Fire shield flashing system and method

A fenestration flashing system includes a body member having a planar header leg extending horizontally from a rearward end to a forward end, a vertical leg extending upward from the forward end of the header leg, and a positively-sloped drainage leg extending upwardly and rearwardly from a top end of the vertical leg. A termination member has a vertical termination leg for attachment to the back-up wall and a positively-sloped drainage leg to overlap and attach to the positively-sloped drainage leg of the body member. The termination member and the body member define a drainage path down and out of the wall cavity. A method of flashing a fenestration of a cavity wall or non-cavity wall is also disclosed.

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates to through-wall flashing systems and fire prevention. More particularly, the present invention relates to flashing systems and methods of installing flashing systems at fenestrations in cavity wall construction.

2. Description of the Related Art

FIG. 1illustrates a perspective view of a portion of a traditional masonry veneer wall10. Traditionally, masonry wall10is constructed having a back-up wall or inner wythe12and an outer wythe14. Inner wythe12is typically made of concrete masonry block16, brick, wood, or steel frame construction elements. Outer wythe14is typically made of brick18, stone, concrete block, stucco, or other cladding products. The inner and outer wythes12,14are separated by a cavity20. The width of cavity20can be specified by building code or architectural design preference, but is commonly dimensioned up to about six inches. Cavity20allows for up to four inches of outbound insulation29and about two inches of an air gap28between face29aof outbound insulation29and inner face14aof outer wythe14(or between outer face12aof inner wythe and inner face14aof outer wythe14.)

The primary purpose of a masonry wall10constructed with a cavity20is to establish a capillary break and drainage plane between the outer face12aof the inner wythe12aand the inner face of outer wythe14a. The break provides an inbound drainage plane, which prevents moisture from transferring from the inner face14aof the outer wythe14ato the outer face12aof the inner wythe12, whether the moisture is due to condensation formed on the inner face14aor to water leaking through the outer wythe14to the inner face14aof the outer wythe14. The cavity20also helps reduce heat transfer by providing a blanket of air between wythes12,14. Water that penetrates the outer wythe14or that condenses on the inner face14aof the outer wythe14will run down the inner face of14aof the outer wythe14to a point where the downward flow19is redirected by the horizontal plane of the through-wall flashing membrane22located at and along the head of a fenestration a steel lintel21. Moisture then continues to travel outward through weeps (not shown) embedded in the outer wythe14. Water that condenses on the outer face12aface of the inner wall12awill drain downward onto the through-wall flashing membrane22and outward through the weeps by way of a weep device. The weep device can be a metal or plastic tube, a rope, or other device that extends horizontally through the outer wythe14.

A through-wall flashing membrane22is one form of above-grade waterproofing that protects inner surfaces12a,14aof a masonry wall10from water intrusion. For water that forms in or enters the cavity20, the through-wall flashing membrane22also directs this water out of masonry wall10. Flashing is mandated in the International Building Code Section 1405.4, which states, “flashing shall be installed in such a manner so as to prevent moisture from entering the wall or to redirect it to the exterior.” Failure to comply with this code exposes the structural and interior wall components to water and associative rot, threatens indoor air quality, and reduces energy efficiency.

Traditional through-wall flashing membrane22is made of a continuously-formed, fitted, and sealed metal material (copper, stainless steel, or lead) or a continuously-formed, fitted, and sealed adhered or loose-laid waterproof membrane, all of which should be sloped to drain. To prevent delamination of a sealed joint, adhered and loose-laid membranes require full structural support to avoid sagging across gaps. Repairing failed joints is expensive.

To direct water out of the wall10, metal through-wall flashing22is affixed to outer face of inner wythe12by any of several methods. One method is to insert an edge of flashing into a horizontal joint of the inner wythe12, such as when the inner wythe12is made of masonry blocks. Another method is to insert the edge of the through-wall flashing22into a reglet, which is a horizontal slot or groove in an inner wythe made of poured concrete. Yet another method is to mechanically fasten the flashing to a cavity face12aof the inner wythe12using screws and a termination bar24. A termination bar24is a strip of metal or plastic with evenly-spaced screw holes and is designed to spread the load of through-wall flashing22evenly across the width of the bar. A termination bar may be used on any kind of inner wythe12.

The through-wall flashing22runs down the cavity face12aof inner wythe12to a horizontal ledge or shelf (e.g., horizontal leg21bof lintel21) or a wall foundation (not shown). Through-wall flashing22then turns and runs horizontally out of the wall10by extending through a mortar joint in the outer wythe14, thereby providing a continuous path19that guides water horizontally through outer wythe14. One such mortar joint is between lintel21and the row of bricks18installed on the lintel21. Through-wall flashing22forms a continuous sheet that guides water to the outside surface14aof outer wythe14and prevents water from reaching the interior of the building.

At a fenestration30(e.g., an opening for a door, window, louver, vents, etc.), an L-shaped lintel21extends across the opening and is supported by masonry members18(e.g., bricks) on either side of fenestration30. Masonry members18above the opening are supported on the lintel21. For an outer wythe14made of brick, lintel21is typically made of steel and has a vertical leg21awith a height of about 3.5 inches and a horizontal leg21bwith a width of about 4.5 inches. Since lintel21is dimensioned to support bricks18, a gap28remains between the inner wall12and the outer wall14at a top edge of fenestration30. To close this gap28so that it is not visible, a piece of wood or polystyrene insulation may be installed between the inner wythe12and vertical leg21aof the lintel21with the wood or metal header trim36extending across the gap28. It is not uncommon to fill the air gap28along the header with spray foam or polystyrene insulation.

