Patent Application
20250101748
The present disclosure relates to wall assemblies using stucco and plaster, including hard coat systems, exterior insulation finishing systems, and other exterior claddings. In particular, the present disclosure relates to a hybrid stucco system and method of application thereof.
Stucco is a composite material made from aggregates, a binder, and water that is applied on construction materials for decorative and structural purposes. As a building material, stucco is a durable, attractive, and weather-resistant wall covering that has become the predominant exterior finishing for both residential and commercial construction.
Traditionally, a three-coat stucco system was used, which comprised a weather barrier (usually a 2-ply tarpaper), a heavier 16-gauge wire lath or equivalent, a cementitious scratch coat, a cementitious brown coat, and a cementitious textured finish coat. This finish coat may be integrally colored or painted, or an acrylic textured finish may also be used. There are a lot of benefits to the three-coat system, like being a high impact system with good fire resistance capabilities. However, some of the negatives of this system include a lot of intense labor due to the depth of the required stucco (usually ¾-inch to one inch of stucco has to be installed on the surface of all the walls and a heavier gauge lath is used, which is much more labor intensive than other options). The scratch coat is hand-applied or spray-applied, then scratched to create a keyed surface to which the brown coat may anchor. The brown coat is also hand-troweled or stucco-pump spray-applied, darbied (flattened with a three-foot, two-handed trowel), shaved, then hand-floated or brushed in preparation for the finish coat. Also, the cure time between the brown coat and color coat is usually two weeks, and it needs to be water cured, which requires being wet down daily for three to four days after it has dried. Another major turn-off for this system is that even though the installer can do everything right, it generally will still crack, which is the number one complaint of customers. Additionally, because of the thickness, it also has a good chance of being wavy and not very flat on the finish. This system is also very heavy, so on larger buildings this has to be considered by the engineers.
One-coat systems (also known as “hard coat” systems) have a base coat of cement that becomes extremely hard when properly cured. Hard coat systems typically comprise a weather barrier (usually two-ply tarpaper) and a 20-gauge wire lath, which is a lighter, more manageable lath than is used in a three-coat system. However, the base coat is usually only ⅜ inch to ½ inch thick. This makes the labor a lot less intensive, but is still a lot of physical work. The base coat is also applied by hand trowel or sprayed on with a stucco pump, then darbied, and then floated or brushed to accept the finish coat. This system is a bit cheaper for the materials and labor, but also is not as impact resistant or as fire resistant. This system is often used in conjunction with a continuous insulation that is installed between the weather barrier and the lath. This is usually a one-pound density tongue and grooved expanded polystyrene (EPS) foam. This does add around an extra R-4 to the energy efficiency of the exterior walls systems, but it lowers the impact resistance. This system also has to be water cured and is subject to cracking and wavy walls. However, the ease of application and weight of the system is better than the three-coat system. Additionally, when incorporating foam into this system, a drainable weather barrier such as Tyvek® stucco wrap is required to enable a better drainage behind the foam. And when using foam this also makes this system technically an exterior insulated finish system. Hard coat systems are governed extensively by building codes and industry standards, and they may be applied directly to a solid base such as masonry or concrete walls or may be applied to a metal lath attached to wood or metal construction framing.
