Finishing and roof deck systems containing fibrous mat-faced gypsum boards

• US 5,704,179 A
• Filed: 01/26/1994
• Issued: 01/06/1998
• Est. Priority Date: 02/27/1984
• Status: Expired due to Fees

• Current Assignee: Georgia-Pacific Gypsum LLC (KOCH Industries Incorporated)
• Original Assignee: Georgia-Pacific Corporation
• Inventors: Randall, Brian G., Lehnert, Charles W.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): WILKENS, KEVIN DOUGLAS
• Application Number:
  US08/187,199
• Time in Patent Office: 1,441 Days
• Field of Search: 52/309.1, 52/309.17, 52/408, 52/481.1, 52/783.1, 52/794.1, 52/796.1
• US Class Current: 52/408
• CPC Class Codes: B28B 19/0092 to webs, sheets or the like, e.g. of paper, cardboard
• CPC Class Codes: B28B 23/0006 the reinforcement consisting of aligned, non-metal reinforcing elements
• CPC Class Codes: B32B 13/14 next to a fibrous or filamentary layer
• CPC Class Codes: E04C 2/043 of plaster E04C2/049 takes precedence
• CPC Class Codes: E04C 2/284 at least one of the materials being insulating
• CPC Class Codes: E04C 2/288 composed of insulating material and concrete, stone or stone-like material
• CPC Class Codes: E04D 11/02 Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17
• CPC Class Codes: E04D 13/1643 the roof structure being formed by load bearing corrugated sheets, e.g. profiled sheet metal roofs
• CPC Class Codes: E04D 13/1668 the insulating material being masses or granules applied in situ
• CPC Class Codes: E04F 13/047 Plaster carrying meshes

Abstract

Finishing systems and roof decks are provided which include a gypsum board having a set gypsum core faced with a fibrous mat. The gypsum core includes one or more additives which are effective in simultaneously improving the water and fire resistance of the board. In preferred embodiments, the board has sufficient water-resistant additive for absorbing less than about 10% water in an ASTM C-473 test.

Claims

1. A plaster lath finishing system for use in a building comprising a support member containing a fibrous mat-faced gypsum board comprising a gypsum core having one or more additives therein which simultaneously improve the water resistance and fire resistance of the core, and a finishing material overlying said board.

2. The plaster lath finishing system of claim 1, wherein said system is located in the interior of a structure, and said finishing material comprises a thin plaster coating.

3. A system comprising a roof deck which includes supporting means and a gypsum board overlying said supporting means, said board comprising:

(a) a gypsum core having one or more additives therein which improve the water resistance of the core; and

(b) a glass fiber mat facing at least one side of said core.

4. A roof deck according to claim 3, wherein insulating material is sandwiched between said supporting means and said gypsum board.

5. A roof deck according to claim 3 including a cementitious composition overlying said gypsum board, and an exterior finishing material overlying said cementitious composition.

6. A roof deck according to claim 5 including a mesh-like material sandwiched between said gypsum board and said cementitious composition.

7. A system comprising a roof deck which includes supporting means and a gypsum board overlying said supporting means, said board comprising:

(a) a gypsum core having one or more additives therein which improve both the water resistance and fire resistance of the core, one of said additives comprising mineral fibers for improving the fire resistance of the core; and

(b) a glass fiber mat facing at least one side of said core.

8. The system of claim 7 wherein said gypsum board has each of its core faces covered with said glass fiber mat, with the mat of at least one of the faces being adhered to the core by set gypsum penetrating into the thickness of the mat.

9. The system of claim 8 wherein said set gypsum penetrates but partway into the thickness of the mat such that the outer surface of said mat is substantially free of set gypsum.

10. The system of claim 7 wherein said support means comprises metal sheet.

11. The system of claim 10 further comprising a finishing material overlying said gypsum board.

12. The system of claim 11 wherein said finishing material comprises one or more alternating layers of asphalt and roofing felt.

13. The system according to claim 12 further including insulating material sandwiched between said metal sheet and said gypsum board.

14. The system according to claim 13 wherein said insulating material is expanded polystyrene.

15. The system according to claim 14 wherein said support comprises corrugated metal sheet.

16. The system of claim 7 wherein said mineral fibers comprise glass fibers.

17. The system of claim 16 wherein said glass fibers comprise chopped glass fibers.

18. The system of claim 7 wherein said core comprises at least about 0.03 wt. % mineral fibers.

19. The system of claim 7 wherein said core has a density of less than about 55 lbs. per cubic foot.

20. The system of claim 19 wherein said core has a density of from about 45 to about 55 lbs. per cubic foot.