Embedded barrier to fluid flow

Abstract

A method for implementing a barrier to fluid passage in which the barrier is embedded within, instead of atop, porous material. This retains the durability of the surface of the porous material. In one embodiment, a thin set mortar is applied to a concrete slab. A pleated metal foil is pressed into the wet mortar and a bond is established. The mortar is allowed to set and a top, or finish, section of concrete is then poured over the foil and finished conventionally. Provisions are made for sealing expansion joints in concrete slab floors and at the juncture of floor and wall. The foil may be provided in multiple layers to provide a mechanical bond via the mortar oozing through perforations or along pleats in each of the top and bottoms layers, while providing a solid layer through which a fluid will not pass, at least in one direction.

1 . A method of creating a barrier to fluid flow at least from below concrete-surfaced flooring placed above a prepared base, comprising: 
 placing a first layer of concrete upon said prepared base;    applying at least one layer of adhesive material to the top surface of said first layer of concrete, said at least one layer of said adhesive material to include a topmost layer of said adhesive material;    placing multiple reinforcing panels, at least one said panel incorporating at least one layer of non-porous material, upon said topmost layer of said adhesive material, overlapping edges of said panels with edges of any said panels placed adjacent thereto,    wherein said panels completely cover said topmost layer of said adhesive material, and    wherein said panels serve to reinforce said first layer of concrete;    sealing all said overlapped edges; and    emplacing at least one second layer of concrete upon said panels such that said panels are confined below said second layer of concrete and above said topmost layer of said adhesive material,    wherein the step of placing said panels, the step of sealing said overlapped edges of said panels and the step of emplacing said second layer of concrete completes said barrier, and    wherein said barrier prevents said fluid flow from said prepared base upward through said second layer of concrete.    
   
   
       2 . The method of  claim 1  in which said panels comprise non-porous material selected from a group consisting of: a metal, a metal alloy, a steel alloy, a stainless steel, a composite material, a composite material containing at least some metal, and combinations thereof.  
   
   
       3 . The method of claim I said non-porous material comprising at least in part a first metal.  
   
   
       4 . The method of  claim 1  said adhesive material comprising at least in part a thin set mortar deposited at a thickness of about 6 mm (¼ inch).  
   
   
       5 . The method of  claim 1  applying said second layer at a thickness of about at least 2.5 cm (1.0 inch).  
   
   
       6 . The method of  claim 1  sealing said overlapped edges at least in part by applying a continuous bead of at least one sealant along the entire length between each said overlapped edge, 
 wherein said sealant remains flexible upon curing.    
   
   
       7 . The method of  claim 6  employing a RTV sealant as said at least one sealant.  
   
   
       8 . The method of  claim 1  providing said panels as at least one plate of a total thickness less than about 6 mm (¼ inch).  
   
   
       9 . The method of  claim 1  providing said panels as at least one foil of a thickness less than about 1 mm (40 mil).  
   
   
       10 . The method of  claim 1  providing said prepared base as an aggregate.