U.S. patent application number 12/416002 was filed with the patent office on 2010-03-18 for outdoor flooring, deck and patio surface system and method.
Invention is credited to David M. Busby, Philip J. Busby.
Application Number | 20100064609 12/416002 |
Document ID | / |
Family ID | 42005981 |
Filed Date | 2010-03-18 |
United States Patent
Application |
20100064609 |
Kind Code |
A1 |
Busby; David M. ; et
al. |
March 18, 2010 |
OUTDOOR FLOORING, DECK AND PATIO SURFACE SYSTEM AND METHOD
Abstract
A system and method for providing an outdoor flooring such as a
lightweight deck surface, employs a fiber reinforced polymer
structural panel with plural grid openings therein. Connectors
adapted to interlock adjacent panels to one another and to a base,
also are adapted for receiving support column members therein for
providing ground or base oriented surface or an elevated surface. A
surfacing material, such as a quarried stone or tile, is attached
to the top of the panel, providing a deck surface without requiring
substantial structural support.
Inventors: |
Busby; David M.; (Beaverton,
OR) ; Busby; Philip J.; (Beaverton, OR) |
Correspondence
Address: |
PATENTTM.US
P. O. BOX 82788
PORTLAND
OR
97282-0788
US
|
Family ID: |
42005981 |
Appl. No.: |
12/416002 |
Filed: |
March 31, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11669586 |
Jan 31, 2007 |
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12416002 |
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60764190 |
Jan 31, 2006 |
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Current U.S.
Class: |
52/283 ;
52/489.2 |
Current CPC
Class: |
E04F 15/02183 20130101;
E04F 15/02194 20130101; E04F 2015/02055 20130101; E04F 2015/02111
20130101; E04F 15/08 20130101; E04F 2015/0205 20130101; E04F
15/0215 20130101 |
Class at
Publication: |
52/283 ;
52/489.2 |
International
Class: |
E04B 5/02 20060101
E04B005/02 |
Claims
1. A flooring system, comprising: a structural panel member having
length and width dimensions, adapted for mounting as a base
framework; said panel member comprising: plural openings therein
defined in a pattern in a portion of said panel member; and cutting
guideline members for assisting in guiding cutting of said
structural panel member into sub-panels, at least one of said
sub-panels having a length or width dimension that is a pre-defined
desired dimension.
2. The flooring system according to claim 1, wherein plural said
cutting guideline members are provided to provided plural said
pre-defined desired dimensions.
3. The flooring system according to claim 2, wherein said plural
pre-defined desired dimensions comprise 24 inches and 16
inches.
4. The system according to claim 1, wherein said structural panel
member comprises a fiber reinforced polymer panel.
5. The system according to claim 1, wherein said structural panel
member is formed with plural openings therein.
6. The system according to claim 5, wherein said plural openings
form a grid pattern.
7. The system according to claim 5, wherein ones of said plural
openings are substantially rectangular in shape.
8. The system according to claim 5, wherein ones of said plural
openings are substantially square in shape.
9. The system according to claim 5, comprising plural ones of said
structural panel members and further comprising a connector member
for connecting adjacent ones of said panel members to one
another.
10. The system according to claim 9, wherein said connector member
comprises engaging members for interacting with ones of said plural
openings on said structural panels for providing engagement.
11. The system according to claim 1, further comprising a connector
member for connecting said panel member to a base, wherein said
connecting member comprises an engaging feature and said structural
panel member comprises a corresponding engagement feature for
interacting to provide engagement therebetween.
12. The system according to claim 11, further comprising a support
column member, wherein said connector member further comprises an
engaging feature for also engaging with said support column member
for providing an elevated support for said panel member.
13. A flooring system, comprising: a structural panel member having
length and width dimensions, adapted for mounting as a base
framework; a connector for engaging with said structural panel
member for securing said panel member to a base or to an adjacent
other structural panel.