Exterior insulated finish system (EIFS) is a modern improvement to stucco that, in contrast to hard coat systems, relies on thinner layers of synthetic materials, rather than cement. EIFS typically comprises a weather barrier (usually a drainable membrane layer like Tyvek® stucco wrap or a liquid applied weather barrier), a one inch or more of two-pound density EPS foam is attached over the weather barrier mechanically with special EIFS washers and rust-proof screws. On the liquid applied weather barrier, an adhesive bond is used using an EPS foam adhesive, which is usually the same product used as the base coat. This is applied with a notched trowel to create a uniform thickness and create the drainage plane for a drainable assembly. The foam must be rasped after it is secured to the wall with foam rasps that remove the high points of the foam to create a uniform flat wall surface. This is very labor intensive and often poorly performed by incompetent craftsmen, which leaves the pattern of the foam sheets visible through the finish coat. Unless a high impact system is requested, which doubles the cost and work of this system, then this system is not very impact resistant and is prone to bird hole issues. However, one of the main benefits of this system is that it is very resistant to cracks and can be grooved to make architectural details. It is also a very light-weight stucco system, so it is preferred for most commercial and high-rise work. The base coat is generally around ⅛-inch thick, so there is a lot less labor involved in the supplying of mud around the building. However, the embedding of the mesh into the surface of the mud is more technical, so this base coat generally takes longer to install than the hard coat bases. However, because the foam is already rasped smooth, there is very little floating that is required to make an acceptable base coat ready for the finish coat. Furthermore, the EIFS system does not normally need to be water-cured and can be color-coated usually the next day.
Although commonly used in the industry, builders and stucco contractors have been frustrated with systemic failures associated with both traditional hard coat systems and EIFS. Hard coat systems, in particular, are labor intensive to install and prone to cracks and waves along the finished surface. Moreover, after the base coat is installed, the wall must undergo a lengthy water curing process over several days wherein the wall is repeatedly sprayed with water and allowed to dry. Builders then wait another week to install the finish coat, resulting in a two-week sitting period to complete the job scope. While the finish coat can be applied immediately after the base coat in EIFS, these systems are more expensive and susceptible to human error at multiple phases of the application process. For example, the rasping phase tends to leave foam joints visible in the finish, reducing the aesthetic quality of the final appearance. In addition, EIFS is generally a low impact system that, by nature, is both more susceptible to impact penetration and more vulnerable to heat damage, especially when using darker colors. Flawed design concepts with EIFS are the subject of ongoing construction defect litigation to this day. Finally, due in part to the physically taxing nature of current stucco installation procedures, the industry experiences high turnover among laborers, plasterers, and lathers.
Accordingly, there is a need for a system that incorporates the speed, efficiencies, and durability of hard coat systems, with the less labor-intensive application and performance of EIFS. Said system would be less labor intensive for workers, reduce the installation and curing timeframes, provide better impact resistance, prevent cracks and waves within the finished surface, and be aesthetically appealing-all at comparable costs to existing alternatives. The hybrid stucco system disclosed herein addresses these problems and others.
In some embodiments, a hybrid stucco system comprises a substrate, a weather barrier membrane, a high-density polyisocyanurate board, an alkali resistant fiberglass mesh, a modified cementitious base coat, and a finish coat. The substrate may be plywood, oriented strand board (OSB), or other structural members that provide a solid backing upon which each subsequent layer of the hybrid stucco system may be assembled. The weather barrier membrane may be two-ply tarpaper, Tyvek® stucco wrap, or other liquid-applied coatings, papers, films, or other code-approved weather barriers.
The polyisocyanurate board is a closed-cell, rigid foam insulation board that, in some embodiments, has a density rating of above 80 PSI. The polyisocyanurate board is attached to the substrate over the weather barrier by wide crown staples or other pneumatic and/or mechanical fasteners in the field. The alkali resistant fiberglass mesh, in some embodiments, incorporates high a Zirconia content (e.g., 19% or greater) and/or a coating that protects the fiberglass mesh from the high alkali cement coatings. The alkali resistant fiberglass mesh is pre-lathed onto the polyisocyanurate board during manufacture or otherwise coupled together by wide crown staples or other pneumatic and/or mechanical fasteners prior to entering the field in order to reduce the costs of labor and materials. However, the fiberglass mesh may also be applied to the polyisocyanurate board in the field. The combination of the polyisocyanurate board with the alkali resistant fiberglass mesh also resists expansion and contraction of the board in response to ambient, external temperatures, thereby reducing cracking and waving in the finished surface of the laminate.
