U.S. patent number 3,842,559 [Application Number 05/293,331] was granted by the patent office on 1974-10-22 for glass-fiber-reinforced gypsum roof deck.
This patent grant is currently assigned to H. H. Robertson Company. Invention is credited to Harold J. W. Payne.
United States Patent |
3,842,559 |
Payne |
October 22, 1974 |
GLASS-FIBER-REINFORCED GYPSUM ROOF DECK
Abstract
A roof deck construction involves trays and decking units
fabricated from glass-fiber-reinforced gypsum. The decking units
preferably are coated with a foamed plastic covering which is in
turn factory-coated with at least one ply of roofing felt.
Inventors: |
Payne; Harold J. W. (Wirral,
EN) |
Assignee: |
H. H. Robertson Company
(Pittsburgh, PA)
|
Family
ID: |
10438291 |
Appl.
No.: |
05/293,331 |
Filed: |
September 29, 1972 |
Foreign Application Priority Data
|
|
|
|
|
Oct 1, 1971 [GB] |
|
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45719/71 |
|
Current U.S.
Class: |
52/309.12;
52/536; 52/793.1; 52/747.11; 52/309.9 |
Current CPC
Class: |
E04B
1/945 (20130101); E04B 7/00 (20130101); E04D
11/02 (20130101) |
Current International
Class: |
E04B
7/00 (20060101); E04B 1/94 (20060101); E04D
11/00 (20060101); E04D 11/02 (20060101); E04c
002/04 (); E04c 002/10 () |
Field of
Search: |
;52/731,619,615,569,579,596,599,602,609,536,409,508,309,479 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Murtagh; John E.
Attorney, Agent or Firm: Keck; Harry B. Manias; George
E.
Claims
I claim:
1. A roof deck structure comprising a plurality of tray units of
glass-fiber-reinforced gypsum, and decking units also of
glass-fiber-reinforced gypsum mounted above and secured thereto,
the decking units each have an effective width twice the width of a
tray unit and each comprises a substantially flat web, a central
pedestal constituted by a thickened region of said web, and end
connection portions; the connection portion at one end comprising a
terminal shoulder extending horizontally from and beneath the flat
web, and a channel extending lengthwise of the tray unit between
said web and said terminal shoulder; and the connection portion at
the other end comprising a thickened rib integral with the web, a
tongue extending horizontally from said thickened rib and
terminating with a depending rib which engages in a channel of the
adjacent decking unit with said tongue resting upon the terminal
shoulder of the adjacent decking unit.
2. A roof deck structure comprising a plurality of tray units
assembled side by side above roof supporting beams, each such tray
unit being fabricated from glass-fiber-reinforced gypsum and
including a generally horizontal flat base, generally vertical side
walls and horizontal flanges extending inwardly from the tops of
the said side walls over the said flat base;
and also including a plurality of decking units disposed above the
said tray units, each of the said decking units having an effective
width which is twice the width of the tray unit and each decking
unit comprising a substantially flat web, a central pedestal
constituted by a thickened region of the said web, and end
connection portions; the end connection portion at one end
comprising a terminal shoulder extending horizontally from and
beneath the flat web, and a channel extending lengthwise of the
tray unit between the said web and the said terminal shoulder; and
the end connection portion at the other end comprising a thickened
rib integral with the web, a tongue extending horizontally from
said thickened rib and terminating with a depending rib which
engages in a channel of the adjacent decking unit with the said
tongue resting upon the said terminal shoulder of the adjacent
decking unit;
fastening means extending between a said horizontal flange and the
said central pedestal; and fastening means extending between a said
horizontal flange and the said thickened rib.
3. The roof structure of claim 2 wherein the top of each decking
unit is coated with a layer of foamed organic plastics and a layer
of weather-resistant plastic coating is applied to the top of the
said layer of foamed organic plastics.
4. The roof deck structure of claim 3 wherein a layer of roofing
felt is applied to the top of the said weather-resistant plastics
coating.
5. A roof deck structure comprising a plurality of thin-wall tray
units of glass-fiber-reinforced gypsum, and preformed, generally
flat decking units also of glass-fiber-reinforced gypsum mounted
above and secured thereto, said decking units presenting
overlapping longitudinal edge portions which overly a longitudinal
edge portion of a subjacent tray unit and which are secured
thereto.
6. The roof deck structure of claim 5, wherein said tray units have
a horizontal flat base, vertical side walls, and horizontal flanges
extending inwardly from the tops of said side walls over said flat
base.
7. The roof deck structure of claim 5, wherein said decking units
include substantially flat top surfaces, a layer of foamed plastics
material covering the top surfaces of the glass-fiber-reinforced
gypsum, and a layer of weather-resistant plastics material applied
to the top of said layer of foamed plastics material.
