Note: Descriptions are shown in the official language in which they were submitted.
CA 02547958 2013-02-14
EXTERIOR FINISH SYSTEM
BACKGROUND
An improved exterior finishing system for use in the building and
construction industry is provided. The improved exterior finishing system
includes
an insulation layer that provides thermal insulation and a means for drainage
of
incidental moisture that may penetrate the exterior surface of the system or
other
components of the building envelope.
Modern techniques for constructing the walls of buildings may take
numerous forms. Among these is the two-by-four (2x4) framed construction.
Conventional 2x4 wall construction begins with framing of the walls with wood
or
steel members. These wood or steel members typically have nominal dimensions
of 2"x 4" and are, therefore, called "two-by-fours" or 2x4s. These 2x4s are
oriented
vertically and spaced at intervals generally either 16" or 24" and are each
connected at the top and bottom to similar, horizontally oriented members.
This
structure is referred to in the relevant art as a "framed" wall.
Traditionally, a sheet of sheathing such as plywood or other material is
applied to the exterior of the framed wall, but such application is not
required in all
circumstances. Such requirements are typically established by governmental
building codes. A weather barrier may then be applied to the exterior of the
sheathing, with an exterior wall covering or exterior finishing materials then
being
applied directly over the weather barrier.
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Any one of numerous materials may be used for the exterior finishing
materials of building structures such as brick, stucco, vinyl or aluminum
siding,
wood siding, exterior insulation and finish systems (EIFS), and the like.
While designed to provide an exterior aesthetic finish, the exterior finishing
materials are also designed to minimize the transmission of moisture from the
external environment into the building structure, thereby protecting the
building
structure and it contents from moisture. Over time, however, an exterior
finish
.
may develop a breach, such as a crack. If a breach or void, such as openings
or
cracks, exist in the exterior finish, then wind loads can potentially act as
the driving
mechanism to force water through the cracks or openings in the exterior
finish.
Incidental moisture may also enter the building structure though windows,
compromised sealants, and the like. If excess water reaches the building wall
substrate, i.e.- the sheathing material, then this exposure of the building
wall
substrate to the water may result in deterioration of the building wall
substrate
material, thus requiring replacement.
Weather barriers may be applied over the exterior surface of the building
wall substrate as a means to accommodate incidental moisture that has breached
the
outermost surfaces of the building envelope. If the weather barrier contains
significant voids, cuts, or gaps, any such water/moisture may find its way
through
or around the openings in the weather barrier, onto the sheathing material,
and
eventually into the wall to cause the deleterious effects described above.
Many commercial and residential building structures utilize exterior
insulation and finish systems (EIFS) as the exterior wall covering. Typically,
the
exterior insulation and finish system includes an insulation board, a base
coat, a
reinforcing mesh, and a finish coat. The insulation board is attached over the
building wall substrate, such as plywood sheathing. A base coat is applied to
the
exterior surface of the insulation board. Next, a reinforcing mesh material is
embedded in the base coat. Finally, a finish coat is applied over the base
coat and
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reinforcing mesh material. A weather barrier can be attached to the sheathing
prior
to installation of the insulation board.
While attempts have been made to provide moisture drainage in the context
of exterior finishing systems in the building and construction industry, there
still
exists a great need for an exterior finishing system having improved moisture
drainage capabilities.
SUMMARY
An exterior finish system for building walls is provided, said system
comprising a moisture drainable insulation layer having a plurality of
openings or
voids, and an exterior finish applied over said insulation layer.
A building wall is also provided, said building wall comprising a frame
having an exterior surface, optionally, a sheathing attached to said exterior
surface
of said frame, a moisture drainable insulation layer having a plurality of
openings
or voids disposed over said exterior surface of said frame, or disposed over
said
sheathing if said sheathing is present, and an exterior finish disposed over
said
insulation layer.
According to certain embodiments, a weather barrier is attached over the
building wall substrate prior to attaching the the moisture drainable
insulation layer.
A process for finishing an exterior building wall is also provided, said
process comprising attaching an insulation layer over a building wall
substrate, said
insulation layer comprising a moisture drainable insulation layer having a
plurality
of openings or voids, and applying exterior finishing materials over said
insulation
layer.
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According to certain embodiments, the process comprises attaching a
weather barrier over the building wall substrate prior to attaching the
moisture
drainable insulation layer.
