US 3812635 A
A combined insulating and waterproofing apparatus, system and method comprising substantially rectangular shaped blocks of expanded polymeric plastic materials having insulative characteristics which blocks are disposed in predetermined adjacent proximate relationship with one another and positioned between the inner and outer wythes of a wall construction with the horizontal edges of the blocks being angularly inclined in a downward direction as viewed from the inner wythe with respect to the outer wythe.
Description (OCR text may contain errors)
United States Patent 1 Hala [111 3,812,635 [451 May 28, 1974 METHOD OF FABRICATING A COMBINATION WATER AND INSULATED WALL ASSEMBLY  Inventor: Alfred A. Hala, 28 Meeks Ln., lslip,
221 Filed: June 8,1973
21 Appl. No.: 368,330
Related U.S. Application Data  Division of Ser. No. 231,206, March 2, 1972, Pat.
 US. Cl 52/741, 52/410, 52/746  Int. Cl. E041) 1/70,-l-l04b 12/28  Field of Search 52/404-410, 52/561-564, 741, 746, 379
 References Cited UNITED STATES PATENTS Woodwurth 52/405 2,718,138 9/1955 Jones 50/410 3,206,805 9/1965 Steenhagen... 52/408 3,426,494 2/1969 Hala 52/410 Primary Examiner-John E. Murtagh Attorney, Agent, or Firm-Philip D. Amins  ABSTRACT A combined insulating and waterproofing apparatus, system and method comprising substantially rectangularshaped blocks of expanded polymeric plastic materials having insulative characteristics which blocks are disposed in predetermined adjacent proximate relationship with one another and positioned between the inner and outer wythes of a wall construction with the horizontal edges of the blocks being angularly inclined in a downward direction as viewed from the inner wythe with respect to the outer wythe.
17 Claims, 25 Drawing Figures PATENTEUMAY 28 1914 SHEET 1 [If 5 PATENTEDmzs I974 SHEET Q 0F 5 FIG. I?
PATENTEDMAY 2 8 m4 SHEEI 5 OF 5 FIG. 2/ FIG. 22 FIG. 23
METHOD OF FABRICATING A COMBINATION WATER AND INSULATED WALL ASSEMBLY The present application is a division of application Ser.'No. 231,206, filed Mar. 2, 1972, now US. Pat. No. 3,772,840 in the name of Alfred A. Hala and entitled INSULATING AND WATERPROOFING APPARA- TUS.
BACKGROUND OF THE INVENTION The present invention pertains to a new and novel combined insulating and waterproofing system and method of fabricating the same employing a new type of block member having both insulating and waterproofing characteristics.
Present edifices and structures are known to employ insulative sheets in the wall systems thereof; i.e., between the inner and outer wythe constructions, to provide insulation for the interior thereof. However, there does not presently exist an effective simple system or method of construction which will provide the more important aspect of being waterproof and which will also serve to insulate the interior of the resultant structure.
Although I have provided an effective waterproofing system, as described in my US. Pat. No. 3,426,494, the same does not provide the insulative qualities which are both necessary and desirable. Thus, there presently exists the need for a simple combination waterproofing and insulating system.
SUMMARY OF THE INVENTION Accordingly, it is the primary object of the present invention to provide a new and novel combination waterproofing and insulative apparatus and method of fabricating the same to result in a new system to be employed in the construction of wall assemblies.
It is another object of the present invention to provide a system of the aforementioned type which is relatively simple to install and which does not require unusual skill in the installation thereof.
It is a further object of the present invention to provide a new and novel block construction when connected as a system in conjunction with a wall assembly is effective to waterproof said wall assembly.
It is yet another object of the present invention to provide a block construction of the aforementioned type which is fabricated from an insulative material so as to provide a combined insulating and waterproofing system.
It is yet a further object of the present invention to provide a system of the aforementioned type employed in conjunction with existent wall-tie structures.
It is still another object of the present invention to provide a system of the aforementioned object wherein the block construction of the wall system is secured simply and efficiently by means of adhesive securement.
The invention encompasses a combined insulating and waterproofing system employing expanded polymer plastic blocks having angularly inclined upper and lower edges disposed in juxtaposed relationship and psitioned between the inner and outer wythes of a wall structure. The individual blocks are secured by use of wall ties in the wall structure or by adhesive securement means.