The base coat comprises portland cement modified with a blend of acrylics, fibers, pozzolans, silica sands, pumice, and other additives to give the base coat a consistency that is workable, with good body, easily applied, and that can be spread throughout the alkali resistant fiberglass mesh, in preparation to receive the finish coat. The finish coat, in turn, may comprise an acrylic polymer, silicone-modified acrylic, or other cementitious or elastomeric compounds used as stucco finishes, wherein colorants, minerals, and aggregates can be further incorporated.
The following descriptions depict only example embodiments and are not to be considered limiting in scope. Any reference herein to “the invention” is not intended to restrict or limit the invention to exact features or steps of any one or more of the exemplary embodiments disclosed in the present specification. References to “one embodiment,” “an embodiment,” “various embodiments,” and the like, may indicate that the embodiment(s) so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment,” or “in an embodiment,” do not necessarily refer to the same embodiment, although they may.
Reference to the drawings is done throughout the disclosure using various numbers. The numbers used are for the convenience of the drafter only and the absence of numbers in an apparent sequence should not be considered limiting and does not imply that additional parts of that particular embodiment exist. Numbering patterns from one embodiment to the other need not imply that each embodiment has similar parts, although it may.
Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Unless otherwise expressly defined herein, such terms are intended to be given their broad, ordinary, and customary meaning not inconsistent with that applicable in the relevant industry and without restriction to any specific embodiment hereinafter described. As used herein, the article “a” is intended to include one or more items. When used herein to join a list of items, the term “or” denotes at least one of the items, but does not exclude a plurality of items of the list. For exemplary methods or processes, the sequence and/or arrangement of steps described herein are illustrative and not restrictive.
It should be understood that the steps of any such processes or methods are not limited to being carried out in any particular sequence, arrangement, or with any particular graphics or interface. Indeed, the steps of the disclosed processes or methods generally may be carried out in various sequences and arrangements while still falling within the scope of the present invention.
The term “coupled” may mean that two or more elements are in direct physical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.
The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments, are synonymous, and are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including, but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes, but is not limited to,” etc.).
As previously discussed, there is a need for a stucco-based system that reduces labor costs and the overall completion time, provides better impact resistance, prevents cracks and waves within the finished surface, and is aesthetically appealing-all at comparable costs to existing solutions. To accomplish these goals, an insulation board is needed with increased impact resistance, sound absorption, and long-lasting performance that is fire, insect, mold, and mildew resistant. Furthermore, a base coat with higher tensile strength and adhesion is required that will not shrink or crack, is fast setting yet workable and pumpable with minimal water curing, is resistant to harsh chemicals, salts, and freeze cycles, and is able to receive the finish coat the same day. The “hybrid stucco system” disclosed herein addresses these problems and others within the industry.
As shown in
The weather barrier membrane 104 may be two-ply tarpaper, Tyvek® stucco wrap, or other liquid-applied coatings, papers, films, or other code-approved weather barriers. The weather barrier membrane 104, in some embodiments, may comprise a grooved surface with cavities or gaps configured to act as a drainage plane within the hybrid stucco system 100. While the finish coat 112 should enable water to run off the exterior of the hybrid stucco system 100, internal drainage properties of the weather barrier membrane 104 provide a secondary means of protection against water damage and subsequent cracking or warping. The weather barrier membrane 104 adheres to the substrate 102 and polyisocyanurate board 106, providing a barrier that prevents water trickling in behind the hybrid stucco system 100 but also allows any water vapor that may permeate the system to escape via apertures in the weep screed. In some embodiments, a rainscreen may be coupled between the weather barrier membrane 104 and the polyisocyanurate board 106 for additional water resistance.
