Patent Abstract:
A flood proof window includes a glazing and a window frame having a glazing backstop. Dual sided tape is positioned between the glazing and the glazing backstop. The window is further provided with a glazing sealant for the glazing.

Full Description:
[0001]    This application is a divisional of application Ser. No. 12/427,069 filed on Apr. 21, 2009. 
     
    
     BACKGROUND OF INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    This invention relates to protecting wood frame and light gauge steel frame buildings from damage by flood water intrusion into the interior of the building. More particularly, method and materials for preventing water from passing through walls, windows and window openings and doors and door openings of buildings are provided. 
         [0004]    2. Description of Related Art 
         [0005]    According to the Federal Emergency Management Administration of the U.S. government (FEMA) and the National Flood Insurance Program (NFU), flash flooding is the most common natural disaster in the U.S. One-third of flood loss claims paid are in “low-risk” areas, and the average flood loss claim payment is $42,000. 
         [0006]    For many years, flood protection methods have been developed and used in protection of commercial, institutional and high-rise multi-family residential buildings. Temporary flood barriers and gates have been developed as an improvement to sand bags to keep rising surface water out of buildings, but there is a need for a “passive” method and corresponding materials for flood proofing wood frame and light-gauge steel frame buildings. A passive method of flood protection is defined as one that does not require human intervention to prevent interior flooding of a building during an unexpected flood event—one that prevents intrusion of rising water into an exterior building envelope. Such method and materials should be applicable to retrofit existing residences, small commercial buildings and other types of structures that are built on concrete slabs and that utilize wood structural framing or light-gauge steel framing in exterior walls. In addition, such method and materials should be applicable to various veneer wall finish materials, i.e. masonry, stucco, and wood or composite siding materials or to new construction. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    Method and materials are provided for sealing the exterior of a building built on a concrete slab to a selected height above the slab. Window frames are sealed and special construction of windows extending below the selected height is provided. Door frames are sealed and special construction of doors extending below the selected height is provided. Doors open outwardly from the building walls. Walls are sealed by waterproof panels that are sealed to the slab. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S 
         [0008]      FIG. 1  is a typical front elevation view of a house having a masonry veneer substrate that has been flood protected using method and materials disclosed herein. 
           [0009]      FIG. 2  is a perspective view of a wall and window, with a cut-away view of the wall over a masonry veneer substrate. 
           [0010]      FIG. 3  is a detailed cross-section view of a window and frame disclosed herein, 
           [0011]      FIG. 4  is an elevation view of the exterior door disclosed herein. 
           [0012]      FIG. 5A  is a lower cross-section view of the exterior door and frame disclosed herein.  FIG. 5B  is an enlarged cross-section view of the exterior door showing gasket seals. 
           [0013]      FIG. 6  is a perspective view of a masonry veneer substrate wall with flood proofing wainscot and an exterior door. 
           [0014]      FIG. 7  is a perspective cut-away view of a masonry veneer wall substrate made flood proof according to one embodiment of method and materials disclosed herein. 
           [0015]      FIG. 8  is a perspective cut-away view of a horizontal siding wall substrate made flood proof according to one embodiment of method and materials disclosed herein. 
           [0016]      FIG. 9  is a perspective cut-away view of a stucco wall substrate made flood proof according to one embodiment of method and materials disclosed herein. 
           [0017]      FIG. 10  is a perspective view of a newly constructed wood framed wall with new cementitious wet-board wall surface installed and exposed, prior to future masonry veneer installation, made flood proof according to one embodiment of method and materials disclosed herein. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0018]      FIG. 1  shows the typical front elevation of a house with masonry veneer substrate protected from flood waters by the method and materials disclosed herein. House  10  has windows  12 , door  14 , exterior masonry veneer substrate  16 , which may also be stone, siding, or stucco, for example, and concrete slab  19 . Methods and materials disclosed herein allow the windows  12 , door  14  and exterior veneer finish  16  of house  10  to be made impervious to rising water to a selected height H, above concrete slab  19  by installing flood proof sections of windows  12  and flood doors  14  to the height H and by forming flood proof wainscot  18  exterior to veneer  16  to height H. A system for flood proofing a structure such as a house must include flood proofing the exterior veneer  16  and all openings in the structure to height H. A residential structure is illustrated in  FIG. 1 , but the structure may also be a warehouse, office structure, shopping center, church, or any other structure built on a concrete slab. 