BRIEF DESCRIPTION OF THE DRAWINGS structed pursuant to the principles of the present invention which is illustrative of a first embodiment thereof;
FIG. 2 is a sectioned elevational view taken on the line 22 of FIG. 1;
FIG. 2A is a sectional view taken on the line 2A2A of FIG. 2;
FIG. 3 is a sectional view taken on the line 3-3 of FIG. 1;
FIG. 4 is a sectional view depicting a combination insulating and water-proofing system representative of a second embodiment of the present invention with the inner wythe of the wall structure being built first;
FIG. 5 is a sectional view similar to FIG. 4 depicting a third embodiment of the present invention wherein the outer wythe of wall structure is built first;
FIG. 6 is a sectional view similar to FIG. 4 depicting a fourth embodiment of the present invention;
FIG. 7 is a sectional view similar to FIG. 4 depicting another embodiment of the present invention employing double layers or blocks of insulation for additional insulation and waterproofing when the vertical joints are in laterally offset relationship;
FIG. 8 is a section elevational view depicting another embodiment of the present invention employed in conjunction with a structural base member and using gypsum board as the inner wythe;
FIG. 9 is a sectional view illustrating a further embodiment of the present invention;
FIG. 10 is a sectional view depicting another embodiment of the present invention wherein the combined insulating and waterproofing system is employed in conjunction with an adjustable wall-tie construction;
FIG. 11 is a top view taken on the line 11-11 of FIG. 10;
FIG. 12 is a top sectional view depicting another embodiment of the new insulating and waterproofing block construction which is therein adhesively secured to the outer wythe of a wall construction;
FIG. 13 is a sectional view similar to FIG. 12 illustrating another manner in which to waterproof the vertical joints of the block construction;
FIG. 13A is a sectional view similar to FIG. 13 illustrating another embodiment of the invention;
FIG. 14 is an elevational section depicting another embodiment of the invention which illustrates theapplication of the system in conjunction with the structural floors of an edifice;
FIG. 15 is an elevational sectional view depicting another embodiment of the angular inclination of the iongitudinal edges of the block construction of the present invention;
FIG. 16 is a view similar to FIG. 15 depicting a third embodiment of the angular inclination of the longitudinal edges of the block construction;
ing another embodiment of a combined insulating and waterproofing system;
FIG. 18 is a sectional view taken on the line 18-18 of FIG. 17;
FIG. 19 is a sectional view taken on the line 1919 of FIG. 17;
FIG. 20 is a section elevation view depicting another embodiment of the present invention;
FIG. 21 is a sectional view illustrating end cap members employed to provide the angular inclination of the longitudinal edges of the block construction;
FIG. 22 is a sectional view similar to FIG. 21 illustrating another embodiment of end caps; and
FIG. 23 is a sectional view similar to FIG. 21 illustrating a further embodiment of end cap members employed to achieve the desired angular inclination.
DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, and more particularly toFIG. 1 thereof, there is shown a combination insulating and waterproofing system constructed pursuant to the principles of the present invention. The system comprises blocks 12 preferably fabricated from an expanded polymer plastic material, such as polystyrene or polyurethane. However, foam glass and fibreglas material may also be employed. The blocks are preferably of rigid construction but capable of deformation or tearing upon the application of a predetermined amount of pressure, as will be discussed more fully hereinafter. The insulating blocks 12 are disposed between the inner wythe l4 and the outer wythe 16 ofa wall structure. As shown in FIG. 1, the wall structure is constructed on a' masonry foundation indicated by the reference numeral 18; however, the foundation may be fabricated from steel or any'other suitable material. The inner wythe I4 is constructed from concrete blocks 20, but may be constructed from brick or other suitable masonry or building material. Similarly, the outer wythe 16 can also be constructed of any suitable masonry or building material, such as brick, concrete block, cement, asbestos, steel, wood, etc. The wall structure itself may employ rows of wall-ties 22 built-in with the outer wythe 16 or built-in reinforcing rod assemblies 24 having tie members 26.
The insulating blocks 12 are fabricated having angularly inclined horizontal edges 28 with the upper and lower horizontal edges being disposed in substantially parallel relationship, whereby the vertical cross-section of the blocks is in the form of an irregular parallelogram. As seen in FIG. 2, it is possible to form the block with only a singular angularly inclined horizontal edge for use as bottom or top members.
