US20020164447A1

US20020164447A1 - Method and apparatus for providing weather protection for buildings under construction, and buildings integrally retaining that protective structure

Info

Publication number: US20020164447A1
Application number: US09/849,104
Authority: US
Inventors: Arthur Asgian
Original assignee: Individual
Current assignee: Individual
Priority date: 2001-05-04
Filing date: 2001-05-04
Publication date: 2002-11-07

Abstract

A sheeting product in the form of a semi-transparent, non-organic and thin grid mesh having substantial inherent structural integrity is applied to exterior walls or similar outward structures at an early stage of building construction, so as to provide protection thereafter for the interior structure against the exterior environment, that sheeting product then becoming an integral part of the building. The strength of the material permits it to be installed through the use of booms or lifts (to the extent of the reach of these) without the use of scaffolding, and also permits elimination of any structural sheathing material and the use of a wider spacing between vertical studs, all of which contribute to savings in materials, labor, and the required time of the construction schedule.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

Not Applicable

FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to methods and apparatus for protecting the interior of buildings against the exterior environment during their construction, especially as to large, non-residential buildings, and particularly to apparatus that will remain and function as an integral part of the building so constructed.

2. Description of the Prior Art

In building construction, especially as to large commercial and industrial buildings for which the time period of construction can extend over many months, there has long been a need to provide weather protection of the interior of the building during its construction. It is important that such protection be provided early in the construction process, so that continued construction of the building interior can be commenced as early as possible without danger of that interior work being compromised in quality as a result of later weather damage. “House wraps” in combination with structural sheathing products and similar such means have long been employed in such construction, but as will be seen from the patents listed below, there remain a number of disadvantages in the methods and practices of this prior art, which it is one purpose of the present invention to remove, and also to provide savings in material and labor costs in the construction process. Alternatively, another approach which has been a standard practice in the field is that the apparatus for weather protection are installed on a temporary basis during the construction phase until such time as the seasonal period of highest risk of inclement weather has passed and/or the permanent building cladding system, which is designed for direct exposure to the elements, becomes available. Either procedure forgoes an opportunity to provide enduring weather protection that will also perform a structural function in the completed building.

U.S. Pat. No. 4,126,721 issued Nov. 21, 1978, to Vitt, describes a sealing sheet for use in waterproofing, protection against ultraviolet radiation and ozone, and other building purposes. The sheeting itself has no structural purpose, however, being intended for use in subterranean construction, as an insulation material for roofs, and as a strip for roof ends.

U.S. Pat. No. 4,567,080 issued Jan. 28, 1986, to Korsgaard, describes a vapor barrier having two vapor-tight layers and a water absorbing layer interposed therebetween, intended for use in roof construction, and provides no structural function.

U.S. Pat. No. 4,625,486 issued Dec. 2, 1986, to Dickinson, describes a laminated vapor barrier especially adapted to prevent moisture from entering into insulation that has been installed below metal roofs. This device likewise has no structural function.

U.S. Pat. No. 5,773,123 issued Jun. 30, 1998 to Anwyll, Jr., describes an air filtration barrier to be applied to the perimeter walls of a building prior to installation of a decorative finish layer. The material is a perforated laminate having a woven polyolefin fabric, a resin and a polyolefin film, the purpose thereof being to provide sufficient dimensional stability that such barrier does not sag downwardly over time, thereby to avoid such a fault in the prior art practice. However, the material provides no structural function to the completed building itself.

U.S. Pat. No. 4,900,619 issued Feb. 13, 1990, to Ostrowski, describes a translucent “house wrap” intended for installation either over the external studs of a building and under the sheathing to be placed thereon, or over the sheathing and under the siding or other such facing and, as with other similar house wraps, is intended to enhance the insulation of the building without causing moisture condensation within the wall structure. The material is itself reinforced with elongate strips of a textile fiber web, but that reinforcement does not serve any structural function in the completed building or during construction.

U.S. Pat. No. 5,091,235 issued Feb. 25, 1992, to Vergnano, describes a laminated sill wrap assembly for providing an air infiltration barrier between and around the sill plate and foundation wall of a building under construction, so as ultimately to prevent heat loss in the winter and heat entry in the summer.