An exterior insulation and finish system is provided, said system comprising
a moisture drainable insulation layer having a plurality of openings or voids,
at least
one base coat layer applied over said insulation layer, at least one
reinforcing layer
at least partially embedded within the base coat layer, and at least one
finish coat
layer applied over said base coat layer and said reinforcing layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG 1 is an exploded side view of one embodiment of the exterior finishing
system.
FIG 2 is a fragmentary view of the moisture permeable insulation layer.
FIG 3 is a perspective view of one embodiment of a building wall
incorporating an exterior finishing system.
FIG 4 is a side view of one embodiment of a building wall incorporating an
=
exterior finishing system and a drainage cavity forming means.
DETAILED DESCRIPTION
An exterior finish system for building walls is provided. The exterior finish
system includes a permeable insulation layer having a number of openings or
voids
and exterior finishing materials that are applied over the permeable
insulation layer.
The insulation layer is permeable to air and incidental moisture. The terms
"moisture permeable insulation layer" and "moisture drainable insulation
layer" are
used interchangeably throughout the specification to refer to an insulation
layer for
an exterior finishing system for building walls that is capable of providing
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insulation to the building wall and drainage of incidental moisture. The
exterior
finish system provides an exterior aesthetic finish to exterior building
walls, while
also providing moisture drainage capabilities.
As discussed in greater detail below, according to certain illustrative
embodiments, the exterior finish system includes an insulation layer that is
comprised of a plurality of discrete bodies that are bonded together at mutual
points
of contact. As the bodies are joined together only at points of contact, the
resulting
insulation layer includes a great number of openings or voids. These openings
to result in
an insulation layer having interconnected voids that permit incidental
moisture to drain through the insulation layer.
According to certain illustrative embodiments, the bodies of the insulation
layer comprise discrete bead- or sphere- shaped bodies. The discrete beads of
the
insulation layer may be manufactured from a polymeric material. According to
certain embodiments, the polymeric material utilized to manufacture the
discrete
beads of the insulation layer is a polyolefin material. The discrete beads of
the
insulation layer may be polyethylene beads, polypropylene beads, or a
combination
of polyethylene beads and polypropylene beads. According to other embodiments,
the insulation layer of the exterior finishing system may comprise a plurality
of
discrete expanded polystyrene shapes, such as expanded polystyrene beads or
spheres. It should be noted, however, that any polymeric material that
provides an
insulation layer having insulative and moisture drainage capabilities will be
suitable
for manufacture of the beads and that one having ordinary skill in the art,
without
undue experimentation, would be able to select a suitable polymeric material
for
manufacture of the beads of the insulation layer that is to be incorporated
into the
exterior finish system.
The discrete polymer beads of the insulation layer should not absorb a
significant amount of moisture. The discrete beads that comprise the
insulation
layer of the exterior finish system may be manufactured from a moisture
resistant
polymeric material or may be provided with a water resistant coating on at
least a
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portion of the exterior surfaces of the discrete beads. According to certain
embodiments having a water resistant coating, substantially all of the
exterior
surface of the individual polymeric beads are coated with a water resistant
coating.
As the beads are coated with a water resistant coating, the insulation layer
is
capable of prolonged exposure to moisture without the beads absorbing any
significant amount of water or having any detrimental effects on the beads.
Without
limitation, water resistant coatings may be selected from water resistant
urethanes,
acrylics, styrene-butadiene, silicones, silanes, and like water resistant
coatings.
The moisture drainable insulation layer should be raspable. By "raspable" it
is meant that the insulation layer may be manipulated by mechanical means to
substantially remove surface irregulatries in the exteriorly facing surface of
the
insulation layer. By rasping the exteriorly facing surfaces of the insulation
layer, a
substantially even surface can be attained for application of the EIFS base,
reinforcing mesh, and finish coats, or other finishing materials, such as
stucco
layer(s). Thus, the rasped moisture drainable insulation has a substantially
even or
smooth surface for application of the exterior finishing materials.
The exterior finish system includes exterior finishing materials that are
applied the drainable insulation layer. Without
limitation, exterior finishing
materials may be selected from brick, wood siding, vinyl siding, aluminum
siding,
stucco, and exterior insulation and finish systems. According
to certain
embodiments, the exterior finishing materials comprise exterior insulation and
finish system materials. According to other embodiments, the exterior
finishing
material comprises at least one layer of a cementitious-based stucco material.
