U.S. patent number 3,909,998 [Application Number 05/336,370] was granted by the patent office on 1975-10-07 for roof construction system.
This patent grant is currently assigned to Star Manufacturing Company of Oklahoma. Invention is credited to Richard Clark McClain, Norman Douglas Rice, Warren Elsworth Scruggs, Harold Graves Simpson.
United States Patent |
3,909,998 |
Simpson , et al. |
October 7, 1975 |
**Please see images for:
( Certificate of Correction ) ** |
Roof construction system
Abstract
A construction plank is disclosed which can be assembled in
contiguous, aligned relationship with other planks into a
construction unit to form a building roof or other section. The
individual planks are of varying geometric shapes and in the
preferred emboidment are a composite construction having a
structural core or panel member and an exterior sheathing member. A
sheet of insulation may be included between the structural panel
and exterior sheathing. Opposite edges of the plank are configured
to complementarily engage the edges of similar planks in a lap
joint to obtain flush assembly. Fasteners secure adjacent panels
together at the complementary edge structures. In the preferred
embodiment, the plank includes transverse straps extending across
the panels which are fastenable to adjacent plank straps and
underlying supporting structural members to pretension the straps
to increase the lateral strength of the assembly against uplift
resulting from wind. A membrane sheet is adhered to the exterior
surface of the plank and includes a flap portion adapted to overlie
the marginal portion of the next adjacent panel to provide a
weatherized covering. The flaps are sealable by flexible
interlocking fasteners carried on the sheet flap and marginal
portions in the form of rib and groove elements. In the corner area
between adjacent planks, overlying membrane flap portions are
sealed by a mechanical fastener extending through the flap layers
or by vulcanization. In another embodiment the flap edges are
sealed by vulcanizing overlapping edges of the membrane sheets. In
still another embodiment the plank is adapted as a fire resistant
wall component having a suitable interior facing and a weatherized
exterior covering.
Inventors: |
Simpson; Harold Graves
(Oklahoma City, OK), Scruggs; Warren Elsworth (Oklahoma
City, OK), McClain; Richard Clark (Moore, OK), Rice;
Norman Douglas (Oklahoma City, OK) |
Assignee: |
Star Manufacturing Company of
Oklahoma (Oklahoma City, OK)
|
Family
ID: |
23315774 |
Appl.
No.: |
05/336,370 |
Filed: |
February 27, 1973 |
Current U.S.
Class: |
52/223.6; 52/520;
52/543; 52/746.11; 52/509; 52/536; 52/537 |
Current CPC
Class: |
E04D
13/1618 (20130101); E04B 7/22 (20130101); E04D
5/145 (20130101); E04D 3/358 (20130101); E04D
3/3602 (20130101); E04D 5/147 (20130101); E04D
5/142 (20130101) |
Current International
Class: |
E04B
7/00 (20060101); E04B 7/22 (20060101); E04D
13/16 (20060101); E04D 3/36 (20060101); E04D
5/14 (20060101); E04D 5/00 (20060101); E04C
002/18 (); E04C 002/36 () |
Field of
Search: |
;52/418,409,478,410,408,518,302,303,520,543,582,583,309,481,23,618,592,222,223 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
|
913,557 |
|
Dec 1962 |
|
GB |
|
102,284 |
|
Jun 1963 |
|
NO |
|
Other References
British Printed Specification No. 424,620, Nov. 20, 1933, (1 sht of
drwg.; 3 pp. of spec.). .
German Printed Application No. 1,274,320, Aug. 1968, (1 sht of
drwg; 2 pp. of specification)..
|
Primary Examiner: Murtagh; John E.
Attorney, Agent or Firm: Hubbard, Thurman, Turner &
Tucker
Claims
What is claimed is:
1. A construction plank comprising:
a core structure including a corrugated metal panel having
longitudinally extending corrugations therein, and adapted to
bridge between spaced support members extending transversely of the
corrugation and support a load applied to the planks, said
corrugations defining spaced apart parallel panel surfaces, a first
wall board member disposed at one surface of said panel, a layer of
insulation disposed at the other surface of said panel, a plurality
of spacer members extending parallel to said ribs and disposed
between a surface of said panel and said first wall board member, a
second wall board member overlying said layer of insulation, said
second wall board having a relatively hard, smooth upper decking
surface; and
a membrane sheet bonded to the said decking surface, said sheet
having two adjacent edge portions extending beyond the
corresponding edge of said core structure and adapted to overlap a
next adjacent plank of similar construction when said panels are
arranged in contiguous aligned relationship to form a generally
weather impervious seal.
2. The plank of claim 1 wherein said membrane sheet is rubber.
3. The plank of claim 1 wherein said membrane sheet is a light
gauge metal.
4. The plank of claim 1 wherein said membrane is plastic.
5. A structural roof member comprising:
a panel member adapted to be supported on subjacent structural
members to form a roof assembly; said panel member including
at least one tension means extending transversely across the panel,
said tension means being connectable to the supporting structural
member at each edge of the panel for placing the tension means
under tension in an assembled position thereby forming a tension
structural element extending transversely across said plank to
improve the strength of said panel to resist upward load; and
a weatherproof flap portion extending beyond the corresponding
panel edge, said flap adapted to overlap a next adjacent panel
member of similar construction when said panel member is arranged
in contiguous relationship to cover the point of connection of the
tension means to the subjacent structural member.
6. The plank of claim 5 wherein said panel is comprised of a
corrugated metal panel and at least an exterior sheathing
member.
7. The plank of claim 5 wherein said tension member comprises strap
means.
8. The plank of claim 5 wherein said tension member comprises an
upper sheathing member substantially coextensive with the upper
surface of said panel.
9. A roof assembly comprising:
a first panel member adapted to be supported on subjacent
structural members and having first and second opposite edges;
a first tension member extending transversely across said first
panel member having first and second opposite end portions
terminating adjacent said first and second opposite edges;
a second panel member adapted to be supported on subjacent
structural members and having first and second opposite edges, said
second panel second edge structure disposed adjacent said first
panel first edge;
a second tension member extending transversely across said second
panel member having first and second opposite end portions
terminating adjacent said first and second edges;
at least one fastener means securing said second end of said first
tension member and the first end of said second tension member to a
subjacent structural member for placing said connected tension
panel when subjected to upwardly directed windloads; and
means sealing between the surfaces of the adjacent panel members
and over the fastener means to form a watertight structure.