In the application of the insulating blocks or sheets 12 with respect to the wall-tie embedded outer wythe 16, which is constructed first, the block 12 is placed flush upon the-base l8 and the upper horizontal edge' is then forced upon the wall-ties 22 by applying pressure upon the front face or surface 30 of the block 12.-
This force causes the deformation of the horizontal edge 28 and forms a vertical tear or slit 32 (FIG.2A); however, the'block is easily placed in position with respect to the outer wythe 16. In this regard, it is to be noted that although the rear surface'34 of block 12 is in substantially flush or abutting relationship with the inner surface of outer wythe 16, it is actually spaced therefrom due to mortar 35 or other debris which adheres to the wythe 16 during construction thereof. Thus, there is formed a vertical channel or space 36 between the wythe 16 and the blocks 12.
The blocks 12 are forced upon the wall-ties 22 or tie members 26 in horizontal rows or courses, usually starting from the bottom up. However, the courses may be commenced from the top or from an intermediate position without adversely affecting the completed system.
Referring now to FIGS. 1 thru 3, it will be seen that the application of two courses of the blocks'12 results in the upper horizontal inclined edge 28 of the lower block and the lower horizontal edge of the upper block being disposed in juxtaposed position and forming a small horizontal angular channel or joint 38 which is directed downwardly from the inner wythe 14 to the outer wythe 16. The channel 38 is formed due to the fact that in the application of progressive courses of edges of adjacent blocks in abutting fluid-tight relationship, even though the edges are parallel.
The vertical edges 40 of horizontal blocks 12 in the same course are also disposed in slightly spaced relationship even when attempting to place them in sideby-side abutting relationship and thus form a vertical joint 42. However, the system is constructed in a manner such that the vertical joints 42 in one course are preferably laterally offset with respect to the vertical joints in the next vertically adjacent course; the importance of which will be discussed hereinafter.
The blocks or sheets 12 of insulating material are preferably fabricated having heights of sixteen inches and lengths of from 4 to 9 feet. The length is much more a matter of design than the height since it is common practice in masonry construction to place the wall-ties 22 in the outer wythe with a vertical'spacing of sixteen inches. However, if the vertical wall-tie spacing is more or less than sixteen inches the height of the blocks l2 can be varied accordingly.
After the system 10 has been installed, as hereinabove described, and the outer and inner wythes of the wall structure completed, the structure is both waterproof and insulated. The structure is insulated by virtue of the insulating material and waterproof by virtue of the construction in the following manner. If any water should permeate between the inner and outer wythes Hand 16, respectively, it. will tend to flow downwardly. If the water flows down upon the rear surface 34 of the blocks 12, it will flow down through channel 36 and be prohibited from permeating the blocks 12 and also the inner wythe 14. If water flows downwardly upon the inner surface 30 of a block 12, it will then It will thus be apparent that any water orvapor which subsequently moisturized will always be directed away from the inner wythe by virtue of the present invention due to the new and novel construction of the insulating blocks 12. It will also be readily apparent to those skilled in the art that the method of installing the system is simplicity itself in that no tools of any kind are required since the system is assembled merely by the pressure applied to the blocks 12 by a workman.
It is to be noted that although the insulating blocks or sheets 12 have herein been described as having an irregular parallelogram cross-section, the term angular inclination is meant to include a configuration wherein the angular inclination extends from the front upper horizontal edge rearwardly towards the rear lower horizontal edge.
Referring now to FIG. 4, wherein similar parts are denoted by similar reference numerals, there is shown a second embodiment of the present invention wherein the inner wythe 14 is constructed prior to the construction of the outer wythe 16. The inner wythe has rein-- forcing rod assemblies 24 built in therewith. The assemblies include tie members 26a of the type described in my US. Pat No. 3,426,494 and includes a plastic disc 44 slidably mounted on the members 26a in tight frictional engagement. The discs are normally uniformly spaced on the tie members 26a wherefore the blocks 12 are pressed upon the tie members 26a with the front surface 30 of the blocks 12, as viewed from the inner wythe 14, in abutting engagement with the discs 44. The outer wythe 16 is then constructed and there is provided the vertical channel 36.