For embodiments utilizing an exterior insulation and finish system, the
exterior insulation and finish system generally includes the moisture
drainable
insulation layer, a base coat applied over the insulation layer, a reinforcing
mesh
layer or layers at least partially embedded in the base coat layer, and at
least one
finish coat layer that is applied over the base coat and reinforcing mesh
layers.
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The base coat layers of the exterior insulation and finish system are
generally polymer-modified cementitious compositions that adhere to the
exterior
surface of the insulation layer. The base coat layer can support a reinforcing
mesh
layer and which, in turn, supports the finish coat layer. Without limitation,
suitable
base coats for use in the exterior insulation and finish system include base
coats
commerically available from Degussa Wall Systems, Inc. (Jacksonville, Florida)
under the trade designations Alpha Base Coat and Alpha Dry Base Coat. Alpha
Base Coat is a water based, 100% acrylic base coat having adhesive properties.
Alpha Base Coat is typically field-mixed with Types I or II Portland cement to
provide a trowelable base coat. Alpha Dry Base Coat is a dry-mix polymer base
coat containing Portland cement. The Alpha Dry Base Coat is field-mixed with
water to provide a trowelable base coat.
The reinforcing layer, without limitation, may be selected from reinforcing
fabrics and meshes. The reinforcing meshes are typically woven or knitted
meshes
of fibers. The fibers of the reinforcing mesh may include organic or inorganic
fibers. The only practical limitations on the type of fibers used to
manufacture the
reinforcing mesh is that the resulting reinforcing mesh be embeddable in the
base
coat, that it have sufficient strength to support the finish coat layers of
the exterior
insulation and finish system, and that it be chemically resistant or inert to
the base
and finish coats. According to certain embodiments, the reinforcing mesh of
the
exterior insulation and finish system is a woven fiberglass mesh.
A building wall incorporating the exterior finish system is also provided.
The building wall comprises a building wall substrate, a moisture drainable
insulation layer having interconnected voids that is attached to the exterior
surface
of the building wall substrate, and exterior finishing materials applied over
the
insulation layer. According to certain embodiments, the building wall also
includes
a weather resistant barrier that is applied to the surface of the building
wall
substrate prior to attaching the moisture drainable insulation layer to the
building
wall.
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The building wall substrate, without limitation, may be selected from
plywood sheathing, wafer board, particle board, oriented strand board, cement
board, gypsum board, concrete block, and masonry block. In one embodiment, the
building wall substrate is a layer of plywood sheathing. According to other
embodiments, the building wall substrate may be a layer of masonry block.
In general, the building wall substrate is attached to a building wall frame
having an exterior surface. However, it should be noted that for embodiments
employing concrete or masonry block as the building wall substrate, the
concrete or
masonry block is not attached to a frame. The moisture drainable insulation
layer is
then attached to the exterior-facing surface of the building wall substrate.
The
insulation layer may be attached to the building wall substrate by any
suitable
attachment means, such as, for example, nails, screws, staples, tacks, rivets
and
adhesives. According to certain embodiments, a weather barrier material, such
as
building papers, polymeric sheets, and trowel and roller applied materials may
be
applied to the exterior-facing surface of the building wall substrate prior to
attaching
the moisture drainable insulation layer to the substrate.
The weather barrier may be a conventional weather barrier that is used in
building construction, such as building paper or tar paper, although other
materials
can be used. The weather barrier is a building code recognized product which
is
typically sold on a roll. Weather barriers resist the transmission of water
therethrough and likewise control the transmission of moisture vapor
therethrough.
An example of a weather barrier which is well known in the art is Jumbo Tex
Vapor Permeable Weather Resistive Barrier manufactured by Fortifiber
Corporation of Incline Village, Nevada.