Since the water travels horizontally when the through-wall flashing22meets the lintel21or other ledge, an end dam25is commonly used to prevent moisture from traveling across the through-wall flashing22and into the wall10. An end dam25also prevents moisture from entering the air cavity20when the through-wall flashing22is flat or has a slight upward slope towards the outside of the outer wall14, a condition that may result in pooling. To further direct water away from outer wythe14, a drip edge26may be installed across the horizontal leg21bof the lintel21, where the drip edge26extends beyond the outside surface14aof outer wythe14. Another option for closing the gap28between the inner and outer wythes along fenestration30is to select lintel21having a wider horizontal leg21bso that vertical leg21aabuts the insulation29on inner wythe12and horizontal leg21bextends to cavity face12aof inner wythe12. A variation on this option is a lintel21having a rearwardly-extending leg (not shown) that extends from vertical leg21ato inner wythe12, thereby at least partially closing gap28.

Through-wall masonry flashing22traditionally is made of heavy gauge copper or lead sheet that requires trained metal workers to install it correctly. Laps and seams need to be soldered, which is difficult to do properly in a watertight fashion.

SUMMARY OF THE INVENTION

Open weeps and the lack of outward-tilting horizontal legs of steel lintels are problematic to effective drainage of cavity walls such as those used in masonry construction. Weep inlet openings are commonly found clogged by mortar or positioned too high on the flashing to be effective. Expecting an outward-tilting horizontal leg21bof a steel lintel21is unreasonable since the position of the steel lintel21is seldom if ever specified in a set of construction drawings.

Another problem with current cavity construction and flashing methods is that the water between the back-up wall and the façade or outer wall (e.g., inner and outer wythes, respectively) is directed in a horizontal direction through the outer wall. When construction materials soften and drool, this causes staining on the outside surface of the outer wall. Construction materials may also have a much shorter life expectancy than the building itself. When these materials degrade, they must be replaced, which is difficult and costly.

Another problem with current cavity construction and flashing methods is that fire in a burning building is often fed by air passing through fenestrations. When flames reach out through the fenestration and up the wall of the building, the intense heat quickly destroys finishes, polystyrene or spray foam, and other materials along the header portion of fenestrations. Of particular concern are the upper corners of the fenestration, where heat from a fire quickly destroys wood, foam insulation, and other materials between the inner and outer walls and then continues to race up through the air gap between inner and outer walls. As may be predicted, the ability of the fire to travel up the wall enables the fire to spread more quickly to upper floors of the building.

Building codes require insulation to be attached to the cavity face of the inner wythe or back-up wall to allow continuous integrated insulation. Also, fire codes in the US now require improved fire blocking around doors and windows to prevent the fire from quickly traveling up the wall between the back-up wall and the outer wall or façade (e.g., inner and outer wythes, respectively.) Specifically, International Building Code (IBC) requires fire testing compliance with NFPA 285 for exterior wall assemblies having non-combustible components such as foam plastic insulation, combustible claddings, and combustible air and water barriers. Buildings over forty feet tall or having foam plastic or foam plastic core materials also require NFPA 285 compliance. The 2015 NFPA 285 1: Fire Code of the National Fire Protection Association is incorporated by reference in its entirety.

In one test, flame spread for a 78″-wide window opening shall not reach ten feet above the top of the window opening or reach five feet laterally from the window's centerline. Also, thermocouples located in the wall to the sides and above the window opening shall not reach 1000° F. during the test. Builders and teams testing for compliance with NFPA 285 have met these performance requirements by adding components to the wall construction that would not otherwise be present. For example, stainless steel sheet metal is bent to a shallow U-shaped channel and wrapped around the horizontal and vertical edges of the window opening. The stainless steel channels prevent flames from reaching the insulation in the wall cavity. As a result, such an approach reduces heat inside the wall and prevents the insulation from burning. This approach, however, facilitates passing the NFPA 285 test, but it is not consistent with actual construction practices. With no available flashing product designed for fire shielding, a need exists for a fire shield flashing system and method of fenestration flashing for masonry construction.

An object of the present invention is to provide a fire shield flashing system that is adaptable to different dimensions of a wall cavity, fenestration width, and/or structural wall assembly.

Another object of the present invention is to eliminate or reduce the need for on-site metal fabrication machinery and personnel schooled in metal fabrication.

Yet another object of the present invention is to provide a fenestration flashing system having a finish material that closes the gap between the façade or outer wythe and the back-up wall or inner wythe when installed along a fenestration header of a cavity wall.