10. The assembly of claim 9 wherein each of said planks includes an
intermediate corrugated metal panel, said adjoining tension members
being secured to said subjacent structural member through said
metal panel.
11. The assembly of claim 10 further including an insulative
compressible spacer intermediate said adjoining strap ends and said
panel.
12. The assembly of claim 10 wherein said strap ends are secured to
said panel adjacent a longitudinally extending corrugated rib in
said metal panel and further including a reinforcing element
respectively secured to said adjoining strap ends and said
subjacent structural member.
13. The assembly of claim 12 wherein said reinforcing element is a
generally Z-shaped clip disposed on said corrugated rib.
14. A construction assembly comprising:
at least three plank members arranged in abutting relationship at a
common corner to form a construction section;
each of said planks being of a composite construction including at
least a corrugated panel adapted to contribute substantial load
bearing strength to the plank when the plank spans supporting beam
structure;
a waterproof membrane sheet adhered to the top surface of said
plank members and adapted to provide a weatherable exterior
surface;
said membrane sheet having an edge portion extending beyond the
corresponding plank edge portion to form a flap adapted to overlie
at least a marginal portion of the next adjacent plank to form a
generally weatherproof seal therebetween and whereby multiple
layers of the edge portions of the planks overlie one another in
the area of said common corner; and
means positioned in the area of said common corner adapted to seal
said multiple layers at the exterior of said membrane thereby
cooperating with said flaps to provide a substantially impervious
continuous membrane covering over said assembly.
15. The assembly of claim 14 wherein said connector means
comprise:
a generally flat bearing plate member underlying said overlying
membrane layers;
a compression member oppositely positioned at the upper surface of
said corner layers; and
fastener means extending between said compression member and said
plate to compress the membrane layers therebetween to seal said
corner.
16. The connector means of claim 15 wherein said plate, compression
member and fastener are heat conductive whereby application of heat
to said compression member will be transferred to said plate via
said fastener thereby bonding said membrane layers together at said
corner.
17. The assembly of claim 14 wherein said connector means
comprise:
a generally flat bearing plate disposed on one side of said
multiple membrane layers;
a second bearing plate member oppositely disposed on the other side
of said layers; and
projection means associated with one of said plates and extending
through said corner layers to contact the other plate whereby
application of heat to either of said plates will be transferred to
the opposite plate via said spike means thereby heat bonding said
corner.
18. The assembly of claim 14 wherein said connector means comprises
a generally flat bearing plate disposed on one side of said layers;
and
a member disposed on the opposite side of said membrane layers
having a generally concave depression projecting through said
layers and contacting said flat plate whereby application of heat
to said concave member will be transferred to said flat plate and
said overlying membrane layers causing said corner to bond forming
a heat seal.
19. The assembly of claim 14 wherein said common corner is formed
at the juncture of four or more planks arranged in contiguous
aligned relationship.
20. A construction member comprising:
a plank including as an element thereof a corrugated metal panel
adapted to contribute substantial load bearing strength when the
plank spans supporting beam structures, said plank having first and
second opposite parallel edges adapted for assembly in contiguous
aligned relationship with a first edge of one plank complementarily
engaging the second edge of the adjacent similar plank;
said plank being covered with a sheet of membrane material, said
sheet having a portion extending beyond said first plank edge to
form a flap adapted to overlie a marginal selvage portion of the
second edge of the next adjacent plank; and
a flexible fastener structure carried on said sheet at the flap
portion and said second marginal portion, said fastener structure
including a grooved member on one portion and a rib member on the
other, said groove and rib members being substantially parallel to
the plank edge and adapted to interlock to seal said flap to said
second adjacent plank edge.
21. The construction member of claim 20 wherein said rib is formed
having a generally hook-shaped extension.
22. The construction member of claim 21 wherein said flexible
fastener includes a plurality of said interlocking ribs and grooves
arranged in parallel.
23. The construction member of claim 22 wherein said sheet is a
vulcanizable rubber.
24. A construction system comprising:
at least first and second planks each having first and second
opposite edges, said planks including as an element thereof a
corrugated panel adapted to contribute substantial load bearing
strength when the plank spans supporting beam structures and
adapted for assembly in contiguous aligned relationship with the
said first edge of one plank complementarily engaging the second
edge of the adjacent plank;
each of said planks being provided with a sheet of membrane
material adhering to one surface of the plank, said sheet having a
portion extending beyond said first plank edge to form a flap
overlying a marginal portion of the second edge of the next
adjacent plank; and
a flexible fastener structure carried on said sheet at said flap
protion and said marginal portion, said structure including a
groove member in one of said portions and a rib member in the other
of said portions whereby said flap is interlocked and sealed to the
membrane of the next adjacent plank to provide a substantially
continuous membrane seal.
25. The system of claim 24 wherein said rib includes a generally
hook-shaped extension.
26. The system of claim 25 wherein an adhesive is included between
said interlocked fastener members.
27. The construction system of claim 24 wherein said membrane is a
non-metallic flexible material.
28. The construction system of claim 24 wherein said membrane is a
metallic flexible material.
29. A construction member comprising:
a plank member including as an element thereof a a corrugated panel
adapted to contribute substantial load bearing strength when the
plank spans supporting beam structures having opposite edges
adapted for arrangement with similar planks in abutting aligned
relationship to form a construction section;
said planks in said section each having a sheet of vulcanizable
membrane adhering to the exterior surface of said planks;
said membrane having at least two adjacent edge portions extending
beyond the corresponding plank edge portion to form a flap adapted
to overlie at least a marginal portion of the adjacent plank, said
flap having a corner portion in the area of intersection of the
adjacent edge portions; and
edge seal means associated with said flap and selvage sheet
portions, said edge seal means including fastener means whereby
said flap protion of said plank can be interlocked to the said
adjacent selvage portion of an adjacent plank, said flap corner
portion adapted whereby said flap corner can be vulcanized to the
adjacent corner portion thereby forming a generally weatherproof
continuous layer over said section.
30. The construction member of claim 29 wherein said fastener means
includes a grooved element on one of said flap and selvage portions
and a mating rib element on the other of said portions.
31. The construction member of claim 30 where said sheet is
non-metallic.