8. The roof deck structure of claim 7, wherein the said layer of
foamed plastics material is foamed polyisocyanurate.
9. The roof deck structure of claim 5, wherein said preformed
decking units each have a longitudinal edge coincident with a
longitudinal edge of one tray unit.
10. The roof deck structure of claim 5, wherein said tray units are
assembled in side abutted relation.
11. The roof deck structure of claim 5, wherein said tray units are
assembled in spaced-apart relation.
12. The roof deck structure of claim 5, wherein said tray units and
said decking units are assembled in mutually parallel relation.
13. The roof deck structure of claim 5, wherein the space between
said decking units and said tray units remains empty.
14. A roof deck structure comprising a plurality of thin-wall tray
units of glass-fiber-reinforced gypsum, and preformed, genrally
flat decking units also of glass-fiber-reinforced gypsum mounted
above and secured thereto; said tray units having a horizontal flat
base, vertical side walls, and horizontal flanges extending
inwardly from the tops of said side walls over said flat base, said
tray units being assembled in spaced-apart relation; and said
decking units each including a substantially flat web, and a
central pedestal constituted by a thickened region of said web; one
horizontal flange of each tray unit being engaged with and secured
to the central pedestal of one of said decking units.
15. A roof deck structure comprising a plurality of thin-wall tray
units of glass-fiber-reinforced gypsum, and preformed, generally
flat decking units also of glass-fiber-reinforced gypsum mounted
above and secured thereto; said tray units having a horizontal flat
base, vertical side walls, and horizontal flanges extending
inwardly from the tops of said side walls over said flat base, said
tray units being assembled in side abutted relation; and said
decking units each including a substantially flat web, and a
central pedestal constituted by a thickened region of said web;
adjacent horizontal flanges of certain adjacent side abutted tray
units being engaged with and secured to said central pedestal.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to building components fabricated from
glass-fiber-reinforced gypsum and to roof deck constructions
utilizing the components.
2. Description of the Prior Art
Glass-fiber-reinforced gypsum is described in British Pat. No.
1,204,541.
SUMMARY OF THE INVENTION
The object of the invention is to provide a fire resistant roof
deck having useful span capabilities, having an aesthetically
attractive undersurface which can be employed directly as a ceiling
for the subjacent building space, and having inherent installation
economies to permit the construction of low cost roof decking.
According to one embodiment of the present invention there is
provided a roof-deck structure comprising tray units of
glass-fiber-reinforced gypsum, and decking units also of
glass-fiber-reinforced gypsum mounted on or against said tray units
and secured thereto.
The present invention also provides a decking unit, for use in the
construction of a roof deck as above described, comprising an
element of glass-fiber-reinforced gypsum, a coating of foamed
plastics material over said element and a covering layer of weather
resistant plastics material over said foamed plastics layer. There
may be a layer of conventional roofing felt or the like
weatherproofing material over said covering layer.
Conveniently the glass-fiber-reinforced gypsum (hereinafter
sometimes referred to as GRG) is the product described in British
Patent specification No. 1,204,541 which contains approximately ten
per cent by weight of randomly oriented chopped glass fibers. The
remainder of the GRG composition is fully hydrated calcium
sulphate, i.e., CaSO.sub.4.sup.. 2H.sub.2 O, formed by combining
the hemihydrate CaSO.sub.4.sup.. 1/2H.sub.2 O with sufficient
water, e.g., about 18.6 per cent by weight. The composition also
may contain other incidental additives for achieving smoothness,
whiteness, desired colorings, improved bonds with the
glass-fiber-reinforcement, etc. Such additives might include, for
example, powdered clay, pigments, dyes, sizes, binders,
surfactants, reactive silicone primers or mold release agents.
As described in the aforementioned British Pat. No. 1,204,541, GRG
compositions possess useful flexural strength, impact resistance,
tensile strength and densities. The materials are suggested in
British Patent No. 1,204,541, for "making glass fibre reinforced
gypsum plaster boards, mouldings or extrusions for constructional
use, for example, in the manufacture of wall, floor, ceiling or
roof structures, doors or cabinets. Such articles can be arranged
to have good fireproof characteristics and high strength,
particularly flexural strength and impact strength."
BRIEF DESCRIPTION OF THE DRAWING(S)
FIG. 1 is a perspective illustration of a tray unit;
FIG. 2 is a perspective illustration of a decking unit; FIG. 3 is a
fragmentary perspective illustration of a roof deck structure
employing the tray units of FIG. 1 and the decking units of FIG.