U.S. Pat. No. 4,372,089 issued Feb. 8, 1983, to Akesson addresses the problem of energy saving in a building as to its air-tight integrity or “tightness.” Reference is made to prior art practices in which during the construction of the building, board sheeting is applied to the outside of the wall studs, followed by application of a diffusion tight film inside of the studs to serve as a vapor barrier, the objection to the practice being that such film, as well as similar films used in the roof and floors, are usually applied separately, with overlapping joints that are typically not jointed or sealed, and hence the building is not truly airtight. The Akesson invention seeks to overcome that deficiency by a method of constructing an energy saving building that comprises applying an integral airtight layer in the floors, the walls and the roofs; sealing off the airtight layer at the edges of the layer; testing the air tightness of the airtight layer; and then repairing any deficiencies in the airtight layer and its edges before the joints of the airtight layer and the sealed edges of the airtight layer are covered. The airtight layer is preferably applied inside the load-bearing part of the walls, and the interior wall surface material is then applied spaced apart from the airtight layer. That airtight layer serves no structural function in the completed building, which is done instead by a sheathing product or other structural backing.

U.S. Pat. No. 4,599,830 issued Jul. 15, 1986, to Nawrot, describes a method of constructing an energy saving building of the usual frame construction, but with particular emphasis on the use of a substantially continuous vapor barrier enclosing two or more stories of a building. Such feature is accomplished through the use of a double wall construction wherein an inner wall is first constructed atop the foundation; a second floor joist assembly is constructed atop the inner wall; both the inner wall and the floor joist assembly are encased in a substantially continuous vapor barrier; an outer wall is erected outside of that vapor barrier, also on the building foundation; the tops of the inner and outer walls are connected together through the vapor barrier, and then a roof assembly comprised of trusses is erected atop both the inner and outer walls. The vapor barrier feature serves no structural function in the completed building.

U.S. Pat. No. 4,635,423 issued Jan. 13, 1987, to Ward, describes an interior ceiling or wall covering system comprising longitudinal parallel flexible panels formed from vapor barrier material applied to flange surfaces of ceiling joists or purlins, or wall girts, wherein the panels extend parallel to the longitudinal extent of the joists, purlins or girts, and are secured to the flanges thereof by a pressure sensitive adhesive. This product application is clearly limited to interior applications within a completed building and serves no structural purpose or function.

U.S. Pat. No. 5,204,176 issued Apr. 20, 1993, to Seiss, et al., discloses a structural siding composition having an impregnated cellulosic layer and an insulating layer, the combination being of substantial strength. In lieu of what is described as a 6-layer wall (e.g., sheet rock, plywood or the like, insulation, vapor barrier, sheathing, siding), the patent discloses the use of the indicated two-layer material, wherein the siding layer forms the outermost surface of the building, so as to reduce the time and labor of construction. The patent does not specifically address the issue of weather protection during building construction, but only the protection from the elements of the resultant building.

U.S. Pat. No. 5,285,607 issued Feb. 15, 1994, to Somerville, discloses an exterior wall panel comprising an insulating plastic foam board having disposed therein one or more structural reinforcing members. The patent describes an exterior siding product that will be the primary weathering surface for its useful life, does not address the issue of sheathing, nor of protecting the interior of the building as it is being constructed.

U.S. Pat. No. 6,125,608 issued Oct. 3, 2000, to Charlson, discloses the use of a rigid insulator attached along at least one edge of a stud to provide a “thermal break” and thereby deepen the thickness of the wall which will then accommodate more insulation. The invention is said to address the problem that insulating sheathing boards are expensive, and lacking sufficient structural strength in themselves they require cross-bracing. In part, Charlson thus discloses a different solution to the problems of sheathing products, while at the same time does not address seeking any economies in the sequence of building steps.

U.S. Pat. No. 4,869,037 issued Sep. 26, 1989, to Murphy, discloses the structure of panels for construction of a moisture-proof back-up wall around the exterior perimeter of a building, the panels to be disposed inwardly from a moisture permeable exterior wall. The panels include a substantially rigid, non-load bearing, moisture-permeable core having two opposing major planar outer sides, and onto one of such sides is applied a moistureproofing material. These panels are adapted for use with a particular three-layer kind of construction in which the exterior walls are masonry, brick, or concrete, and are intended to eliminate a problem wherein gypsum that has been installed on the wall studs must then be rendered moisture-proof either by covering the same with a treated felt paper, or a moistureproofing mastic material is troweled over the gypsum, thereby incurring high labor costs. Again, however, the issue of providing protection to the interior of the building during its construction is not addressed.

