Patent Publication Number: US-2010107352-A1

Title: Exterior insulation and finish system and method and tool for installing same

Description:
This application is a divisional of U.S. application Ser. No. 11/166,563 filed on Jun. 24, 2005 which is still pending and the disclosure of which is incorporated hereinto in its entirety by reference. 
    
    
     The present exemplary embodiments relate to the construction arts. They find particular application in conjunction with exterior insulation and finish systems (EIFS), and to a hand tool for use therewith, and will be described with particular reference thereto. However, it is to be appreciated that the present exemplary embodiments are also amenable to other like applications. 
     BACKGROUND 
     Basic drainage type exterior insulation and finish systems (EIFS) and construction techniques therefor are well known in the art. In the general case, as shown in  FIG. 1 , exterior insulation and finish systems are applied over a first layer of a sheathing substrate which is normally applied to the exterior of a building under construction. The sheathing  12  may be a gypsum sheathing, exposure oriented strand board (OSB), exterior or exposure  1  grade plywood, or cementitious materials. EIFS may also be applied over other masonry substrates such as cement masonry unit blocks or bricks. 
     Using a paint roller, an adhesive and seal layer  14  is applied onto the first layer  12  of sheathing. Preferably, the adhesive is water based and fast drying and, once dried, is flexible so as to bridge normal movement in the first layer  12 . The adhesive and seal layer  14  forms a weather proof seal for the first layer  12 . 
     After drying, an insulation board  16  is adhered to the first layer  12  by the adhesive and seal layer  14 . In the prior art system illustrated, the insulation board  16  is special in that it includes a plurality of grooves  18  provided for purposes of conducting fluid which may accumulate between the insulation board  16  and the first layer  12 . 
     An initial base coat  20  is then applied to the surface of the insulation board  16  opposite the surface which is secured to the substrate layer  12  by the adhesive and seal layer  14 . The initial base coat may be applied over the insulation board with spray equipment or a trowel to a uniform thickness. Next, a mesh layer  22  is immediately embedded in the wet base coat  20  by troweling or using other techniques. An additional base coat  24  may be applied over the surface of the mesh material  22  as needed and, lastly, a finish coat  26  is applied to the base coat  24  by spraying or troweling, depending on the specific finish desired. 
     Although drainage type EIFS of the type described above have been very successful, some limitations in application have been encountered. More particularly, the insulation board  16  must either be provided with a plurality of grooves  18 , or have some other means in order for the system to properly conduct fluid. Also, during installation, the grooved insulation board  16  must be oriented in the proper direction with the grooves  18  oriented vertically and facing the sheathing substrate  12  of the structure. Still further, although the system described above functions to conduct fluid, care is required in order to position ends of insulation boards  16  so that the grooves  18  formed are in alignment to provide a continuous fluid evacuation conduit. Also, a delay is necessary to allow the seal coating to fully cure prior to adhering the insulation board. Such a delay is usually a minimum of 24 hours and can result in additional costs to the contractor both in delays as well as costs of providing weather protection for the additional time cause by the delay. 
     Lastly, if construction workers are impatient or for other reasons apply the insulation board  16  onto the sheathing  12  before the adhesive layer  14  is adequately cured, the adhesive layer material could migrate into the grooves  18  formed in the board  16  and thereby obstruct the fluid path. 
     Accordingly, there is a need for an improved method and tool for installing exterior insulation and finish systems which overcomes the above limitations and others and provides an inexpensive and convenient solution thereto. 
     BRIEF DESCRIPTION 
     In accordance with one aspect of a first present exemplary embodiment, a drainage type exterior insulation and finish system for a building is provided. The system is applied over a sheathing substrate and includes an insulation board, a single adhesive and sealing layer, a base coat, a mesh layer, and a finish layer. The sheathing substrate is adapted for attachment to a frame of an associated building or other structure. The single adhesive and sealing layer adhesively secures the insulation board to the sheathing substrate. The layer is disposed between the sheathing substrate and the insulation board and defines at least one via adapted to conduct fluid such as water for example. The base coat is applied onto the insulation board, followed by a mesh layer, and then a finish layer. In its preferred form, the sheathing substrate has a flat front face and the insulation board has opposite flat front and rear faces. The flat rear face of the insulation board is oriented toward the flat front face of the sheathing substrate with the at least one via being defined by the single adhesive and sealing layer and disposed between the sheathing substrate and the insulation board. In another form, a plurality of viae are defined in the single adhesive and sealing layer to conduct fluid therethrough. 
