diff --git a/src/mesh/autoMesh/autoHexMesh/meshRefinement/meshRefinementBaffles.C b/src/mesh/autoMesh/autoHexMesh/meshRefinement/meshRefinementBaffles.C
index d9ec65959c..5cdab910ac 100644
--- a/src/mesh/autoMesh/autoHexMesh/meshRefinement/meshRefinementBaffles.C
+++ b/src/mesh/autoMesh/autoHexMesh/meshRefinement/meshRefinementBaffles.C
@@ -51,9 +51,6 @@ License
 
 // * * * * * * * * * * * * * Private Member Functions  * * * * * * * * * * * //
 
-// Repatches external face or creates baffle for internal face
-// with user specified patches (might be different for both sides).
-// Returns label of added face.
 Foam::label Foam::meshRefinement::createBaffle
 (
     const label faceI,
@@ -131,46 +128,6 @@ Foam::label Foam::meshRefinement::createBaffle
 }
 
 
-//// Check if we are a boundary face and normal of surface does
-//// not align with test vector. In this case there'd probably be
-//// a freestanding 'baffle' so we might as well not create it.
-//// Note that since it is not a proper baffle we cannot detect it
-//// afterwards so this code cannot be merged with the
-//// filterDuplicateFaces code.
-//bool Foam::meshRefinement::validBaffleTopology
-//(
-//    const label faceI,
-//    const vector& n1,
-//    const vector& n2,
-//    const vector& testDir
-//) const
-//{
-//
-//    label patchI = mesh_.boundaryMesh().whichPatch(faceI);
-//    if (patchI == -1 || mesh_.boundaryMesh()[patchI].coupled())
-//    {
-//        return true;
-//    }
-//    else if (mag(n1&n2) > cos(degToRad(30)))
-//    {
-//        // Both normals aligned. Check that test vector perpendicularish to
-//        // surface normal
-//        scalar magTestDir = mag(testDir);
-//        if (magTestDir > VSMALL)
-//        {
-//            if (mag(n1&(testDir/magTestDir)) < cos(degToRad(45)))
-//            {
-//                //Pout<< "** disabling baffling face "
-//                //    << mesh_.faceCentres()[faceI] << endl;
-//                return false;
-//            }
-//        }
-//    }
-//    return true;
-//}
-
-
-// Determine patches for baffles on all intersected unnamed faces
 void Foam::meshRefinement::getBafflePatches
 (
     const labelList& globalToMasterPatch,
@@ -385,11 +342,11 @@ Foam::Map<Foam::labelPair> Foam::meshRefinement::getZoneBafflePatches
             }
         }
     }
+
     return bafflePatch;
 }
 
 
-// Create baffle for every face where ownPatch != -1
 Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::createBaffles
 (
     const labelList& ownPatch,
@@ -509,6 +466,7 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::createBaffles
             }
         }
     }
+
     // Pick up neighbour side of baffle (added faces)
     forAll(faceMap, faceI)
     {
@@ -535,7 +493,6 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::createBaffles
 void Foam::meshRefinement::checkZoneFaces() const
 {
     const faceZoneMesh& fZones = mesh_.faceZones();
-
     const polyBoundaryMesh& pbm = mesh_.boundaryMesh();
 
     forAll(pbm, patchI)
@@ -664,27 +621,26 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::createZoneBaffles
         Info<< "Created " << nZoneFaces << " baffles in = "
             << mesh_.time().cpuTimeIncrement() << " s\n" << nl << endl;
     }
+
     return map;
 }
 
 
-// Extract those baffles (duplicate) faces that are on the edge of a baffle
-// region. These are candidates for merging.
-// Done by counting the number of baffles faces per mesh edge. If edge
-// has 2 boundary faces and both are baffle faces it is the edge of a baffle
-// region.
 Foam::List<Foam::labelPair> Foam::meshRefinement::freeStandingBaffles
 (
     const List<labelPair>& couples,
     const scalar planarAngle
 ) const
 {
+    // Done by counting the number of baffles faces per mesh edge. If edge
+    // has 2 boundary faces and both are baffle faces it is the edge of a baffle
+    // region.
+
     // All duplicate faces on edge of the patch are to be merged.
     // So we count for all edges of duplicate faces how many duplicate
     // faces use them.
     labelList nBafflesPerEdge(mesh_.nEdges(), 0);
 
-
     // This algorithm is quite tricky. We don't want to use edgeFaces and
     // also want it to run in parallel so it is now an algorithm over
     // all (boundary) faces instead.
@@ -698,10 +654,8 @@ Foam::List<Foam::labelPair> Foam::meshRefinement::freeStandingBaffles
     // So now any edge that is used by baffle faces only will have the
     // value 2*1000000+2*1.
 