The weather barrier may also comprise a polymeric material. Preferably,
the weather barrier is comprised of a non-woven sheet of polymeric fibers. The
weather barrier may comprise a non-woven sheet of polyolefin fibers. Without
limitation, the polyolefin fibers that are useful in the preparation of the
weather
barrier may be selected from polypropylene fibers and high density
polyethylene
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fibers. According to certain embodiments, the weather barrier may comprise a
non-
woven sheet of spun-bonded high density polyethylene fibers. Without
limitation,
suitable non-woven sheets of spun-bonded high density polyethylene fibers are
commercially available from E.I. DuPont de Nemours & Co., Inc. (Wilmington,
Delaware) under the trademarks Tyvek HomeWrapTM, Tyvek StuccoWrapTM and
Tyvek CommercialWrapTM. The non-woven structure provides excellent resistance
to water and air penetration. In addition, the non-woven structure has
excellent
strength and tear resistance. It should be noted that the polymeric weather
barrier is
= not limited to those commercially available from E.I. DuPont de Nemours &
Co.,
Inc., as any commercially available polymeric sheet material possessing the
desired
weather resistant properties may be used.
Without limitation, trowel and roller applied weather barriers suitable for
use in the present invention may include those weather barrier materials
commercially available from Degussa Wall Systems, Inc. (Jacksonville, Florida)
under the trade designations SENERSHIELD and SENERSHIELD-R.
SENERSHIELD is a 100% acrylic-based, fiber reinforced weather resistive
barrier
material. SENERSHIELD is a trowel-applied continuous membrane.
SENERSHIELD is suitable for direct application to gypsum sheathing, cement
board, poured concrete substrates, unit masonry, and the like. SENERSHIELD-R
is
a flexible, liquid coating material. SENERSHIELD-R provides a roller- or brush-
applied continuous membrane that is suitable for direct application to a wide
variety
of approved building wall substrates, such as plywood sheathing, cement board,
gypsum sheathing, oriented strand board and the like.
Once the insulation layer is attached to the building wall substrate, then the
exterior finish materials are applied over the insulation layer. The exterior
finish
materials that may be used in conjunction with the construction of the
building wall
include, without limitation, brick, wood siding, vinyl siding, aluminum
siding,
stucco, and exterior insulation and finish system materials. According to
certain
embodiments, the exterior finish material used in conjunction with the
building wall
is an exterior insulation and finish system. As described above, the exterior
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insulation and finish system that may be incorporated into the building wall
includes
= the moisture drainable insulation layer, a base coat applied over the
insulation layer,
one or more reinforcing mesh layers substantially embedded in the base coat
layer,
and at least one finish coat layer is applied over the base coat and
reinforcing mesh
layers.
According to other embodiments, a process for finishing an exterior building
wall is further provided. The process includes attaching a moisture drainable
insulation layer having interconnected voids over a building wall substrate,
and
applying exterior finishing materials over the drainable insulation layer.
According
to certain embodiments, the process for finishing an exterior building wall
also
includes applying a weather resistant barrier to the surface of the building
wall
substrate prior to attaching the mositure drainable insulation layer to the
building
wall.
With respect to the building wall incorporating the exterior finish system,
the moisture drainable insulation layer may be attached to the building wall
substrate by means of an adhesive attachment, by means of a mechanical
attachment, or by a combination of an adhesive and a mechanical attachment.
According to other embodiments, the exterior finish system and building
wall incorporating the same may also include a drainage space located between
the
insulation layer and the exteriorly-facing surface of the building wall
substrate to
provide additional water and moisture vapor drainage. The drainage space may
be
created by an open, three-dimensional spacing means. The spacing means may be
provided in the form of an open, three-dimensional mat.
The mat is preferably manufactured from a polymeric material. A
= particularly well-suited polymeric material that can be used to
manufacture the mat
includes a thermoplastic polyamide resin such as nylon 6, although other
materials
may be used without departing from the spirit of the present invention. Such
other
materials that can be used to manufacture mat include, but are not limited to,
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=
=
polyolefin fibers, such as polypropylene, high density polyethylene,
polyvinylchloride, polystyrene fibers and polyester fibers.
The polymeric mat is preferably of a type described and manufactured in
accordance with U.S. Patent Nos. 4,212,692, 3,691,004, and/or 3,687,759,
although
other configurations are possible.
The filaments of the polymeric mat form a peak and valley structure
undulating in the longitudinal and/or transverse directions, preferably to
provide a
waffle-like structure. Due to its filamentatious structure, the polymeric mat
contains a great number of mutually interconnected voids which allow gases and
liquids to flow freely therethrough.
The polymeric mat has a crush resistance allowing it to withstand a level of
compressive load without crushing the peak and valley configuration thereof.
