Cavity wall through-wall flashing support system and method

Abstract

A through-wall flashing support system for supporting a through-wall flashing membrane installed in a cavity wall. The system includes multiple support parts, multiple spline parts and a through-wall flashing membrane. Each support part has a flange, configured to abut and be attached to an inner wall of the cavity wall, and a base, extending with a downward slope from the lower portion of the flange such that the outer portion of the base penetrates an outer wall of cavity wall. Spline parts are configured to connect adjacent support parts. The through-wall flashing membrane extends across the cavity and covers the bases of the support parts and the spline parts. Weep holes are installed to enable water to flow through the outer wall along through-wall flashing membrane. Methods for installing this system in a new cavity wall and retrofitting an existing cavity wall are also provided.

Claims

1. A through-wall flashing support system for supporting a through-wall flashing membrane installed in a cavity wall comprising an inner wall having a lateral extent and an outer wall having substantially the same lateral extent, the inner and outer walls defining a cavity therebetween, the flashing support system comprising: a plurality of thermoplastic flashing support parts, each thermoplastic flashing support part comprising: a flange having a lateral extent and having a lower portion, the flange being configured to abut and be attached to the inner wall; and a base integrally formed with the flange and extending laterally along the lateral extent of the flange, and extending with a downward slope from the lower portion of the flange, the base having an outer portion, wherein the base is configured so that when the thermoplastic flashing support part is installed the outer portion of the base penetrates the outer wall and the outer wall supports the base; a plurality of thermoplastic flashing H-channel spline parts, each of the plurality of thermoplastic flashing H-channel spline parts configured to connect the bases of two adjacent thermoplastic flashing support parts, wherein each spline has a front and a rear, and has a flat upper surface and a flat lower surface and the distance between the upper and lower surfaces increases from the front to the rear; a through-wall flexible flashing membrane having a lateral extent and having rear and front edges, the rear edge of the membrane being adhered to the flanges of the thermoplastic flashing support parts, the through-wall flashing membrane configured to extend across the cavity and covering the bases of the thermoplastic flashing support parts, wherein when the thermoplastic flashing support part is installed a portion of the through-wall flashing membrane comprising the front edge of the through-wall flashing membrane extends through the outer wall, wherein a plurality of weep holes extend through the outer wall, the weep holes being located immediately above the front edge of the through-wall flashing membrane when the membrane is installed, thereby enabling water to flow along the portion of the through-wall flashing membrane covering the bases of the thermoplastic flashing support parts and through the weep holes.

2. The through-wall flashing support system of claim 1 wherein the plurality of thermoplastic flashing support parts comprise a plurality of straight run parts, each of the plurality of straight run parts having a substantially straight flange and a substantially straight rectangular base.

3. The through-wall flashing support system of claim 1 wherein the plurality of thermoplastic flashing support parts comprise one or more than one inner corner parts, each of the inner corner parts being configured to be attached to an inner corner of the cavity wall, the flange of each of the inner corner parts comprising two segments, the segments being substantially perpendicular to each other to allow the flanges to be attached to the inner wall at an inner corner of the inner wall.

4. The through-wall flashing support system of claim 1 wherein the plurality of thermoplastic flashing support parts comprise one or more than one outer corner parts, each of the outer corner parts being configured to be attached to an outer corner of the cavity wall, the flange of each of the outer corner parts comprising two segments, the segments being substantially perpendicular to each other to allow the flanges to be attached to the inner wall at an outer corner of the inner wall.

5. The through-wall flashing support system of claim 1 wherein the plurality of thermoplastic flashing support parts comprises: a plurality of straight run parts, each of the plurality of straight run parts having a substantially straight flange and a substantially straight rectangular base; one or more than one inner corner parts, each of the inner corner parts being configured to be attached to an inner corner of the cavity wall, the flange of each of the inner corner parts comprising two segments, the segments being substantially perpendicular to each other to allow the flanges to be attached to the inner wall at an inner corner of the inner wall; and one or more than one outer corner parts, each of the outer corner parts being configured to be attached to an outer corner of the cavity wall, the flange of each of the outer corner parts comprising two segments, the segments being substantially perpendicular to each other to allow the flanges to be attached to the inner wall at an outer corner of the inner wall.