-
     const label baffleValue = 1000000;
 
-
     // Count number of boundary faces per edge
     // ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
 
@@ -729,11 +683,9 @@ Foam::List<Foam::labelPair> Foam::meshRefinement::freeStandingBaffles
         }
     }
 
-
     DynamicList<label> fe0;
     DynamicList<label> fe1;
 
-
     // Count number of duplicate boundary faces per edge
     // ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~
 
@@ -927,7 +879,6 @@ Foam::List<Foam::labelPair> Foam::meshRefinement::freeStandingBaffles
 }
 
 
-// Merge baffles. Gets pairs of faces.
 Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::mergeBaffles
 (
     const List<labelPair>& couples
@@ -1059,7 +1010,6 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::mergeBaffles
 }
 
 
-// Finds region per cell for cells inside closed named surfaces
 void Foam::meshRefinement::findCellZoneGeometric
 (
     const pointField& neiCc,
@@ -1279,7 +1229,6 @@ void Foam::meshRefinement::findCellZoneInsideWalk
     const labelList& locationSurfaces,  // indices of surfaces with inside point
     const labelList& namedSurfaceIndex, // per face index of named surface
     const labelList& surfaceToCellZone, // cell zone index per surface
-
     labelList& cellToZone
 ) const
 {
@@ -1298,6 +1247,7 @@ void Foam::meshRefinement::findCellZoneInsideWalk
             blockedFace[faceI] = true;
         }
     }
+
     // No need to sync since namedSurfaceIndex already is synced
 
     // Set region per cell based on walking
@@ -1433,14 +1383,11 @@ bool Foam::meshRefinement::calcRegionToZone
             }
         }
     }
+
     return changed;
 }
 
 
-// Finds region per cell. Assumes:
-// - region containing keepPoint does not go into a cellZone
-// - all other regions can be found by crossing faces marked in
-//   namedSurfaceIndex.
 void Foam::meshRefinement::findCellZoneTopo
 (
     const point& keepPoint,
@@ -1449,6 +1396,11 @@ void Foam::meshRefinement::findCellZoneTopo
     labelList& cellToZone
 ) const
 {
+    //  Assumes:
+    // - region containing keepPoint does not go into a cellZone
+    // - all other regions can be found by crossing faces marked in
+    //   namedSurfaceIndex.
+
     // Analyse regions. Reuse regionsplit
     boolList blockedFace(mesh_.nFaces());
 
@@ -1652,8 +1604,6 @@ void Foam::meshRefinement::findCellZoneTopo
 }
 
 
-// Make namedSurfaceIndex consistent with cellToZone - clear out any blocked
-// faces inbetween same cell zone.
 void Foam::meshRefinement::makeConsistentFaceIndex
 (
     const labelList& cellToZone,
@@ -1843,7 +1793,21 @@ Foam::labelList Foam::meshRefinement::freeStandingBaffleFaces
     const labelList& faceNeighbour = mesh_.faceNeighbour();
 
 
-    DynamicList<label> faceLabels(mesh_.nFaces()/20);
+    // We want to pick up the faces to orient. These faces come in
+    // two variants:
+    // - faces originating from stand-alone faceZones
+    //   (these will most likely have no cellZone on either side so
+    //    ownZone and neiZone both -1)
+    // - sticky-up faces originating from a 'bulge' in a outside of
+    //   a cellZone. These will have the same cellZone on either side.
+    //   How to orient these is not really clearly defined so do them
+    //   same as stand-alone faceZone faces for now. (Normally these will
+    //   already have been removed by the 'allowFreeStandingZoneFaces=false'
+    //   default setting)
+
+    // Note that argument neiCellZone will have -1 on uncoupled boundaries.
+
+    DynamicList<label> faceLabels(mesh_.nFaces()/100);
 
     for (label faceI = 0; faceI < mesh_.nInternalFaces(); faceI++)
     {
@@ -1853,7 +1817,7 @@ Foam::labelList Foam::meshRefinement::freeStandingBaffleFaces
             // Free standing baffle?
             label ownZone = cellToZone[faceOwner[faceI]];
             label neiZone = cellToZone[faceNeighbour[faceI]];
-            if (max(ownZone, neiZone) == -1)
+            if (ownZone == neiZone)
             {
                 faceLabels.append(faceI);
             }
@@ -1872,13 +1836,14 @@ Foam::labelList Foam::meshRefinement::freeStandingBaffleFaces
                 // Free standing baffle?
                 label ownZone = cellToZone[faceOwner[faceI]];
                 label neiZone = neiCellZone[faceI-mesh_.nInternalFaces()];
-                if (max(ownZone, neiZone) == -1)
+                if (ownZone == neiZone)
                 {
                     faceLabels.append(faceI);
                 }
             }
         }
     }
+
     return faceLabels.shrink();
 }
 
@@ -2135,7 +2100,6 @@ void Foam::meshRefinement::consistentOrientation
     }
 
 
-
     DynamicList<label> changedEdges;
     DynamicList<patchFaceOrientation> changedInfo;
 