         [0019]    The height H of the wall surface to be flood-protected is preferably selected according to anticipated flood conditions that may be experienced and the load-bearing capacity of the frame of the building. The height to be flood protected will usually not be greater than 3 feet above the concrete slab  19  on wood frame and light-gauge steel frame buildings, because of the limited strength of the structural frame. Strength enhancement options for increased flood height requirements may be installed, allowing an increase in height H. 
         [0020]    The order of application of the materials disclosed here may vary; the method and materials will be described here beginning with the installation of replacement flood windows in an existing structure. New construction methods will also be described in  FIG. 10  to the extent that they diverge from procedures for retrofitting an existing structure. 
         [0021]    Referring to  FIG. 2 , replacement window assembly  20  is shown, which is a custom flood window unit having glazing  22 , which is preferably laminated high impact-resistant safety glazing, with hydro-sealing of the glazing into the vinyl frame segment  27   a , as will be described in more detail below. Frame segment  27   b  may be a conventional frame structure with standard residential glazing features. Replacement window assembly  20  is installed after an existing window has been removed from the rough opening. Glazing  22  extends from the bottom sill of window  20  to height H. Horizontal mullion  24  divides glazing  22  from conventional window structure  26 . Frame  27  a and b may be formed from fusion-welded vinyl material, which is standard in the residential window industry. 
         [0022]      FIG. 3  shows a horizontal detailed cross-section view of a window and frame assembly and of the hydro-sealing structure for glazing  22 . The frame may be fastened into the existing rough window opening with 3-inch side-mounted coated wood screws  39 . The perimeter of replacement window assembly  20  is caulked, preferably with 100% silicone glass block caulking  35   a  between rough framing members and vinyl frame segment  27  a and b, and then surface caulked with an elastomeric acrylic waterproof caulk and sealant  35   b , such as PERMAPATCH, available from Nationwide Coating Mfrs., Inc. of Sarasota, Fl (herein “Nationwide”). To provide further sealing, a 2-inch adhesive flashing strip  36 , such as Grace Vycor flashing, Quick Roof Flashing, available from Cofair Products, Inc., or equal, is heat applied and overlaid by a continuous filament, spun-laced fabric membrane  37 , such as PERMATAPE, available from Nationwide. Fabric membrane  37  is saturated and sealed with an elastomeric waterproofing adhesive bonding primer, such as ACRYLOPRIME sealer (available from Nationwide), overlapping the outer edge of the vinyl window frame and the adjacent wall substrate surface, preferably a minimum of ½ inch on the window frame and 1 inch on the adjacent wall substrate. The above process should be repeated for all window elements extending below height H until the window retrofit procedure has been completed. 
         [0023]    Window frame segment  34  is an extruded portion of the frame assembly, designated the “glazing backstop,” against which glazing  22  is sealed and compressed when pressure is applied from the window exterior. Double-stick glazing silicone base tape  35   c  is applied continuously to backstop  34  to prevent movement of the glazing once it is attached to frame  27   a . Premium glazing silicone sealant  32  is applied to backstop  34  to further seal the glazing into place and to prevent water leakage. Exterior glazing trim  33  may be clipped into place and sealed with silicone sealant  32 . Special care is taken so as not to soil glazing  22  with silicone sealant. 
         [0024]      FIG. 4  illustrates replacement door assembly  40 , which may be a new or existing retrofitted door installed after an existing door and door jamb have been removed from the rough opening of a structure. Door  42  is preferably supported in door jamb frame  49  by three (3) ball-bearing surface mounted hinges  46   a . All steel surfaces are primed and painted with rust preventative products. Door  42  may contain raised panels  47  top and bottom or bottom raised-panels. Door  42  may be insulated metal clad construction, insulated fiberglass clad construction, or solid wood construction with urethane applied as a surface coating (to wood doors only). In all cases, the lower door panel extending to height H, is watertight and preferably has strength to resist impact from a floating object. The door is hinged to open outwardly. Standard new or existing door lockset device  46 B may be utilized as a door locking mechanism. 