6. The through-wall flashing support system of claim 1 wherein the flange of each of the thermoplastic support parts comprises tie holes for attaching the flange to the inner wall using fasteners.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A is a perspective view of an embodiment of a straight run part of the through-wall flashing support system.

(2) FIG. 18B is a perspective view of an embodiment of an inside corner part of the through-wall flashing support system.

(3) FIG. 1C is a perspective view of an embodiment of an outer corner part of the through-wall flashing support system.

(4) FIG. 1D is a perspective view of an embodiment of a spline part of the through-wall flashing support system.

(5) FIG. 2 is a side sectional view of a cavity wall with an embodiment of a prior art through-wall flashing system installed.

(6) FIG. 3 is a side sectional view of a cavity wall with an embodiment of the through-wall flashing support system installed.

(7) FIG. 4 is a top view of cavity wall illustrating a sequence of steps for an embodiment of the method of installing a through-wall flashing support system in a new cavity wall.

(8) FIG. 5 is a top view of cavity wall illustrating a sequence of steps for an embodiment of the method of installing a through-wall flashing support system in a retrofit cavity wall.

(9) FIG. 6 is a perspective view of a cavity wall at step of the method thereof with a first plurality of thermoplastic parts installed.

(10) FIG. 7 is a perspective view of a cavity wall at step of the method thereof with a second plurality of thermoplastic parts installed.

DESCRIPTION OF THE INVENTION

(11) The present disclosure describes a through-wall flashing support system (TWFSS) which provides support for the width of a cavity wall system to allow flexible flashing products, also known as through-wall flashings, to maximize their performance of intended use. The support system consists of thermoplastic flashing support parts (or just parts), namely; inside (or inner) corners, outside corners, straight runs and splines. The parts can be joined together to create a continuous substratum, sloped to the exterior to allow moisture and water that penetrates the outer masonry wythe to drain at an exterior wall to roof intersection or at the base of a cavity wall system.

(12) The use of embodiments of the TWFSS disclosed herein provide an exceptional ability to bridge the cavity along the length of the exterior wall. The parts provide full support of the through-wall flexible flashing membrane. Each part is installed onto the outer masonry support, pushed back to the inner wall and anchored to the inner wall using appropriate fasteners through the flange via integrated tie holes. The TWFSS is not intended to act as a lintel in any structural capability; it strictly provides support for the through-wall flexible flashing membrane. A positive slope is integrated into the base of each support part ensuring that water is directed outside.

(13) FIG. 1A depicts a straight run part 101 of a preferred embodiment of the TWFSS. The straight run part may be formed from a single piece of thermoplastic, the part having a surface with a base 105, a flange 109 and a curve 111. The base forms a rectangular shape with, in the depicted example part, a length of 4 feet and a width of 7 inches. The base, along the edge opposite to the curve, has a drop of .sup.th of an inch. The curve opposite side of the base may also be cut along its length 106 to fit various cavity walls. The flange also forms a rectangular shape with a length of 4 feet and a width of 3 inches. The flange has tie holes 108 spaced along the length of the flange approximately every four inches. All of the dimensions stated herein are examples only.

(14) FIG. 1B depicts an inner corner part of a preferred embodiment of the TWFSS. The inner corner part 102 may be formed from a single piece of thermoplastic with two segments, each segment having a surface with a curved portion to form a base 105, a flange 109 and a curve 111. The base 105 of both the first and second segments of the part, along the edge opposite to the curve, has a drop of .sup.th of an inch and may be cut along its length 106 to fit various cavity walls. The flange of both the first and second segments also form a rectangular shape with a length of 4 feet and a width of 3 inches. Each flange has tie holes 108 spaced along its length approximately every four inches.