32. A construction assembly comprising:
at least three generally rectangular plank members each including
as an element thereof a corrugated panel adapted to contribute
substantial load bearing strength when the plank spans supporting
beam structures arranged in abutting relationship at a common
corner to form a construction section;
each of said planks having a sheet of vulcanizable membrane
material adhering to the exterior surface of the plank members;
said sheets each having edge portions extending beyond the
corresponding plank edge to form a flap adapted to overlie at least
a marginal selvage portion of the adjacent plank whereby multiple
layers of the said membrane overlap one another at said common
corner;
edge seal means for securing said flap to the adjacent selvage
portion; and
corner seal means for securing said multiple membrane layers
together at said corner, said corner seal means including a heat
conductive connector penetrating the layers at a location displaced
from the juncture of said planks whereby application of heat to
said connector will vulcanize said layers together to seal
same.
33. The construction assembly of claim 32 wherein said edge seal
means include fastener means in the form of rib and groove elements
oppositely carried in said flap and selvage portions.
34. A roof construction section adapted for support on a
substructure comprising:
a plank including a structural member supporting an exterior
sheathing member having a relatively smooth exterior surface, a
membrane sheet bonded to the exterior surface of the exterior
member, said sheet having a flap portion extending beyond the
corresponding edge of the plank, said flap portion adapted to
overlay a marginal portion of a next adjacent similar plank when
said planks are arranged in contiguous relationship, said flaps
overlapping at a common corner area of three or more similar
planks;
said plank being configured at complementary edges to interengage
the mating edges of other similar planks when the planks are
arranged in a contiguous relationship;
a cooperable flexible fastener structure carried on the sheet flap
and marginal portion;
said corner flap area adapted for sealing by mechanical fastener
means including compression means for securing said overlapping
flaps; and
at least one strap member extending transversely across said plank
having opposed end portions adapted to be secured to said
substructure at said plank edges and stressed in tension to
increase the lateral strength of said plank.
35. A roof construction section adapted for support on a
substructure comprising:
a plank including a corrugated metal panel having longitudinally
extending corrugations therein, said corrugations being in the form
of ribs having a flattened portion defining with said panel spaced
apart parallel surface, a first wall board member disposed at one
surface of said metal panel, a sheet of insulation material
disposed at the other surface of said metal panel, a plurality of
spacer members extending parallel to said ribs and disposed between
a surface of said panel and said first wall board member, a second
wall board member covering said insulation, said second wall board
having a hard, flat exterior decking surface, and a rubber membrane
sheet bonded to the decking surface, said sheet having two adjacent
edge portions extending beyond the corresponding edge portion of
said composite plank and adapted to overlay a marginal selvage
portion of a next adjacent similar plank when said planks are
arranged in contiguous aligned relationship, said adjacent flaps
intersecting at a corner;
said plank being configured at opposite edges to complementarily
engage in a lap joint the mating edges of other similar planks when
arranged in an aligned contiguous relationship;
a flexible fastener structure carried on the sheet flap and
marginal portion, said structure including a groove member on one
portion and a rib member on the other adapted to interlock said
flap and selvage portion together; and
said corner flap area adapted for sealing in the common area at the
juncture of several planks by mechanical fastener means extending
through said corner flap area.
36. The construction section of claim 35 further including at least
one strap member extending transversely across said plank having
opposed end portions adapted to be secured to said metal panel and
roof substructure at said plank edges and pre-stressed in tension
to increase the lateral strength of said plank.
37. A fire resistant wall structure comprising:
a generally rectangular first structural plank member having an
intermediate corrugated panel adapted to contribute substantial
load bearing strength to the plank when the plank spans supporting
beam structure sheathed between an interior and exterior panel
member, said first plank having an exterior weatherized protective
covering, the opposite longitudinal edges of said plank being
adapted for complementary engagement with other similar panels in
an aligned side-by-side relationship;
at least a second structural plank member having an intermediate
corrugated panel sheathed between an interior and exterior panel
member, said second plank having an exterior weatherized protective
covering, said second panel having an edge in complementary
engagement with one of the edges of said first panel in a lap
joint; and
means securing said structure including mechanical fastener means
at said lap joint and caulking means to seal said joint.
38. The wall structure of claim 37 wherein said weatherized
protective cover comprises metal sheeting lapped over the opposite
longitudinal plank edges.
39. The wall structure of claim 37 wherein the interior surface of
said interior panel is provided with a finished interior
treatment.
40. The wall structure of claim 37 including a longitudinally
extending reinforcing member associated with one of said plank
members at said lap joint and wherein said mechanical fastener
means comprises screw means extending through overlapping
corrugated panel postures into said reinforcing members.
41. A construction plank comprising:
a composite core including a structural panel member having
longitudinally extending corrugations and adapted to bridge between
spaced support members extending transversely of the corrugation
and support a load applied to the planks, a sheathing member
disposed on one side of said structural member forming a relatively
hard smooth exterior surface adapted to support foot traffic, and
longitudinally extending spacer members disposed in parallel
relationship to said corrugations between said panel member and
said sheathing member; and
a membrane sheet adhering to said exterior surface, said sheet
being weatherproof and adapted to function as the exterior surface
of the plank and having at least one edge flap portion extending
beyond the corresponding edge portion of said composite core, said
flap adapted to overlap a next adjacent plank of similar
construction when said planks are arranged in contiguous
relationship to form a generally weatherproof seal therebetween.
Description
This invention relates to building construction and more
particularly relates to a prefabricated building plank structure
adapted for assembly with similar planks to form a roof, wall or
other construction section.
Conventional built-up roofing systems have been employed for many
years. In this method of construction, a horizontal roof deck is
supported on underlying structural beams. The roof deck is covered
by a weatherproof membrane usually comprising alternate layers of
felt and bitumen to prevent penetration of moisture into the
building interior. The membrane is applied in a field operation by
application of alternate layers of hot bitumen and felt. Once the
membrane is applied to the desired thickness, gravel, rock or
similar aggregate material is spread upon the roof to provide
protection against weathering. To reduce heat transfer through the
roof deck, insulation is often applied to the underside of the roof
deck at the interior of the building. Insulation may also be
applied on the exterior of the roof deck and subsequently covered
with the water resistant membrane.
There are many difficulties with built-up roof systems of the type
described above. Since the construction of the built-up roof is
entirely a field operation, there is little uniformity of quality
from one building to another and consequently the integrity of such
a roof structure varies considerably. A built-up roof membrane has
a tendency to bubble and crack. This deterioration is due to a
number of reasons including expansion and contraction from severe
temperature changes, moisture trapped below the water membrane and
improper construction techniques. Further, built-up roofs do not
withstand heavy foot traffic and are susceptible to damage from
traffic. Also considerable safety and environmental hazards exist
in the application of hot tar which often gives off toxic fumes and
polluting matter. Because of the undesirable nature of the hot tar
process, local and federal safety and pollution standards often
prohibit or restrict the use of built-up systems which formerly had
wide acceptance.
