Foundation waterproofing system and method

Abstract

Systems and methods for making a waterproofed concrete wall assembly, such as for a basement wall. A waterproof liner is present at the pouring of the concrete of the wall assembly, and has a fibrous layer into which concrete can infuse before hardening. The waterproof liner may include one or more boards including a polymer foam. The boards may line a form used to make the wall assembly, or may make up part of the form.

1 . A waterproofed concrete wall assembly, comprising:
 a vertical wall of hardened concrete, the wall having a first side and a second side;   one or more boards forming a waterproof liner adjacent the first side of the wall of hardened concrete, each of the boards comprising a polymer foam and a fibrous facer joined to the polymer foam, wherein some of the concrete is infused into the fibrous facer, the fibrous facer having been present at an inner surface of a form during pouring of the concrete.   
     
     
         2 . The waterproofed concrete wall assembly of  claim 1 , wherein the fibrous facer is a nonwoven facer. 
     
     
         3 . The waterproofed concrete wall assembly of  claim 2 , wherein the polymer foam is polyisocyanurate foam. 
     
     
         4 . The waterproofed concrete wall assembly of  claim 2 , wherein the polyisocyanurate foam has a density between 2.5 lb/ft3 and 25 lb/ft3. 
     
     
         5 . The waterproofed concrete wall assembly of  claim 2 , wherein the polyisocyanurate foam has a density between 4 lb/ft3 and 15 lb/ft3. 
     
     
         6 . The waterproof concrete wall assembly of  claim 1 , wherein a plurality of boards are present, and further comprising tape sealing joints between the plurality of boards. 
     
     
         7 . The waterproof concrete wall assembly of  claim 6 , wherein the tape is on an inner side of the plurality of boards, in contact with the concrete. 
     
     
         8 . The waterproof concrete wall assembly of  claim 6 , wherein the tape is on an outer side of the plurality of boards. 
     
     
         9 . A method of making a waterproofed concrete wall assembly, the method comprising:
 constructing a form, the form having a first side and a second side, the first and second sides defining a gap between the first and second sides for receiving poured concrete, wherein the first side is made of one or more boards comprising a polymer foam and a fibrous layer;   pouring concrete in the gap between the first and second sides of the form;   allowing the concrete to harden, some of the concrete having infused into the fibrous layer; and   leaving the boards of the first side of the form in place adjacent the hardened concrete.   
     
     
         10 . The method of  claim 9 , further comprising removing the second side of the form. 
     
     
         11 . The method of  claim 9 , wherein the boards comprise polyisocyanurate foam. 
     
     
         12 . The method of  claim 9 , wherein each of the boards comprises a fibrous facer on at least one side of the board. 
     
     
         13 . The method of  claim 9 , further comprising sealing joints between the boards using a tape, a sealant, or a combination of tape and sealant. 
     
     
         14 . The method of  claim 9 , further comprising sealing joints between the boards using a tape before the concrete is poured. 
     
     
         15 . The method of  claim 9 , wherein the joints between the boards are sealed with a tape initially having a split release liner. 
     
     
         16 . The method of  claim 9 , wherein the joints between the boards are sealed at an inside surface of the boards, adjacent the gap. 
     
     
         17 . The method of  claim 9 , wherein the joints between the boards are sealed at an outside surface of the boards. 
     
     
         18 . The method of  claim 9 , further comprising:
 installing form ties between the first and second form sides before pouring the concrete, to prevent expansion of the gap due to hydrostatic pressure of the poured concrete, wherein the form ties protrude from both sides of the form;   removing the protruding portions of the form ties once the concrete is hardened; and   sealing the points at which the form ties formerly protruded through the boards using a tape, a sealant, or a combination of tape and sealant.   
     
     
         19 . The method of  claim 9 , wherein the boards form an outside surface of the wall. 
     
     
         20 . The method of  claim 9 , wherein the second side of the form is made of one or more boards comprising a polymer foam.