The present invention accomplishes these and other objectives by providing a fenestration flashing system and method of fire shield flashing for cavity wall and non-cavity wall construction. In one embodiment, a fenestration flashing system includes a body member having a planar header leg extending horizontally from a rearward end to a forward end, a vertical leg extending upward from the forward end of the header leg, and a positively-sloped drainage leg extending upwardly and rearwardly from a top end of the vertical leg. A vertical termination leg extends vertically from a position proximate a rearward end of the positively-sloped drainage leg and may be monolithically formed as part of the body member or may be a part of a distinct termination member. In one embodiment, an optional weep fabric is affixed to the vertical leg. The vertical termination leg and the positively-sloped drainage leg define a downward drainage path or drainage plane to the vertical leg. The weep fabric wicks moisture along the vertical leg of the flashing header member downward and out of an air cavity of the cavity wall.

In another embodiment, the body member includes the vertical termination leg formed continuously with the positively-sloped drainage leg.

In another embodiment, the vertical termination leg is part of a distinct termination member. The vertical termination leg is constructed to abut or contact a cavity face of a back-up wall or inner wythe. The termination member also includes a positively-sloped transition leg extending downwardly and forward from a lower end of the vertical transition leg, where the positively-sloped transition leg is sized and constructed to adjustably overlap and abut the positively-sloped drainage leg of the body member.

In another embodiment, the flashing system includes an end member sized and shaped to be installed in contact with an inside surface of the body member and to fit within a flashing cavity that is substantially defined by the cavity face of the back-up wall or inner wythe, the horizontal leg, the vertical leg, and the positively-sloped drainage leg.

In another embodiment, the end member has an end-facing body portion defined within a plurality of edges and a plurality of side faces extending substantially perpendicularly from respective ones of the plurality of edges of the body portion. Each side face is constructed for attachment to the body member.

In another embodiment, the flashing system includes a quantity of insulation disposed within the flashing cavity, whether contemporaneous with manufacture or with installation of the body member.

In another embodiment, the flashing system includes at least one coupler member having a coupler member positively-sloped leg and a coupler member vertical leg, where the coupler member is sized and shaped to abut inside surfaces of the corresponding positively-sloped drainage leg and the vertical leg of the body member.

In another embodiment, the flashing system includes at least one jamb member having a jamb member face portion and a jamb member body portion extending substantially perpendicularly from the face portion to define an L-shape, and a jamb member tab portion extends substantially perpendicularly from the top margin of the jamb member body portion in a second L-shape, where the tab portion is configured to overlap the header leg of the body member. The jamb member is configured to be installed with the body portion against the jamb of the fenestration opening and the face portion abutting the cavity face of the back-up wall or inner wythe.

In another embodiment, the vertical leg and the vertical transition leg are substantially parallel, thereby defining an angle between the vertical leg and the positively-sloped drainage plane that is an alternate interior angle of a transition angle defined between the vertical transition leg and the positively-sloped drainage leg.

In another aspect of the present invention, a method of flashing a fenestration (e.g., a cavity wall) includes the steps of providing one or more body members each having a planar header leg extending horizontally from a rearward end to a forward end, a vertical leg extending upward from the forward end of the header leg, a positively-sloped drainage leg extending upwardly and rearwardly from a top end of the vertical leg; providing a vertical termination leg extending vertically from a position proximate a rearward end of the positively-sloped drainage leg; and installing the body member(s) along a fenestration header portion with the header leg abutting an underside of a rough opening header of the fenestration header portion and extending forward of a cavity face of an inner wythe or back-up wall of the cavity wall, the vertical leg abutting or positioned in close proximity to a cavity face of an outer wythe or facade of the cavity wall, and the vertical transition leg being fixedly attached to the cavity face of the inner wythe or back-up wall. The method of flashing similarly applies to non-cavity walls, where a cladding or finish material (e.g., stucco or EIFS) is installed against the structure.

In another embodiment, the method includes selecting the body members with the vertical transition leg constructed to abut a cavity face of an inner wythe or back-up wall and including a positively-sloped transition leg extending downwardly and forward from a lower end of the vertical transition leg, where the vertical transition leg and the positively-sloped termination leg define a termination member that is adjustably attachable to the body member with the positively-sloped termination leg overlapping and abutting the positively-sloped drainage leg of the flashing header member. The method also includes installing the vertical termination leg in abutment with the cavity face of the inner wythe or back-up wall and the positively-sloped termination leg overlapping and abutting the positively-sloped drainage leg of the body member.

In another embodiment, the step of providing one or more body members includes selecting the body member(s) having the vertical termination leg being formed as a continuous with the positively-sloped drainage leg of the body member.

In another embodiment, the method also includes providing at least one end member sized and shaped to close a flashing cavity substantially defined by the cavity face of the inner wythe or back-up wall, the horizontal leg, the vertical leg, and the positively-sloped drainage leg, thereby substantially blocking airflow into the flashing cavity; and installing the end member in abutment with an inside surface or an outside surface of the header member.

In another embodiment of the method, the step of providing at least one end member includes selecting the at least one end member comprising an end-facing body defined within a plurality of edges and a plurality of side faces extending substantially perpendicularly from respective ones of the plurality of edges of the end-facing body, wherein the end member is constructed for fixed attachment to the flashing header member.

In another embodiment, the method includes affixing a weep fabric to the vertical leg of each of the one or more body members. In another embodiment of the method, the step of providing one or more body members includes selecting the body member(s) to include a weep fabric affixed to the vertical leg. In some embodiments, the weep fabric extends below a lower end of the vertical leg. In some embodiments, a lower end of the weep fabric defines a plurality of tabs.

