FLASHING SYSTEM

Description

CROSS-REFERENCE

This application is a continuation-in-part of U.S. Ser. No. 18/398,470 filed Dec. 28, 2023, which claims the benefit of priority of U.S. provisional application number 63/471,131, filed Jun. 5, 2023, both of which are herein incorporated by reference.

TECHNICAL FIELD

The present invention relates to flashing used in building construction and, more particularly, to a flashing system.

BACKGROUND

Many types of buildings have overhangs, balconies, eyebrows, and/or other features that require protection from water intrusion. Preventing water from getting behind stucco and other cladding systems saves money and prolongs the life of the structure and finishes. Flashing the edge of slabs, balconies, and structural eyebrows is intended to make these features watertight with minimal maintenance. Balconies and overhangs often require a transition over the top of the slab face to prevent water intrusion into the finishes and building structure. Concrete is not perfectly flat or even like metal flashing, so the flashing will not sit completely flat on the concrete surface. When flashing is installed over concrete, the differences in the tolerance between a straight piece of flashing and an irregular concrete surface causes an “oil canning” effect to occur, which makes sealing between the two materials difficult and causes more areas for water infiltration.

Existing flashing systems are attached to the top of an overhang, balcony, eyebrow, and/or other feature, generally after the concrete is placed, and often require the flashing to be secured to the structure with either exposed sealants or anchors that penetrate the structure and are exposed to the elements. The exposed anchors must then be sealed to prevent future water intrusion. The attachments often leave exposed sealants as the primary means of waterproofing the joint and thus do not provide a clean and neat appearance when installed. Exposed sealants require regular and expensive maintenance. When the systems fail, the stucco or other finish of the building is often damaged and may fall off.

Another option is mounting the flashing or stop to a face of the overhang, balcony, eyebrow, and/or other feature, which relies solely on an exposed caulk joint at the top of the transition to prevent water intrusion into the building envelope. These currently available solutions require sealants to be placed in locations that are exposed to the elements, which causes rapid deterioration of the sealants and leads to expensive and frequent repairs to the waterproofing system.

When existing buildings are being remodeled or require repairs to improve waterproofing at overhangs, balconies, eyebrows, and/or other features, these current solutions are limited to the same types of install as new construction, with the same limited life and ability to seal the system and maintain the water tightness of the transition from the waterproofing to the finish of the slab edge.

As can be seen, there is a need for a watertight flashing system for integration into the construction of a slab that does not rely on exposed sealants or penetrative fasteners, does not require excessive maintenance, and is pleasant in appearance.

SUMMARY

Embodiments provided herein relate to a flashing system. Some embodiments of the flashing system include a reglet that includes a central shaft with a first stem, a second stem, a third stem, a fourth stem, and a parallel extension that extend from the central shaft. In some embodiments, the first stem and the second stem are positioned colinearly and on opposing sides of the central shaft. In some embodiments, the third stem and the fourth stem extend from a common side of the central shaft to define a bituminous water stop. In still some embodiments, the parallel extension includes a connection portion that is coupled to the central shaft, a length portion that is disposed substantially parallel with the central shaft, and a receiver that is coupled to an end of the length portion and disposed toward the central shaft to create an acute angle with the length portion.

Some embodiments include a reglet that includes a central shaft, a third stem that is coupled to the central shaft, a fourth stem that is coupled to the central shaft, where the third stem and the fourth stem extend from a common side of the central shaft to define a bituminous water stop and a parallel extension that extends from the central shaft. In some embodiments, the parallel extension includes a connection portion that is coupled to the central shaft, a length portion that is disposed substantially parallel with the central shaft, and a receiver that is coupled to an end of the length portion and disposed toward the central shaft to create an acute angle with the length portion for receiving a counterflashing.