14. The system according to claim 13, wherein said connecting
member comprises an engaging feature and said structural panel
member comprises a corresponding engagement feature for interacting
to provide engagement therebetween.
15. The system according to claim 13, wherein said base comprises a
support column member, wherein said connector member further
comprises an engaging feature for also engaging with said support
column member for providing an elevated support for said panel
member.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 11/669,586 filed Mar. 31, 2007, which claims
priority of U.S. provisional patent application 60/735,348, filed
Mar. 31, 2006.
BACKGROUND OF THE INVENTION
[0002] This invention relates to outdoor flooring, surfaces for
decks, patios and the like, and more particularly, to a decking
system and method for enabling use of surface materials that would
ordinarily lack suitable structural features to accommodate deck or
patio applications.
[0003] Stone walkway and step surfaces are frequently used at homes
and businesses, as the appearance is attractive and enjoyed by
many. Walkway and step stones are typically rather thick, to
provide sufficient structural properties to support weight
necessary in walkway and step use. As such, given the weight of
stone, elevated deck surfaces such as for home decks, do not employ
stone surfaces, as the weight of the stone requires substantially
structural support beyond what is typically employed for deck
construction.
SUMMARY OF THE INVENTION
[0004] In accordance with the invention, a deck and patio surface
system comprises a fiber reinforced structural panel employed as a
substrate, a mounting fastener for enabling the panel to be secured
to a deck, patio, or the like, and a surfacing material bonded or
otherwise attached to the structural panel.
[0005] Accordingly, it is an object of the present invention to
provide an improved deck system to enable use of stone surface in
above-ground deck applications.
[0006] It is a further object of the present invention to provide
an improved system for deck or patio applications to allow use of
surface material not normally by itself having sufficient
structural properties for such use.
[0007] It is yet another object of the present invention to provide
an improved method for providing a deck surface.
[0008] Another object of the present invention is to provide a deck
or patio system adapted for use over waterproofed living space
without requiring penetration of the waterproof membrane.
[0009] It is still another object of the present invention to
provide a system and method for providing a new surface over an
existing damaged patio surface.
[0010] It is an additional object of the present invention to
provide a system and method for providing a raised deck or surface
for receiving tile, stone or other paver type surfacing.
[0011] The subject matter of the present invention is particularly
pointed out and distinctly claimed in the concluding portion of
this specification. However, both the organization and method of
operation, together with further advantages and objects thereof,
may best be understood by reference to the following description
taken in connection with accompanying drawings wherein like
reference characters refer to like elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is an exploded perspective view of a portion of the
system according to the invention;
[0013] FIG. 2 is a top view of the fastener of FIG. 1, during an
initial forming phase;
[0014] FIG. 3 is a top view of the fastener of FIG. 2 when formed
to final shape;
[0015] FIG. 4 is a sectional view of the fastener of FIG. 3 taken
along line 4-4 of FIG. 3;
[0016] FIG. 5 is a side view of the fastener of FIG. 3 taken in the
direction of arrow 5 of FIG. 3;
[0017] FIGS. 6-19 are illustrations of the steps of the method of
installing a deck system in accordance with the invention;
[0018] FIG. 20 is a view of an alternate structural panel;
[0019] FIG. 21 is a close up perspective view of a panel of FIG.
20;
[0020] FIG. 22 is a perspective view of a connector for connecting
adjacent panels and/or for mounting panels to an under support;
[0021] FIG. 23 is a top view of an installation of plural panels
using plural connectors;
[0022] FIG. 24 is a side view of an installation where connectors
are floating;
[0023] FIG. 25 is a perspective view of a panel for use in pedestal
mounting configurations;
[0024] FIG. 26 is a view of underneath a corner of a panel;
[0025] FIG. 27 is a top view of an installation of plural panels
using plural connectors;
[0026] FIG. 28 is a perspective view of two adjacent panels
positioned on a connector disk;
[0027] FIG. 29 is a top perspective view of a spacer/aligner;
[0028] FIG. 30 is a top perspective view illustrating use of the
connector disks and pipes to provide an elevated mounting for
panels;
[0029] FIG. 31 provides an up close perspective view of a pipe
mounted in a connector;
[0030] FIG. 32 is a top perspective view of a panel mounted on a
connector disk, with a support pipe and bottom connector disk,
providing a raised deck portion for mounting of pavers, stones, or
tiles, for example;
[0031] FIGS. 33 and 34 are side sectional views showing the
mounting of connectors with pipes and panels 70, with stone/tile in
FIG. 33, and pavers in FIG. 34; and
[0032] FIGS. 35 and 36 are top and side views of an alternate
fasteners.