The polyisocyanurate board 106 is a closed-cell, rigid foam insulation board. In a preferred embodiment, though without limitation, the polyisocyanurate board 106 has a 201b density (or other density) rated at or above 80 PSI. It will be appreciated that polyisocyanurate boards 106 have among the highest R-value (i.e., resistance to heat flow) per inch (e.g., R-5 per inch) of any foam board available on the market. In some embodiments, the polyisocyanurate may be a high-density polyisocyanurate board 106 similar to those used in the commercial roofing industry. It will be appreciated that use of the polyisocyanurate board 106 in place of expanded polystyrene foam boards and/or gypsum boards, as known in the prior art, overcomes susceptibility to expansion and contraction of the board in response to ambient, external temperatures. When used, for example, with dark exterior colors and/or in hot climates, polystyrene foam boards can melt underneath EIFS during periods of intense sun exposure. The plasticity of those boards on the inside of a stucco system thereby leads to gradual degradation that, over time, contributes to cracking and warping in the surface layers of the laminate.
Alternatively, in the prior art, cement backer boards (e.g., Hardiebacker®) similar to those used for tile flooring and walls were incorporated due to their high R-value. While the cement backer boards had superior impact resistance over EIFS, the use of existing base coats known in the prior art with these cement backer boards led to exposed board joints that weakened the final finish and aesthetics of previous systems. In contrast, the polyisocyanurate board 106 features high density fibers that are resilient against deformation, thereby strengthening the laminate against cracking and warping. The polyisocyanurate board 106 is thus resistant to the expansion and contraction that occurs in polystyrene foam boards and gypsum boards and enables easier application of the base coat 110 as compared to cement backer boards.
It will further be appreciated that the polyisocyanurate board 106 is chlorofluorocarbon (CFC) and hydrochlorofluorocarbon (HCFC) free, which has both zero ozone depletion potential and zero global warming potential. Moreover, the polyisocyanurate board 106 will not rust or corrode under the harsh alkali conditions of cement or other potential base coat 110 materials.
In some embodiments, the hybrid stucco system 100 may further comprise expansion and termination joints configured to further prevent the base coat 110 and the finishing coat of the laminate from either cracking or warping. In some embodiments, as shown in
The alkali resistant fiberglass mesh 108 comprises high zirconia alkali-resistant glass fibers that, in preferred embodiments, though without limitation, have a zirconia (ZrO2) content of at least 19%. The alkali resistance of glass fiber when used as a reinforcing material for cement is determined by the ZrO2 content in the glass. The higher the ZrO2 content, the greater the alkali resistance. A ZrO2 content of at least 19% is made possible by its original glass composition as well as by a direct melt method using an all-electric furnace. In preferred embodiments, though without limitation, the alkali resistant fiberglass mesh 108 has a density of 170 pcf, a fiber diameter of 0.00053 inches, a tensile strength of more than 1.85×103 psi, a Young's Modulus of 1.1×107 psi, and a strain of more than 1.5%. Alkali resistivity for the alkali resistant fiberglass mesh 108 may exhibit weight loss of 0.85% and tensile strength retention of 75%.
E-type glass fiber, for comparison, features weight loss of 10.5% and tensile strength retention of 14%. The weight loss rate percentage of a strand is determined as held at 176 F for 200 hours in saturated cement solution. The tensile strength retention rate percentage of cement paste applied to a strand is determined as held at 122 F for 300 hours in 100% RH. The alkali-resistant fiberglass mesh undergoes significantly less weight loss and demonstrates significantly more tensile strength as compared to common electrical glass with E-type glass fibers. These properties enable the alkali resistant fiberglass mesh 108 to provide more structural support to the polyisocyanurate board 106 and the hybrid stucco system 100 as a whole such that cracks and waves in the laminate are less frequent. However, it will be appreciated that while alkali resistant glass fiber is preferred, other fibers and fiberglass coatings may be used without departing herefrom. In some embodiments, the fiberglass 108 is ½-inch to 1 and ¼-inch thick, although other thicknesses may also be used.