2;
FIG. 4 is a perspective illustration of an alternate embodiment of
a roof deck structure employing the tray units of FIG. 1 and the
decking units of FIG. 2;
FIG. 5 is a cross-sectional illustration showing a preferred side
joint connection of the decking units of FIG. 2;
FIGS. 6 and 7 are enlarged fragmentary cross-sectional
illustrations of the roof deck structures of FIGS. 3 and 4
respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENTS(S)
Referring to FIG. 1, there is illustrated a typical tray unit 10
which is formed from GRG so as to have a flat base 11, formed
vertical side walls 12, and re-entrant flanges 13. The width of the
tray unit 10 between the vertical side walls 12 is selected as a
convenient construction module, for example, 45 centimeters. The
height of the tray unit 10 from the bottom of the base 11 to the
top of the re-entrant flange 13 likewise is selected according to
the strength requirements of the tray unit 10 and may be about 4
centimeters, although deeper trays of 6 centimeters and more are
comprehended. The re-entrant flanges 13 have a width approximately
2.5 centimeters each. The thickness of the tray unit 10 from skin
to skin is conveniently carried by two workmen.
Referring to FIG. 2, the decking unit includes a GRG decking unit
14, a factory applied coating 15 of foamed organic resin such as
foamed polyisocyanurate or foamed polyurethane, and a covering
layer 16 of weather resistant plastics substance such as a urethane
elastomer film or PVF or PVC film. Optionally and preferably the
covering layer 16 also includes one factory applied layer 29 or
conventional roofing felt on top of a suitable weather resistant
coating. The GRG decking unit 14 includes a substantially flat web
17 presenting a substantially flat top surface 17a; a central
pedestal 18 which is merely a thickened integral region of the
unitary GRG decking unit 14; and end connection portions generally
designated by the numerals 19, 20. In a preferred embodiment
illustrated in FIG. 2, the end connection portion 19 includes, as
shown more particularly in FIG. 5, a terminal shoulder 21 extending
horizontally from the web 17 and having its upper surface coplanar
with the bottom surface of the web 17; a channel 22 having a first
side wall 23 connecting its bottom with the web 17; a second side
wall 24 connected to the terminal shoulder 21 to provide a groove
25 disposed lengthwise of the GRG decking unit 14 between the
terminal shoulder 21 and the web 17. The channel 22 extends below
the bottom surface of the terminal shoulder 21.
The corresponding lateral end connection 20 includes a lateral
pedestral portion 26 which constitues a thickened rib integral with
the web 17. Extending to the side of the web 17 is a tongue 27 with
a terminal depending rib 28. The rib 28 engages the groove 25
whereby the tongue 27 rests upon the terminal shoulder 21. The
undersurface of the terminal shoulder 21 is coplanar with the
undersurface of the lateral pedestal portion 26 whereby a lateral
pedestal can be formed by connecting the lateral end connections
19, 20. The lateral pedestal includes the underside of the terminal
shoulder 21 and the underside of the lateral pedestal portion 26.
The upper surface of the web 17 is essentially flat. Typically the
thickness of the web 17 will be 0.5 to 0.6 centimeter, but it may
be more or less. The thickness of the central pedestal 18 may be
1.0 to 1.2 centimeter as may the thickness of the lateral pedestal
portion 26. The effective or cover width of the GRG decking unit 14
is twice the width of the tray unit 10 of FIG. 1. Accordingly, if
the tray unit 10 of FIG. 1 is, as preferred, about 45 centimeters,
then the preferred width of the decking unit 14 of FIG. 2 will be
about 90 centimeters.
The GRG decking unit 14 may be formed as a continuous element which
is cut into lengths of 4 to 8 meters, which can be conveniently
handled by two workmen. The thickness of the organic foamed resin
coating 15 is preferably 1.0 to 2.0 centimeters. The width of the
central pedestal 18 along its underside about 6 centimeters, i.e.,
more than the width of two reentrant flanges 13 appearing in FIG.
1.
A preferred embodiment of the roof deck structure is illustrated in
FIG. 3 wherein the roof is supported by generally parallel purlins
30. Individual tray units 31a, 31b are installed on the purlins 30
in spaced-apart relation by means of suitable spacing jigs. The
tray units 31a, 31b are secured to the purlins 30 by means of
suitable fasteners such as explosive-driven pins 32, or screws,
extending through the base of the trays 31a, 31b and through a
flange of the purlin 30.
