Open grid fabric for reinforcing wall systems, wall segment product and methods of making same

A pre-coated open grid fabric wall reinforcement that reinforces and provides impact resistance to a wall system comprising a rigid surface and a stucco layer, the wall reinforcement comprising:

• a first set of substantially parallel strength-imparting rovings comprising an effective strength-imparting amount of a direct-sized silane sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch;
• a second set of substantially parallel strength-imparting rovings comprising an effective strength-imparting amount of a direct-sized silane sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch;
• the first and second sets of rovings being arranged next to each other with the rovings of one set being arranged at a substantial angle to the rovings of the other set, without compressing rovings of one set between rovings of the other set, to form an open grid fabric wall reinforcement weighing between 50 and 650 gm/square meter to provide strength and impact resistance to the wall system;
• and
• an effective strength-imparting amount of polymeric coating on the rovings of the wall reinforcement at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the open grid fabric wall reinforcement,
• wherein the coating and the silane sizing are selected to assure that the wall reinforcement remains an open grid which permits the stucco-like layer to penetrate therethrough during fabrication of the wall system, that the wall reinforcement has pliability and body for application during fabrication of the wall system, and that the wall reinforcement imparts improved strength to the wall system as compared to a wall system in the absence of a wall reinforcement comprising said rovings having said arrangement.

A pre-coated open grid fabric wall reinforcement that reinforces and provides impact resistance to a wall system comprising a rigid surface and a stucco layer, the wall reinforcement comprising:

• a first set of substantially parallel impact resistant and strength-imparting rovings comprising an effective impact-resisting and strength-imparting amount of a direct-sized silane containing sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch;
• a second set of substantially parallel impact resistant and strength imparting rovings comprising an effective impact-resisting and strength-imparting amount of a direct-sized silane containing sizing, having a linear density between 130 and 400 grams per thousand meters, and being arranged in the set at an average of 1.5 to 12 ends per inch;
• the first and second sets of rovings being arranged next to each other with the rovings of one set being arranged at a substantial angle to the rovings of the other set, without compressing rovings of one set between rovings of the other set, to form an open grid wall reinforcement fabric weighing between 50 and 650 gm/square meter to provide strength and impact resistance to the wall system;
• and
• an effective strength-imparting amount of polymeric coating on the rovings of the wall reinforcement at a level of 10 to 150 parts dry weight of resin to 100 parts by weight of the open grid fabric wall reinforcement,
• wherein the coating and the silane containing sizing are selected to assure that the wall reinforcement remains an open grid which permits the stucco layer to penetrate therethrough during fabrication of the wall system, that the wall reinforcement has pliability and body for application during fabrication of the wall system, and that the wall reinforcement imparts improved impact resistance and strength to the wall system as compared to a wall system in the absence of a wall reinforcement comprising said rovings having said arrangement.