@@ -2224,7 +2188,6 @@ void Foam::meshRefinement::consistentOrientation
         }
 
 
-
         // Walk
         PatchEdgeFaceWave
         <
@@ -2326,7 +2289,6 @@ void Foam::meshRefinement::consistentOrientation
 
 // * * * * * * * * * * * * * * * Member Functions  * * * * * * * * * * * * * //
 
-// Split off unreachable areas of mesh.
 void Foam::meshRefinement::baffleAndSplitMesh
 (
     const bool doHandleSnapProblems,
@@ -2517,7 +2479,6 @@ void Foam::meshRefinement::baffleAndSplitMesh
 }
 
 
-// Split off (with optional buffer layers) unreachable areas of mesh.
 Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::splitMesh
 (
     const label nBufferLayers,
@@ -2804,8 +2765,6 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::splitMesh
 }
 
 
-// Find boundary points that connect to more than one cell region and
-// split them.
 Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::dupNonManifoldPoints
 (
     const localPointRegion& regionSide
@@ -2859,8 +2818,6 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::dupNonManifoldPoints
 }
 
 
-// Find boundary points that connect to more than one cell region and
-// split them.
 Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::dupNonManifoldPoints()
 {
     // Analyse which points need to be duplicated
@@ -2870,7 +2827,6 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::dupNonManifoldPoints()
 }
 
 
-// Zoning
 Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::zonify
 (
     const point& keepPoint,
@@ -3172,22 +3128,23 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::zonify
 
 
     // Get coupled neighbour cellZone. Set to -1 on non-coupled patches.
-    labelList neiCellZone(mesh_.nFaces()-mesh_.nInternalFaces(), -1);
+    labelList neiCellZone;
+    syncTools::swapBoundaryCellList(mesh_, cellToZone, neiCellZone);
     forAll(patches, patchI)
     {
         const polyPatch& pp = patches[patchI];
 
-        if (pp.coupled())
+        if (!pp.coupled())
         {
+            label bFaceI = pp.start()-mesh_.nInternalFaces();
             forAll(pp, i)
             {
-                label faceI = pp.start()+i;
-                neiCellZone[faceI-mesh_.nInternalFaces()] =
-                    cellToZone[mesh_.faceOwner()[faceI]];
+                neiCellZone[bFaceI++] = -1;
             }
         }
     }
-    syncTools::swapBoundaryFaceList(mesh_, neiCellZone);
+
+
 
     // Get per face whether is it master (of a coupled set of faces)
     const PackedBoolList isMasterFace(syncTools::getMasterFaces(mesh_));
@@ -3228,6 +3185,13 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::zonify
             Info<< "Detected " << nFreeStanding << " free-standing zone faces"
                 << endl;
 
+            if (debug)
+            {
+                OBJstream str(mesh_.time().path()/"freeStanding.obj");
+                str.write(patch.localFaces(), patch.localPoints(), false);
+            }
+
+
             // Detect non-manifold edges
             labelList nMasterFacesPerEdge;
             calcPatchNumMasterFaces(isMasterFace, patch, nMasterFacesPerEdge);
@@ -3326,22 +3290,19 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::zonify
         if (surfI != -1)
         {
             // Orient face zone to have slave cells in max cell zone.
+            // Note: logic to use flipMap should be consistent with logic
+            //       to pick up the freeStandingBaffleFaces!
+
             label ownZone = cellToZone[faceOwner[faceI]];
             label neiZone = cellToZone[faceNeighbour[faceI]];
 
             bool flip;
 
-            label maxZone = max(ownZone, neiZone);
-
-            if (maxZone == -1)
+            if (ownZone == neiZone)
             {
                 // free-standing face. Use geometrically derived orientation
                 flip = meshFlipMap[faceI];
             }
-            else if (ownZone == maxZone)
-            {
-                flip = false;
-            }
             else
             {
                 flip = true;
@@ -3384,26 +3345,18 @@ Foam::autoPtr<Foam::mapPolyMesh> Foam::meshRefinement::zonify
 
                 bool flip;
 
-                label maxZone = max(ownZone, neiZone);
-
-                if (maxZone == -1)
+                if (ownZone == neiZone)
                 {
                     // free-standing face. Use geometrically derived orientation
                     flip = meshFlipMap[faceI];
                 }
-                else if (ownZone == neiZone)
-                {
-                    // Free-standing zone face or coupled boundary. Keep master
-                    // face unflipped.
-                    flip = !isMasterFace[faceI];
-                }
-                else if (neiZone == maxZone)
-                {
-                    flip = true;
-                }
                 else
                 {
-                    flip = false;
+                    flip =
+                    (
+                        ownZone == -1
+                     || (neiZone != -1 && ownZone > neiZone)
+                    );
                 }
 
                 meshMod.setAction