A decking unit 34a is applied above the pair of the tray units 31a,
31b. The central pedestal 18 rests upon the reentrant flange 13a of
one tray unit, and the terminal shoulder 21a rests upon the
re-entrant flange 13b of the said tray unit 31a. The channel side
wall 24a (see FIG. 5) abuts the inbound edge of the re-entrant
flange 13b. The tongue 27c, of the decking unit 34c, rests upon the
shoulder 21a of the neighboring decking unit 34a. It will be
observed (FIG. 3) that the organic foamed resin coating 15a of the
decking unit 34a abuts the corresponding foamed resin coating 15b,
15c, respectively, of the decking units 34b, 34c. Similarly the
outer covering layers 16c, 16a, 16b of the decking units 34c, 34a,
34b, respectively, is butted along joints 35, 36 to form a more or
less continuous complanar top surface for the roofing assembly.
The decking units are joined to each other and to the underlying
tray units in the manner more clearly illustrated in FIG. 6 wherein
a suitable fastener 37 is driven through the tongue 27a, the
shoulder 21b and a re-entrant flange 13b. The decking unit 34a and
the underlying tray unit 31a may be joined by a fastener 38, driven
through the central pedestal 18 and through the re-entrant flange
13a. The fasteners 37, 38 may be explosive driven pins or threaded
fasteners or any other suitable fastening devices. A cylindrical
core (not shown) may be removed from the covering layer 16 and the
organic foamed resin coating 15 to provide access for mounting
fasteners 37, 38. The number and spacing of the fasteners 37, 38
will be determined by the spacing between purlins 30 and the
anticipated loading of the structure.
Considering the roof structure of FIG. 3 from the underside, it
should be apparent that a viewer located in the subjacent building
space can observe only the relatively smooth flat undersurface of
the base 11 of the tray units 31a, 31b and the relatively smooth
undersurface of the decking unit 34a which is located between (for
example) the side walls 12a, 12b. Because of the smooth, relatively
attractive appearance of GRG materials, no additional finishing is
required to complete the ceiling structure. If desired, the
undersurface may be painted or otherwise decorated.
The alternative embodiment of a roof structure, shown in FIG. 4,
employs abutted ones of the tray units of FIG. 2 as the supporting
component of the roof structure in contrast to the spaced-apart
tray units presented in FIG. 3. It will be observed that the
roofing structure of FIG. 4 differs from the roofing structure of
FIG. 3 by the inclusion of additional tray units identified by the
numerals 40, 41. The numeral 42 has been assigned to the supporting
purlin in FIG. 4. The corresponding joint elements of the roof
structure of FIG. 4 are presented in FIG. 7 wherein the side walls
12c of the tray unit 41 abuts the side wall 12a of the tray unit
31a. The re-entrant flanges 13c, 13a have coplanar upper surfaces
which engage the undersurface of the central pedestal 18. Suitable
fasteners 43 are employed to secure the base 11d of the tray unit
41 to the purlin 42. Suitable fasteners 44 extend through the
central pedestal 18 and the re-entrant flange 13c. The fasteners 44
are installed in staggered relation with the fasteners 38 in order
to minimize development of localized stresses in the central
pedestal 18.
The tray unit 41 has its side wall 12d in abutment with the side
wall 12b of the tray unit 31b. A suitable fastener 45 is provided
to extend through the lateral pedestal portion 26 and the
re-entrant flange 13d. The fasteners 45 are provided in staggered
relation with the fasteners 37 to minimize the development of
localized stresses in the joint assembly.
Referring to the roof structure of FIGS. 4 and 7, it will be noted
that the undersurface as viewed by an observer located in the
subjacent building space presents for inspection an essentially
flat undersurface consisting of the bottom surfaces of the abutted
tray units 31a, 41, 31b.
One of the properties of GRG articles is a sensitivity to moisture.
It will be observed that the GRG components of the present roofing
structure are disposed in such manner that they are protected from
moisture. In the final assembly of a roof, two or more layers of
roofing felt will be applied by the building installers over the
covering layer 16 of the assembled decking elements.
The present building roof components are delivered to the job site
in a ready-to-install condition. The roof is assembled from
essentially two components plus fasteners, i.e., the tray unit of
FIG. 1 and the decking unit of FIG. 2. Subsequent application of
additional plies of roofing felts complete the installation.
Because one ply of the roofing felt can be shop installed, less
on-site labor is required to complete the roof.
Because the roofing structure consists essentially of
non-combustible components, the structure of FIG. 3 will achieve
one-half hour fire ratings and the structure of FIG. 4 will easily
achieve one hour fire ratings. The present roofing structure is
intended to span distances of about 4 meters. By providing somewhat
deeper tray units, i.e., deeper than 4 centimeters, spans of up to
7 meters can be readily achieved with an assembly according to the
invention. The factory installed organic foam coating 15 provides
acoustical and thermal insulation for the resulting roof
structure.
* * * * *