In an attempt to overcome the problems inherent in built-up roofing
construction, it has been suggested to construct roofs of
prefabricated roofing panels. Roof panels of the prefabricated type
generally include some form of insulation such as a polystyrene or
urethane foam and wallboard of asbestos or cement sandwiched
together. A problem arises in sealing the panel from the weather
and water once the panels are arranged in a roof assembly. Often
sealing is accomplished by placing a membrane similar to that used
in a built-up roof over the roof panels. Obviously, such
fabrication procedures require considerable field labor and do not
avoid the shortcomings of built-up roofs.
In some instances, prefabricated roof panels have been formed with
a weather resistant sheet material preadhered to the panels prior
to installation. The preadhered sheet material may be coextensive
with the panel. In such a case an additional operation is required
to seal the roofing panels at the joints as by use of a mastic or
tape. It is also known to provide the panel with a flap along one
or several edges which is adapted to overlie and is adhesively
secured to an adjacent panel. However, such prior art
prefabricating roofing construction has met with limited success
because of the manner of assembly and lack of integrity of the
adhesively joined membrane sections. The prior art prefabricated
roofing construction panels generally require additional field
operations, such as application of insulating material to the
underside of the panel, to form a completed roofing structure. The
unreliability of the prior art prefabricated structures along with
the requirement of additional field work substantially adds to the
cost of construction of such panels.
In view of the above, there clearly exists in the building industry
a need for a prefabricated building plank adapted for assembly to
form a construction section with provision for convenient,
structurally sound connection and sealing of the planks. The
present invention provides such a composite plank having an
intermediate structural member preferably in the form of a
corrugated sheet metal having longitudinally extending
corrugations. A suitable interior sheeting such as a wallboard is
provided at one side of the corrugated panel. A layer of insulation
and sheeting is provided at the opposite exterior side of the
plank. The exterior sheeting may be a plywood or composite board
material. A membrane of weatherproof material is bonded to the
outer surface of the composite plank. The membrane is formed with a
flap along one or several edges which is adapted to overlie a
marginal portion of an adjacent panel. The membrane flap is adapted
to sealingly engage the marginal portion of the next plank by
vulcanization or by virtue of interlocking fastener members
cooperable with the flap and the marginal portion of the adjacent
plank. The interlocking fastener may also take the form of a
mechanical clip or interengageable flexible rib and groove member.
The present invention further provides a corner seal to complete an
assembled structure. At the common juncture of several planks a
condition exists where several flaps overlie one another. A
mechanical fastener is used to compress the layers together at this
juncture and seal the exterior surface of the membrane in the
corner area.
A further aspect of the invention provides for assembly of a number
of planks to form a roof having good longitudinal and lateral
strength. The individual planks have opposite edge portions which
are complementary and which engage the edge of adjacent planks to
form a lap joint with the internal structural panel forming a part
of the joint. When used as a roof or wall plank and when the plank
must resist a load tending to separate the plank from its
structural support, an additional member in the form of a
transversely extending strap member is included to extend across
each plank and connect to an adjoining plank strap member and to
the supporting structural member. The straps are pretensioned to
provide excellent lateral strength to resist wind loadings that
tend to lift the roof assembly.
The basic plank structure is also adaptable for use in construction
of firewalls and other partitions. As a wall component the plank is
modified and is fabricated with a suitable interior facing such as
a vinyl or paper covering and has a suitable exterior weatherized
covering such as metal or simulated brick or stone. The planks are
complementary and can be assembled in interlocking fashion at their
edges to form a wall. Caulking or joint compound applied along the
plank edges seals the structure.
The plank of the present invention is a highly efficient structural
member giving adequate support and resistance to imposed loads. The
plank can be factory assembled with a minimum of labor and a
maximum of quality control resulting in an economical product with
minimum field maintenance problems. The plank is highly versatile
and can be fabricated with varying characteristics to meet
different requirements of shape, strength, weight, thickness ratio,
fire characteristics and thermal conductivity. Field installation
is relatively simple using mechanical fasteners and conventional
bonding agents. The plank can be easily altered in the field to
meet special requirements by normal drilling, sawing, screwing and
cutting operations. As a roof or wall member, the plank may
incorporate the tension strap members as well as a membrane which
is preadhered to each plank. The membrane is easily sealable at
edge and corner portions to provide a tight, protective covering.
As a firewall or other partition, the plank includes suitable
exterior and interior coverings to eliminate the requirement for
any additional finish work.
The above and additional objects and advantages of the present
invention will become more apparent by reference to the following
specification, claims and appended drawings in which:
FIG. 1 is a fragmentary perspective view illustrating the plank of
the present invention is applied to the roof structure of a typical
building;
FIG. 2 is an enlarged cross-sectional view of a portion of the
structure taken along lines 2--2 of FIG. 1;
FIG. 3 is an enlarged cross-sectional view taken along lines 3--3
of FIG. 1;
FIG. 4 is a cross-sectional view taken along lines 4--4 of FIG.
1;
FIG. 5 is an enlarged fragmentary sectional view of a connection
between adjacent roof panel members;
FIG. 6 is an enlarged sectional view showing in detail one form of
the connection between mating roof membrane sections;
FIG. 7 is a plan view of a single plank;
FIG. 8 is a fragmentary sectional view showing an alternate method
of sealing adjacent membrane sections;
FIG. 9 is a sectional view of a mechanical clamp for securing
adjacent membrane sections;
FIG. 10 is a fragmentary plan view of a corner joint at the
juncture of adjacent panels;
FIG. 11 is a sectional view taken along lines 11--11 of FIG.
10;
FIGS. 12 and 13 are sectional views showing alternate sealing
structures for the corner joint;
FIG. 14 shows a cross-sectional view of another embodiment of the
present invention adaptable for use as a firewall component;
FIG. 15 shows the joint between the wall planks of the embodiment
of FIG. 14; and
FIG. 16 shows a fragmentary perspective view of the connection of
FIG. 5.
Referring now to the drawings, FIG. 1 shows a roof assembly
generally designated by the numeral 10 supported on an underlying
support generally designated 11 having a primary and secondary
structure. More particularly, the primary roof structure 11
includes transversely extending beam or rafter members 12 which, as
is known in the building art, are supported on columns or bearing
walls. The secondary support structure includes longitudinally
extending purlins 13 supported on the upper surface of rafters 12.