FIG. 5 illustrates another embodiment wherein similar parts are denoted by similar reference numerals. In this embodiment the outer wythe 16 is constructed first and the blocks 12 are pressed upon the tie members 260 until they abut the discs 44. Thereafter, the wall structure is completed by building the inner wythe 14. It is to be noted that there is herein provided a larger vertical channel 36 whereby the blocks 12 are spaced in closer adjacent relationship to the inner wythe 14.
In FIG. 6 there is illustrated another embodiment wherein the blocks 12 are positionally secured between the inner and outer wythes 14 and 16, respectively, by means of an adjustable wall-tie member 46. The member includes a tie portion 26b having an eye 48 and an arm portion 50 having a hook 52. The outer wythe 16 is constructed first and the blocks 12 press fitted upon the tie portion 26b between the eye 48 and the inner surface of the outer wythe 16. As discussed previously, the mortar 35 actually prevents the blocks 12 from resting flush against the outer wythe 16 and contributes to the formation of the vertical channel 36 necessary for the downward flow of water away from the inner wythe 14.
After the blocks 12 have been inserted in place, the hooks 52 which also serve to position the blocks within the wall structure, are placed in the eyes 48 and arm portions 50 are built-in with the inner wythe 14 to complete the wall structure. Thus, any water flow will pass either through joints 38 into channel 36 or directly into channel 36 and then outwardly-from the wall structure, as will be discussed hereinafter.
Referring now to FIG. 7, there is shown another embodiment of the present invention wherein similar parts are denoted by similar reference numerals. In this em-' bodiment, the inner wythe 14 is constructed first and two layers or thicknesses of blocks 12 herein denoted 37 and 39 are mounted between adjacent rows of vertical tie members 26. This construction results in the formation of a secondary. vertical channel 54 which is disposed between the two layers of insulating blocks 37 intended by the use of this terminology in the present and 39. After the two layers are press fittd upon tie members 26, the outer wythe 16 is constructed to complete the wall structure. Thus, any water flowing downwardly upon the inner face of the blocks 12 of layer 37 will flow through joint 38 and then downwardly in channel 54. If the water should flow over upon the face of the blocks 12 of layer 39, it will flow downwardly through the secondary joint 138 into vertical channel 36.
It is to be noted that the spacing between the adjacent layers of blocks 12 to form vertical channel 54 is dependent to some extent upon the workman s installation and the environmental cleanliness. However, whether there is any spacing between the adjacent layers of blocks 12 is unimportant. Moreover, the present embodiment is constructed in a manner wherein the vertical joints in layer 37 are laterally offset with respect to the vertical joints in layer 39'. Thus, any water permeation through the vertical joints in layer 39 will flow downwardly in the secondary vertical channel 54 until it reaches the horizontal joint 138 adjacent the outer wythe l6. Thereafter, the water flows downwardly within the horizontal joint 138, from where it is directed into vertical joint 36.
This system may be employed where additional insulating qualities of the finished wall structure are required.
With reference now to FIG. 8, there is shown another embodiment of the present invention wherein the outer wythe 16 is constructed first and the insulating blocks 12 are secured to the outer wythe by means of glue or any other suitable adhesive 56 placed on the inner surface of the outer wythe or on rear surface 34 of blocks 12. The blocks 12 are then placed upon the inner surface of the outer wythe 16 in courses, as discussed previously, and securely connected by means of the adhesive. The adhesive 56 may be of the epoxy type which dries rather quickly and which renders a firm bond. The adhesive 56 is applied on outer wythe in a random pattern whereby there is provided the vertical flow channel 36.
The present embodiment includes a structural base member 58 fabricated of concrete, steel or other suitable material to which is secured a Iintel 60 by means of an anchor bolt 62. The outer wythe l6 rests upon the lintel 60. The base 58 has the upper corner thereof champhered as at 64 so that the angular inclination there is complementary with the lower horizontal edge 28 of the lower most ones of the insulating blocks 12 which together form an angularly downward inclined channel 66 similar to the channel 38 formed by the complementary horizontal edges of vertically adjacent blocks 12. The bottom portion of the outer wythe 16 is provided with weep holes as indicated by the dash line 68.