In another embodiment, the method includes the step of disposing a quantity of insulation within a flashing cavity substantially defined by the cavity face of the inner wythe or back-up wall, the horizontal leg, the vertical leg, and the positively-sloped drainage leg. In one embodiment, the insulation is a non-combustible insulation, such as mineral wool.

In another embodiment, the method also includes providing one or more jamb members that each include a jamb member face portion, a jamb member body portion extending substantially perpendicularly from the jamb member face portion and defining an L-shape, and a jamb member tab portion extending substantially perpendicularly from a top margin of the jamb member body portion to define a second L-shape. The jamb member(s) is (are) installed with each jamb member body portion abutting a jamb of the fenestration opening, each jamb member tab portion positioned between and abutting the header leg of the body member, and the jamb member face portion abutting the cavity face of the inner wythe or back-up wall of the cavity wall.

In another embodiment, the method includes providing at least one coupler member having a coupler member positively-sloped leg and a coupler member vertical leg, wherein the coupler member is sized and shaped to abut an inside surfaces of the corresponding positively-sloped drainage leg and the vertical leg of the header member.

In another embodiment, the step of providing one or more body members includes selecting each of the one or more body members with the vertical leg and the vertical termination leg being substantially parallel, thereby defining an angle between the vertical leg and the positively-sloped drainage plane that is an alternate interior angle of a transition angle defined between the vertical termination leg and the positively-sloped drainage plane.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiments of the present invention are illustrated inFIGS. 2-9.FIG. 2is a front, side, and top perspective view of one embodiment of a fire shield flashing system100of the present invention. Fire shield flashing system100includes a body member110, a vertically-oriented weep fabric200affixed to a vertical leg120of body member110, a termination member300with a vertical termination leg302that connects body member110to inner wythe612(shown inFIG. 7), and one or more optional end member400. To connect together adjacent body members110and prevent water from seeping through seams between them, fire shield flashing system100optionally includes one or more couplers500, each of which is installed behind and overlapping adjacent body members110.

Although embodiments of fire shield flashing system100are discussed herein with reference to a masonry cavity wall, fire shield flashing system also applies to non-masonry construction having a back-up wall (rather than inner wythe612) and a façade (rather than outer wythe614). Accordingly, it is understood that the terms “back-up wall” and “façade” may be used interchangeably with the terms “inner wythe” and “outer wythe,” respectively.

For the purposes of this disclosure, the terms up and down are used to refer to fire shield flashing system100when it is installed in a fenestration of a cavity wall and oriented as shown inFIG. 2. The terms “forward” and “rearward” are used in this disclosure consistent withFIGS. 2-8, where “forward” means towards the outside of the building and the term “rearward” means towards the inside of the building.

Turning now toFIG. 3, one embodiment of fire shield flashing system100is illustrated in an exploded, perspective view. Body member110includes a planar header leg112that extends substantially horizontally and is sized to extend rearward partially or completely across an underside of rough opening header610of inner wythe612and also extend forward beyond inner wythe612across cavity620towards outer wythe614(shown inFIGS. 7-8). When installed with header leg112on an underside of rough opening header610of a fenestration of a cavity wall, body member110is adjusted to substantially close air cavity620between inner wythe612and outer wythe614.

In one embodiment, body member110is approximately six to twelve inches in length114from rearward end116to forward end118, with a portion of length114extending forward across an underside of a rough opening header610and between zero and about six inches extending across air cavity620towards cavity face614aof outer wythe614(shown inFIGS. 7-8). Length114of header leg112can be sized as needed for the thickness of inner wythe612(i.e., thickness of the underside of rough opening header610) and size of air gap620. Air gap620typically is between zero and six inches. For most effective fire protection, length114is sized to fully cover underside of rough opening header610.

A vertical leg120extends upwardly from forward end118of header leg112. In one embodiment, vertical leg120is about two inches or more in height122from a vertical leg lower margin124to a vertical leg upper margin126. In one embodiment, vertical leg120is the forward-most portion of body member110. When installed, vertical leg120is positioned in air cavity620and in close proximity to, abutting, or in contact with cavity face614aof outer wythe614. As such, body member110extends across air cavity620to substantially close air flow to cavity620. In some installations, body member110is installed with vertical leg120spaced about ⅜ inch or less from cavity face614aof outer wythe614. Any resulting gap between vertical leg120and cavity face614acan be closed with placement of a backer rod and/or intumescent sealant as needed.

A positively-sloped drainage leg130extends upwardly and rearwardly from vertical leg upper margin126and rearwardly towards cavity face612aof inner wythe612(i.e., extending in the general direction as rearward end116, but with an upward slope.) In some embodiments, positively-sloped drainage leg130extends a horizontal distance132sufficient to abut or nearly abut inner wythe612when vertical leg116abuts cavity face614aof outer wythe614. Positively sloped leg130defines an internal angle α with vertical leg120. In one embodiment, angle α is from about 105° to 120°, with some embodiments having angle α of about 105°. A forward end136of positively-sloped drainage leg130is directly connected to or continuous with upper margin126of vertical leg120. Positively-sloped drainage leg130functions as a drainage plane for moisture between inner wythe612and outer wythe614that provides a continuous moisture drainage path away from inner wythe612and down the forward face120aof vertical leg120. As is commonly used on moulding at exterior window sills and the like, a slope of about 15° to a horizontal plane (i.e., 105° to a vertical plane) is adequate to drain water from the structure.