While EIFS requires that mesh be either glued or screwed onto an insulation board in the field, which necessitates added labor and expense to the overall project, the polyisocyanurate board 106, in contrast, may be coupled together with the alkali resistant fiberglass mesh 108 via pneumatic or mechanical fasteners 114 (e.g., wide crown staples or roofing nails) before entering the field (e.g., during manufacture and production). In some embodiments, the alkali resistant fiberglass mesh 108 may be pre-lathed or otherwise laminated onto the polyisocyanurate board 106. In some embodiments, the alkali resistant fiberglass mesh 108 is embedded into the base coat 110 on a surface of the polyisocyanurate board 106. In one non-limiting example, the alkali resistant fiberglass mesh 108 of about 4 oz or greater may be embedded into the base coat 110 onto the surface of the polyisocyanurate board 106. However, in a light duty application, such as a ceiling or soffit, the alkali resistant fiberglass mesh 108 may be applied at foam joints only and then the base coat 110 can be applied directly to the polyisocyanurate board 106. The alkali resistant fiberglass mesh 108 may be tacked on with R-19 tacker staples prior to applying the base coat 110 or spread the alkali resistant fiberglass mesh 108 directly into the base coat 110.
The alkali resistant fiberglass mesh 108 enables the polyisocyanurate board 106 to be coupled to the weather barrier membrane and the substrate 102 with conventional wide crown staples 114. This process results in fewer perforations to the weather-resistive barrier than installations using screws, thereby preserving the integrity of the weather-resistive barrier. The use of staples 114 is also inexpensive compared to the use of screws, adhesives, and/or washers, resulting in significant savings. In some instances, the use of staples may cost 1/10th the price of screws, adhesives, and/or washers. The alkali resistant fiberglass mesh 108 also improves the impact resistance and the tensile strength of the hybrid stucco system 100, which preserves it against impacts from foreign objects such as hail, golf balls, etc. Furthermore, the alkali resistant fiberglass mesh 108 acts as a mechanical key for the base coat 110 to more firmly hold onto.
In the prior art, the need in EIFS to glue on an insulation board necessitates the accompanying use of a liquid applicable weather barrier. The liquid applicable weather barrier is more expensive and time consuming to install than using either Tyvek® stucco wrap or two-ply tarpaper for the weather-resistive barrier as taught in the current disclosure. Furthermore, EIFS has an inherently low impact resistance without also incorporating a high impact mesh in the field. Installation of this mesh in the field, however, significantly increases the costs of labor and is prone to human error. In the hybrid stucco system 100, the alkali resistant fiberglass mesh 108 may be preinstalled or otherwise manufactured together as a single unit before ever entering the field, thus reducing the necessary installation time and associated labor costs on the job site. It will also be appreciated that the alkali resistant fiberglass mesh 108 has three times more tensile strength than steel but can be cut by workers with a razor blade, facilitating ease of use in the field, especially to fit around tight corners and smaller, piecemeal surface areas on a wall.
The base coat 110 may comprise portland-based cement modified with a blend of acrylics, fibers, pozzolans, silica sands, pumice, and other additives to give the base coat 110 a consistency that is workable, with good body, easily applied, and that can be spread throughout the alkali resistant fiberglass mesh, in preparation to receive the finish coat. Prior to application, water may be mixed with the base coat 110 by using a power-drive mechanical mixer, such as a mortar mixer, to achieve a lump free, uniform consistency, usually within 1-3 minutes. It will be appreciated that the glass fiber reinforced concrete exhibits non-shrink, fast-setting properties that enable the base coat 110, upon mixture, to set within one hour. Once the base coat 110 is applied, it is darbied and floated to achieve a smooth, flat wall. After the base coat 110 cures for two more hours, the finish coat 112 can be applied on the same day to complete the hybrid stucco system 100. The hybrid stucco system 100 does not require water-curing, allowing for a much faster cure and therefore is ready for color coating much sooner.
It will be appreciated that this stucco assembly process is faster than EIFS, hard coat systems, or any other system in the industry. The base coat 110 has 70% less shrinkage than Portland® based cement, higher flexural strength, as well as compressive strengths 14 times greater than traditional hard coat stucco systems. The base coat 110 is configured to bond directly to not only the polyisocyanurate board 106, but also the alkali resistant fiberglass mesh 108, which, in some embodiments, has been previously coupled together with staples 114. Accordingly, the base coat 110 becomes embedded with the alkali resistant fiberglass mesh 108 which is mechanically coupled to the wall.