U.S. Pat. No. 4,906,504 issued Mar. 6, 1990, to Skjold Petersen, discloses an exterior, water-repellant but air permeable facing for a roof or wall, the material of which is in the form of plates or slabs, and comprises mineral wool together with a bonding agent. The manner of use is simply to place the plate or slab exterior to the building wall, and is intended for use in buildings of simple construction such as storage sheds, the material thereby providing both insulation and ventilation as a means of reducing water condensation within the building. This product is also intended for use in unheated buildings, and cannot be configured in an air or water tight fashion.

U.S. Pat. No. 5,979,131 issued Nov. 9, 1999, to Remmele et al., discloses a combination weather resistant seal formed of a sheathing substrate onto which is bonded an expanded polystyrene (EPS) insulation board, thereby to replace the use of two weather resistant seals in the practice of the prior art and the associated materials and labor costs. A wood or gypsum sheathing substrate is attached to the building frame, to which is then applied a contact adhesive that because of its particular properties acts also as a secondary weather resistive barrier.

U.S. Pat. No. 5,966,877 issued Oct. 19, 1999, to Hawes, discloses a rapidly deployable protective and structural cover system applicable to outdoor construction in general, e.g., to bridge repair or ship building, etc. Although primarily intended for the circumstance in which an instance of the device is separately fabricated and then attached to a structure to be protected, the manner of construction of the device also lends itself to permanent incorporation into the structure being built, i.e., to act in the manner of sheathing. However, this product requires extensive use of tensioning devices and springs in its installation, thus to render virtually impossible any permanent installation in buildings that would not conflict with the structure of that building. It would also be virtually impossible to install in a vapor or air tight fashion, and hence differs substantially from the present invention.

To summarize this prior art, FIG. 1 shows a partially exploded, cross-sectional elevation view showing a method of building construction, and a wall produced thereby, that is summarized from the prior art.

Apparatus

10 of FIG. 1 is formed firstly by installation of stud 12 (taken to be representative of an entire wall) onto foundation 14 by way of bottom horizontal metal stud track 16, and also by top horizontal metal stud track 18, above which is disposed an I-beam 20 which serves to support elevated floor and roof structure 22. (The term “foundation” and the corresponding elements shown or described herein, both with respect to this prior art and to the description and drawings of the invention, are intended to include as well an elevated structural floor in the case of a multistory building. Exterior to that structure there is placed in turn a layer of exterior structural sheathing board product 24, which is extended at the upper distal end thereof to pass over the top of and then downwardly past an opposite side of stud extensions 12 a, similar to studs 12, followed then by an exterior “weather adjustive” structure 26 that generally in a “heating climate” environment (e.g., the Northern United States) would comprise a vapor permeable air barrier building wrap, or in a “cooling climate” environment (e.g., the Southern United States) would comprise a vapor retarding barrier or vapor retarding air barrier.

Ultimately there will be added

exterior building cladding

28, which can be extended in the manner of sheathing 24 so as to encompass the roof-top parapet region, but before that step is taken, there is first installed through and between studs 12 any required plumbing, electrical wiring, television cable or phone lines and the like, collectively represented in FIG. 1 by the small boxes 30, and also exterior insulation 32, represented schematically by the cyclical S-shaped lines. On the interior side of studs 12 there may be installed an interior “weather adjustive” structure 34, although this is not required in all cases, and if installed would generally be, as required, a vapor retarding barrier or a vapor retarding air barrier in a heating climate or a vapor permeable air barrier in a cooling climate, followed by an interior gypsum board 36. In the parapet region there is added a water-proof membrane 38 of durable construction that encompasses the distal, “hooked” end of sheathing 24 and the upper distal end of weather adjustive structure 26. Between the distal ends of stud extensions 12 a,

cladding

28 and membrane 38, on the one hand, and floor and roof structure 22 on the other, there is added the actual roof system 40. (The outboard end of system 40 abuts the distal terminus of stud extensions 12 a.) The interior construction is completed by installation of ceilings 42 and the interior finish 44 such as paint, wall paper, carpet, and the like.