The purlins are generally Z-shaped having upper horizontal flange
member 14. The primary and secondary roof support structure shown
is for purposes of explanation only and, as will be appreciated,
forms no part of the present invention. It will be obvious to those
skilled in the art that other supporting structures could be
similarly used.
The roof assembly 10 includes a plurality of individual planks 15.
As is seen in FIG. 1, planks 15 are generally rectangular and
adapted to span several purlins 13. The geometric shape, however,
may vary with the specific requirements. The individual planks 15
are contiguously aligned in a side-by-side and end-to-end
arrangement to form the roof structure 10, abutting at common
corner junctures 16. Roof planks 15 include an outer membrane sheet
20 of weather resistant sheet material preadhered to the exterior
surface in a manner providing a pair of adjacent edge portions or
flaps 36 and 37 which extend beyond the corresponding plank edges
and overlap the marginal portion of adjacent planks. At the corner
juncture 16 of several planks, multiple layers of membrane overlay
one another and are sealed at corner seal 21. The edge seal and
corner seal arrangement will be explained in detail with reference
to subsequent drawing figures.
Referring additionally to FIGS. 2 through 7 which illustrate the
details of construction of the plank sections 15, the individual
plank sections 15 are of a longitudinal composite structure having
intermediate structural panel member 24. Panel 24 is shown as a
corrugated sheet metal section having parallel upper surface 25 and
lower surface 26 formed by the laterally spaced, longitudinally
extending corrugations 27 in the panel. The particular
cross-sectional shape and configuration of corrugations 27 is
subject to wide variation as the panel serves as the core member of
the composite plank 15 providing spacing and structural support for
the remaining members of the plank. Spacers 29, shown as generally
rectangular members of plastic or wood, longitudinally extend along
the underside of corrugated panel 24. The depth of spacers 29
approximately corresponds to the depth of the corrugations 27 in
panel 24 so that the bottom surface of the spacers 29 is coplanar
with lower panel surface 26. Interior sheathing panel 30 is affixed
to the underside of corrugated panel 24 and to spacers 29.
Preferably panel 30 is a wallboard or plasterboard. A sheet of
insulating material 32 is applied across the upper surface 25 of
panel 24. Insulating sheet 32 may be a material such as ceramic,
polystyrene or urethane foamed in place or as a rigid panel.
Exterior sheathing is provided by panel 34. Panel 34 covers the
upper surface of insulation 32 and provides a hard, smooth exterior
surface. Panel 34 may be of a variety of materials and is
preferably a rigid panel of a composite hard board, plastic or
plywood. Thus it will be seen that the core of the plank is a
composite structure having an intermediate structural panel
interposed between exterior and interior sheathing panels. The core
structure may be secured together by adhesives or bonding agents at
the interface of the various layers or, as is shown, fasteners or
staples 35 may extend through the core to secure the various panel
components of the structure together.
Other materials may be selected. For example, insulation layer 32
may be a foamed urethane of relatively low density covering panel
24. Panel 24 may be formed in place by an application of a second
layer of relatively dense urethane. The outer layer of dense
urethane is suitable as sheathing. This type of construction will
speed production and eliminate the need for adhesives or fasteners
to secure the plank components into a composite structure.
The basic plank or core structure is stronger than the individual
components because the sandwich construction serves to stabilize
the corrugated panel and increase the load carrying capacity. The
construction is relatively deep in cross section utilizing the
insulation material as a web so that the interior and exterior
sheathing function similar to structural flanges. This results in
increased flexual strength and good deflection characteristics.
The upper surface of plank 15 is covered with a sheet of membrane
20 in the form of a weather resistant material to protect and seal
the roof system 10. Sheet 20 is substantially coextensive with the
plank along adjacent lateral and longitudinal edges 43 and 41.
Along the two opposite adjacent edges, 40 and 42, a flap portion 37
and 36, respectively, extend laterally beyond the corresponding
edge adjoining at corner 21 adapted to overlie a marginal or
selvage portion of the membrane on an adjacent plank. Membrane 20
is preferably a natural or synthetic rubber or plastic bonded or
adhesively joined to the upper surface of upper panel 34 and for
example may be a material known under the tradename "Hypalon"
manufactured by the DuPont Chemical Company. Similarly, the
membrane can be fabricated from a light gauge metal such as
aluminum.
The opposite longitudinal edges 40 and 41 of adjacent planks are
complementary and engage to form a lap joint when the planks are
assembled in abutting engagement to form a construction unit or
section. Edge 41 of the plank is formed having interior panel
member 30 recessed laterally inward of panel members 52 and 34.
Opposite plank edge 40 is complementarily configured having inner
panel member 30 projecting laterally beyond upper panel members 32
and 34. A spacer member 28 extends longitudinally along edge 40
centered below the terminal edges of panels 32 and 34 to receive
fastener members and to stiffen and reinforce the joint at the
plank edges. When the edges 40 and 41 of adjacent planks are
abutted, a lap joint results, sometimes referred to as a "ship lap"
joint.
At plank edge 41, corrugated panel 24 is formed with a horizontally
extending section 48 terminating at edge 21. Inwardly spaced from
the outer end of section 48 is abutment or projection 49.
Corrugation rib 50 extends laterally beyond the terminal edge panel
30 at plank edge 41 and is connected to panel member 48 by
diagonally extending leg 51.
At plank edge 40, horizontal lip 53 of panel 24 projects beyond the
edge of panel 32. Member 54 extends diagonally between corrugated
panel member 53 and member 55. The shoulder formed at the
intersection of members 53 and 54 corresponds to projection 49 on
the opposite panel edge 40. When adjacent planks are placed in
contiguous alignment with edges 40 and 41 engaged, a joint is
formed with opposite edge structures of corrugated panel 24
overlapping and reinforcing the joint. Projection 49 carried on
panel 24 engages opposite panel member 54 to regulate the depth of
relative engagement between adjacent planks in an assembled
position.
The plank assembly consisting of the individual planks 15 is
secured at intervals along adjacent longitudinal panel edges 40 and
41 by fastening members 60 which penetrate through lapped panel
members 48 and 53 and into reinforcing member 28. Member 28
stiffens the lap joint and provides backup material for penetration
by fastener 60. Fastener 60 is displaced laterally from the crevice
between abutting exterior panels 34 in a recess 61 provided in the
edge of panel 41. Fastener 60 for convenience is shown as a
self-tapping metal screw but obviously may be in the form of a
rivet, bolt or other means of mechanical fastener.