DETAILED DESCRIPTION
[0033] The system according to a preferred embodiment of the
present invention comprises a composite deck surface having a
structural panel, fastener elements to secure the structural panel
to a deck base, and a surfacing material bonded to the structural
panel.
[0034] Referring to FIG. 1, an exploded perspective view of a
portion of the system 10, a structural panel 12, suitably
comprising a fiber reinforced polymer panel having a grid pattern
of openings 14 in the illustrated embodiment, is adapted to be
received on top of a deck base structure, which may suitably
comprise wood deck framing timbers 16. A fastener element 18,
described in further detail in connection with FIGS. 2-5 herein, is
adapted to be received in an opening 14 so as to engage with the
structural panel 12, seating such that the top surface of the
fastener is below the top surface of the panel 12. The fastener
includes a central hole 20 adapted to receive a fastener
therethrough, to allow securing the panel to the deck framing
timber 16.
[0035] A surfacing material 22, which may comprise a cut stone
having an aesthetically pleasing appearance, color and/or pattern,
is suitably bonded to the structural panel, using a bonding
material 24, for example. The surfacing material may also comprise
tile, dry laid brick, concrete or stone pavers, for example.
[0036] The structural panel is suitably provided in sheets having
dimensions of 4 foot by 8 foot, with a 1.5 inch square grid size,
in the illustrated embodiment. The panel is suitably approximately
1 inch thick. The individual grid openings narrow somewhat from the
top of the panel to the bottom, such that they are wider at the top
face than at the bottom. In the particular embodiment, the opening
is 1 5/16.sup.th inch at the top measured from interior edge to the
opposite edge of an individual grid opening, but is 11/4th inch at
the bottom face of the panel.
[0037] A suitable panel that is employed with the system and method
may be a fiber reinforced general purpose polyester molded resin
panel, although other materials may be used. The panel size is
preferably 4 foot by 8 foot in the preferred embodiment, based on
construction standards and practices, but may be otherwise re-sized
to the desired dimensions, within a 1/16.sup.th inch tolerance, so
as to provide a system that functions with 16 inch framing
dimensions typically used in deck applications. The panel can be
provided in other sizes than the illustrated example, chosen to
have sufficient support while spanning the supporting elements
supporting the panel. Preferably the panel is a pre-configured
dimensional size suitable for compliance with customary building
practices.
[0038] Referring now to FIGS. 2-5, which are views illustrating the
fastener 18 and explaining how it is manufactured, the fastener in
a preferred embodiment is made of a stainless steel material,
stamped to the shape shown in FIG. 2. The fastener is provided with
a row series of twelve teeth 26 on each of 2 sides thereof in a
central region, as well as a corner tooth 28 at each of the four
peripheral corners of the fastener. The corner teeth 28 are on
extended arm portions 34 of the fastener having a slight taper
inwardly on the outer faces thereof, and an arcuate shape on the
inward sides thereof. Teeth 26 and 28 are suitably 3/64.sup.th inch
in height. A central hole 30 is provided in the fastener, as are
two side tabs 32 on opposing sides, next to the sides carrying the
rows of teeth. A slight notch is defined between the tabs 32 and
the arm portions 34.