From the foregoing it is seen that this prior art method generally involves the use of two “weather adjustive” structures, one exterior and one interior. In moderate climates, only one weather adjustive structure might be used, and where neither inward nor outward vapor flow predominates, vapor retardants are generally not needed, so the “weather adjustive” material for a moderate climate would generally be an exterior located vapor permeable air barrier. Secondly, during the process of installing the plumbing and

wiring

30 and the insulation 32, and doing other such interior work, it is only the “weather adjustive” structure 26 firstly and then the sheathing 24 that protects such interior installation and construction processes from the then-existing weather elements, e.g., rain, snow, or the like, unless temporary weather protection is installed by the contractor.

Because of the limited load-carrying capacity of the sheathing, the foregoing procedure also requires that the building studs be placed apart by no more than approximately 16 to 24 inches, depending on load. Available sheathing materials are generally limited to gypsum board which may have a weather protective facing material for improved water/moisture resistance, wood sheathing products, e.g., plywood, particle board and the like, or a cementicous material bonded to one or more layers of a flexible fiber mesh. The sheathing product is integrated into the completed building and must then meet governing building code requirements for wind forces based upon the height of the structure, geographic location, the exposure conditions as determined by terrain, and increased wind pressure at discontinuities such as corners, parapets, overhangs, and the like. But since wood and especially gypsum sheathing absorb moisture, and are of organic composition, by the time a building has been fully encircled and the “weather adjustive”

structure

26 has been installed, if such construction steps had been carried out during a period of inclement weather, substantial moisture would have been absorbed into that gypsum so as to remain present in the completed building, thereby to cause future building damage by way of rot, fungal growth and the like, as well as a degradation of indoor air quality and a risk to human health. Also, standard sheathing board is ½ to ¾ in. thick, so that when exterior cladding 28 is later anchored through the sheathing board, the screws so used must be designed in terms of a high shear tension and sufficient strength to avoid bending. Such anchoring is also weakened as a result of a loss of strength of the sheathing as a result of water absorption, which degrades its fastener holding capacity. Such sheathing products also require additional layout time in order to locate the underlying studs when being installed.

This prior art procedure also addresses only the sealing of joint terminations such as at sill conditions, head conditions, and roll overlaps in the product in an airtight and weather tight fashion. No mention is made or concern expressed to maintaining the same kind of seal at individual fasteners within the field. “House wraps” or the like must then be used in addition to the sheathing in order to prevent air and water intrusion, particularly at the joints. Alternatively, all horizontal and vertical joints in a sheathing board product with weather protective facing material can be sealed with an exterior sealant. In either case, a multiple step process is required that involves several different building trade type people. Also not addressed is any method of improving the holding capacity of the material at its anchorage points, particularly as to negative air pressure loads, or alternating positive and negative air pressure loads due to changes in wind direction.

The “weather adjustive”

structures

26 and 34 have the purpose of providing some degree of adaptation by the completed building to the geographic climate conditions within which the building will reside following its construction, and are not principally intended, nor do they well serve, to protect the building interior from such weather elements during the course of constructing the building. Conventional air or vapor barrier products are not usually designed in themselves to resist direct exposure to the exterior environment, and certainly not to any significant wind force, even though there is a substantial period of time during the construction of most buildings, prior to the installation of the exterior cladding, when that exterior air or vapor barrier product is exposed to the external environment. Inclement weather during that interim is likely to cause rips, tears and punctures in such products that, even if pin-hole size, can significantly affect water vapor movement through the exterior wall so as to leave a building of lesser quality and indeed to cause substantial damage to the building interior. Especially when using water absorbent sheathing product 24 externally adjacent to the wall studs 12, moisture can enter into the space between studs 12, and because of mechanical and electrical penetrations that have not been properly sealed, as well as other rips and tears in the weather adjustive structures 26 and/or 34, such moisture can cause future damage.

Building codes have long since recognized that there exists both an inwardly acting (positive) and outwardly acting (negative) air pressure loading on all exterior surfaces of a building subjected to wind loads. Also, these forces alternate back and forth between positive and negative with the direction of the wind. It is also well known by those versed in the art that the pressure in the air space separating the exterior building cladding from the exterior structural backing in cavity wall drainage systems and rain screen systems can be positive or negative as well. The magnitude of this pressure is determined by the combined effects of wind speed, stack effect, and mechanical ventilation.