         [0025]    Referring to  FIGS. 5A and 5B , door flange frame  43 , which may be about 1½-inches wide, extends around the perimeter of the door and is mounted flush with the exterior surface of door  42  with the flange facing the interior. Door  42  is mounted into door flange frame  43  using premium polyurethane construction adhesive between the frame and door surface edge and 2-inch coated wood screws  45  at 16-inch intervals. A continuous twin strand of ⅜-inch by ⅜-inch rubber weatherseal gasket  48  ( FIG. 5B ), Thermal Blend, Inc. or equal, is glued with premium polyurethane construction adhesive to the interior side of door flange frame  43  so that the gasket compresses against the exterior surface of door jamb frame  44  (a part of door jam frame  49  in  FIG. 5A ) when door  42  is in the closed position. A single or more strand of weatherseal gasket may also be glued to the interior surface of door flange frame  43 , as shown in  FIG. 5B .  FIG. 5A  shows a lower cross-section view of door assembly  40  when the door is in the closed position. Door assembly  40  is fastened to existing house structure  50 .  FIG. 5B  shows an enlarged cross-section view of door  42  with enhanced details of the gasket  48  features. Surface  49  of door jamb frame  44  may be an existing surface of door jamb frame  44  or may be provided by a metal or other material glued to door jamb frame  44 . Door assembly  40  is set into the rough-opening frame  50 , plumbed and leveled utilizing wood shims if necessary, and anchored into place using 3-inch coated wood screws  51 ( a ) side mounted into door jamb frame  49  and existing wood frame  50 .  FIG. 5C  shows a detail of the hinged side of door  42 , with gasket  48  applied to this side also and inside flange  43 . 
         [0026]    The void between door jamb frame  49  and the existing opening framing members can be sealed with silicone sealant. All exterior surface perimeter joints around the door jamb frame  49  should be sealed with an elastomeric acrylic waterproof caulk and sealant compound  53  such as PERMAPATCH. To provide further sealing, a minimum 2-inch adhesive flashing strip  54 , such as Grace Vycor flashing, Quick Roof Flashing by Cofair Products, Inc., or equal, is preferably heat applied and overlaid by a continuous filament, spun-laced fabric membrane  55 , such as PERMATAPE, available from Nationwide, Fabric membrane  55  is thoroughly saturated and sealed with an elastomeric waterproofing adhesive bonding primer, such as ACRYLOPRIME sealer, overlapping the outer edge of the door jamb frame  49  and the adjacent wall substrate surface, preferably a minimum of 1-inch on the door frame and 1-inch on the adjacent wall substrate. The concrete slab area where the existing door sill was removed should be thoroughly cleaned and silicone sealant should be applied immediately before installing replacement door assembly  40 . The door sill is firmly set onto previously applied silicone sealant. The front edge of door jamb frame  49  at the sill-to concrete slab joint should be sealed to concrete slab  19  with silicone glass block caulking, taking care not to overlap any elastomeric acrylic caulk and sealant with the silicone. The above installation process should be repeated for all exterior door elements extending below height H until the door retrofit procedure has been completed. 
         [0027]      FIG. 6  illustrates the position of a rubber weatherseal gasket  45  (which may be same as gasket  48  shown in  FIG. 5 ) located on the interior surface of door flange frame  43 , thus providing for compression against the surface face of door jamb frame  49  when the door is in the closed position. The illustration shows masonry veneer substrate with flood proof wainscot  18  applied thereon. 
         [0028]    Referring to  FIG. 7 , method and material for flood proofing masonry (brick) veneer substrate  70  is shown. In preparation for flood proofing a building having a concrete slab and any veneer substrate material on the exterior walls, the following steps are taken: if less than 6 inches of concrete slab surface area is exposed above existing grade, excavate as required to expose several inches, preferably about 6 inches, of concrete. Then power-wash the exposed slab and preferably the wall surface areas to be flood-protected, using normal procedures. 
         [0029]    Other steps to be taken before flood proofing a building using any of the methods and materials disclosed herein are to: relocate exterior electrical receptacles and other electrical apparatus which may be located within the established flood zone wall surface area defined by height H, temporarily remove other exterior wall surface mounted devices for reconnection after exterior wall coatings have been applied, and seal all remaining wall penetrations, preferably with an elastomeric acrylic waterproof caulk and sealant such as PERMAPATCH. 