In prior art, a calcium-sulfoaluminate cement, known as rapid-set cement, was used. While the faster curing process was intended to reduce the overall installation time, the rapid-set cement contributed to a hard and brittle base coat susceptible to extensive cracks and waves. In practice, the wall would begin to set up before being properly leveled by the plasterer, making the base coat difficult to work with. The rapid setting nature of the calcium-sulfoaluminate cement further led to wasted product when not immediately used in the field.
Accordingly, the base coat 110, as described, is also easier to work with when using a darby, float, or other hand implement to evenly spread around the alkali resistant fiberglass mesh 108 and polyisocyanurate board 106. In contrast, existing base coats known in the prior art are difficult to adequately spread along the insulation board in order to cover the joints and create a professional looking finish. The joints of the insulation board are, instead, often visible through the finish coat, depreciating the final aesthetic quality of other systems.
Existing base coats are very droopy and would slide off the wall in the thicker areas if attempted to be used with the present hybrid stucco system 100. Likewise, existing base coats are also gummy such that they would stick to the tools and would not be floatable. For these reasons and more, the rasping phase of EIFS is particularly labor intensive. Here, instead of rasping, a screeding device such as a 3-foot trowel or darby can be used to spread the base coat 110 around the surface of the alkali resistant fiberglass mesh 108 and polyisocyanurate board 106. In other words, the base coat 110 can be darbied to fill in low points within dips and recessed areas of the alkali resistant fiberglass mesh 108, rather than rasping off high points. This method can be ten times faster than current EIFS and hard coat system alternatives. Overall, the consistency and texture of the base coat 110 fills in the spaces surrounding the alkali resistant fiberglass mesh 108 to create a more uniform distribution and covering in preparation to receive the finish coat 112. The base coat 110 can further be brushed, floated, troweled, or textured as desired and colorants may be added to the base coat 110 to achieve a one coat application.
The finish coat 112 may comprise an acrylic polymer, silicone-modified acrylic, or other elastomeric compounds known in the art. The finish coat 112 may further comprise added colorants, minerals, and/or aggregates therein. While the finish coat 112 may be comparable to other finish coats in the prior art, the final appearance of the laminate in the hybrid stucco system 100 is much flatter and smoother than other stucco-based systems. Better coverage with the finish coat 112 is achieved, in part, due to the flatter base coat 110. This may result in improved overall coverage equating to more than a 20% savings on the application of the finish coat 112. While the hybrid stucco system 100 is discussed in relation to wall assemblies, it will be appreciated that the hybrid stucco system 100 may also be used to create castings, concrete counter tops, stucco and concrete repairs, mortar beds, underlayments, and formed work. It is further suitable for horizontal, vertical, and overhead applications.
The hybrid stucco system 100 addresses current and future concerns in the construction industry related to efficient energy use and environmental sustainability. ASHRAE Standard 90.1 is the energy reference in the International Building Code and the International Energy Conservation Code that defines the minimum standards for the classes of construction covered by this disclosure. In 2008, ASHRAE increased the minimum required prescriptive R-value for roof and wall installations because without continuous wall insulation, a building envelope has an insulation break at every stud wherein the traditional wall insulation is unable to be placed, thus jeopardizing the building energy efficiency and certification. This is especially critical in a steel stud wall assembly wherein the steel is a conductor of heat.
As codes and standards continue along the trend line promulgated by regulatory bodies, it is anticipated that future versions of ASHRAE standards will require the installation of a layer of continuous insulation over the entire exterior of all walls within both residential and commercial construction. This requirement will provide for a thermal break and R-value of 5 or greater for the structure-making the building significantly more airtight and energy efficient, as compared to prior construction. The hybrid stucco system 100 will help conserve energy by increasing resistance to heat flow across the hybrid stucco system 100. It will be appreciated that the hybrid stucco system 100 will also likely meet or exceed future industry standards and thereby potentially qualify for available energy tax credits, LEED points, and/or Energy Star product ratings.