Still some embodiments of a flashing system include a reglet that includes a central shaft with a third stem, a fourth stem, and a parallel extension that extend from the central shaft. The third stem and the fourth stem may extend from a common side of the central shaft to define a bituminous water stop. In some embodiments, the parallel extension includes a connection portion that is coupled to the central shaft, a length portion that is disposed substantially parallel with the central shaft, and a receiver that is coupled to an end of the length portion and disposed toward the central shaft to create an acute angle with the length portion. In some embodiments, the flashing system includes a counterflashing that is removably disposed between the parallel extension and the central shaft.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description, and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a side view of a reglet component of a flashing system according to embodiments provided herein;

FIG. 2 depicts a side elevation view of a counterflashing component of the flashing system of FIG. 1, according to embodiments provided herein;

FIG. 3 depicts a schematic side view of the reglet of FIG. 1 and the counterflashing of FIG. 2, according to embodiments provided herein;

FIG. 4 depicts a perspective view of installation of a prefabricated outside corner flashing component, according to embodiments provided herein;

FIG. 5 depicts another perspective of installation of a prefabricated inside corner flashing component, according to embodiments provided herein;

FIG. 6 depicts a side view of a form clip component, according to embodiments provided herein;

FIG. 7 depicts a schematic side view of the reglet component and the form clip component, according to embodiments provided herein;

FIG. 8 depicts a perspective view of the reglet component and the counterflashing component, according to embodiments provided herein;

FIG. 9 depicts a side view of the ringlet component being used against the wall, according to embodiments provided herein; and

FIG. 10 is a side view of another embodiment of a reglet component of a flashing system, according to embodiments provided herein.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, one embodiment includes a flashing system comprising flashing or counterflashing retained in an extrusion or a unitary reglet with integral sealant that may be placed in a form prior to pouring the concrete structure. The reglet (or extrusion), whether embedded or installed post construction, may be fabricated by any suitable process known in the art. The reglet may be formed by extrusion molding in some cases and is therefore sometimes called an “extrusion” herein. Extrusions are used in all types of window and railing systems. The extrusions may be any suitable length to form complete edge assemblies.

The embedded extrusion may be set into the concrete or other poured surface when it is poured, resulting in no conflict in tolerances between the flashing and the concrete that causes “oil canning” of the flashing. Some embodiments may utilize snap in flashings, end caps, pre-made outside corners, and pre-made inside corners are generally made of sheet metal.

In some embodiments, the components of the flashing system disclosed herein may be manufactured of metal or a polymer. The metal may be selected to be resistant to degradation when embedded in concrete, such as certain grades of stainless steel, or may be coated with a protective material that prevents degradation, such as coated aluminum. The polymer may be any suitable polymeric material that exhibits chemical resistance and durability, such as polyvinyl chloride (PVC).

An extrusion may be placed into a concrete form prior to concrete placement and may have an integral waterproofing material which creates a seal between the concrete and the flashing. This also allows the flashing to be installed without drilling holes or installing fasteners which may be exposed and or may require exposed sealant used to protect fasteners installed after the structure is poured. In some embodiments, the concrete form may include having an asymmetric, substantially T-shaped frame with at least one protrusion operative to engage the reglet 100. Thus, the system eliminates the need for frequent maintenance a traditional flashing system requires. The reglet embedded in concrete, containing a pre-installed sealant such as bituminous water stop, provides a leak proof, watertight edge of slab construction joint. The embedded extrusion provides a square and even edge of slab. The bituminous water stop provides long-lasting protection against water infiltration at the top of the deck. When installed post-construction, the extrusion also provides protection against water infiltration at the fastener at a top of the extrusion.

The extrusion, whether embedded or installed post-construction, accommodates snap-in flashing. The flashing is installed with minimal exposed sealants which otherwise require frequent and expensive maintenance. The use of these embodiments may reduce costs for reworking failed flashings and/or lack of maintenance on flashing and sealants. These embodiments provide a watertight connection to the building with minimal exposed sealants. These embodiments also provide a smooth surface for the waterproofing system on top of a deck to be installed, which prevents water build up and reduced drainage of the balcony or slab edge. These embodiments provide a clean look (e.g., to balcony edges, etc.) intersecting with the walls or structure of the building that is aesthetically pleasing and requires little to no maintenance over the life of the building on which it is installed.

The unique process in which the flashing is installed allows nearly all the sealant to be protected from the elements. The unique design of the extrusion and flashing enable installation of the flashing immediately after the finish of the slab edge is completed.