         [0030]    Before beginning flood proofing of masonry veneer substrate  70 , it is preferable to saw-cut all protruding masonry window sills and raised accent appointments flush with the wall substrate surface within the flood zone area to insure a smooth and level finished surface area. 
         [0031]    An exterior masonry veneer substrate typically possesses a 1-inch air-space  77  between the backside of the masonry substrate  70  and the wall board underlayment  78  attached to the wood frame structure. This air space must be filled solid with mold-resistant material  79 , which may be a slurry admixture of sodium silicate and cement grout, up to height H prior to the application of the flood protective materials. All existing masonry weep holes  70   a  located at the base of the existing masonry substrate should be filled to within 1-inch of the outer surface with 100% silicone caulking sealant. The balance of the opening will preferably be smoothed over with masonry grout to match the existing mortar material and allowed to dry prior to pumping cement admixture  79  into air-space cavity  77  through new weep holes  70   b  drilled into the existing mortar joints and located above height H. This procedure seals off potentially trapped moisture from the inner wall cavity and allows air and moisture to circulate within the remaining portion of unsealed air-space to prevent mold growth. 
         [0032]    Moisture- and mold-resistant cementitious wall board  72 , which may be ¼-inch or ½-inch HARDIBOARD Wet Area Cement Board, may be installed over the entire wall surface area to be flood-protected, including an area extending 3 inches below the intersection of wall substrate  70  and concrete slab  19 , referred to as base joint  75 . Board  72  is then preferably attached to slab  19  using 2-inch masonry anchors  71 . A 6-inch continuous strip of Adhesive Flashing  73 , which may be Grace Vycor flashing, Quick Roof Flashing by Cofair Products, Inc., or equal, is applied to slab  19  and board  72 , preferably in a 50/50 percentage of coverage of each above and below base joint  75 . A strip of PERMATAPE  74 , saturated and sealed with ACRYLOPRIME, should be the applied, overlapping the top and bottom of the flashing. 
         [0033]    All masonry door and window jamb and sill returns should be wrapped with wall board  72 , fitting board  72  flush with door jamb frame  49  and window sills/jambs, as shown in  FIG. 5  and  FIG. 2 , and then the perimeter joint should be caulked with an elastomeric acrylic waterproof caulk and sealant  35   b  and  54 , such as PERMAPATCH. Decorative styrofoam stucco molding  76  may be installed across the top edge of cementitious wall board  72  as a transition piece between old and flood-proofed substrates, Prior to the installation of flood protective coatings, all masonry anchor screws  71  should be sealed with PERMAPATCH. 
         [0034]    A coat of elastomeric waterproofing bonding primer such as ACRYLOPRIME sealer should preferably be applied evenly over cementitious wall board  72 . Then a decorative waterproof acrylic sand/knock-down/swirl texture coating may be applied (by trowel or spray), such as ACRYLOSAND or ACRYLOSTUK (available from Nationwide), in a selected pattern and texture. Then a single coat of elastomeric adhesive waterproofing and bonding primer sealer, such as PERMABOND should be applied. Finally, two coats of elastomeric acrylic ceramic polyurea finish-coat topping, such as PERMAKOTE SUPER PLUS, color-matched as selected, should be applied. Normally, a minimum 12-hour curing time is allowed before all chemical coating applications 
         [0035]    Referring to  FIG. 8 , concrete slab  19  of a building has existing structural framing  91  supporting horizontal siding substrate  80 . The same procedure and materials may be used for flood proofing as described above. 
         [0036]    A 6-inch continuous strip of adhesive flashing  85  is applied evenly to slab  19  and board  82  intersection, over base joint  83 . Base-joint flashing is then sealed with a strip of membrane  86  saturated and sealed with sealer, overlapped top and bottom. Other coating and sealers may be applied as described above. Decorative molding  87  may be added. 
         [0037]    If a building has concrete exterior siding, it may be flood proofed by caulking, sealing, and coating of the existing substrate without the installation of the cement board underlayment and decorative textured coating finish disclosed above. 