- Secured. to the front surface of the blocks 12 by means of adhesive 56 is a gypsum board inner wall,
which for the purposes of the present invention is deemed to be the inner wythe identified by the reference numeral 70. It is to be understood that although an inner wythe is normally construed to be one which is fabricated of masonry material, no such limitation is application. It is herein to be noted that the present wall system due to the camphered edge 64, resulting channel 66 and weep holes 68 results in a system which is self flashing, i.e., one wherein the water is directed ets 72 are secured to the blocks 12. The channel members 72 may be secured by means of vertical support members (not shown), by adhesive .securement to blocks 12 or secured through the insulating blocks 12 into the brick outer wythe 16 by means of fasteners 74,
as shown. The gypsum board inner wythe 70 is then secured to the channel members 72 by means of fasteners 76. The channel members 72 may also be disposed vertically and may be free standing; i.e., secured only at the top and bottom portions thereof.
FIGS. and-ll illustrate another embodiment of the invention wherein the inner wythe 14 is constructed I first having tie members 26b embedded therein and upon which are mounted discs 44. The blocks 12 are pressed upon tie members 26b in abutting engagement with discs 44. The arm portions 50 are then secured to the tie members by inserting the hooks 52 into the eyes 48. The inner wythe 16 is then constructed with the arms 50 embedded therein.
It is herein to be noted that although in several embodiments of the invention one wythe is deemed to be built prior-to the other, it is possible to have the heights of both the inner and outer wythes built substantially simultaneously and have the insulating blocks inserted therebetween course by course. Similarly, the order of construction of the wythes may also be varied.
While the present embodiment has been described as utilizing the discs 44 to space the blocks 12 from inner wythe 14 to prevent water seepage through said inner wythe, it is possible, but not preferable, to omit discs 44 and have the blocks substantially flush with the inner wythe 14. In this instance, almost all water would be directed outwardly of the wall system but the vertical joints between horizontally adjacent blocks could present a somewhat limited problem, which subsequent embodiments of the invention obviate.
An embodiment of the present invention which obviates the problems created at the vertical joints of the combined waterproofing and insulating system of the invention is depicted in FIG. 12. The vertical joints 78 which are formed by the joinder of the vertical edges 80 of the blocks 12 are champered asat 82 to provide a V-shape indentation or joint whereby any water flowing down the rear face 34 of the blocks 12 and through the vertical joints 78 will flow inwardly along the inner portion of the V-shaped joint'78 away from the inner I wythe. Since the vertical joints are laterally offset with respectto one another from course to course, the water running downwardly along a particular indented joint 78 will thereafter be directed outwardly by horizontal joints 38 into the rear vertical channel 36. Therefore,
the water will be prevented wythe.
Another embodiment of. the invention to solve the problems created at the vertical joints is shown in F IO. 13, wherein a pressure sensitive and waterproof tape 83 from seeping into the inner is secured along the entire vertical joint 78 inner surface of adjacent blocks 12.
In FIG. 13A is depicted another embodiment for solving the water seepage problem which might occur at the vertical joint 78. In thisv embodiment, thelateral ends of the blocks 12 are effectively sealted by molding strip 84 which has a T-section configuration. The strip 84 may be fabricated of metal or preferably plastic and extends along the entire height of the blocks 12 in an integral configuration. The strip. 84 includes a serrated shank portion 86 and an arcuate or beaded head portion 88. The shank portion 86 is force fitted into the joint 78 and grippingly engages the edges of adjacent blocks 12 to effectively seal the vertical joint 78 from the inner wythe. In this regard, anypossible water permeation, such as that .whichmight occur from a heavy rainstorm, through the outer wythe 16 and into the rear of joint 78 would be prevented from passing through the joint by head 88 and thus, would be prevented from seeping into the inner wythe. Any water passing into joint 78 would be directed downwardly-therein until it reached'the horizontal joint 38 and from there would be diverted outwardly of the inner wythe, as discussed in detail hereinbefore.
Referring now to FIG. 14, there is depicted a further embodiment of the invention for use in conjunction with edifices having structural floor members such as the concrete floor slab 92. The slab 92 has a cutout portion 94 which may be rectangular as illustrated or of any other suitable configuration. The reduced slab portion 96 is secured with respect to theouter wythe upon the 16 in a well known manner. The lowermost block 12 of the wall above slab 92 is positioned within cutout 94 with the lower rear horizontal edge 28 of the block 12 being positioned substantially upon or in slight spaced relationship to the upper surface of the slab portion 96. The upper front horizontal edge 28 of the block immediately below slab 92 isdisposed in substantially abutting engagement withthe underside of slab 92. The outer wythe 16 is provided with weep holes, as indicated by the dashed line 68, at spaced locations disposed horizontally adjacent cutout portion 94. Thus, any water flow within the wall system would flow downwardly in channel 36 and. any water flowing on the front face of the lowermost block 12 would flow into cutout portion 94 and thence outwardly from the wall structure via weep holes 68. Thus, the present embodiment comprises a self flashing system.