     In accordance with an aspect of a second exemplary embodiment, an exterior insulation and finish system for use with associated insulation and substrate layers of a building is provided. The exterior insulation and finish system includes primary and secondary water resistive barriers. The primary water resistive barrier is disposed on a first surface of the associated insulation layer. The secondary water resistive barrier is disposed on a second surface of the associated insulation layer. The secondary water resistive barrier includes a single adhesive and sealing layer defining at least one channel and adhesively securing the second surface of the associated insulation layer to the associated substrate layer. In one form, the single adhesive and sealing layer defines a plurality of channels, each being adapted to conduct fluid therethrough. The channels are formed between the second surface of the insulation layer and a surface of a groove provided in the single adhesive and sealing layer. 
     In accordance with an aspect of another exemplary embodiment, an exterior insulation and finish system for a building is provided. The system is applied over a sheathing substrate for attachment to a frame of an associated building, and includes first and second insulation boards, a single adhesive and sealing layer securing the insulation boards to the sheathing substrate and defining at least one via adapted to conduct fluid, a base coat, a mesh layer, and a finish layer. The at least one via defined by the single adhesive and sealing layer extends from a first location disposed between the sheathing substrate and the first insulation board to a second location disposed between the sheathing substrate and the second insulation board. In that way, at least one via is provided between the insulation boards and the sheathing substrate and extending between the first and second insulation boards. In another form, the at least one via extends uninterrupted from the first location to the second location. Still further, a plurality of viae are provided. They are defined by the single adhesive and sealing layer and extend uninterrupted from the first location to the second location. 
     In accordance with a still further aspect of another exemplary embodiment, an exterior insulation and finish system is provided for use with associated first and second insulation panels applied over an associated substrate layer of a building. The system includes primary and secondary water resistive barriers. The primary water resistive barrier is disposed on a first surface of the associated first and second insulation panels. The secondary water resistive barrier is disposed on a second surface of the associate first and second insulation panels. The secondary water resistive barrier includes a single adhesive and sealing layer defining at least one channel and adhesively securing the second surface of the associated first and second insulation panels to the associated substrate layer with at least one edge of each of the first and second insulation panels being in substantial abutment. The at least one channel extends from the first insulation panel to the second insulation panel and is adapted to conduct fluid therethrough. 
     Still further, in accordance with yet another aspect of an exemplary embodiment, a hand tool is provided for working an adhesive and sealing layer in an exterior insulation and finish system. The hand tool includes a flat inflexible rectangular plate connected with a handle. At least a first one of the longer edges of the inflexible rectangular plate is upwardly curved and includes a plurality of spaced apart teeth. In use, the plurality of teeth form grooves defining the viae and channels described above for conducting fluid between the sheathing substrate and the insulation board. Preferably, the plurality of spaced apart teeth are defined by a plurality of notches formed in the longer edge of the rectangular plate of the hand tool. In their preferred form, the plurality of notches include an elongate first section having a substantially uniform predefined width terminating at a rounded bight having a diameter substantially conforming to the uniform predefined width of the first section of the notches. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may take form in certain components, structures, and steps, the preferred embodiments of which will be illustrated in the accompanying drawings. 
