of retaining and supporting the weight of a wet stucco matrix applied thereto;

(e) applying at least a first stucco layer to said lath; and

(f) permitting said stucco layer to set to form a hard protective finish.

46. A method of constructing an exterior insulation and finish system comprising:

(a) affixing a substrate to a frame;

(b) optionally disposing a weather barrier over said substrate;

(c) disposing an insulation board over said substrate or said secondary weather barrier, if present;

(d) affixing a corrosion resistant reinforcing mesh over said insulation board, said reinforcing mesh comprising a porous layer containing non-metallic fibers and a coating disposed over at least a portion of said fibers, said lath having a thickness of at least about 0.125 inches (3.175 mm) and being capable of retaining and supporting the weight of a wet base coat applied thereto; and

(e) applying at least a first layer of base coat over said reinforcing mesh.

47. The method of claim 46 further comprising applying at least one layer of a finish coat over said base coat and said reinforcing mesh.

48. A method of constructing an exterior insulation and finish system comprising:

(a) affixing a substrate to a frame;

(b) optionally disposing a weather barrier over said substrate;

(c) disposing an insulation board over said substrate or said secondary weather barrier, if present;

(d) applying at least a first layer of wet base coat over said substrate, or over said secondary weather barrier, if present; and

(e) embedding a corrosion resistant reinforcing mesh in said wet base coat, said reinforcing mesh comprising a porous layer containing non-metallic fibers and a coating disposed over at least a portion of said fibers, said reinforcing mesh having a thickness of at least about 0.125 inches (3.175 mm) and being capable of retaining and supporting the weight of a wet base coat applied thereto.

49. The method of claim 48 further comprising applying at least one layer of a finish coat over said base coat and said reinforcing mesh.