Because of this pressure, the weather adjustive material again experiences both positive and negative air pressure loads. It is clear that although a positive (inwardly) acting pressure can be accommodated by the conventional weather adjustive system, a negative (outwardly) acting pressure cannot. That is, the structural sheathing is ineffective since the membrane is separated by such pressure from the sheathing and must endeavor to span on its own. The only way a conventional weather adjustive material can then be truly effective is either to be fully adhered to the structural backing, fastened at a very close spacing so that the deflection of the membrane under negative pressure is minimal, or else the membrane must be sandwiched between two layers of structural backing. Neither of the these options are found in current construction practices or manufacturers' recommended installation for these products. What is thus needed and would be useful in the art, with respect both to more solidly constructed buildings and savings in material, labor costs, and the duration of the construction schedule, is a method for providing enduring weather protection during building construction that leaves intact within the building both that weather protection and further combines the enhanced insulating benefits of a house wrap and the structural load carrying capacity of the sheathing within the same material. Advantageously, such a method should provide savings in materials and labor costs as well as a shorter construction schedule. All of the aforesaid advantages are provided by the present invention, as shall be described hereinafter.

BRIEF SUMMARY OF THE INVENTION

The invention comprises a method of using a sheeting product for the purpose of protecting the interior of a building that is under construction from the weather and like elements. Use of the sheeting product, which because of its inherent strength and light weight can be applied by means that do not require the use of scaffolding, eliminates the need for sheathing board products such as wood or gypsum, since the sheeting product itself serves as an all purpose weather barrier for the building exterior wall system inclusive of the roof parapet, further as means for controlling air and water vapor movement in the completed building that are adaptable to geographic driven climatic conditions, and also permitting greater horizontal spacing of vertical studs, all of which contribute to better protected and higher quality buildings, and also to economies of construction in materials, labor, and the construction schedule.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partially exploded, cross-sectional elevation view showing a method of building construction, and a wall produced thereby, taken from the prior art. [0032]
FIG. 2 is a partially exploded, cross-sectional elevation view similar to that of FIG. 1, but showing a method of building construction, and a wall produced thereby, according to a preferred embodiment of the invention. [0033]
FIG. 3 shows a perspective view of a sheet of protective material to be employed in a preferred embodiment of the invention. [0034]
FIGS. 4 and 5 show respectively front elevation and top plan views of the manner of anchoring a protective material to the studs of an external wall in constructing a building.[0035]