Termination member300is a separate component adapted to join inner wythe612to positively-sloped drainage leg130. Termination member300includes vertical termination leg302and a positively-sloped termination leg312that define an internal angle β. Termination leg302is constructed to interface with positively-sloped drainage leg130. In one embodiment, angle β is substantially equal to angle α. That is, when vertical termination leg302is parallel to vertical leg120, angle α and angle β are alternate interior angles. In other embodiments, angle β is not the same as angle α, but termination member300and body member110together are constructed to interface and optionally be attached together with positively-sloped termination leg312abutting and extending partially along positively-sloped drainage leg130of body member110.

Positively-sloped termination leg312may be attached to or installed in abutment with positively-sloped drainage leg130of body member110. Typically, attaching these members together is accomplished by using mechanical fasteners (e.g., screws, rivets, etc.), an adhesive disposed between abutting portions of these members, or by welding. Other methods known in the art are also acceptable. In some embodiments, termination member300is installed in contact with body member110, but the two members300,110are not connected to each other.

Vertical termination leg302is constructed to be fixedly attached to inner wythe612, such as by using fasteners that extend through pre-defined fastener openings102and into inner wythe612, by using a reglet in inner wythe612, or by using a termination bar24attached to inner wythe612as discussed above. Therefore, termination member300, positively-sloped drainage leg130, and vertical leg120define a moisture drainage path625(shown inFIG. 8) from inner wythe612that extends away from inner wythe612, out, and down from air cavity620.

When termination member300is a separate component, horizontal length132of positively-sloped drainage leg130does not have to be accurately determined in advance for the particular structure in which fenestration flashing system100is to be installed. Instead, since positively-sloped termination leg312overlaps positively-sloped drainage leg130, termination member300allows flexibility in the placement of body member110while also enabling water to drain from inner wythe612onto the drainage plane of positively sloped drainage leg130and out of air cavity620.

To facilitate drainage of water out of air cavity620, weep fabric200is optionally affixed to vertical leg120where it functions as a dedicated pathway for water movement. In one embodiment, positively sloped drainage plane130is contiguous with weep fabric200on vertical leg120. In one embodiment, weep fabric200is or contains natural or synthetic fibers that move water by way of a wicking action or capillary action. Wicking is also known as fiber tow infiltration. In other embodiments, weep fabric200is porous. In contrast to prior-art through-wall flashing and drainage systems, weep fabric200is installed along a vertical face, namely, vertical leg120, where lower fabric end portion204optionally extends vertically below lower margin124of vertical leg120. In some embodiments, lower fabric end portion204extends about ⅛ inch to ½ inch (e.g., ¼ inch) below lower margin124. By extending below lower margin124, lower fabric end portion204is less likely to be covered by caulking or the like, which interferes with water removal from air cavity620. Also, lower fabric end portion204wicks water directly to the ambient air where it can evaporate or drip from weep fabric200.

Optionally, lower fabric end portion204includes a plurality of tabs206that extend vertically downward from weep fabric body202. Due to the increased fabric edge path length along tabbed lower fabric end portion124, such an embodiment has shown to improve water transfer to the ambient compared to a linear edge across weep fabric200. In one embodiment, tabs206are about one inch in width and spaced about eight inches apart. Preferably, tabs206are located at each end of header member110. In one embodiment, tabs206are initially sized intentionally longer than necessary, and then are trimmed after installation to be flush or to extend about ⅛ inch below a cured sealant.

In one embodiment, wicking fabric200is made of polyester, polypropylene, polypropylene nylon, or polyethylene. Wicking fabric200is preferably about 0.050 inches thick and weighs between five and seven ounces/square yard. Wicking fabric200is porous can be either woven or non-woven. A synthetic fiber material is preferred for long life, mildew resistance, and strength. The primary criterion is that wicking fabric200has suitable wicking characteristics to remove water from air cavity620by capillary action. This is unlike fibers such as cotton, which absorb and retain water.

When installed at a fenestration, body member110, including portions of termination member300in some cases, defines a flashing cavity106bounded by inner wythe612and body member110. Prior to installation, during installation, or after installation, flashing cavity106is optionally filled with insulation633(shown inFIG. 8), such as mineral wool insulation or non-combustible insulation. In one embodiment, for example, body member110is provided or purchased with mineral wool insulation633already disposed in and secured as needed within flashing cavity106. Of course, insulation633may be added to flashing cavity106during or after installation.

Disposing insulation633within flashing cavity106buffers the transfer of heat to rigid inner wythe insulation629located above positively sloped drainage plane130. In combination with inner wythe insulation629, insulation633also provides a substantially continuous layer of insulation (shown inFIG. 8) that extends all the way to an underside of rough opening header610of fenestration header portion619. Insulating flashing cavity106also provides a heat shield that slows heat transfer from below body member110to air cavity620in the event of a fire.