[0039] After the fastener is formed as in FIG. 2, it is then bent
along lines 36, approximately 90 degrees downwardly, to provide the
configuration visible in FIGS. 1 and 5, where the arm portions 34
and teeth 28 form "legs". The central portion of the fastener about
hole 30 is countersunk to provide a 17/32 inch inner diameter flat
bottom countersink, for receiving a fastener head discussed
below.
[0040] FIGS. 35 and 36 illustrate a top view (FIG. 35) and
sectional view (FIG. 36) along line A-A of FIG. 35 of an
alternative embodiment of the fastener 18', which in a preferred
embodiment is made of a stainless steel material, stamped to the
shape shown in FIG. 35. The fastener is provided with a row series
of twelve teeth 26' on each of the 4 sides thereof in a central
region, 1 inch being the length of the toothed portion in the
illustrated embodiment. Teeth 26' are suitably 0.0312 inch (0.79248
cm) in height. A central hole 30' is provided in the fastener
center, countersunk. Side wall portions 31 extend upwardly to
define the teeth at a level above the position of the hold 30', the
side wall being at an angle of 92 degrees as illustrated in FIG.
36. The distance from outermost tooth edge on one side to the
corresponding outermost tooth edge on the opposite side is suitably
1.43 in (3.6322 cm)
[0041] In employing the system to provide a deck or patio surface,
the installation steps illustrated in FIG. 6-19 are employed. The
example shown in FIGS. 6-19 is in a deck installation, where a wood
frame deck is present and the system is installed thereon.
[0042] Referring to FIG. 6, first, a waterproof membrane 38, such
as a 40 mil bituminous based material, is placed over the wood
framing to protect the framing from water damage over time. Next,
in FIG. 7, plural structural panels are cut and positions as
necessary to fit over the area of the deck framing that the system
is to be installed upon. Next, (FIG. 8) fasteners 18 (or 18') are
placed into openings 14 in the structural panel in locations where
the panel is to be secured to the frame 16. The fasteners are
tapped with a hammer so as to have the top surface of the fasteners
be flush with the top surface of the structural panel. Next, as
shown in FIG. 9, a punch (e.g., a 1/2 inch punch) is used with a
hammer to set the fastener in the structural panel. Use of the
punch results in the teeth of the fastener "biting" into the inner
walls of the opening in the structural panel, as well as setting
the fastener to be below the top surface of the structural
panel.
[0043] Referring now to FIG. 10, a bead of adhesive material (for
example, fiberglass adhesive) is applied between the joints of the
panel sections. Stainless steel screws are then screwed through the
openings 30 in each fastener, to secure the structural panels to
the deck frame 16, as shown in FIGS. 11 and 12, FIG. 12 being a
split view showing both a close up view of a single secured
fastener/screw and a father away view illustrating a wider area,
with 5 fasteners visible.
[0044] An edge trim 40 may now be applied to the peripheral edges
of the assembled structural panel group, by cutting the trim to
length and applying adhesive thereto (to the inside corners of the
edge trim) and then mounting the edge trim to the edges of the
panels (FIGS. 13-15). The edge trim can be, for example, metal edge
trim and may be provided in a variety of colors and finishes, as
desired for the aesthetic taste of the user.
[0045] The surface material 22 is now prepared and applied to the
structural panel, illustrated in FIGS. 16-18. In the illustrated
embodiment, surfacing material 22 comprises quarried stone tiles
having dimensions of 153/4 inch by 153/4 inch, and approximately
11/32.sup.nd inch thickness. The surface material tiles are first
dry set and cut to fit around any obstacles 42 (a vertical post in
FIG. 16). Next, an adhesive is applied to the back of the stones
and spread with a notched trowel in the particular embodiment
shown. The adhesive suitably comprises Hold-Tite brand adhesive,
suitably an elastomeric polymer. The surface material is now placed
adhesive side down onto the structural panel surface, positioned
suitably with 1/8.sup.th inch spacing between the tiles. The joints
between tiles are not grouted, but are left open, allowing drainage
and room for expansion and providing an appearance that is visually
appealing. FIG. 18 illustrates the steps of placing the tiles in
left, middle and right portions. FIG. 19 illustrates a finished
deck surface employing stone tiles as the surfacing material, with
edge trim on the peripheral edges of the structural panel.