The opposite lateral edges or ends 42 and 43 of planks 15 are
configured to abut in a lap joint when panels are abutted
end-to-end as seen in FIG. 4. Panel member 24 and interior member
50 are longitudinally recessed at edge 42. Opposite plank edge 43
is formed with members 32 and 34 inwardly recessed. Flap portion 36
of membrane 20 projects beyond edge 42 to cover the joint formed
between abutting panel sections and overlap the marginal or selvage
portion of the membrane of the adjacent plank. Preferably as seen
in FIG. 4, the major portion of the interface of the shiplap joint
between lateral ends of abutting panels directly overlies the
flange 14 of purlin 13 to give support to the joint.
The lateral strength of the assembly 10 is reinforced by the
inclusion of laterally extending tension members 70 extending in
parallel at spaced intervals across the planks. As seen in FIG. 1,
the individual planks are of substantial length traversing several
purlins. Preferably a lateral tension member 70 in the form of one
or more flexible straps is included in the plank at a position
corresponding to location of intermediate purlins. The detail of
strap members 70 is best seen in FIGS. 3, 5 and 16. Strap members
70 extend laterally across the upper surface of the panel 34
beneath membrane sheet 20. The opposite ends 71 and 72 of straps 70
extend beyond the edges of the corresponding panel 34. When planks
15 are placed in engagement, the strap ends 71 and 72 are secured
to corrugated panel 29 by an appropriate fastener such as
self-tapping metal screw 74. Fastener 74 secures the strap ends 71
and 72 and penetrates into the corrugated panel section 53 and
reinforcing member 28. FIG. 5 shows in phantom lines the position
assumed by the strap ends prior to being secured in place. Once the
ends of the strap are secured in place, the fasteners 74 are
tightened and the strap is placed in tension or prestressed to
resist upward loads on the plank such as are induced by wind
currents blowing across the upper surface of the roof plank causing
reduced pressure at the roof surface. Recesses 75 and 76 are
provided at opposite longitudinal plank edges at a location
corresponding to the strap ends to facilitate tensioning the strap
and to locate the strap ends to obtain a proper distribution of
forces and minimize excessive crushing of the panel edges. The use
of the straps permits assembly of the planks without the necessity
of placing fasteners through surface of the individual planks.
A Z-section clip 78 is provided at the connection of strap ends to
reinforce the connection. Clip 78 conforms in shape to corrugated
panel sections 53 and 54 and has upper and lower flanges 77 and 79.
As seen in FIGS. 5 and 15, clip 78 is interposed between the
overlapping section of panel 24 with fastener 74 secured to flange
77 of the clip. A second fastener 80 extends through the the lower
flange 79 of the clip 78 trying the strap ends through the clip to
the flange 14 of subjacent purlin 13. If necessary, several
longitudinally spaced fasteners 74 and 80 may be provided in the
clip flanges 77 and 78.
One or more spacers 65 are provided between the adjoining ends of
the straps and panel section 48. Spacers 65 are preferably a
compressible insulative material. The strap ends 71 and 72 lay
against the spacers which give support to start fastener 74 through
the metal. As fastener 74 penetrates the lapped panel sections, the
spacer is compressed. The compressed spacer serves to minimize heat
conductivity between straps 70, panel 24, and supporting purlin
13.
When the assembly is complete, each tension strap 70 is tied at
opposite ends to purlin 13 and, under upward loadings caused by a
reduced pressure at the roof surface from wind, assumes the general
shape of a catenary curve. The panel will correspondingly deflect
slightly to assume a similar shape. Normal loadings due to weight
are resisted in the roof supporting structure at the purlins and
rafters. The strap 70 is designed so the angle of the straps over
the corner of panel 34 minimizes compression over the panel while
maintaining the shape of a catenary curve which gives transverse
strength to the plank.
The tension straps 70 may be embedded within upper sheathing 34.
With certain materials, the upper sheathing 34 may itself provide
the function of laterally strengthening the plank where the
sheathing has adequate tensile strength characteristics. The
sheathing could be directly tied to the supporting structure or
could be tied to the supporting structure through clips 78. Either
way, the sheathing could serve to distribute loadings across the
panel to the supporting structure so as to reduce the number of
fasteners transverse of the planks.
One form of a closure assembly for securing overlying flap portions
36 and 37 to adjacent panels is shown in FIGS. 6 and 7. Closure
assembly 85 includes a member 86 formed on the underside of the
edge of flaps 36 and 37. Member 86 has downwardly projecting rib
sections 91 extending parallel to the respective panel edge. The
spaced apart rib portions 91 define parallel extending grooves 92
in the underside of flap 36. The opposite coacting member 88 of
fastener 85 is provided in the upper surface of membrane 20 at a
location on the selvage adjacent edges 41 and 43. Fastener member
88 is similar to member 86 and comprises a parallel series of
upwardly projecting ribs 93 which define parallel grooves 94. The
ribs and grooves of fastener sections 86 and 88 are adapted to
interlock when force is applied, for example, to member 86 forcing
ribs 91 into corresponding grooves 94. The coacting sections 86 and
88 are thus capable of being interlocked in zipper fashion to form
a tight mechanical lock. Various configurations of the ribs and
grooves are suitable for the fastener arrangement. A preferred
configuration of this general type of fastener is shown and
described in U.S. Pat. No. 3,373,464.
The flexible interlocking fastener 85 is particularly suitable for
securing the membrane covering 20 over an assembly of the planks
15. The entire closure 85 can be fabricated into the membrane as
part of the plank at the factory. The coacting fastener portions 86
and 88 are weatherproof and waterproof when engaged. Sealing can be
accomplished by the workmen when the panels are assembled. No
special equipment is required to seal the adjacent membrane
sections. Obviously an adhesive or a vulcanizing agent can be
applied between the grooves and ribs at the time of securing the
membranes together to further ensure against penetration of
moisture and seal the interior plank structure.
FIG. 8 shows an alternate form of the flap portions and of the
membrane 20. In this structure a plank flap section 36a is
associated with the panel and is adapted to be sealed to the
adjacent panel membrane by vulcanization or application of an
adhesive. Flaps 36a do not carry an integral mechanical seal but
are substantially flat and adapted to lap the adjacent plank
membrane. The material of the membrane is preferably a natural or
synthetic rubber of a thermosetting resin which characteristically
is adaptable to vulcanization. Once the panels are assembled with
flaps 36a overlying the adjacent panel, the membrane can be sealed
by application of heat along flaps 36a with heating unit 98 which
is a flat iron having appropriate temperature control. Following
application of heat, a pressure member 99, shown as a weighted
roller, serves to compress the overlying membrane members together
to ensure a good seal. The temperature applied at flaps 36a should
be sufficient to at least partially melt the upper membrane so that
the underlying layer is heated and bonded to the flap 36a. The flap
36a can also be adhered to the surface of adjacent panels by use of
a suitable bonding agent or adhesive with or without the
application of heat. Vulcanization can also be carried out by use
of sonic, electromagnetic or heat waves to cause molecular bonding
when the flaps are brought together under pressure.
