Insulated roofing structure

• US 4,090,336 A
• Filed: 04/14/1975
• Issued: 05/23/1978
• Est. Priority Date: 10/29/1973
• Status: Expired due to Term

• Current Assignee: Frank E. Carroll
• Original Assignee: Carroll Research, Inc.
• Inventors: Carroll, Frank E.
• Primary Examiner(s): Bell, James J.
• Application Number:
  US05/567,621
• Time in Patent Office: 1,135 Days
• Field of Search: 52/309, 52/328, 52/408, 52/411, 52/405, 52/412, 52/404, 52/409, 52/615, 52/332, 428/256, 428/260, 428/310, 428/313, 428/251, 428/325, 428/141, 428/321, 428/423, 428/247, 156/71
• US Class Current: 52/309.7
• CPC Class Codes: E04D 13/1606 Insulation of the roof covering characterised by its integration in the roof structure self-supporting insulating slabs E04B7/22, E04B7/225
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/249968 Of hydraulic-setting material
• CPC Class Codes: Y10T 428/249981 Plural void-containing components
• CPC Class Codes: Y10T 428/24999 Inorganic

Abstract

A poured concrete insulated roofing structure installed over roof support members and having gypsum formboard with its underside adjacent the roof support members and secured to with its upper side adjacent rigid synthetic polymer foam, the polymer foam having spaces vertically therethrough over more than about 5 percent of the area of the gypsum formboard, and poured concrete over the foam and extending through the spaces into contact with more than about 5 percent of the formboard.

Claims

1. A poured insulated deck structure comprising:

deck support members;

moisture permeable gypsum formboard having an underside adjacent said deck support members;

strips of rigid synthetic polymer foam having an underside adjacent the upperside of said gypsum formboard and having openings between said strips providing communication from above said foam to said formboard, said openings having an area of about 5 to 20 percent of the area of said formboard;

reinforcing wire mesh over said foam;

poured concrete adjacent the upperside of said foam and extending through said openings into contact with and adhering to about 5 to 20 percent of the area of the upperside of said gypsum formboard, said concrete continuing drying by escape of moisture through the formboard in the area of contact between the concrete and formboard, said concrete surrounding the portion of the deck support members above said formboard resulting in a reinforced concrete beam structure including the deck support members;

additional concrete beam structures formed by concrete extending through openings between said strips of foam about midway between said deck support members, said additional beam structures adhering to said formboard preventing sagging; and

a waterproof wearing surface to the exterior of the poured concrete.

2. The poured insulated deck structure of claim 1 wherein said deck support members are sheet metal structural shapes which are symmetrical about a vertical bisecting plane having a central vertical web, two legs projecting at outward angles downwardly from the bottom of said web, each leg having a substantially horizontal flange projecting outwardly at its lower extremity upon which said formboard rests, and a stiffening member at the upper edge of said web.

3. The deck structure of claim 1 wherein said area of said strips is about 5 to 10 percent.

4. The deck structure of claim 1 wherein said foam is selected from the group consisting of polystyrene, styrene-maleic anhydride, phenolic, such as phenol formaldehyde, polyurethane, vinyl, such as polyvinyl chloride and copolymers of polyvinyl chloride and polyvinyl acetate, epoxy, polyethylene, urea formaldehyde, acrylic, and polyisocyanurate.

5. The deck structure of claim 4 wherein said foam is selected from the group consisting of polystyrene and polyurethane.

6. The deck structure of claim 1 wherein said concrete has a thickness of about 1 to about 3 inches over the surface of the polymer foam.

7. The deck structure of claim 1 wherein said foam has a thickness of about 1 to about 4 inches.

8. The deck structure of claim 1 wherein said concrete is lightweight concrete of a portland cement base.

9. A poured insulated deck structure comprising:

sub-purlins of sheet metal structural shapes of a box section having a horizontal base, opposing vertical sides and upper horizontal flanges extending inwardly from the top of said sides forming an open slot between the terminus of said flanges;

moisture permeable gypsum formboard adjacent to and secured against the top of said upper horizontal flanges of said sub-purlins;

sheet metal clips having a vertical portion extending upwardly and downwardly from opposing slots, each of said opposing slots engaging one of said horizontal flanges of said box section when the axis of said clip and box section are at about 90°

to each other, said upwardly extending vertical portion bending to a horizontal portion to engage the top of said formboard securing it against the top of said flanges, then bending to a substantially vertical upward portion and then bending to a substantially horizontal portion to provide uplift resistance when surrounded by concrete;

strips of rigid synthetic polymer foam having an underside adjacent the upperside of said gypsum formboard and having openings between said strips providing communication from above said foam to said formboard, said openings having an area of about 5 to 20 percent of the area of said formboard;

reinforcing wire mesh over said form;

poured concrete adjacent the upperside of said foam and extending through said openings into contact with and adhering to about 5 to 20 percent of the area of the upperside of said gypsum formboard, said concrete continuing drying by escape of moisture through the formboard in the areas of contact between the concrete and formboard, said concrete surrounding the portion of said clips above said formboard resulting in a reinforced concrete beam structure including the deck support members;

additional concrete beam structures formed by concrete extending through openings between said strips of foam about midway between said sub-purlins, said additional beam structures adhering to said formboard preventing sagging; and

a waterproof wearing surface to the exterior of the poured concrete.