In some embodiments, a method of assembling a hybrid stucco system 100 comprises installing a weep screed and a weather barrier membrane 104 in accordance with manufacturer's installation instructions and local code requirements. When installed directly to studs, a polyisocyanurate board 106 is then installed vertically along a longitudinal plane of the hybrid stucco system 100 with sheathing edges bearing directly on framing members. Vertical edges of abutting panels should be in moderate contact with each other, and horizontal joints should be avoided unless sheathing edges bear on horizontal framing members or the wall has already been sheeted. A side of the polyisocyanurate board 106 comprising an alkali resistant fiberglass mesh 108 is positioned to face away from framing. The method further comprises securing the polyisocyanurate board 106 to substrate 102 and framing using, without limitation, ⅜″ diameter head galvanized roofing nails or galvanized (¾ inch minimum) wide crown staples 114 that are long enough to penetrate framing a minimum of ¾-inch. For metal stud applications, galvanized metal screws with a minimum ⅜-inch diameter pan head may be used, but no mechanical fastener 114 should penetrate the sheathing facer. Mechanical fasteners 114 may be spaced at 6 inches intervals on center in both a field and perimeter of the polyisocyanurate board 106.
In some embodiments, an alkali resistant fiberglass mesh 108 may then be coupled to joints of the polyisocyanurate board 106. A butterfly mesh or joint aid 114 as shown in
As described earlier, there is a need for a stucco-based system that reduces labor costs and overall completion timelines, provides better impact resistance, prevents cracks and waves within the finished surface, and is aesthetically appealing, all at comparable costs to existing solutions. The hybrid stucco system 100 uses higher density board (e.g., 80+ PSI vs. 20 PSI in the art), is capable of using wide crown staples or roofing nails to secure the board 106 to structure, eliminates the need to attach mesh to insulation boards while in the field, and circumvents the rasping phase of a base coat by utilizing the buildable adhesive base coat 110 that remains workable. The hybrid stucco system 100 also enables application of the finish coat 112 on the same day as the base coat 110, thereby reducing the water curing phase and significantly reducing associated labor and materials costs. In addition, use of the polyisocyanurate board 106 and alkali resistant fiberglass mesh 108 further strengthens the wall assembly and prevents cracks and waves in the finished surface. Accordingly, the hybrid stucco system 100 disclosed herein solves the aforementioned problems in the art by being faster and easier to apply, reducing cracks, resulting in a flatter, smoother appearance, while remaining at a competitive cost, among others.
It will be appreciated that systems and methods according to certain embodiments of the present disclosure may include, incorporate, or otherwise comprise properties or features (e.g., components, members, elements, parts, and/or portions) described in other embodiments. Accordingly, the various features of certain embodiments can be compatible with, combined with, included in, and/or incorporated into other embodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting application or inclusion of said features to the specific embodiment unless so stated. Rather, it will be appreciated that other embodiments can also include said features, members, elements, parts, and/or portions without necessarily departing from the scope of the present disclosure.
Moreover, unless a feature is described as requiring another feature in combination therewith, any feature herein may be combined with any other feature of a same or different embodiment disclosed herein. Furthermore, various well-known aspects of illustrative systems, methods, apparatus, and the like are not described herein in particular detail in order to avoid obscuring aspects of the example embodiments. Such aspects are, however, also contemplated herein.
Exemplary embodiments are described above. No element, act, or instruction used in this description should be construed as important, necessary, critical, or essential unless explicitly described as such. Although only a few of the exemplary embodiments have been described in detail herein, those skilled in the art will readily appreciate that many modifications are possible in these exemplary embodiments without materially departing from the novel teachings and advantages herein. Accordingly, all such modifications are intended to be included within the scope of this invention.
This application claims the benefit of U.S. Provisional Application Ser. No. 63/584,798 filed on Sep. 22, 2023, which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63584798 | Sep 2023 | US |