To retain insulating material633within cavity106and to also block air and water flow into flashing cavity106, an optional end member400is attached to an open end113of body member110that in part defines flashing cavity106. In one embodiment, end member400has a planar, vertical body portion401sized and shaped to close open end113. One or more side faces402extend substantially perpendicularly from body portion401along respective bottom, front, and upper edges of body portion401. Preferably, one or more side face402is pre-punched with fastener openings102and ready to be attached to body member110. For example, one or more end members400are connected to body member110by using fasteners that extend through a fastener opening102in end member400that aligns with a corresponding fastener opening102in vertical leg120, positively-sloped leg130, and/or header leg112. Optionally, a sealant, an adhesive, a caulk, or the like is used between end member400and body member110in conjunction with or in place of fasteners. A sealant can further reduce or eliminate air flow into flashing cavity106through seams between body member110and end member(s)400.

In one embodiment, body portion401of each end member400substantially has the same cross-sectional size and shape as that of flashing cavity106, which is typically a quadrilateral. Thus, end member400can be installed within flashing cavity106with at least one of side faces402abutting header member110and/or cavity face612aof inner wythe612. In some embodiments, body portion401substantially matches the cross-sectional shape of flashing cavity106where positively-sloped drainage leg130and vertical leg120are curved or define another shape.

In some embodiments, end member also includes a vertical tab403extending substantially perpendicularly in an upward direction from upper side face402c. Vertical tab403is substantially parallel to and laterally spaced apart from body portion401by upper side face402c. Preferably, vertical tab403has an upper margin403athat is parallel to upper edge of body portion401. Vertical tab403guides water to positively-sloped drainage leg130rather than flowing over open end113, where it may drip or enter cavity106.

In some embodiments, a plurality of body members110are used to span the width of underside of rough opening header610. In these cases, a flashing coupler member500is optionally positioned to overlap and is connected to neighboring body members110. For example, coupler member500has coupler member header leg512, coupler member vertical leg520, and coupler member sloped leg530that correspond respectively to header leg112, vertical leg120, and positively-sloped drainage leg130of body members110. Accordingly, coupler member500is positioned to abut the inside surface110aof neighboring body members110, thereby substantially closing a gap between these members. Optionally, a sealant or an adhesive is used at the mating faces between coupler member500and body members110to ensure a watertight seal.

To facilitate connection of components and installation of fire shield flashing system100, a plurality of optional pre-punched, pre-machined, or pre-formed fastener openings102are defined in body member110, termination member300, end member400, jamb member450, coupler member500, and/or any other member of fire shield flashing system100. Fastener openings102can be holes, slots, or have other shapes. Fastener openings102preferably extend through a member, but optionally are formed as a knockout or mere indentation with a thickness suitable for sheet metal screws or other fastener. In one embodiment, fastener openings102on downwardly-sloping transition leg312and on positively-sloped leg130are slots, thereby permitting adjustable positioning and connection of these members. Fastener openings102in one member (e.g., body member110) correspond to fastener openings102in another member (e.g., end member400), which facilitates easy and rapid installation of fire shield flashing system100.

Referring now toFIG. 4, a front perspective view illustrates one embodiment of a jamb member450shaped to be installed along the jamb adjacent an upper left fenestration corner. Since jamb member450for an upper right corner of fenestration is symmetrical to jamb member450for an upper left corner of fenestration, only the upper left jamb member450is discussed. In some embodiments of fenestration flashing system100, jamb members450are installed on the jamb adjacent one or both upper corner of the fenestration. Each jamb member450protects the jamb and cavity surface612aof the inner wythe612at the upper corner of a fenestration605. In the event of a fire, jamb member450helps prevent burning or scorching and reduces heat transfer to insulation and structural members at corners of a fenestration.

In one embodiment, jamb member450substantially has an L-shape that includes a jamb member face portion452extending transversely from a jamb member body portion454. Jamb member face portion452is constructed to abut cavity surface612aof inner wythe612at an upper corner of fenestration605. In one embodiment, jamb member face portion452has a rectangular shape, but may have other shapes, such as an inverted right triangle. When installed, jamb member body portion454extends rearwardly into fenestration605towards the inside of the building. In one embodiment, a jamb member tab456extends perpendicularly from a top margin454aof jamb member body portion454, where jamb member tab456is configured to extend slightly along header and overlap body member110. Preferably, jamb member tab456defines one or more fastener openings102that correspond to fastener opening(s)102on header leg112of body portion110.

As shown inFIG. 4, jamb member face portion452is a rectangle with the same height as jamb member body portion454and that does not extend vertically above top margin454a. In other embodiments as shown inFIG. 4A, jamb member face portion452has an inverted L-shape with one leg452athat extends along the jamb and laterally away from the fenestration opening. Another leg452bextends above top margin454aand along fenestration opening. Thus, jamb member face portion452protects cavity surface612of inner wythe612from flames that lick up and around the upper corners of the fenestration.