Thus,
air and water can still flow directly and transversely through the mat, even
when the
mat is under a compressive load. The ability of the mat to withstand a given
compressive load must necessarily vary with factors such as the filament
diameter,
the material of which the mat is composed, the extent to which self-bonding
has
occurred, the height of the peaks and valleys, as well as a plurality of other
such
variables. Thus, the crush-resistant properties of the mat, while inherent in
the
design of the mat, vary with numerous parameters regarding the construction of
the
mat.
The exterior finish system and building wall will now be described in greater
detail with reference to FIGS. 1-4. It should be noted that the invention is
not
limited to the illustrative embodiments shown in FIGS. 1-4, but should be
construed
in accordance with the appended claims.
With reference to FIG. 1, an exterior finish system 10 is shown. The
exterior finish system 10 includes a moisture drainable insulation layer 11
and an
exterior finish layer applied over the insulation layer 11. According to the
embodiment shown in FIG. 1, the exterior finish layer includes exterior
insulation
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and finish system materials. Base coat 12 is applied uniformly over the
exterior
surface of insulation layer 11. Once the base coat layer 12 is applied over
the
insulation layer, then the reinforcing means 13, which is shown as a
reinforcing
mesh layer 13, is substantially embedded in the base coat layer 12. The finish
coat
layer 14 of the exterior insulation and finish system 12 is applied over the
base coat
12 and reinforcing mesh layer 13.
Referring to FIG. 2, a portion of the insulation layer 11 is shown. The
insulation layer 11, includes a plurality of discrete beads having exterior
surfaces.
to Illustrative discrete beads 22 and 23 are shown as having exterior
surfaces 24 and
25, respectively. Discrete beads 22 and 23 are bonded or joined together at
mutual
points 26 of contact on their exterior surfaces. By this construction, an
insulation
layer 11 having a number of openings 27 or voids created by the bond points of
the
spheres is provided. These openings 27 provide the insulation layer 11 with
the
capability of draining incidental moisture that has breached the exterior
finishing
materials or the outermost surface of the building envelope. Due to the
openings,
the insulation layer is capable of draining incidental moisture vertically to
weep
holes or other vent means provided near the bottom of the building wall, or at
other
desired locations.
A building wall 30 incorporating an exterior finish system having a moisture
permeable insulation layer is shown in FIG. 3. As shown in illustrated FIG. 3,
Building wall 30 is of a typical 2x4 frame construction, although other
construction
techniques and configurations are equally suitable.
= Building wall 30 is generally constructed of a frame, a building wall
substrate, the moisture drainable insulation layer, and an exterior finish.
The frame
typically includes a plurality of studs 31, which are members of wood or steel
having nominal dimensions of 2" x 4". Studs 31 are vertically oriented and are
parallel and spaced apart a distance of typically 16" or 24", although these
dimensions are merely illustrative. Studs 31 are each typically fixedly
attached at
upper and lower ends to a horizontal plate, with the plate typically being a
member
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of similar dimension to studs 31 and oriented horizontally such that multiple
vertical
studs 31 in a wall 30 are fixedly attached to a single plate running along
their
bottom edges and also to another single plate running along their top edges.
Studs
31 are usually fixedly attached to the plate by means of mechanical fasteners
such as
nails and/or screws (not shown). Moreover, studs 31 are each typically
attached to
a lower sill plate (not shown) which is of a similar construction. Typically,
a
building wall substrate 33 is attached to the exterior surface of the framed
wall.
A starter track 34 may be mounted along the bottom edge of the wall 30 and
to may extend along substantially the entire length of the bottom edge of
the wall 30.
The starter track 34 may be provided as a rigid L-shaped structure, formed of
a
non-corrosive material, such as aluminum or UV-resistant polyvinyl chloride.
The
starter track 34 is mounted onto the wall 30 in a position that is
substantially
parallel to the foundation of the building structure. The starter track 34 may
be
applied or mounted onto the wall 30 by means of adhesives or mechanical
fasteners.
A sealing membrane 35 may be utilized in conjunction with the starter track 34
to
prevent the flow of incidential moisture behind the starter track 34. The
sealing
membrane 35 may be a composite membrane or a trowel-applied membrane.