         FIG. 1  is a schematic representation of various layers forming a drainage type exterior insulation and finish system of the prior art; 
         FIG. 2  is a schematic representation of the various layers forming the drainage type exterior insulation and finish system of the present application; 
         FIG. 3  illustrates application of an adhesive sealer onto a layer of sheathing substrate using a hand tool in accordance with the present application; 
         FIG. 4  is a cross-sectional illustration taken along line  4 - 4  of  FIG. 3 ; 
         FIG. 5  is a cross-sectional illustration taken along line  5 - 5  of  FIG. 3 ; 
         FIG. 6  is a perspective view of a hand tool formed in accordance with the present application; 
         FIG. 6   a  is an enlarged view of portion A from  FIG. 6 ; 
         FIG. 7  is a cross-sectional view taken along line  7 - 7  of  FIG. 2 ; and, 
         FIG. 8  is a schematic representation of various layers forming a drainage type exterior insulation and finish system using a plurality of insulation boards in accordance with the present application. 
     
    
    
     DETAILED DESCRIPTION 
     The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. 
     With reference to the drawings in general, and to  FIG. 2  in particular, an exterior insulation and finish system (EIFS) embodying the teachings of the subject invention is generally designated at  30 . With reference to its orientation in  FIG. 2 , the exterior insulation and finish system  30  is applied onto an associated sheathing substrate  32  which normally forms the exterior of a building under construction. The sheathing  32  may be gypsum sheathing, oriented strand board (OSB), exterior plywood, or other cementitious materials. In addition, the exterior insulation and finish system of the present application is equally applicable to other associated building substrates such as masonry, cement, cement masonry unit blocks, and the like. 
     The exterior insulation and finish system includes an adhesive and sealing layer  34  that is applied to the sheathing or other outer layer  32  of the associated building using a hand tool, the details and use of which will be described in greater detail below. Preferably, the adhesive is 100% water based and fast drying so as to decrease installation time. Preferably, the adhesive and sealing layer  34  is a polymer modified cementitious material available from Dryvit Systems, Inc. Once dried, the adhesive and sealing layer is preferably sufficiently flexible so as to permit normal movement and bridge across gaps in the sheathing layer  32 . The adhesive and sealing layer  34  forms a water resistant seal for the sheathing layer  32 . More particularly, as illustrated, the adhesive and sealing layer  34  is applied onto the outer layer  32  of the associated building (not shown) in a manner to result in a first portion  38  of material having a substantially uniform thickness to completely cover the substrate  32 , and a second portion  40  having a nonuniform thickness to provide at least one via  42  for conducting fluids therethrough. 
     Immediately following the application of the adhesive and sealing layer  34  of the present EIFS, an insulation board  44  element of the EIFS having a flat front face  46  is adhered to the first sheathing layer  32  by the adhesive and seal layer  34 . Simple hand pressure is applied over the entire insulation board surface to ensure a complete bond. It is to be appreciated that many types of insulation boards can be used equivalently including polyisocyanurate board and others. 
     A further element of the EIFS includes an initial base coat  50 . The initial base coat is applied to the flat outer surface  48  of the insulation board  44  which is secured to the substrate layer  32  by the adhesive and seal layer  34 . The base coat  50  is applied over the insulation board using spray equipment, a trowel, or the like, to realize a uniform thickness of approximately 1/16 of an inch. 
     Another component of the EIFS includes a mesh layer  52 . The mesh layer is embedded into the base coat  50  while it is wet by troweling from the center of the mesh toward the outer edges. In some cases, additional base coat material  54  may be applied over the surface of the mesh material  52  in order to ensure that the mesh is completely embedded into the base coat  50 . 
     Lastly, a further component of the EIFS includes a finish coat  56  of an acrylic base or silicone enhanced textured wall coating applied onto the base coat  54 . The finish coat  56  is applied by spraying, rolling, troweling, or the like, depending on the specific finish desired. 
     In  FIG. 3 , the adhesive and sealing layer  34  is shown being applied onto a substrate layer  32  which, in this example, is exterior plywood of an associated building (not shown). The adhesive and seal layer  34  is applied using a hand tool  100  preferably formed as a trowel  102  having a flat inflexible rectangular plate  104  and a handle  106  as illustrated. The hand tool  100  will be described in greater detail below. 
     With continued reference to  FIG. 3 , the hand tool  100  includes a toothed bent edge  108  adapted to form a series of ridges  60  and valleys  62  in the adhesive and sealing layer  34  applied onto the sheathing layer  32  as the hand tool  100  is dragged therealong in the direction marked D in the figure. As can be seen, the ridges  60  and valleys  62  are formed in an alternating pattern beneath the tool as the edge  108  moves through the moist adhesive and sealing layer  34 . 