In some embodiments, the reglet may be installed after concrete has been placed, such as for a remodel or remediation job remodeling or repairing flashing systems which have failed on previously constructed buildings, keeping the fasteners sealed without exposed sealants. The extrusion can be attached to the face of the slab edge using fasteners installed into the existing construction. The pocket of the extrusion may have sealant pre-installed to seal any top penetrations that attach the extrusion to an existing structure. The pocket protects the sealant from the elements by nature of its shape and location of attachment. The lower fastener installed on previously constructed structures is protected from the elements by the flashing clipped into the extrusion.

Pre-made outside corners and pre-made inside corners provide protection at the outer and inner corners of a slab edge which are much more reliable than field installed applications. In some embodiments, outside corners and inside corners may be fabricated on site.

Referring to the figures, FIG. 1 illustrates reglet 100, a receiver 12, a second stem 14, a first stem 16, third stem 18, and a top pocket return 20. In some embodiments, the reglet 100 may be configured as an embeddable extrusion. A “C” shaped portion 22 formed at the top of the reglet 100 may be filled with a bituminous water stop 24 or other suitable sealant known in the art. In the cross-section representation of FIG. 1, the reglet 100 has a central shaft 23 with a substantially “C” shaped portion 22 formed at a first end of the central shaft and a perpendicular bar 25 formed at a second end. The “C” shaped portion 22 generally has right angles. The perpendicular bar 25 extends to form a first stem 16 (which may be “L” shaped and may function as an anchor) at a first end and a second stem 14 (which may also be “L” shaped and may function as an anchor) at a second end, the second stem 14 being rotated 180° from the first stem 16, such that the first stem 16 and the second stem 14 are joined and legs of the “L” shapes are spaced from the central shaft 23. A third stem 18 (which may also be “L” shaped and function as an anchor) extends normal to the central shaft 23, substantially parallel to and spaced from the first stem 16. A receiver 12 descends from a stem of the “C” shaped portion 22, substantially parallel to the central shaft 23, with a length of about half the length of the central shaft 23, with an end that is bent at an acute angle into an area between the receiver 12 and the central shaft 23.

It will be understood that the first stem 16 and the third stem 18 are not limited to the “L” shaped configuration shown in FIG. 1 and may have another configuration, such as exhibiting a bend upward from horizontal between 0° and 90°, such as an angle of about 45°.

Similarly, the “C” shaped portion 22 with bituminous water stop 24 is not limited to the position shown in FIG. 1 above the receiver 12 and the third stem 18. In some embodiments, the “C” shaped portion 22 with bituminous water stop 24 may be formed above the position of the first stem 16 and the third stem 18, leaving an open cavity between the receiver 12 and the top horizontal surface. In some embodiments, the lower horizontal wall of the “C” shaped portion 22 may be formed by the third stem 18. The “C” shaped portion 22 may be advantageous, for example, for use with a post tension slab in which the reglet has a maximum height limit to prevent conflict with the post tension anchors, such as about 1½ inches.

It will be understood that in some embodiments, the first stem 16 and the third stem 18 may be absent, enabling use on a pre-existing structure. Similarly, some embodiments may be configured with the “C” shaped portion 22 having a dividing wall (not shown) extending through a counter of the “C” shaped portion 22, dividing the “C” shaped portion 22 into two mirror image chambers.

FIG. 2 depicts a side elevation view of a counterflashing component 200 of the flashing system of FIG. 1, according to embodiments provided herein. As illustrated, the counterflashing component 200 (which may be configured as a snap-in flashing body) may include a top clip 26, a vertical top side 28, a horizontal seat 30, a vertical bottom side 32, and a drip edge 34. As further illustrated, the counterflashing component 200 has a horizontal seat 30 having a first right angle at a first end thereof and a second right angle at a second end thereof. Extending from the first right angle, a vertical bottom side 32 having a bent tip with an obtuse angle forms the drip edge 34. A vertical top side 28 extending from the second right angle has a top clip 26 bent at an acute angle. As will be understood, the top clip 26 (and/or the receiver 12 from FIG. 1) is pliable and resilient, allowing the counterflashing component 200 to snap into the reglet 100 (FIG. 1). Specifically, when the reglet 100 engages with the counterflashing component 200, the top clip 26 is inserted past the receiver 12 to lock the counterflashing component 200 into place.