According to certain embodiments, the self-adhering membrane 35 is a composite
membrane comprising a rubberized asphalt layer and a polyester layer.
Still referring to FIG. 3, the insulation layer and exterior finish are
attached
to the building wall substrate 33. According to FIG. 3, the exterior finishing
material is an exterior insulation and finish system (40-43). Optionally, a
weather
barrier 50 is applied over the exterior surface of the building wall substrate
33,
prior to the installation of the insulation layer. The weather barrier 50, may
be
selected from building papers or polymeric sheet barriers. Although a pre-
formed
sheet weather barrier may be utilized, the weather barrier 50 may also
comprises a
roller, brush- or trowel-applied material barrier layer.
The exterior finish is applied over the weather barrier 50. The exterior
insulation and finish system typically includes, the insulation layer 40, a
base coat
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41, a reinforcing mesh 42, and a finish coat 43. The base coat 41 is applied
directly to the exterior surface of the insulation layer. The insulation layer
40 is
generally provided in the form of an insulation board. The reinforcing mesh 42
is
applied to and substantially embedded within the base coat 41 layer. Once the
base
coat 41 has dried, the exterior finish coat 43 is applied over the dried base
coat 41
and mesh 42 to provide an aesthetically pleasing exterior finished surface.
With reference to FIG. 4, a cavity forming or spacer means 60 may
optionally be positioned between the exterior surface of the building wall
substrate
= 10 30 and the insulation layer 40.
EXPERIMENTAL
The following test results set forth to describe exterior finish system in
further detail. It shouuld be noted, however, that the test results should not
be
construed as limiting the exterior finish system, building wall incorporating
the
exterior finish system or assocaited processes in any manner.
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A sample of a type of moisture drainable insulation was evaluated for core
density, water absorption, compressive properties, shear properties, water
vapor
permeance, tensile properties, dimensional stability, and freeze-thaw tensile
adhesion.
Core Density Testing
A layer of the moisture permeable insulation was evaluated for core density
in accordance with the ASTM C303 test method. The results of the core density
testing are reported in Table I below.
TABLE I
Results
No Drying 2.22 0.02 lb/f3
= Dried for 2 hours at 105
C 2.14 0.03 lb/ft3
Dried for 24 hours at 50 C 2.15 0.04 lb/f3
Water Absorption Testing
A layer of the moisture drainable insulation was evaluated for water
absorption in accordance with the ASTM C272/C578 test method. The results of
the water absorption testing of the moisture drainable insulation layer having
interconnected voids was compared to a layer of standard expanded polystyrene
foam insulation. The water absorption of the insulation layer is expressed as
a
function of the percent weight gain of the insulation layer, due to the
absorption of
water. The moisture permeable insulation layer exhibited an average weight
gain of
61 4%. Standard expanded polystyrene insulation board exhibited a weight
gain
of 206 19.
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Compressive Resistance Properties Testing
The moisture drainable insulation was evaluated for compressive resistance
properties in accordance with the ASTM D1621 test method. The results of the
compressive resistance properties testing are reported in Table II below.
TABLE II
Compressive Resistance Property Results
=
Stress at 0.5% Strain 0.6 0.3 psi
Stress at 1% Strain 0.7 0.3 psi
Stress at 10% Strain 4.1 0.1 psi
Modulus of Elasticity 840 215 psi
1() Shear Properties Testing
The moisture drainable insulation was evaluated for shear resistance in
accordance with the ASTM C273 test method. The results of the shear resistance
testing for the moisture permeable insulation layer were compared to standard
expanded polystyrene (EPS), and are reported in Table III below.
TABLE III
Shear Properties EPS Air/Moisture
Permeable
Insulation
Shear Strength 11 1 psi 27 1 psi
Shear Modulus 58 4 psi 33 1 psi
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Water Vapor Permeance Testing
The moisture drainable insulation was evaluated for water vapor permeance
in accordance with the ASTM E96 test method. The results of the water vapor
testing for the moisture drainable insulation were compared to standard
expanded
polystyrene (EPS), and are reported in Table IV below.