[0046] In an alternative embodiment, the bonding material 24 is
provided in the form of a sheet membrane 24', such as an EPDM
rubber or similar material, which is flexible and soft. The sheet
is suitably 1/16.sup.th inch thick, of dimensions corresponding to
those of the surfacing material 22, and is coated on both sides
with a pressure sensitive contact adhesive. The sheet membrane 24'
is placed onto the surfacing material 22 and then the surfacing
material is placed onto the structural panel 12. This alternative
manner of adhering the material to the panel results in a flexible
bond.
[0047] Accordingly, as system and method are provided whereby a
deck surface of quarried stone is feasible. The use of the fiber
reinforced polymer structural panels, the fasteners and the
adhering of the stone tiles results in a lightweight high strength
system weighing only 8 to 10 pounds per square foot in the
preferred embodiment. The bonding of the surface material to the
structural panel provides further strength to the overall system.
As noted above, other surface materials may be employed, including
but not limited to tile, brick, concrete and stone pavers.
[0048] Under an ASTM #E72-98 test, an exemplary system withstood
6282 lbs. of force with no failure, a maximum 1.47'' deflection and
a maximum 0.35'' set deflection.
[0049] The preferred material for the surfacing material 22 is
natural quarried stone, which includes slates, quartz and
sandstone. All stones are suitably from deep cuts producing the
highest quality and highest density stone for exterior
applications.
[0050] In preferred embodiments, all stones have an ASTM #C121
Water Absorption of 0.10%-0.37%. and an ASTM #C1026 Freeze Thaw
unaffected rating or a natural resistance to damage under these
conditions. Generally all stones have an ASTM #1028 Coefficient of
Friction equal to or greater than most wood or composite products,
so as to not be overly slippery as a walking surface. In most cases
sealing of the surface is not required due to the high density of
this material. However, sealing can enhance the natural beauty if
applied, but it is not required for long term durability.
[0051] Although the illustrated embodiment shows an outdoor
flooring system use for a deck surface mounted to a wood frame,
other uses are also possible. For example, the system and method
can be employed as ground level patios, either as new construction
or to cover a cracked or otherwise undesirable patio, providing
positive drainage. Application to steps is also another use.
Further, the system and method can be employed over waterproofed
living spaces, for example, by placing the structural panels over
the top of the waterproof deck on sleepers (horizontal structural
member on or near the ground that support weight) as a level,
floating deck, without penetrating the waterproof membrane.
[0052] FIG. 20 is a diagram of an alternative structural panel 12',
while FIG. 21 is a close-up perspective view of a portion of a
panel 12'. Panel 12' includes plural openings 14', which are
substantially square in the illustrated configuration, provided in
a grid-like pattern. The panel 12' is suitable 4 feet long in
dimension of arrow 44 by 4 feet long in the dimension defined by
arrow 46 illustrated embodiment.
[0053] Approximately centrally of the panel spanning from edge to
edge is a cut line 50, defined by a double sidewall 58, 58' between
openings 14' adjacent one another along the cut lines, with a
central opening 60 defined therein. A solid portion 56 is provided
across the cut line at regularly spaced intervals, the interval
being the size of the spacing of the openings in the illustrated
embodiment, The cut line 50 provides an easy to cut dividing line
along the panel providing subdividable portions to easily cut the
panel (or a portion thereof) into 2 parts or to cut out a standard
size portion. Along the other direction of the panel, a pair of cut
lines 52 and 54 are defined, suitably evenly spaced, to provide an
easy to cut line defining 3 sub-dividable portions of the panel in
that direction for sub-dividing the panel in to 3 subportions. In
the illustrated embodiment, the cut lines enable easy cut lines
with 2 foot and 16 inch spacings, which are typical joist spacings
employed in deck construction, for example. Other dimension may be
employed as desired to provide easy to cut lines along typically
desired spacings.
