Configuration implementing waterproofing under a concrete surface coat of a concrete floor

Abstract

A barrier to fluid passage is embedded within, instead of atop, porous material to retain 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 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 configuration preventing fluid passage in discrete structures in at least one direction, comprising:
 at least a topmost layer of adhesive material applied to a topmost surface of a first section of first porous material comprising a flowable mixture that hardens upon curing, said first porous material provided as an underlayment in said discrete structures;   at least one panel of non-porous material having a top side and a bottom side, said bottom side affixed to said topmost layer of adhesive material so as to completely cover said topmost surface of said first section,   
     wherein if more than one said panels are required, all edges of each said panels are overlapped with any adjacent said panels and sealed continuously along each said overlapped edge; and
 a second section of second porous material emplaced such that said second porous material flows over said at least one panel in a contiguous mass that completely covers said at least one panel, 
 
     wherein said second porous material is similar in composition and method of emplacement to said first porous material such that said second porous material hardens upon curing, and 
     wherein placement of said second section establishes a durable surface and affixes said configuration in place. 
   
   
       2 . The configuration of  claim 1  in which said panel comprises non-porous material selected from the group consisting essentially 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 configuration of  claim 1  in which said non-porous material comprises at least in part at least one metal. 
   
   
       4 . The configuration of  claim 1  in which said first porous material and said second porous material comprise at least in part concrete. 
   
   
       5 . The configuration of  claim 1  in which said adhesive material comprises at least in part a thin set mortar applied at a thickness of about at least 6 mm. 
   
   
       6 . The configuration of  claim 1  in which said first porous material comprises at least in part concrete applied at a thickness of about at least 2.5 cm. 
   
   
       7 . The configuration of  claim 1  in which said overlapping edges of said panels are sealed with a sealant that remains flexible upon curing. 
   
   
       8 . The configuration of  claim 7  in which said at least one sealant is a Room Temperature Vulcanizing (RTV) sealant. 
   
   
       9 . The configuration of  claim 1  in which said at least one panel comprises at least one plate of a total thickness less than about 6 mm. 
   
   
       10 . The configuration of  claim 9  in which said at least one plate comprises a first perforated section, having a top side and a bottom side, and a second solid section, having a top side and a bottom side, said top side of said first perforated section abutted to said bottom side of said second solid section, each said first and second sections being of a total thickness of less than about 3 mm. 
   
   
       11 . The configuration of  claim 10  in which said first perforated section and said second solid section are joined via means selected from the group consisting of:
 tack welding, soldering, gluing, heating, applying pressure, and combinations thereof.   
   
   
       12 . The configuration of  claim 9  in which said at least one plate comprises a first perforated section, having a top side and a bottom side, a second solid section, having a top side and a bottom side, and a third perforated section, having a top and bottom side, said top side of said first perforated section abutted to said bottom side of said second solid section, and said bottom side of said third perforated section abutted to said top side of said second solid section, each said first, second and third sections being of a total thickness of less than about 3 mm. 
   
   
       13 . The configuration of  claim 12  in which said first and third perforated sections are joined to said second solid section via means selected from the group consisting of: tack welding, soldering, gluing, heating, applying pressure, and combinations thereof. 
   
   
       14 . The configuration of  claim 1  in which said at least one panel comprises at least foil having at least one layer, said foil having a thickness less than about 1.0 mm. 
   
   
       15 . The configuration of  claim 14  in which said foil comprises a first perforated section, having a top side and a bottom side, and a second solid section, having a top side and a bottom side, said top side of said first perforated section abutting said bottom side of said second solid section, each said first and second sections being of a total thickness of between about 0.25 mm and about 0.76 mm. 
   
   
       16 . The configuration of  claim 15  in which said first perforated section and said second solid section are joined via means selected from the group consisting of:
 tack welding, soldering, gluing, heating, applying pressure, and combinations thereof.   
   
   
       17 . The configuration of  claim 15  in which said each said first perforated section and said second solid section is further configured with a pleated edge along at least one edge,
 wherein said at least one pleated edge facilitates flexion of said foil when under load thereby resisting breach of said foil via shear forces.   
   
   
       18 . The configuration of  claim 1  in which said first and second sections each incorporate at least one expansion joint and said configuration further comprises a non-porous expandable strip overlapping the entire length of said edges of any said panels that abut said expansion joint, each overlap of a width less than about 5.0 cm,
 wherein said strip is sealed along each longitudinal edge of said strip between said strip and said topmost portion of each said panel that abuts said expansion joint with a continuous bead of sealant along the entire length of said expansion joint, said sealant remaining flexible upon cure.   
   
   
       19 . A configuration preventing fluid passage in at least one direction in discrete structures, comprising:
 means for adhering that comprises at least a topmost layer, said means for adhering applied to a topmost surface of a first section of said discrete structure;   means for inhibiting fluid flow, said means for inhibiting affixed to said topmost layer of said means for adhering to completely cover said topmost surface,   
     wherein if more than one said means for inhibiting are required, all edges of each said means for inhibiting are overlapped with any adjacent said means for inhibiting and sealed continuously along each said overlapped edge; and
 means for covering, said means for covering having a top side and a bottom side abutting said topmost layer of said means for adhering, 
 
     wherein said means for covering is emplaced upon said means for inhibiting so a to completely cover said means for inhibiting, and 
     wherein placement of said means for covering establishes a durable surface and affixes said configuration in place. 
   
   
       20 . The configuration of  claim 19  in which said first section of said discrete structure and said means for covering comprise at least in part concrete.