         [0038]    Referring to  FIG. 9 , concrete slab  19  of a building has existing structural framing  91  supporting existing stucco substrate  92 . A strip of adhesive flashing  94  is applied evenly to slab  19  and existing stucco substrate  92  as described above. Flashing  94  is covered with PERMATAPE  95  saturated and sealed with sealer overlapped top and bottom as described above. Molding  96  may be added as a decorative transition piece between existing textured stucco substrate  18  (above) and newly applied base-joint materials  95  (below). If not existing, styrofoam stucco molding  97  may be added as a transition agent at the top edge at height H. A coat of elastomeric waterproofing bonding primer may be applied, followed by two coats of elastomeric acrylic ceramic polyurea finish-coat topping, as described above. 
         [0039]    Referring to  FIG. 10 , concrete slab  19  of a new residence under construction has new structural framing exposed with no wall veneer materials yet installed. One-half inch or 1-inch cementitious wall board  101  may be attached directly to new wood framing members  100  with 2-inch coated wood screws  102 . It is preferable that the building design assures placement of all windows above height H and therefore flood windows will not be required. Should new flood windows be required for the building design, steps illustrated in  FIG. 2  and  FIG. 3  for windows and installation procedures should be followed. In addition, steps illustrated in  FIG. 4  for the installation of new flood doors should be followed. 
         [0040]    For base joint  103  flood protection, the following application is preferred: a 6-inch continuous strip of adhesive flashing  104  is applied evenly to slab  19  and cement wall board substrate  101  over new framing  100 , preferably in a 50/50 percentage of coverage of each above and below base joint  103 . Flashing  104  is then sealed with a strip of membrane  105  saturated and sealed with sealer overlapped top and bottom, as described above. Horizontal brick ledge  106  may exist in lieu of a vertical concrete slab  19  surface, in which case the above procedure may encompass horizontal brick ledge  106  in addition to the vertical slab surface as part of the flood protection procedure. Masonry elements will be installed on top of flood protected horizontal brick ledge  106 . 
         [0041]    All wall board substrate  101  joints are sealed with a strip of membrane  105  saturated and sealed with sealer. A coat of elastomeric waterproofing bonding primer, followed by two coats of elastomeric acrylic ceramic polyurea finish-coat topping, such as PERMAKOTE SUPER PLUS (available from Nationwide), should be applied, as described above. 
         [0000]    In all installations using the method and materials disclosed herein, plumbing modifications are preferred. A 4-inch backflow prevention device with before/aft clean-out capability should be installed in the main sanitary sewer line between the house structure and the street. An individual anti-siphon back-flow prevention device should be installed on each exterior hose bib located within the flood zone. Also, all thru-wall penetrations for gas and plumbing should be sealed with PERMAPATCH caulk and sealant material prior to coating application procedures and silicone caulking after completion of industrial coatings application. 
       Examples 
       [0042]    A model building was constructed according to the methods and materials described herein and tested under real-flood test conditions as follows: 
       Prototype I. 
       [0043]    A concrete slab-on-grade residential foundation was constructed, 8 ft×8 ft in dimension, with an exposed foundation 12 inches above the existing grade. Thereafter, a wood-frame structure was constructed thereon using standard 2×4 stud framing at 16-inch on center, with a single base-plate attached to the concrete foundation with standard anchor bolts at 4 ft on center, standard metal cross-bracing strips, a single 2×4 plate as a header at the top of the 4 ft wall height, and exterior foil-faced particle board sheathing applied to the exterior face of the stud wall—all materials typically used in a wood framed residential structure. 
         [0044]    Watt finishes typical to residential construction and additional special features were included in the prototype for testing as follows:
       Standard masonry face-brick veneer was applied to the exterior surface of one wall with a 1-inch air space between the brick and the exterior wail sheathing and typical masonry ties and weep holes included in the masonry installation.   Metal lath with a 1-inch stucco finish was applied as the surface material on one wall.   Standard siding materials, HARDIPLANK in 4 ft×8 ft solid sheets cut to size appropriate to the wall conditions were installed on two separate walls.   One standard 3-ft wide door opening was provided for the testing of various door samples.   One standard 4-ft wide window opening was provided for the testing of various window samples.   A continuous 3-ft wide by 3-ft high waterproof moat was constructed around the perimeter of the residential prototype with the floor level of the moat 4 inches below the finish floor level of the concrete foundation of the prototype in order to accommodate foundation/wall base joint flood protection requirements.       