     With continued reference to  FIG. 3  but with additional reference to  FIGS. 4-6 , the subject hand tool  100  includes a flat substantially inflexible rectangular plate  104  and a handle  106 . A first edge  110  of the longer edges of the rectangular plate  104  is upwardly curved as shown in  FIGS. 5 and 6 . Preferably, the second edge  112  of the longer edges of the rectangular plate  104  is substantially planar together with the plate  104 . However, the second edge could be bent upwardly as well, likewise the shorter edges  116 ,  118 . A plurality of spaced apart teeth  120  are defined along the first edge  110  of the plate  104 . The teeth  120  are formed between notches  122  provided in the plate at desired spaced apart locations. Preferably, as illustrated, the plurality of spaced apart teeth  120  are formed substantially along the entire length of the first edge  110  of the plate  104 . With specific reference to  FIG. 6   a , each of the notches  122  includes an elongate first section  124  having a substantially uniform predefined width w. Each of the notches  122  terminate at a rounded bight  126  having a diameter d substantially conforming to the uniform predefined width w of the elongate first section  124 . It is to be appreciated that other shapes and sizes of notches can be provided as desired. 
     The subject exterior insulation and finish system  30  is installed onto the substrate  32  of the associated building using a hand tool  100 , preferably the trowel  102  described above, by dragging the trowel across an adhesive and sealing layer  34  applied onto the sheathing layer  32 . The trowel both “plows” through and “floats” on a thick layer  130  of adhesive and sealing material as shown in  FIGS. 4 and 5 . The upwardly curved portion  114  of the rectangular plate  104  “floats” the plate  104  along the material  130  as the trowel is dragged therealong in the direction D leaving behind a first portion  132  of adhesive and sealing layer  34  having a substantially uniform thickness to completely cover the associated substrate layer  32 . Correspondingly, the notches  122  provided along the first edge  110  permit the formation of a series of ridges  60  to be formed as the tool is used thus creating a second portion  134  of adhesive and sealing layer  34  formed on the associated sheathing layer  32 . In that way, at least one via  64  is created by the valleys  62  defined between the ridges  60  formed by the hand tool  100 . 
     More particularly, with reference next to  FIG. 7 , a plurality of channels  140  are formed at the interface between the flat front face  46  of the insulation board  40  and the first portion  132  of the adhesive and sealing layer  34 . The channels  140  are adapted to conduct fluid therethrough. It is also important to point out, however, that the first portion  132  of adhesive and sealing layer  34  has a substantially uniform thickness to completely cover the associated substrate layer  32 . This provides a safe and secure secondary water barrier coating. As described above, however, additional primary coatings can be formed onto the flat outer face  48  of the insulation board such as by adding a base coat  50 , mesh layer  52  and one or more additional base coats  54 ,  56  ( FIG. 2 ). 
       FIG. 8  illustrates another advantage of the subject EIFS system  30  applied to an associated wall assembly  32 . A plurality of individual channels  150  are formed between an associated sheathing layer  32  and a plurality of insulation boards  44  including an upper or first insulation board  152  and a lower or second insulation board  154 . As shown there, a single adhesive and sealing layer  34  secures the first and second insulation boards  152 ,  154  to the associated sheathing layer  32 . A first edge  156  of the first insulation board  152  is disposed proximate the first edge  158  of the second insulation board  154 . At least one via  160  is formed in the adhesive and sealing layer  34  using a hand tool  100 , preferably of the type described above. The at least one via  160  extends from a first location  162  between the sheathing substrate  32  and the first insulation board  152 , to a second location  164  located between the sheathing substrate  32  and the second insulation board  154 . Preferably, a plurality of channels  166  are formed for conducting fluids from a first location  170  above the insulation boards  152 ,  154  to a second location  172  located beneath the insulation boards  152 ,  154 . In that way, fluid conduction away from the area between the insulation boards and the sheathing substrate is provided. 
     The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.