The lapping lateral and longitudinal edges of the weathering
membrane can also be sealed by a mechanical clip as shown in FIG.
9. To adapt the membrane to the mechanical fastener shown in FIG.
9, the edge of the membrane opposite flap 36b is provided with a
loose selvage portion 100. Clip 101 has a rounded upper surface 102
and intermediate section 103 and a reversely bent lower lip 104.
Clip 101 is continuous and is closed at end 105. Ribs 106, 107 and
108 extend longitudinally along one edge of the clip and are
adapted to engage one another when clip 101 is in a closed
position. Selvage 100 is received between clip elements 102 and 103
and flap portion 36b oppositely extends between clip elements 103
and 104. Vertical projections 110 extend downwardly from
intermediate element 103 engaging opposite sides of the juncture
between the planks. An additional projection 111 at end 105 engages
one of the planks. Fastener 112 extends vertically between clip
elements 102 and 103. In assembly of the clip, mastic or adhesive
may be applied in ribs 106 and 107 to seal the membrane to the
clip. It will be obvious that as fastener 112 is tightened and the
clip compressed, the overlapping portions of the membrane will be
sealed to the clip and the vertical projections 110 on the
underside of the clip will be placed in tension to apply pressure
to the membrane. One advantage of the clip arrangement is that any
water entering around fastener 112 does not penetrate the membrane
but simply will run out the end of the clip. The clip effects a
seal at 106, 107 and 108 which allows the use of the four-way
corner seal 21 to completely weatherproof the membrane at the edge
and corner junctures. The corner seal is described in detail in the
following paragraphs.
The present invention also makes provision for sealing the membrane
in the corner area of the planks. At the juncture of three or four
planks, a corner area 118 is formed with a number of membrane
sections overlying one another. This is best seen in FIGS. 10 and
11. It will be noted that the common membrane corner area 118 is
diagonally disposed from the corner 16 formed between adjacent
corresponding planks. A corner seal assembly generally designated
by the numeral 21 seals the overlying membrane sections in the
common corner area of planks. A flat metal bearing plate 120
underlies the overlying membrane section. Preferably plate 120 is
formed as an integral part of the plank structure to facilitate
assembly. The membrane flaps are lapped over lower plate 120. The
opposite side of the corner joint is defined by generally convex
cap or disk member 125 having an annular lip portion 126. Mastic
may be applied around the periphery of the lip 126. A fastener 127
extends through disk 125 into opposite bearing plate 120 and into
subjacent plank 15c. Tightening of the mechanical fastener will
draw the disk 125 down, tightly compressing the membrane sections
together between disk 125 and plate 120 providing a watertight
seal. The area of bearing plate 120 and the area encompassed by the
disk 125 should be large enough to provide for any misalignment
which might occur in the assembly of the plank sections.
FIG. 12 shows an anternate embodiment of the corner seal.
Embodiment of FIG. 12 is generally designated by the numeral 131
and includes flat bearing plate member 130 underlying the joint
between adjacent plank members. Membrane flaps are lapped across
plate 130. The upper side of the joint includes member 155 which
has a center cup 136 with annular flange 137 projecting around the
upper lip of the cup. Flange 137 engages the surface of the
outermost membrane and the inner end of cup 136 contacts bearing
plate member 130 through an appropriate cutout in the membranes.
Bearing plate 130 and joint member 135 are both of a heat
conductive material. Once the joint is assembled, heat is applied
to member 135 within the cup 136. The substantial surface area of
cup 136 conducts heat to member 130 and serves to bond or vulcanize
the overlying layers of membrane to one another and to the joint
members 130 and 135. The vulcanization or bonding results in a
secure weathertight seal.
FIG. 13 shows still another embodiment of the corner seal joint
generally designated by the numeral 141. Joint 141 includes a
bottom bearing plate 140 formed as part of the plank at the
membrane lap. The upper joint member 145 includes a generally flat
plate 146 supporting downwardly projecting spikes or pins 147. The
joint is formed by first placing bearing plate 140 in place and
then lapping the adjacent membrane sections over plate 140. Member
145 is then aligned over plate 140 and pressure is applied to plate
146 to cause the spike members 147 to pierce through the layers of
the membrane until contact with bottom plate 140 is established.
Members 140 and 145 are of a heat conductive material and the joint
is sealed by application of heat to plate 146 which is conducted by
pins 147 to plate 140. This results in a substantially uniform
heating of the joint and the membranes in the area of the joint,
resulting in a vulcanized secure seal.
The present invention will be better understood from the following
description of assembly of a typical roof assembly using the
construction planks of the present invention. A substructure
comprising primary and secondary roof support members in the form
of the lateral extending rafters 12 and longitudinally extending
purlins 13 will be erected in place by a field construction crew.
Once the substructure is in place the construction of the roof can
proceed. It will be noted that while the planks are described as
being roof panels, it will be obvious that the planks are adaptable
for use as other construction sections or units such as floors or
load bearing or non-load bearing partition members.
The construction crew will position the proper number of planks on
the purlins with the planks 15 transversely resting across the
purlins as seen in FIG. 1. Generally the relationship of the length
of the planks to the purlin spacing is such that the individual
planks traverse several purlins having opposite plank ends 42 and
43 terminating above a flange 14 of the purlins. The planks are
contiguously aligned in an end-to-end and side-by-side relationship
with the complementary edge structures in engagement. The adjacent
longitudinal edges 40 and 41 of the planks are secured together by
fasteners 60 extending through overlapping sections 48 and 53 of
the panel 24 at locations intermediate the purlins. To further
increase the lateral strength of the sections and to resist applied
stresses induced by wind loadings, tension members 70 are then
secured in place. This is done by securing Z-clip 78 in place over
the subjacent purlin 13 by means of fastener 80 extending through
lower leg 79 of the clip. Adjacent ends 71 and 72 of the tension
strap 70 are secured together by fastener 74 and pulled tight to
place tension on the members extending across the panels. Spacer 65
between the straps and the panel section 48 gives adequate support
to the fastener to allow the fastener to start through the metal at
the desired location. As the fastener penetrates the metal, the
head of the fastener pulls the strap 70 in tension and compresses
the foam spacer 65. In the compressed condition, spacer 65 serves
to seal around the fastener as well as reduce heat transfer between
the panel 24 and the tension member 70.