FIG. 3 depicts a schematic side view of the reglet 100 of FIG. 1 and the counterflashing component 200 of FIG. 2, according to embodiments provided herein. As illustrated, the reglet 100 may be embedded into the concrete 36 of a balcony slab. The reglet 100 is secured to the concrete 36 by the third stem 18 and the first stem 16 when the concrete 36 is placed. The bituminous water stop 24 in the “C” shaped portion 22 is in direct contact with the concrete 36. The top pocket return 20 of the reglet 100 forms the top edge of the slab edge and a termination point on top of deck 38. The concrete 36 is shown with a tile 46 adhered over the waterproofing system to a top of deck 38 with thin set 48. A weep bead 44 may be positioned below the tile 46. Stucco J bead (not shown) and stucco 40 may be installed onto the face and underside of the concrete 36. After the stucco 40 installation is complete, sealant 42 is installed on top of the stucco J Bead (and/or weep bead) prior to installing the counterflashing component 200. The top clip 26 is inserted upward into the region between the central shaft 23 and the receiver 12, and then pushed down until the horizontal seat 30 is fully embedded into the sealant. The counterflashing component 200 is thus snugly coupled to the reglet 100. The vertical bottom side 32 and the drip edge 34 hang down over the top of the stucco 40. A water drainage route 50 is shown schematically in FIG. 3.

FIG. 4 depicts a perspective view of installation of at least one prefabricated outside corner flashing component, according to embodiments provided herein. As illustrated, a pre-made outside corner cap 52 having a clip formed on both sides of its top edge may be installed over the reglet 100 and counterflashing component 200, including the top clip 26, horizontal seat 30, vertical bottom side 32, and drip edge 34. The pre-made outside corner cap 52 generally conforms to the configuration of the counterflashing component 200 and reglet 100. As also depicted in FIG. 3, the reglet 100 of FIG. 4 is embedded in concrete 36, which has a veneer of stucco 40. The pre-made outside corner cap 52 and the counterflashing component 200 may have a full bed of sealant installed therebetween.

FIG. 5 depicts another perspective of installation of at least one prefabricated inside corner flashing component 54, according to embodiments provided herein. As illustrated, the prefabricated inside corner flashing component 54 has a clip on both sides of its top edge. The counterflashing component 200 may include the top clip 26 that is installed first over stucco 40, as shown in FIG. 3. A full bed of sealant may be installed between the prefabricated inside corner flashing component 54 and the counterflashing component 200. The prefabricated inside corner flashing component 54 generally conforms to the counterflashing component 200 and reglet 100.

FIG. 6 depicts a side view of an extrusion form clip body 300 with a first arm 72, a receiver clip 74, and a bottom leg clip 76 (which may be “L” shaped). A second arm 78 and a stem 80 are used to secure the extrusion form clip body 300 to a concrete form 56 (FIG. 7) using fasteners (not shown). For example, nails may be driven through the horizontal surface of the second arm 78 into the concrete form 56 and nails may be driven through the vertical surface of the stem 80 into the concrete form 56, holding the reglet 100 in position while concrete is poured. In cross-section, the extrusion form clip body 300 has an asymmetric “T” shape, having a stem 80, a first arm 72 and a second arm 78, with the second arm 78 being longer than the first arm 72. A bottom leg clip 76 (which may be “L” shaped) extends from the stem 80 distal from the first arm 72 and/or the second arm 78. Approximately midway along the length of the stem 80, a receiver clip 74 extends at an acute angle with respect to the portion of the stem 80 proximal to the first arm 72. The first arm 72, the receiver clip 74, and the bottom leg clip 76 protrude from one side of the stem 80.