DETAILED DESCRIPTION OF THE INVENTION

The method of overcoming the disadvantages in the prior art as just described is initially sketched out with reference to FIG. 2, which is a partially exploded, cross-sectional elevation view of an exterior wall similar to that of FIG. 1, but according to a preferred embodiment of the invention. FIG. 2 should be taken as exemplary only, and is representative of applications to similar exterior wall systems that use different materials and construction as would be obvious to a person of ordinary skill in the art. Moreover, the method and apparatus of the invention apply equally to horizontal dispositions, e.g., structural studs that span horizontally between columns (in which case the “studs” are called “girts”) may sometimes be used, and the description and drawings shown herein should be taken to represent any such horizontal dispositions as well. [0036]
Specifically, [0037] structure 100 comprises a series of studs 102 that, as before, are erected onto a foundation 104 (which again is taken to include either a lower story top surface or a ground level foundation) by way of bottom and top metal stud tracks 106, 108. Also as before, an I-beam 110 support for an elevated floor and roof structure 112, above which extend stud extensions 102 a for the roof parapet. Unlike the prior art structure shown in FIG. 1, however, in this preferred embodiment of the invention the exteriors of studs 102, stud extensions 102 a, and elevated floor and roof structure 112 have installed on the exterior sides thereof sheets of a protective material 114, which differs substantially in its characteristics from sheathing or the house wrap materials and the like of the prior art.
Specifically, [0038] protective material 114 will have the following features:
a) it has (or can be given) sufficient structural integrity as to be both self-supporting and structurally span between supporting studs of the building to which it is attached, while withstanding substantial wind or air pressure loads; [0039]
b) is formed of a substance that does not absorb moisture and is of non-organic composition; [0040]
c) can be of minimal (e.g., less than ⅛ in.) thickness, thereby permitting more positive anchoring and attachment; and [0041]
d) the manufacture of the material can be adjusted so as to allow particular instances thereof to serve either as a vapor permeable air barrier or a vapor retardant barrier or vapor retardant air barrier, as the need may require. [0042]
d) durable construction permits usage to armor the parapet roof. Thus, a weather tight seal between the building exterior wall system and the roofing system can be performed using a single product, to be installed by the same building trade. [0043]
Additional and significant advantages of the use of such material are that: [0044]
a) as related to feature (a) above, stud spacing can be substantially increased, and lighter gauge and less expensive infill studs can be used between the structural load carrying studs; [0045]
b) the material is less costly than sheathing board products, and [0046]
c) the light weight and structural integrity of the material permits it to be installed through the use of lifts (within their height limits) rather than scaffolding. [0047]
The infill studs serve principally to hold the insulation and wiring and the like, and to support installation of interior sheathing. The thinner wall that results from the use of [0048] protective material 114 provides additional square footage of useable space within the building.
[0049] Protective material 114 may comprise a high-grade woven textile made up of polyolefins and polyesters that has been extruded and laminated into the form of a mesh, that material also being both ultra-violet insensitive and flame retardant. Such materials are found in those sold by Nicolon under the names Nicoprotect 250 SE, designated as “Flame Retardant Scaffold Sheeting and Netting”; Nicofol 210 SE MP, designated as “Flame Retardant Breather Roofing Membrane”; Nicofol SUV, designated as “Vapor Control Layer; and “SCAF-LITE” Scaffold Sheathing sold by Eagle Tarps, although other materials having like properties would also serve for the purposes of the invention. These materials have the same basic textile structure, comprising a woven reinforcing grid with fairly high tensile strength and tearing resistance, are semi-transparent, light in weight and flexible, and have a high ductility (with respect to elongation), but vary principally in terms of air and water vapor permeability and the amount of additional reinforcement needed to an array of reinforcing strips (to be shown further below) that give to protective material 114 its necessary structural integrity for the purposes of the invention. That is, Nicoprotect 250 SE is fully useable in the invention “as is,” whereas Nicofol 210 SE MP and Nicofol SUV would require added strengthening in the reinforcing grid and reinforcing strips.
One aspect of the invention lies in the recognition that to serve as a wind or air barrier, a material need not be rigid, nor of a thick, heavy construction as in the case of gypsum or other kinds of sheathing of the prior art. One can protect against wind forces during construction when the building is incomplete and to air pressure forces (positive or negative) within the exterior wall cavity of the completed building by the use of a structural membrane material that has sufficient tensile strength to resist imposed loads with limited deflection and can be firmly anchored. The materials useable as [0050] protective material 114 noted above are generally about 0.15-0.25 mm (6-10 mils) thick (exclusive of fabric and reinforcing strips) and weigh about 250 gm/m²(0.45 lb/yd²), but nevertheless can protect against a wind load of up to 100 mph or more. Their light weight permits one or two workers to hand carry protective material 114 to the ground level site of installation, or onto a lift for the higher elevation installation. The aforesaid materials are also semi-transparent, whereby significant amounts of any available sunlight will pass therethrough, thus providing lighting to workers in those parts of a building that do not have externally facing windows. Technical specifications of the products noted above will either be already known by a person of ordinary skill in the art, or are readily discernible from product literature, e.g, from Ten Cate Nicolon or Eagle Tarps. Of course, the scope of the invention is not limited to the particular materials that were described above for illustrative purposes, but should be taken to encompass any like materials that have the required characteristics.
Turning again to FIG. 2, similarly to the case of the prior art there must later be installed the cladding, here designated as [0051] exterior cladding 116. Such cladding may of course be of any type. Again before that installation, however, the interior work of installing the usual plumbing and wiring between and through the studs, as represented in FIG. 2 by the small boxes 118, will be carried out, then to be followed by installation of exterior insulation 120 (represented by cyclical S curves) in the usual manner, followed by an interior “weather adjustive” structure 122, and then followed where required or desired by an interior gypsum board 124. The interior construction is completed by installation of ceilings 126 and the interior finish 128 such as paint, wall paper, or the like. In the present instance, unlike that of the prior art, during all of the aforesaid interior work the protective material 114 that had previously been installed protects both the worker and stored materials against inclement weather, and also against the effects that such weather could have on the quality of that interior work, while similarly protecting against actual damage as a result of high winds.