With reference now to FIGS. 15 and 16, there is therein illustrated alternate embodiments of the angular inclining horizontal edges 28 of the block 12. The edge 28 of FIG. 15 is of substantially sawtooth configuration while that of FIG. 16 is of an arcuate configuration.
It is herein to be understood that the terms angular inclination and angularly inclined are deemed to mean any configuration wherein the edge on one face of the block is at a different elevation with respect to the edge on the other face of the block when the block is placed in its normal vertical orientation; in the present embodiments when the faces of the block are disposed in parallel relationship with the-vertical plane.
Referring to FIG. 17, there is illustrated an alternate embodiment of the present invention, wherein the problems of water seepage from both the horizontal and vertical joints are solved simultaneously by the novel system to be discussed hereinafter. FIGI17 is similar to FIG. 1 and. similar parts are denoted by similar reference numerals.
In this embodiment, the outer wythe 16 is constructed first and rests upon the foundation 18. The wythe 16 has ties 22 and tie-members 26 disposed therein. The waterproofing system 100 is constructed by employing blocks 12 of the type discussed previously but the blocks are inserted upon the ties 22 in overlapping relationship (FIG. 18). The blocks 12 are pressed upon ties 22 in a manner whereby the vertical edges 80 of two adjacent blocks are disposed in laterally offset relationship to one another. Similarly, the rear face 34 of a block 12a is disposed in abutting engagement with the front face of the two blocks 12b and 12c, respectively (FIG. 18).
From FIG. 19, it will be apparent that any water flowing between the inner and outer wythes 14 and 16, respectively, will always be directed outwardly toward the outer wythe via horizontal joint 38 into the vertical downward channel 36. Moreover, since this system encompasses placing the blocks 12 in overlapping relationship, effectively by just slapping the blocks on top of one another without requiring the fitting of one block next to another, the amount of skill required to effect this combined insulating and waterproofing system is minimal. In the present era where highly skilled labor is difficult to obtain, the present system is a significant advancement in the field of building construction by providing a vastly superior system which is easily installed.
From FIG. 18, it will be readily apparent that the present embodiment obviates the problem of water seepage through vertical joints since this type of joint, per se, no longer exists. In this regard, the edge 80 of a block is never disposed next to nor is it coextensive with another similar edge of an adjacent block. Instead the edge 80 is positioned upon either the front face 30 or the rear face 34 of another block, whereby it is virtually impossible for any waterflow upon edges 80 to seep into the inner wythe 14.
It will also be apparent to those skilled in the art that it is within the purview and scope of the present invention to secure the blocks 12 with respect to the ties 22 in a lancing fashion; i.e., by press fitting a block upon a singular or plurality of ties 22 with the ties piercing or extending through the central portion of the blocks 12, as opposed to the edge portions of said blocks.
With reference to FIG. 20, there is depicted still a further embodiment of the present invention wherein the tie members 260 are provided with a pair of discs 44. The outer wythe 16 is constructed first and the blocks are interposed between the pairs of discs. Thus, blocks 12 are positionally secured between the outer wythe 16 and the inner wythe 14 with the discs 44 in abutment with the blocks 12 insuring that the positional disposition of the blocks will remain constant due to the frictional engagement of the discs 44 upon the tie member 260..
Although the blocks 12 have herein been described as being integral members fabricated having the angularly inclined horizontal edge 28, the blocks may be fabricated of a substantially rectangular configuration having end cap members secured in relation to the horizontal edge to provide the necessary angular inclination. Embodiments of this portion of the invention are depicted in FIGS. 21 through 23. FIG. 21 depicts a block member 120 having angular end caps 102 which are preferably formed of a hardened inert plastic material but which may be formed of metal or any other suitable material. The end caps 102 include beads or ridges 104 which when the end caps are placed upon the blocks 12a, grippingly engage the blocks. The end caps may be placed uon blocks and the sides 106 of the end caps pressed together to cause the ridges 104 to seat themselves with respect to blocks 12a by forming longitudinal grooves or slots 108 in which the ridges are seated. The angular inclined edges 28a of the end caps 102, then cooporate to form the horizontal joint 38.