FIG. 7 depicts a side view of a concrete form 56, comprising boards, with an extrusion form clip body 300 attached thereto with fasteners (not shown). The reglet 100 is clipped into the extrusion form clip body 300. The first arm 72 holds the top pocket return 20, the receiver clip 74 secures the receiver 12, and the bottom leg clip 76 secures the second stem 14. The extrusion form clip body 300 is used to hold the reglet 100 in place during the placement of concrete 36 and is removed when the concrete form 56 boards are removed.

FIGS. 8 and 9 depict perspective view of a slab edge with reglet 100 and an adjacent exterior wall 64. The counterflashing component 200 is capped at the end to create a tab of flashing 66 which seals the inside corner flashing component 54 where stucco 40 and a waterproofing system on a vertical face of wall 60 and a waterproofing system on a vertical face of slab edge 62 intersect.

FIG. 10 is a side view of another embodiment of a reglet 500 of a flashing system, according to embodiments provided herein. As illustrated, the reglet 500 may include a parallel extension 522 that includes a connection portion that is coupled to the central shaft 523, a length portion that is disposed substantially parallel with the central shaft 523, and a receiver 512 that is coupled to an end of the length portion and disposed toward the central shaft 523 to create an acute angle with the length portion. The reglet 500 may further include a second stem 514, a first stem 516, a third stem 518, and a fourth stem 520. In some embodiments, the reglet 500 may be configured as an embeddable extrusion. While the reglet 100 from FIG. 1 included a “C” shaped portion 22 formed at the top of the reglet 100, the embodiment of FIG. 10 illustrates that the receiver 512 is defined by the parallel extension 522 that extends from a central shaft 523. Depending on the embodiment, the parallel extension 522 may be “L” shaped and then couple do the receiver 512 at an acute angle for locking the reglet 500 to a counterflashing.

In some embodiments, first stem 516 and the second stem 514 are positioned colinear and on opposing sides of the central shaft 523. The first stem 516 may include a first stem connection portion coupled to the central shaft 523 and a first stem length portion that is disposed substantially parallel to the central shaft 523. The second stem 514 may include a second stem connection portion coupled to the central shaft 523 and a second stem length portion that is disposed substantially parallel to the central shaft 523. In some embodiments, the first stem connection portion is disposed away from the parallel extension 522 and the second stem connection portion is disposed towards the third stem 528. In some embodiments, the third stem 518 includes a third stem connection portion that is coupled to the central shaft 523 and a third stem length portion that is disposed substantially parallel to the central shaft 523. The third stem length portion may be directed toward the fourth stem 520.

The reglet 500 may also include the fourth stem 520 that is coupled to the central shaft 523 and substantially colinear with a portion of the parallel extension 522. The third stem 518 and the fourth stem 520 may define a bituminous water stop 524, which may be filled with a suitable waterproofing sealant. In some embodiments, the third stem 518 and the fourth stem 520 may extend from a common side of the central shaft 523 to define a bituminous water stop 524. In some embodiments, the fourth stem 520 includes a fourth stem connection portion that is coupled to the central shaft 523 and a fourth stem length portion that is disposed substantially parallel to the central shaft 523. The fourth stem length portion may be directed toward the third stem 528.

It will be understood that the first stem 516, the second stem 514, the third stem 518, and the fourth stem 520 are not limited to the “L” shaped configuration shown in FIG. 10 and may have another configuration, such as exhibiting a bend upward from horizontal between 0° and 90°, such as an angle of about 45°.

As will be understood, the reglet 500 may be configured to gain space for receiving the counterflashing (or a larger counterflashing than received by the reglet 100 from FIG. 1). Specifically, the reglet 100 (FIG. 1) is configured to receive the counterflashing in the space provided by the receiver 12. Above that space (in the orientation of FIG. 1) is the “C” shaped portion 22 for receiving the bituminous water stop 24. However, the reglet 500 may be configured to extend the receiving space defined by the parallel extension 522 and the receiver 512 to the top of the reglet 500. This allows for the bituminous water stop 524 to be positioned laterally from the parallel extension 522 and the receiver 512 (in the orientation of FIG. 10). Depending on the particular embodiment, this may gain about an extra ½ inch, ¾ inch, 1 inch, etc. of space for receiving the counterflashing.

It should be understood that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.