[0054] FIGS. 22-34 illustrate embodiments for use to provide a
terrace surface, optionally on pedestals.
[0055] FIG. 22 is a perspective view of a connector for connecting
adjacent panels and/or for mounting panels to an under support. The
connector 62 is a disk-shaped member having 4 central raised
members 64 suitably of substantially square profile when viewed
from above. Centrally of the members 64 is a recessed portion 66.
Radially positioned about the edge of the disk 62 are 8 raised
members 68. Member 64 and 68 are of size and shape so as to be
receivable in openings 14 or 14' of panels 12, 12', and as
discussed below, to engage with alternate panel 70. In a particular
embodiment, disk 62 has a diameter of 6 inches.
[0056] FIG. 23 is a top view of an installation of plural panels
12' using plural connectors 62. In the illustration of FIG. 23, at
the leftmost edge of the installation of panels 12', the connectors
62 are moved inwardly slightly from the edge of the panel,
illustrating the case where there is some obstruction, for example,
that would prevent the connectors from extending beyond the left
most edge of a panel, as contrasted with the rightmost portion of
the drawing, where the connectors are able to extend beyond the
edge of the panels, and are accordingly positioned.
[0057] There are 6 panels 12' shown in FIG. 23, with a portion of
one panel having illustrative pavers or bricks 64 placed thereon
and dry-laid over optional construction fabric (nonwoven) 65
(perimeter pavers being secured with adhesive), and a portion of
another panel 12' having tiles or stones 67 placed thereon, either
secured to the panels with adhesive applied to the tiles or stones
or via sheet adhesive. A metal trim 69 may be applied to peripheral
edges of the panels, a portion being illustrated in FIG. 23. The
connectors may be floating or secured to the underlying layer.
[0058] FIG. 24 is a side view of an installation where connectors
62 are floating (i.e. not secured to any base or substrate) on a
concrete base, for example.
[0059] FIG. 25 is a perspective view of a panel 70 for use in
pedestal mounting configurations. The panel 70 is suitably 315/8
inch by 315/8 inch dimensions in a particular embodiment and 1.25
inch thickness. Panel 70 includes central portions 72, 74 that
define thicker edges of the openings along portions 72, 74,
subdividing the panel into 4 equal size quadrants. The edges 76 of
the panel are wider (as contrasted with panels 12, 12' which have
edges with substantially the same width as the portion between any
2 adjacent openings).
[0060] FIG. 26 is a view of underneath a corner 78 of panel 70,
wherein a recessed region 80 is defined, of depth and shape profile
so as to correspond to the height and shape of raised members 64 of
disk 62.
[0061] FIG. 27 is a top view of an installation of plural panels 70
using plural connectors 62. In the illustration of FIG. 27, at the
leftmost edge of the installation of panels 12', the connectors 62
are moved inwardly slightly from the edge of the panel,
illustrating the case where there is some obstruction, for example,
that would prevent the connectors from extending beyond the left
most edge of a panel, as contrasted with the rightmost portion of
the drawing, where the connectors are able to extend beyond the
edge of the panels, and are accordingly positioned. The connectors
62 are suitably positioned to be 313/4 inches on center, placed so
as to be positioned at intersection points of any adjacent panels
and at the corners of any 4 adjacent panels.
[0062] Referring to FIG. 28, a perspective view of two adjacent
panels 70 positioned on a connector disk 62, a spacer/aligner
member 82 is received in recessed portion 66 of the disk 62 and
acts to space adjacent panels 70 with approximately 1/8 inch
between. Portions 64 are received in recessed region 80 to secure
the panels to the connector disks.
[0063] FIG. 29 is a top perspective view of spacer/aligner 82,
wherein a lower portion 84 is of a shape and profile to be received
within portion 66 of a connector 62, and upper arm portions 86
define the alignment and spacing of corners of adjacent panels
70.