Referring now toFIG. 5, another embodiment of body member110′ is illustrated in front, side, and top perspective view. Here, body member110′ is a single, contiguous piece of metal that includes vertical termination leg302. Vertical termination leg302extends vertically from a lower end306that is connected to a rearward end134of positively-sloped drainage leg130. In one embodiment, vertical termination leg302extends about two to four inches vertically from lower end306to an upper end304; other suitable dimensions are acceptable. In the embodiment shown inFIG. 5, vertical termination leg302is a continuous with and extends from positively-sloped drainage leg130. This monolithic embodiment differs from other embodiments discussed above in which vertical termination leg302is part of termination member300that is a separate component of fenestration flashing system100and that also includes a positively-sloped termination leg312for overlapping positively-sloped drainage leg130of body member110when installed.

Referring now toFIG. 6, a perspective view illustrates embodiments of an optional internal heat shield member600and optional internal jamb member650. Internal heat shield member600has a header leg602sized and configured to abut the rough opening header and overlap or abut header leg112of body member110. An interior vertical leg604extends perpendicularly from header leg602in an upward direction to abut the interior framing members of the fenestration opening. Preferably, header leg602and interior vertical leg604of internal heat shield member600are pre-punched with one or more fastener openings102. Internal heat shield member600enables fire shield flashing system100to completely cover the header of a fenestration while also allowing for easy adjustment to variations in wall thickness.

Like internal heat shield member600, internal jamb member650provides an extension of jamb member body portion454of jamb member450along the jamb of a fenestration. Internal jamb member has a internal jamb member body portion652and an internal jamb member face portion654that extend at right angles to one another in an L shape. Internal jamb member body portion652is sized to extend along the jamb to abut or overlap body portion454of jamb member450. Internal jamb member face portion654is configured to abut the internal framing of the fenestration. As with other components, it is preferred that internal jamb member650is pre-punched with one or more fastener openings102.

Referring now toFIGS. 7 and 8, a side sectional view and a perspective view, respectively, are illustrated of a portion of one embodiment of a cavity wall600with one embodiment of fenestration flashing system100installed at fenestration605between inner wythe612and outer wythe614. A lintel621supports masonry members618of outer wythe614with outer wythe614being spaced apart from inner wythe612by air cavity620. In one example, air cavity620is about four inches from cavity surface612aof inner wythe612to cavity surface614aof outer wythe614. For clarity, jamb member450is not shown inFIG. 7.

Body member110is installed on inner wythe612with header leg112positioned below and abutting fenestration header portion619of inner wythe612. Header leg112of body member110extends forward towards outer wythe614and turns upward forming vertical leg120, to which weep fabric200is affixed. Header leg112extends rearward at least partially along underside of rough opening header610to interior insulation, framing, or finish materials (e.g., drywall). For example, header leg112extends rearward (i.e., towards the inside) along underside of rough opening header610at least two inches. Interior heat shield member600is attached to rough opening header610with header leg602overlapping header leg112and secured by a fastener99. Interior vertical leg604is secured by fastener99to inside face of rough opening header610.

Vertical leg120(with weep fabric200affixed thereto) is in close proximity to (e.g., about ⅜ inch or less) or abuts lintel621and/or cavity face614aof outer wythe614. When vertical leg120abuts lintel621(or inner face614aof outer wythe614, when no lintel621is present), air flow access into air cavity620is blocked, thereby reducing the ability of fire to spread through air cavity620. Weep fabric200extends below lower margin124of vertical leg120to vacate water down and out of cavity wall600behind outer wythe614.

Positively-sloped drainage leg130extends upwardly and rearwardly at angle α from vertical leg120towards cavity surface612aof inner wythe612. In the embodiment shown inFIG. 7, positively-sloped drainage leg130may or may not extend sufficiently to contact cavity surface612a. Accordingly, separate termination member300is attached to cavity surface612aof inner wythe612and optionally to positively-sloped drainage leg130, thereby defining a continuous path625(shown inFIG. 8) for water in air cavity620to travel down and out of air cavity620via positively-sloped drainage leg130and vertical leg120with weep fabric200. By draining water out and down from air cavity620, rather than horizontally through outer wythe614, fenestration flashing system100improves the aesthetic appeal of the façade by reducing or eliminating staining caused by water drainage, particularly when the water contains contaminants.

Inner wythe insulation629(e.g., rigid fiberglass board) is installed against cavity surface612aof inner wythe612and optionally contacts positively-sloped transition leg312and/or positively-sloped drainage leg130. Flashing cavity106of fire shield flashing system100is filled with non-combustible flashing cavity insulation633(e.g., mineral wool insulation). With inner wythe insulation629installed along cavity surface612aand flashing cavity insulation633disposed in flashing cavity106, cavity wall600is insulated substantially continuously to underside of rough opening header610. End member400(not shown inFIG. 7for clarity; shown inFIG. 8) is installed in flashing cavity106to hold insulation633in place as well as to block air flow into flashing cavity106. As shown inFIG. 8, jamb member450is installed at the upper left corner of fenestration605with jamb member face portion452against cavity surface612aof inner wythe612.

Referring now toFIG. 9, a method800of flashing a fenestration605of a cavity wall600is now described. In some embodiments, cavity wall600is a masonry wall, however, method800applies to cavity walls600with claddings made of other materials. Although method800is described for cavity wall600, flashing system100of the present invention may similarly be installed on non-cavity walls, such as EIFS and stucco finishes. For example, in non-cavity construction, the exterior cladding assumes the role of the façade or outer wythe614and is installed in abutment with insulation629or the back-up wall or inner wythe612. Similar to as shown inFIG. 7, this could be where gap620is completely filled with insulation or where the cladding (e.g., EIFS instead of bricks618) is installed against face612aof a back-up wall or inner wythe612.