(15) The base 105 of both the first and second sections of the inner corner part form a trapezoidal shape with a length of approximately 2 feet along the curve adjacent side and a length of approximately 17 inches along the curve opposite side. The corners of the trapezoidal base are angled at 90, 90, 45 and 135 degrees respectively. The first section of the part is joined to the second section of the part at the base such that the 45 degree corners of the first and second sections of the part are joined and that the 135 degree corners of the first and second pieces of thermoplastic are joined. Where a support terminates at an end wall, inside corners may have a leg sawed off 107 leaving an end dam to prevent water from running off the end of the support. Similarly, on the curve opposite side of the base, the part may be cut to fit various cavity walls.

(16) FIG. 1C depicts an outer corner part of a preferred embodiment of the TWFSS. The outer corner part 103 may be formed from a single piece of thermoplastic with two segments, each segment having a surface with a curved portion to form a base 105, a flange 109 and a curve 111. The base 105 of both the first and second segments of the part, along the edge opposite to the curve, has a drop of .sup.th of an inch. The flange of both the first and second segments form a rectangular shape with a length of 4 feet and a width of 3 inches. Each flange also has tie holes 108 spaced approximately every four inches along its length.

(17) The base of each of the first and second segments form a trapezoidal shape with a length of approximately 17 inches along the curve adjacent side of the base and a length of approximately 2 feet along the curve opposite side of the base. The corners of the trapezoidal shaped bases are angled at 90, 90, 45 and 135 degrees respectively. The first segment of the part is joined to the second segment of the part at the base such that the 45 degree corners of the first and second segments of the part are joined and that the 135 degree corners of the first and second segments are joined. Similar to the straight run and inner corner parts, the outer corner part may be cut along the curve opposite side of the base 106 to allow the part to fit various cavity walls.

(18) FIG. 1D depicts a spline part of a preferred embodiment of the TWFSS. The spline part is designed to allow the later ends of the bases of the straight run, inner corner and outer corner run parts to fit in the spline part. The spline part may be formed from two rectangular segments 104 attached by a connector segment 112 extending along the center of the length of a face of each of the two rectangular pieces. Each rectangular piece and the connector strip has a length of approximately 6 inches. The connector strip is of an inch wide and its height varies from 1/16.sup.th high on one side to the thickness of the base of the straight run, inner corner run or outer corner run parts 6 inches in from the lip of the base towards the curve. Each of the rectangular pieces are approximately wide and 1/16.sup.th thick.

(19) FIG. 2 depicts a side view of a prior art through-wall flashing system installed in a building without a support system. A flexible membrane 203 is attached to the inner wall 206 and is installed through the outer wall 205. Weep holes (or brick vents) are installed and the outer wall wythe 213 is constructed, on top of the flexible membrane, along the base wall 211. The base wall may be supported by structural members 207. A weep hole, for the purposes of this disclosure, refers to any device that serves to as a way to remove moisture from the cavity and includes open head joints, wicking, tubes, corrugated channels or any other device that defines a fluid path from the cavity to outside the outer wall.

(20) Moisture or fluid that escapes from the cavity is directed outside of the outer wall. Once the flexible membrane is installed, insulation 204 is applied to the inner wall so that moisture is directed down the inner cavity 202 to the flexible flashing membrane and the weep holes.

(21) A through-wall flashing system without support, particularly when installed incorrectly, often suffers from membrane sagging between the point where the membrane is installed in the outer wall and the where it is attached to the inner wall. This sagging creates a gutter 201 where moisture can collect. This moisture can potentially leak past the barrier at the flashing seams or otherwise and make its way into the building.

(22) FIG. 3 depicts a side view of a through-wall flashing system with an embodiment of the TWFSS installed. The TWFSS system is installed along the the base wall 211. Flexible flashing membrane 203 is then attached to an inner wall 206 and is installed on top of the TWFSS 314 through the outer wall 205. Weep holes (or brick vents) are installed and the outer wall wythe 213 is constructed, on top of the flexible membrane, along the base wall. The base wall may be supported by structural members 207. Once the flexible membrane is installed, insulation 204 may be applied to the interior wall 206 so that moisture is directed down the cavity 202 to the flexible flashing membrane and the weep holes. The through-wall flashing system depicted by FIG. 3 does not suffer from membrane sagging between the point where the membrane is installed in the outer wall wythe and where it is attached to the inner wall wythe 301. The slope of the support system ensures that moisture is directed to the weep holes so that it may escape the building.