TABLE IV
Sample Method Results
Inventive 1 Dry Cup 6.3 0.7 perms
Inventive 2 Wet Cup 20.2 1.9 perms
Inventive 3 Dry Cup 6.5 0.6 perms
Inventive 4 Wet Cup 22.9 1.6 perms
Standard EPS 6 Dry Cup 2.9 0.2 perms
Standard EPS 7 Wet Cup 5.2 V 0.8 perms
Tensile Properties Testing
The moisture drainable insulation was evaluated for tensile properties in
accordance with the ASTM C297 test method. The results of the tensile
properties
testing for the moisture permeable insulation were compared to standard
expanded
polystyrene (EPS), and are reported in Table V below.
TABLE V
Sample Tensile Property Results
Inventive Tensile Strength 30 3 psi
Inventive Elongation at Max. Stress 27 2%
Comparative EPS Tensile Strength 16 1 psi
Comparative EPS Elongation at Max. Stress 18 1 %
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,
Dimensional Stability Testing
The moisture drainable insulation was evaluated for dimensional stability in
accordance with the ASTM D2126 test method. The results of the dimensional
stability testing for the moisture drainable insulation were compared to
standard
expanded polystyrene (EPS), and are reported in Table VI below.
TABLE VI
Sample Method Results
Inventive -26 C 0%
Inventive 38 C/95% relative humidity 9.7 0.3%
Comparative EPS -26 C 0%
Comparative EPS 38 C/95% relative humidity 1.8 0.5%
Freeze-Thaw Tensile Adhesion Testing
The moisture drainable insulation was evaluated for freeze-thaw resistance in
accordance with the criteria set forth in International Conference of Building
, 15 Officials (ICBO) AC24, and also for tensile adhesion in
accordance with the ASTM
C297 test method.
With respect to the freeze-thaw testing, exterior insulation and finish
systems
were constructed. Each system included the moisture drainable insulation layer
having interconnected voids, a base coat applied for the insulation layer, a
reinforcing mesh embodied in the base coat layer, and a finish coat layer
applied
over the base coat layer and reinforcing mesh. Two different base coats were
used
in the testing, namely, Alpha Base Coat and Alpha Dry Base Coat, both
commercially available from Degussa Wall Systems, Inc. of Jacksonville,
Florida.
The exterior insulation and finish systems were assembled and the assembled
systems were subjected to freeze-thaw cycles, in accordance with ICBO AC24. No
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COC.SNR.P.0554
surface changes or delaminations were noticed after exposure to freeze-thaw
cycling.
The results of the tensile adhesion testing before and after freeze-thaw
cycling are reported in Table VII below. The building wall substrate utilized
in the
illustrative testing was a building sheathing material commercially available
from
Georgia Pacific under the trade designation Dens Glass Gold.
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TABLE VII
Sample Test Method Results
Inventive insulation layer Flatwise Tensile Adhesion 27 3 psi
adhered to wall substrate No freeze-thaw cycling
with Base Coat 1
Inventive insulation layer Flatwise Tensile Adhesion 27 1 psi
adhered to wall substrate No freeze-thaw cycling
with Base Coat 2
Full EIFS with inventive Flatwise Tensile Adhesion 27 3 psi
insulation layer adhered to No freeze-thaw cycling
wall substrate
with Base Coat 1
Full EIFS with inventive Flatwise Tensile Adhesion 28 1 psi
insulation layer adhered to No freeze-thaw cycling
wall substrate
with Base Coat 2
Full EIFS with inventive Flatwise Tensile Adhesion 27 3 psi
insulation layer adhered to After freeze-thaw cycling
wall substrate
with Base Coat 1
Full EIFS with inventive Flatwise Tensile Adhesion 25 3 psi
insulation layer adhered to After freeze-thaw cycling
wall substrate
with Base Coat 2
Base Coat 1 = Alpha Base Coat from Degussa Wall Systems, Inc.
Base Coat 2 = Alpha Dry Base Coat from Degussa Wall Systems, Inc.
While various illustrative embodiments have been described above and
shown in the various figures, it should be understood that other similar
embodiments may be used or modifications and additions may be made to the
described embodiments for performing the same functions without deviating
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therefrom. Further, all embodiments disclosed are not necessarily in the
alternative, as various embodiments may be combined to provide the desired
characteristics. Variations can be made by one having ordinary skill in the
art
without departing from the spirit and scope of the disclosure. Therefore, the
exterior finish system, building wall, and process should not be limited to
any
single embodiment, but rather construed in breadth and scope in accordance
with
the recitation of the attached claims.
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