Exterior finishing system and building wall containing a corrosion-resistant enhanced thickness fabric and method of constructing same

A stucco system comprising:

• a corrosion-resistant lath including an open, woven fabric comprising high strength, non-metallic weft and warp yarns, whereby a portion of said yarns are fixed in a substantially sinusoidal pattern, when viewed in the plane of the fabric, wherein said lath provides furring to fur the body of said lath from a substrate;
• said lath being applied to a building wall substrate or framed wall, said lath capable of retaining and supporting the weight of a wet stucco matrix applied thereto;
• and
• a stucco matrix applied over said lath.

A stucco system comprising:

• a corrosion-resistant lath including an open woven fabric comprising weft and warp yarns containing non-metallic fibers, whereby a portion of said weft yarns are undulated, when viewed in the plane of the fabric, to provide furring to fur the body of said lath from a substrate;
• a polymeric coating disposed over at least a portion of said yarns for substantially fixing said weft yarns in said undulated condition, said polymeric resin being substantially non-soluble in a wet composition of said stucco;
• said coated fabric being capable of retaining and supporting the weight of a wet stucco matrix applied thereto;
• and
• a stucco matrix applied to said lath.

An exterior insulation and finish system comprising:

• a substrate;
• a layer of insulation attached over said substrate;
• a base coat applied over said insulation;
• a corrosion-resistant reinforcing mesh substantially embedded within said base coat, said corrosion-resistant reinforcing mesh including a porous fabric containing non-metallic fibers and a coating disposed over at least a portion of said non-metallic fibers, said reinforcing mesh having a layer thickness of at least about 0.125 inches (3.175 mm) and being capable of retaining and supporting the weight of a wet base coat applied thereto, without sloughing or sagging;
• and
• a finish coat applied over said base coat and said reinforcing mesh.

An exterior insulation and finish system comprising:

• a substrate;
• a layer of insulation attached over said substrate;
• a base coat applied over said insulation;
• a corrosion-resistant reinforcing mesh substantially embedded within said base coat, said reinforcing mesh including an open, woven fabric comprising high strength, non-metallic weft and warp yarns, whereby a portion of said yarns are fixed in a substantially sinusoidal pattern, when viewed in the plane of the fabric, by a resinous coating;
• said mesh being applied to said substrate, said reinforcing mesh capable of retaining and supporting the weight of wet base coat applied thereto;
• and
• a finish coat applied over said base coat and said reinforcing mesh.

An exterior insulation and finish system comprising:

• a substrate;
• insulation attached over said substrate;
• a base coat applied over said insulation;
• a corrosion-resistant reinforcing mesh including an open woven fabric comprising weft and warp yarns containing non-metallic fibers, whereby a portion of said weft yarns are undulated, resulting in a layer thickness for said reinforcing mesh of at least about 0.125 in (3.175 mm);
• a polymeric coating disposed over at least a portion of said yarns for substantially fixing said weft yarns in said undulated condition, said polymeric resin being substantially non-soluble in a wet composition of said base coat;
• said coated reinforcing mesh being capable of retaining and supporting the weight of a wet base coat applied thereto;
• and
• a finish coat applied over said base coat and said reinforcing mesh.

A method of constructing a stucco system comprising:

• (a) affixing a substrate to a frame;
• (b) optionally disposing a secondary weather barrier over said substrate;
• (c) optionally disposing a layer of insulation over said weather barrier or said substrate;
• (d) affixing a corrosion resistant lath over said substrate, or secondary weather barrier, if present, or said insulation layer, if present, said lath comprising a porous layer containing non-metallic fibers and a coating disposed over at least a portion of said fibers, said lath having a thickness of at least about 0.125 inches (3.175 mm) and being capable of retaining and supporting the weight of a wet stucco matrix applied thereto, and providing furring to fur the body of said lath from a substrate;
• (e) applying at least a first stucco layer to said lath;
• and
• (f) permitting said stucco layer to set to form a hard protective finish.

A method of constructing an exterior insulation and finish system comprising:

• (a) affixing a substrate to a frame;
• (b) optionally disposing a weather barrier over said substrate;
• (c) disposing an insulation board over said substrate or said secondary weather barrier, if present;
• (d) affixing a corrosion resistant reinforcing mesh over said insulation board, said reinforcing mesh comprising a porous layer containing non-metallic fibers and a coating disposed over at least a portion of said fibers, said lath having a thickness of at least about 0.125 inches (3.175 mm) and being capable of retaining and supporting the weight of a wet base coat applied thereto, and providing furring to fur the body of said lath from a substrate;
• and
• (e) applying at least a first layer of base coat over said reinforcing mesh.

A method of constructing an exterior insulation and finish system comprising:

• (a) affixing a substrate to a frame;
• (b) optionally disposing a weather barrier over said substrate;
• (c) disposing an insulation board over said substrate or said secondary weather barrier, if present;
• (d) applying at least a first layer of wet base coat over said substrate, or over said secondary weather barrier, if present;
• and
• (e) embedding a corrosion resistant reinforcing mesh in said wet base coat, said reinforcing mesh comprising a porous layer containing non-metallic fibers and a coating disposed over at least a portion of said fibers, said reinforcing mesh having a thickness of at least about 0.125 inches (3.175 mm) and being capable of retaining and supporting the weight of a wet base coat applied thereto, and providing furring to fur the body of said lath from a substrate.