 
         [0051]    Flood protection methodologies were implemented and tested as follows:
       The installation of one layer of Fiber Reinforced Polymer (FRP) applied to the exterior wall surfaces of the prototype was tested initially and although 100% successful under real-flood test conditions to a flood height 3 ft above the foundation level, the process was deemed too labor intensive, too climate restrictive in the installation process, and too expensive due to the requirement of extensive architectural finishing of the flood protected area. The complete protection of wall-to-window and wall-to-door joints also proved insufficient to prevent 100% leakage due to the potential of minor shrinkage of the FRP product during curing. Environmental-related issues also created some concern due to the required use of epoxy products in the procedure.   Once the above flood protective application procedures were completed, the enclosed moat surrounding the prototype was flooded to a height of 3 ft and sustained at that level for a 24-hour duration. There was zero leakage in the protective wall finishes; however, various methodology adjustments were required to prevent leakage around the door and window. Various door and window components were installed within the prescribed prototype openings. Surprisingly, in subsequent tests a 100% leak-free structure was achieved using the methods and materials disclosed herein.   The installation of the multi-stage protective coating system disclosed here proved to be an excellent remedy as a durable, environment friendly, easily applied, exterior watt surface protective finish. The architectural finish is accomplished within the water proof coating system itself, thus eliminating the need for a separate surface finish process. The use of linen mesh in sealing the foundation to wall base joint and the door and window units into place in conjunction with the appropriate coating materials provided a 100% leak-free solution.       
 
       Prototype II. 
       [0055]    An existing free-standing concrete stab-on-grade garage structure with a ½-inch×8-inch horizontal lap-and-gap HARDIPLANK siding exterior was utilized as the second prototype for real-flood simulations. As with Prototype I, a 3-ft×3-ft continuous moat was constructed across an 8-ft section of the rear wall of the existing building with the floor level of the moat constructed 4 inches below the finished concrete floor level of the existing garage. There was an existing troublesome base joint condition to contend with; the concrete slab having a 2-inch bow in it due to poor concrete forming when the building was originally constructed. This condition served to enhance our testing of flood protection at the base joint utilizing the multi-stage coating system, and it provided a critical real-life condition that could reasonably be encountered in field conditions. 
         [0056]    The existing siding material was tested in two ways:
       (1) The existing horizontal HARDIPLANK siding, the foundation/wall base joint, and all other joints and wall penetrations were sealed and coated utilizing the system disclosed herein without the installation of the wet board underlayment product and the subsequent application of a stucco wainscot architectural finish. This test proved that existing HARDIPLANK siding can be flood-protected without the additional cost of the architectural stucco wainscot application. This represents a considerable cost savings for buildings with existing HARDIPLANK siding on the exterior walls.   (2) The existing horizontal HARDIPLANK siding was covered with ½-inch wet board underlayment and then covered with the multistage coating system and textured with a stucco finish utilizing the system disclosed herein, including the installation of decorative molding at the header of the new stucco wainscot.   Both of the above applications were flooded to a height of 3 ft for a 24-hour time period without any leakage into the interior garage space. In addition, flood conditions to a height of 12 inches above the slab level were maintained for several months without flooding at the critical base joint or through the walls.       
 
         [0060]    In addition to the above test, an existing 3 ft×6 ft-8 inches pedestrian door providing entry into the garage area was retro-fitted according to the disclosure and tested independently by constructing a 4 ft×3 ft×3 ft moat across the front of the retro-fitted door assembly after the completed installation. The door assembly was tested for a 24-hour period without leakage. This test proved that an existing door can be properly modified and retro-fitted for use in the disclosed flood protection system in addition to the use of a new flood door assembly. 
         [0061]    It should be noted that several independent tests of door and window assemblies were repeatedly tested utilizing the same procedures, each test documenting points of weakness and/or failure, until the disclosed door and window systems were found to be waterproof. 
         [0062]    Although the present invention has been described with respect to specific details, it is not intended that such details should be regarded as limitations on the scope of the invention, except to the extent that they are included in the accompanying claims.

Technology Classification (CPC): 4