FIG. 22 illustrates an end cap 110 which is of angular L-shaped configuration with the base portion 112 thereof being secured to one of the faces of blocks 12a adhesively, such as by means of double backed adhesive strip 114; however, any suitable fastening means may be employed. The arm portion 116 comprises the angularly inclined edge 28a.
FIG. 23 illustrates an end cap member 118 secured to the upper horizontal edge of the blocks 12a. In this embodiment, the lower horizontal edge may be flush since the member 118 includes an upwardly extending edge portion 120 which protrudes above the lower horizontal edges of the blocks 12a to thereby produce a horizontal joint 38a which will direct all water flow downwardly and rearwardly of the inner wythe.
It will be apparent to those skilled in the art that the tear slits, horizontal joints and vertical channels provide a breathing system which will allow water vapor to pass through the wythes.
It is herein to be noted that the blocks have been described as formulated of expanded plastic material so as to be insulative; however, this cellular construction does not provide a highly wettable surface. If a highly wettable surface is desired for special constructions, then the blocks may be coated with a wetting agent on one or more surfaces thereof. The blocks may also be coated with a water absorbent layer for specialized construction requirements.
While I have shown and described the various preferred embodiments of my invention, it will be apparent to those skilled in the art that there are many modifications, changes and improvements which may be made therein without departing from the spirit and scope of the invention.
What is claimed is:
1. The method of fabricating a combination waterproof and insulated wall assembly having an inner wythe and an outer wythe comprising the steps of building one of said wythes,
securing a plurality of insulative block members disposed in contiguous horizontal rows with respect to said wythe wherein said block members have upper and lower horizontal edges which are angularly inclined in a downward direction from the inner wythe to the outer wythe, and
building said otherone of said wythes to complete the wall assembly.
2. The method of claim 1, wherein said one of said wythes constructed first is said outer wythe.
3. The method of claim 1, wherein said one of said wythes constructed first is said inner wythe.
4. The method of claim 1, including the step of placing the upper and lower horizontal edges of vertically adjacent block members in adjacent proximate relationship to form horizontal angularly inclined joints for diverting water flow from the inner wythe toward the outer wythe.
5. The method of claim 4, including the step of placing the block members in spaced relationship with said outer wythe to form a vertical channel between said outer wythe andsaid rows of block members, and wherein saidhorizontal angularly inclined joints and said vertical channel are in fluid flow communication.
6. The method of claim 5, including the step of forming said block members of substantially rectangular configuration, and
securing said blockmembers in rows wherein the side edges of adjacent ones of said rectangular block members are disposed in substantially abutting engagement.
7. The method of claim 1, including the step of forming said block members of substantially rectangular configuration, and
securing said block members in rows wherein adjacent ones of said block members are disposed in overlapping relationship.
8. The method of claim 6, including the step of securing the side edges of adjacent ones of said rectangular block members which side edges form vertical joints, to thereby render said vertical joints waterproof. 9. The method of claim 8, wherein the step of waterproofing said vertical joints is accomplished by the application of a waterproof tape thereover. 10. The method of claim 8, wherein the step of waterproofing said vertical joints is accomplished by the insertion of a T-strip into said joint with the head of said T-strip overlying said vertical joint.
11. The method of claim 1, including the step of building one end of wall-tie members into said one of saidwythes constructed first,
securing said block members with respect to said one of said wythes by press fitting said block members between vertically adjacent rows of said wall-tie members with the horizontal edges of said block members being deformed by but in frictional engagement with said wall-tie members, and
thereafter building the other end of said wall-tie members into the other one of said wythes.
12. The method of. claim 11, including the step of fabricating said wall-tie members with means for positionally securing said block members in spaced relationship with respect to at least one of said wythes.
13. The method of claim 12, wherein said wall-tie member means are selected to positionallysecure said block members in spaced relationship to both said inner and outer wythes.
14. The method of claim 11, including thestep of building said outer wythe first.
15. The method of claim 1, wherein said inner and outer wythes are built substantially simultaneously.
16. The method of claim 1, wherein at least one of the surfaces of said block members has a wetting agent applied thereon.
17. The method of claim 1, wherein,
at least one of the surfaces of said block members has a water absorbent layer applied thereon.