Unlike the prior art of FIG. 1, an additional water-proof membrane that would encompass the upper distal end of [0052] protective material 114 and stud extensions 102 a is not required, since protective material 114 already possesses these properties. Optionally or as may be required by a building code, and as shown by the dashed lines in FIG. 2, added sheathing 132 may also be used interior to protective material 114. Between the distal ends of stud extensions 102 a, cladding 116 and membrane 130, on the one hand, and floor and roof structure 112 on the other, there is added the roof system 134. (The outboard end of roof system 134 abuts the distal ends of stud extensions 102 a.) The most specific distinction between this preferred embodiment of the invention and the prior art is the presence of that protective material 114 and its use to overcome the disadvantages of the prior art procedures previously described.
FIG. 3 shows a perspective view of a section of material useable as [0053] protective material 114. Specifically, material 114 is formed from a woven mesh 136 that is made up of mutually parallel and crossed or intermeshed strips of material 138 that have been laminated between a first facing material 140 and a second facing material 142. Although the strips of material comprising mesh 138 are shown in FIG. 3 as crossing at essentially right angles, it will be obvious to one of ordinary skill in the art that such a mesh having a different geometry could also be formed and serve just as well for the purposes of the invention. Mesh 136 basically provides the structural strength of material 114, and it is in part mesh 136 that with respect to the example products Nicofol 210 SE MP and Nicofol SUV mentioned above would have to be strengthened in order to serve as protective material 114, while using Nicoprotect 250 SE mesh 136 already has the necessary strength for such purpose.
The Nicolon products are generally formed from high density polyethylene (HDPE) or low density polyethylene (LDPE) using a polyester geotextile grid and reinforcing straps, laminated together to form the composite material. That composite material is then coated to provide other beneficial properties, or perforated with holes in the case of a need to provide vapor permeability, and so on in accordance with the needs previously described. Other similar materials might also be employed as previously noted, and such materials again may or may not require further strengthening, as the case may be. The principal relevant aspect of mesh [0054] 136 (or essentially of any protective material 114), as previously noted, lies in the manner of transferring wind or air pressure-induced forces from the protective material to the structure 102 of FIG. 2, and in doing so in such a manner that by virtue of its robust, grid-like structure and reinforcing strips 152 of FIGS. 4 and 5 as will be explained below, the material will have sufficient anchoring capacity to hold the material in place without failure, ripping, or tearing, and also in not allowing the material to deflect excessively under load, so that its protective function during construction and in the completed structure becomes assured.
These materials are compatible with standard roofing materials, with various sealants and adhesives, and can thus be sealed in an air-and weather tight manner to the roofing and wall systems at the terminations. The materials are also sufficiently ductile as to be workable at low installation temperatures in cold climates, while conversely being able to withstand any damage, e.g., from contact with hot asphalt, and moreover have a durability that will last for the life of the building, with respect to its high tensile and tearing strength, high puncture resistance, rip-stop construction and dimensional stability. Use of such material also provides versatility in that by the addition of fire retardant coatings, it can be used in all occupancy-type buildings, i.e., as to fire resistivity restrictions under the building codes. The material may also be rendered ultra-violet resistant. Particularly with respect to labor costs and layout requirements, that the material can be semi-transparent obviates any need for stud location as can occur with regard to gypsum or wood sheathing. Being of non-organic character, these materials will also be free of bacterial, mold, mildew and fungal growth. The method and apparatus may also be used in the context of modular building construction, panelized systems built on- or off-site, and using slanted or sloped walls, horizontal framing members, or exterior soffits. [0055]
It may be recalled that FIG. 2 is an exploded view of the relevant structure, so made in order to show more clearly the manner and sequence of construction. FIG. 4, on the other hand, shows in schematic form, in a top plan view wherein the building interior is downward, the actual manner of installing protective material [0056] 114 (those parts of the building further exterior to protective material 114 are not shown, since that aspect of the structure is indicated adequately in FIG. 2), and specifically how the wind load transfer and anchoring as previously described are accomplished. The structure in FIG. 4 shows at the bottom (the inward part of the building) a pair of studs 144 (which as previously noted could instead be horizontally disposed girts), shown here as being metal studs just to emphasize that either metal or wood studs, or any other structural backing material capable of transferring load to the structural framing system such as a concrete or masonry wall, may be employed. Connected directly to studs 144 is a sheet of sheathing 146, which as indicated with respect to sheathing 132 in FIG. 2 is optional with respect to the present invention, but may in fact be required under some building codes. Protective material 114, specifically designated as mesh 136 in FIG. 3, is next attached along the strategically placed reinforcing strips 152 shown end-on in FIG. 4 and in top plan in FIG. 5 and through sheathing 146 if present directly to studs 144. Anchoring is accomplished by the use of fasteners 148, which are characterized in having wide heads, preferably having a minimum ⅜ inch diameter, and further by washers 150 through which fasteners 148 are passed before being anchored into protective material 114, sheathing 146 (if present) and then into studs (or girts) 144. Washers 150 are of rubber or neoprene or the like so as to provide a weather tight connection.
FIG. 5 shows in top plan view a portion of [0057] protective material 114 to which has been added in the drawing an exemplar integral reinforcing strip 152. Strips 152 are used multiply to improve the holding capacity of protective material 114 at anchorage points to structure 144 against the various wind loading conditions to which the protective material 114 would be subjected during and after the building construction. The spacing and orientation of strips 152 can of course be varied to meet the requirements of particular circumstances, and the particular configuration shown in FIG. 4 is for illustrative purposes only. The result of the aforesaid construction is that both during construction and upon completion of the building there is provided protection against adverse environmental effects arising at the construction site that would otherwise be lacking, on the building workers, on the materials they use, and on the completed building.
Other arrangements and disposition of the aforesaid or like components, the descriptions of which are intended to be illustrative only and not limiting, may also be made without departing from the spirit and scope of the invention, which must be identified and determined only from the following claims and equivalents thereof. [0058]