In step805, one or more body members110are provided, where each body member110has a planar header leg112extending horizontally from a rearward end116to a forward end118, a vertical leg120extending upward from forward end118of header leg112, and a positively-sloped drainage leg130extending upwardly and rearwardly from a top end134of vertical leg120.

Optionally, one or more body members110′ may be selected instead of body members110. Flashing body member(s)110′ include a vertical termination leg302extending vertically from a rearward end134of positively-sloped drainage leg130. For example, vertical termination leg302is continuous with and integrally attached to positively-sloped drainage leg130of body member110. In another embodiment as discussed below in steps815and820, vertical termination leg302is part of termination member300.

Whether selecting body member110or body member110′, there is the option of having a weep fabric200affixed to the vertical leg120. In one embodiment, weep fabric200is sized to have a lower end204extend below the forward end of the header leg112. Optionally, weep fabric200includes a plurality of tabs206along a lower end204.

When more than one body member110is required to span a fenestration opening, one or more coupler members500are provided as noted in step810. Each coupler member500has coupler member positively-sloped leg530and coupler member vertical leg520, where the coupler member500is sized and shaped to abut an inside surface110aof the corresponding positively-sloped drainage leg130and the vertical leg120of body member110. Each coupler member500may optionally include coupler member header leg512.

In step815, the flashing header member(s)110or110′ are installed along a fenestration605with header leg112abutting underside of rough opening header610and extending forward of a cavity face612aof a back-up wall612of the cavity wall600and the vertical leg120abutting or positioned in close proximity to a cavity face614aof a façade614of the cavity wall600. When an optional weep fabric200is attached to vertical leg120, vertical leg120is considered to be abutting back-up wall612when weep fabric is in contact with back-up wall612whether or not vertical leg120directly contacts back-up wall612. The flashing header member(s)110or110′ extend from a first upper corner (e.g., upper left corner) to a second upper corner (e.g., upper right corner) of the fenestration. When one or more body members110or110′ are installed in a single fenestration, optional coupler members500may be provided where a coupler member500is installed between neighboring body members110or110′, as the case may be.

In step825, positively-sloped termination leg304is positioned to overlap and abut positively-sloped drainage leg130of body member110. In one embodiment, positively-sloped termination leg304is fixedly attached to positively-sloped drainage leg130of body member110, such as by using fasteners, adhesive, welding, or other method known in the art of sheet metal fabrication.

In step830, vertical termination leg302is fixedly attached to the cavity face612aof the back-up wall612.

In step835, insulation is optionally disposed in the flashing cavity. In either case where body member110or body member110′ is used, a quantity of optional, non-combustible insulation633is disposed within flashing cavity106substantially defined by the cavity face612aof the back-up wall612, horizontal leg112, vertical leg120, and positively-sloped drainage leg130. Step835may be performed contemporaneously with forming body member110or with installation of body member110.

In step840, one or more end members400is optionally provided, where each end member400is sized and shaped to close a flashing cavity106substantially defined by cavity face612aof the back-up wall612, horizontal leg112, vertical leg120, and positively-sloped drainage leg130of body member110,110′, thereby substantially blocking airflow into flashing cavity106. In one embodiment of the method, end member(s)400have a body portion401and a plurality of side faces402extending substantially perpendicularly from a corresponding edge of body portion401, where each side face402is constructed for fixed attachment to the body member110.

In step845, end member(s)400are installed on body member110,110′ so as to close or substantially close an opening to flashing cavity106. In one embodiment, end member400is installed in abutment with an inside surface110aof body member110. Attachment may be accomplished using fasteners, adhesive, or other methods known in the art of sheet metal fabrication.

In step850, weep fabric200is optionally installed if it is not present. As when selecting a body member110,110′ without the optional weep fabric already affixed to the vertical leg120, a weep fabric may be affixed to vertical leg120of each body member110,110′. In one embodiment, weep fabric200is optionally sized to extend below forward end118of the header leg112. In another embodiment, weep fabric200includes a plurality of tabs206along a lower end204.

In step855, one or more jamb members450optionally are provided. Jamb member(s)450include a jamb member face portion452and a jamb member body portion454.

Fenestration flashing system100interrupts, redirects, and stops water from entering a fenestration header portion and thereby protects fenestration header portion from water dams. Components of fenestration flashing system100are made of stainless steel, such as stainless steel sheet metal having a gauge of 22, 24, 26, or 28.

The life expectancy of stainless steel is approximately 100 years or more and is UV stable, waterproof, weather resistant, will not soften or drool, and is compatible (i.e., inert) with a full range of sealants. The quick-connect joints with pre-defined fastener openings102allows for secure coupling and joining of system components. Consistent spacing and hole sizes of fastener openings102are pre-defined in the factory, so fenestration flashing system100can be assembled by low-skill-set tradespeople. Fenestration flashing system100also enables installation compliance to be done prior to installation of the exterior façade. Fenestration flashing system100supports membrane flashing overlays, such as through-wall masonry flashing.