(23) This TWFSS may be used in new construction and in the retrofit of existing through-wall flexible flashing membranes. Where a part is required to be cut to the correct length to complete the system, a jig and router is needed to route in a spline channel. In this instance, only the bottom or horizontal leg is required to be routed.

(24) FIG. 4 depicts a plan view of a cavity wall and a preferred embodiment of a method for installing the TWFSS on said cavity wall for new construction. In the preferred embodiment depicted by FIG. 4, the method begins with the installation of a corner part. The installation steps are as follows: 1. Install an inside corner part onto a corner of the base wall and fasten the inside corner part to the inner wall 401. 2. Install a full length straight run part adjacent to the last part installed 402. Repeat this step until the most recently installed part is within 4 feet of a corner. 3. Install an outer corner part in the corner of the base wall and fasten to the inner wall 403. 4. Measure the remaining distance between the most recently installed corner and straight run parts (should be less than 4 feet), cut straight run part to suit length and fasten to inner wall 404. 5. Install spline parts between each adjacent support part 405. 6. Install a flexible flashing membrane to the specific manufacturer's specifications over length of TWFSS. 7. Repeat procedure on adjoining walls of the building until perimeter is complete. 8. Install masonry and weep holes above TWFSS once the through-wall flashing system is installed.

(25) FIG. 5 depicts a plan view of a cavity wall and a preferred embodiment of a method for installing the TWFSS on said cavity wall for retrofit construction. In the preferred embodiment depicted by FIG. 5, the method for installing the TWFSS with retrofit construction scenario is similar to the embodiment of the method depicted by FIG. 4 for installing the TWFSS with new construction except that the builder is now required to remove sections of the existing wythe in the outer wall order to install the TWFSS. The outer wall wythe is removed in alternating sections such that any section that is removed is flanked by two support sections supporting the remaining wythe. Once the TWFSS is installed in each of the alternating sections, the outer wall wythe is filled in and the support sections are removed. The filled in sections of the outer wall wythe become the new support sections and the former support sections become the new installation sections. Example installation steps for a preferred embodiment of the retrofit installation method are as follows: 1. Install a corner section by cutting an approximately 2 foot 4 inch wide opening and fasten the inside or outside corner part to inner wall. Next, install flashing over the corner part within 2 inches of both ends of the part 501. Install new masonry pier approximately 1 foot 8 inches wide in each direction leaving ends of flashings exposed. 2. Sawcut approximately 5 feet wide openings in the existing masonry leaving a 2 foot 8 inch wide pier in between openings alternating along the length of wall. Install a straight run part centered in each opening and fasten to the inner wall. Install a length of approximately 3 feet 8 inches of flashing centered on the TWFSS 502. Install new masonry pier approximately 4 feet 8 inches wide in line with the brick coursing head joints above on TWFSS and flexible flashing membrane. 3. Once all new masonry piers in openings have been installed and the mortar used in the masonry piers have reached a minimum strength, remove the remaining piers. Measure distance remaining between the TWFSS, cut a straight run part to suit length. Install cut straight run and fasten to the inner wall 503. Install splines between any adjacent parts 506. Install a flexible flashing membrane over the parts and overlap the flexible flashing membrane according to the manufacturer's recommendations. 4. Sawcut an approximately 2 feet 4 inch wide opening in each direction, install outside corner part and fasten to the inner wall. Install a length of approximately 22 inches of flexible flashing in each direction leaving the ends exposed and install new masonry pier approximately 16 inches wide 504. 5. Once a new masonry pier in an opening has been installed in step 4, and the mortar has achieved its minimum strength, remove existing piers remaining in location 505. Measure the distance between each installed part and cut a straight run part to suit the length. Next, install the cut straight run parts and fasten to the interior wall 505. Once all the support parts are installed, install the spline parts between each adjacent support part 506. Finally, install a flexible flashing membrane over TWFSS and overlap the membrane as per manufacturer's installation instructions. 6. Install masonry to fill in the opening and restore the outer wall.