[0064] Referring again to FIG. 27, field pavers 88 may be dry-laid
on the panels 70 over optional nonwoven construction fabric. Edge
pavers 90 in this configuration would be glued to the panels 70
with adhesive. Stones or tiles 92 can be adhered to the panels 70
with adhesive applied to the panels individually or with sheet
adhesive. The stone/tile 92 can be fit to the individual panels 70
edges so that the panes can be removed at a later time if desired,
FIG. 27 showing one panel 70' being so fit with stone/tile.
[0065] FIG. 30 is a top perspective view illustrating use of the
connector disks 62 in connection with ABS pipe members 94 to
provide an elevated mounting for panels 70. The spacing and
configuration of raised members 68 on connector 62 are such that
lower end of pipe member 94 is received on the connector, inwardly
of the raised member 68, for mounting of the connector to the pipe.
The lower connector provides a bottom mounting of the pipe member.
On the top of pipe member 94, a second connector 62 is mounted,
whereby the top of connector 62 is thereby positioned to receive
panels 70. Plural pipe member 94 and connectors are positioned to
define a mounting field for plural panels 70, providing a raised
deck portion for mounting of pavers, stones, or tiles, for example,
as shown in FIG. 32.
[0066] FIG. 31 provides an up close perspective view of pipe 94
mounted in a connector 62. The connectors are suitably secured to
the pipes by adhesive.
[0067] FIGS. 33 and 34 are side sectional views showing the
mounting of connectors with pipes and panels 70, with stone/tile in
FIG. 33, and pavers in FIG. 34.
[0068] Accordingly, with the herein described systems, gauged stone
or tile may be employed in any outdoor living space (or indoor) in
any climate and without the requirement of the use of traditional
cement based mortars grouts or adhesives. Also, on grade pavers can
be provided to surface the underlayment system with
brick/concrete/stone pavers without the need for traditional sand
beds.
[0069] The components of the systems described herein provide a
strong yet light-weight underlayment assembly for a durable and
secure exterior flooring surface, supplying strength, durability
and creative flexibility.
[0070] In a particular embodiment, the outdoor floor system
described herein weighs only 8-10 lbs. per square foot combined
weight of the outdoor floor system underlayment and an average
weight of a 1/4''-1/2'' gauged stone or tile, which falls within
the "10-15 lbs./sq' of dead load" calculations for residential deck
construction. Under these conditions the system can be placed over
conventionally framed deck structures with joist spacing 16''-24''
O.C. A roof top terrace will also only need to be designed for
standard load conditions. Paver deck applications will be 10-20
lbs./sq' dead load and will require additional structural
reinforcement and consultation with a licensed structural
engineer.
[0071] The system can cover an existing cracked patio if the
subgrade is stable. The finished patio can be installed as a level
surface with positive drainage, and no cracks will migrate through
the new finished stone surface. It can also be placed over any
solid bearing surface. Each panel is supported by the interlocking
connectors 62.
[0072] The high strength panel members have dimensional stability
and minimal deflection under load conditions and require no
additional surfacing material to achieve strength. This solid
underlayment adds reinforcing strength to a stone/tile surface and
bearing strength to a dry-laid paver surface.
[0073] The system further provides lateral strength or side-to-side
stability, achieved in part by using adhesive to bond panel edges
edge-to-edge.
[0074] In accordance with the above, a structural underlayment
system used for outdoor floors is provided that can be placed over
wood or metal joist framing or on a pedestal system. It supports
natural gauged stone or tile, brick, concrete or stone pavers and
can be used in place of other materials used for elevated decks or
roof top terraces.
[0075] While plural embodiments of the present invention have been
shown and described, it will be apparent to those skilled in the
art that many changes and modifications may be made without
departing from the invention in its broader aspects. The appended
claims are therefore intended to cover all such changes and
modifications as fall within the true spirit and scope of the
invention.
* * * * *