Claims

I claim:

1. A method of constructing a building, comprising:

providing a foundation bounded by a periphery;

installing atop said foundation at predetermined locations thereon a multiplicity of bottom stud tracks, including peripheral bottom stud tracks near to said periphery of said foundation;

installing above each of said bottom stud tracks, in respectively mutually facing relationships, a multiplicity of top stud tracks, including peripheral top stud tracks;

installing a multiplicity of studs having spaces therebetween and inwardly and outwardly facing sides with respect to said periphery of said foundation, said studs being disposed so as to extend between respective ones of said peripheral bottom stud tracks and peripheral top stud tracks that lie in respective mutually facing relationships;

installing on sides of said studs a protective material;

installing plumbing, wiring, cabling and insulation within said spaces between said studs;

providing an inwardly facing finish around inwardly facing sides of said studs; and

installing outwardly from said protective material a layer of exterior cladding material.

2. The method of claim 1 wherein said protective material comprises planar sheets.

3. The method of claim 2 wherein said planar sheets are formed from polyolefin and polyester materials.

4. The method of claim 2 wherein said planar sheets comprise a woven textile fabric.

5. The method of claim 2 wherein said planar sheets have been formed by extrusion and lamination into the form of a mesh.

6. The method of claim 2 wherein the manufacture of said planar sheets is adaptable to allow particular instances thereof to serve as a vapor permeable air barrier, a vapor retardant barrier or a vapor retardant air barrier.

7. The method of claim 2 wherein said planar sheets have a structure whereby the passage of air therethrough has been minimized.

8. The method of claim 2 wherein said planar sheets have a high tensile strength that is resistant to wind forces.

9. The method of claim 2 wherein said planar sheets are semi-transparent.

10. A building having external walls that are covered over externally by a protective material.

11. The building of claim 10 wherein said protective material comprises planar sheets.

12. The building of claim 11 wherein said planar sheets are formed from polyolefin and polyester materials.

13. The building of claim 11 wherein said planar sheets comprise a woven textile fabric.

14. The building of claim 11 wherein said planar sheets have been formed by extrusion and lamination into the form of a mesh.

15. The building of claim 11 wherein the manufacture of said planar sheets is adaptable to allow particular instances thereof to serve as a vapor permeable air barrier, a vapor retardant barrier or a vapor retardant air barrier.

16. The building of claim 11 wherein said planar sheets have a structure whereby the passage of air therethrough has been minimized.

17. The building of claim 11 wherein said planar sheets have a high tensile strength that is resistant to wind forces.

18. The building of claim 11 wherein said planar sheets are semi-transparent.

19. The building of claim 11 wherein said planar sheets further comprise reinforcing strips.

20. An exterior building wall for protecting the interior of a building from inclement weather, comprising:

a wall frame disposed about the periphery of a building and having an outwardly facing side; and

a protective material disposed over said outwardly facing side of said wall frame.