(26) FIG. 6 depicts a front perspective section view of the cavity wall with the TWFSS partially installed according to the embodiment of the retrofit installation method depicted by FIG. 5. Openings in the existing masonry have been cut to allow an inner corner part 102, a straight run part 101 and an outer corner part 103 to be installed while leaving support piers 602 along the lateral extent of the outer wall supporting the outer wall wythe 601. In the center of each of the opening, the thermoplastic support parts are fastened to the inner wall. An inner corner part, a straight run part, and an outer corner part is shown. A flexible flashing membrane is installed on each of the TWFSS support parts.

(27) FIG. 7 depicts a front perspective section view of the cavity wall with the TWFSS partially installed according to the embodiment of the retrofit installation method depicted by FIG. 5 and FIG. 6. FIG. 7 represents the installation method of FIG. 5 at later step in the installation process 503. The support piers 601 have been removed and an inner corner part, a straight run part and an outer corner part have been previously installed in the cavity wall. New support piers have been constructed on top of the base of each respective inner corner 701, straight run 702 and outer corner part 703. The new support piers are constructed out of masonry, similar to the outer wall wythe, and are of sufficient strength to support the outer wall wythe above each pier 305 and over each opening 601.

(28) In openings where the original support piers 602 have been removed, new straight run parts 101 have been installed. These parts are placed along the base wall and attached to the inner wall 306. The straight run parts may also be cut so that they are of a suitable length to fit between previously installed parts. Each part is connected 506 to its adjacent thermoplastic support parts using the spline parts 104. A flexible flashing membrane 303 is also installed on top of the parts covering the base of each of the straight run parts, spline parts and an overlapping portion of each thermoplastic support part previously installed (i.e. the parts located behind the new support piers). The flashing is to be installed, according to the manufacturer's directions, so that it covers the entirety of the base and extends through the outer wall to provide a fluid path for any moisture in the cavity wall to the exterior. The depicted cavity wall at this step in the retrofit method has the TWFSS installed and all that remains is to install masonry to complete the opening.

(29) Where, in this document, a list of one or more items is prefaced by the expression such as or including, is followed by the abbreviation etc., or is prefaced or followed by the expression for example, or e.g., this is done to expressly convey and emphasize that the list is not exhaustive, irrespective of the length of the list. The absence of such an expression, or another similar expression, is in no way intended to imply that a list is exhaustive. Unless otherwise expressly stated or clearly implied, such lists shall be read to include all comparable or equivalent variations of the listed item(s), and alternatives to the item(s), in the list that a skilled person would understand would be suitable for the purpose that the one or more items are listed. Unless expressly stated or otherwise clearly implied herein, the conjunction or as used in the specification and claims shall be interpreted as a non-exclusive or so that X or Y is true when X is true, when Y is true, and when both X and Y are true, and X or Y is false only when both X and Y are false.

(30) The words comprises and comprising, when used in this specification and the claims, are used to specify the presence of stated features, elements, integers, steps or components, and do not preclude, nor imply the necessity for, the presence or addition of one or more other features, elements, integers, steps, components or groups thereof.

(31) It should be understood that the above-described embodiments of the present invention, particularly, any preferred embodiments, are only examples of implementations, merely set forth for a clear understanding of the principles of the invention. Many variations and modifications may be made to the above-described embodiment(s) of the invention as will be evident to those skilled in the art. That is, persons skilled in the art will appreciate and understand that such modifications and variations are, or will be, possible to utilize and carry out the teachings of the invention described herein.

(32) The scope of the claims that follow is not limited by the embodiments set forth in the description. The claims should be given the broadest purposive construction consistent with the description and figures as a whole.