The inclusion of the straps is an important factor in the
construction of a roof or other section where the plank loading
tends to separate the planks from their support structure. The
straps extends laterally across the roof, being attached to the
support structure only at the plank edges. All necessary fasteners
can be secured from the top and intermediate fasteners extending
through the planks are not required. Thus potential sources of
leakage are eliminated and field assembly is expedited.
The lateral edges 42 and 43 of abutting planks are simply placed in
engagement forming a shiplap joint as seen in FIG. 4. As explained
above, the end joint is preferably located immediately above the
purlins to provide support for the joint.
Once the planks are in place, the weatherproof membrane 20 can be
sealed. End flap 36 is overlayed on the next adjacent panel.
Fastener assembly 86 carried on the marginal portion of the
membranes is secured by applying force to one of the fastener
members 86 or 88 to engage the fastener members in coacting
relationship. This can be done by simply applying manual force to
the upper surface of member 86 or the interlocking portion may be
fastened together by progressively mating the sheets with a slide
fastener so that the projections of one of the sheets fits into the
channel of the other. The concurrent application of a bonding or
adhesive agent may be included when the fastener sections are
engaged. Edge flap sections 37 are secured in place in similar
fashion with the fasteners engaged.
Alternately the overlying end and edge seal flaps 36 and 37 can be
sealed to the adjacent marginal membrane portion by application of
heat to obtain a seal. With this method, a source of heat such as a
flat iron or blower emitting hot air will be run along the
overlapping flap. The temperature must be at least the melting
point or vulcanization point of the membrane material. Heat is
applied to the top side of the overlap and causes the top layer of
the membrane to melt or partially melt to form a bond between the
members. Application of pressure immediately following application
of heat will compress the joint and further ensure the integrity of
the joint.
Once four contiguous planks have been placed with the membrane
edges sealed, membrane corner seal 21 can be completed. Disk 125 is
placed on the top membrane layer above lower plate 120. Fastener
127 is driven through member 125 and into lower plate 120 causing
the intermediate overlying membrane layers to be compressed
together tightly sealing the corner. Factory applied mastic at lip
126 will further serve to seal the corner. Any misalignment of
planks occurring during assembly can be accommodated and taken up
at the corner seal. As explained above in a further aspect of the
present invention, the corner seal may include the step of
vulcanizing the overlaying membrane portions together. Heat applied
to the exterior member 125 is conducted to the lower bearing plate
120 causing the membrane layers to vulcanize to one another and to
the corner seal structure. The assembly of the roof system
continues substantially as described until the entire roof is
completed.
The plank can be formed into a roof section with relative speed as
compared to former built-up roof systems. A roof system using the
basic plank structure can be installed in a wide range of weather
conditions. Ambient temperature is not critical as with application
of bitumen. Because of the modular nature of the plank, the plank
can be placed and erected quickly to enclose the building in a
minimum of time allowing crews to complete interior work in a
protected environment.
The plank, because of its structural design, provides a smooth hard
surface which is very resistant to exterior damage from foot
traffic, weather and vibration. With the increased trend toward
roof mounted accessories, foot traffic is an increased problem. The
unique combination of materials of the present plank provides a
hard walking surface directly under the weather resistant membrane
where it is most needed to support the membrane. The plank is also
particularly adaptable for use with a wide variety of accessories.
The panel can be cut, sawed or bored to accept various fittings and
accessories such as windows, ventilators, or conduits for
electrical or mechanical accessories.
Other advantages to the present system reside in the composite
construction of the plank element. The insulation panel is placed
over the primary structural member rather than under it so as to
minimize the expansion and contraction of the primary structural
element. This configuration also helps to spread concentrated loads
over a wider part of the roof element thus reducing the possibility
of localized roof failure. The inner wall panel may be used with no
additional interior treatment as a wall surface presenting an
aesthetically pleasing construction. Another advantage of the roof
plank of the present invention is that the vapor barrier, which is
generally defined by the corrugated panel 29, can be located on the
interior or the "hot" side of the panel. This way damaging and
deteriorating condensation within the plank interior is
avoided.
The fire resistance of the roof plank is also particularly good
since the composite materials are low flammable or not flammable.
Further, application of asphalt or flammable or toxic material is
not required in the construction. It is known that built-up roofs
present a fire hazard since the asphalt surface, when heated by
fire, can generate gaseous combustible fumes which contribute to
the spread of fire.
Because of its good structural and fire resistant characteristics
the panel of the present invention lends itself to use in the
construction of a floor or wall on other construction units. FIG.
14 illustrates a cross sectional view of a modification of the
invention adapted for use as a vertical firewall structure. The
embodiment of FIG. 14 is generally designated by the numeral 150.
The basic core structure of the plank is similar to that described
with reference to FIG. 3 and includes intermediate corrugated panel
27a enclosed on one side by interior sheet member 30a and on the
other by insulation 32a and exterior sheet 34a. Panel 27a can be
corrugated in a wide variety of shapes. Spacers 29a and reinforcing
member 28a extend longitudinally within plank 150. Preferably
spacers 28a and 29a are of a fire resistant material such as gypsum
or a foamed plastic. Opposite edges structures 40a and 41a are
configurated for lapping engagement with reference to the
previously described embodiment. Similarly, the opposite lateral
edges may be adapted to abut in a lap joint if the height of the
wall exceeds the length of a panel. For most installations the
plank ends will be squared as the typical wall will not require
vertically stacking the planks 150.
Panel 30a on the interior of the plank is wallboard or a similar
material having a good fire rating. An interior treatment such as a
vinyl or paper 151 covers the interior side of panel 30a. Panel 34a
may be plywood or a hardboard or similar composite material.
The exterior surface of upper panel 34a is weatherized with a
covering 153. Covering 153 protects the plank and also is selected
to give the desired exterior surface appearance such as aluminum,
painted steel or simulated stone.
To form a firewall structure, the wall panels 150 are vertically
aligned with edges 40a and 41a lapping and secured with fasteners
60a penetrating into reinforcing members 28a as seen in FIG. 15.
Fasteners 80a project into appropriately spaced vertical structural
members 156. The crevice between the panel edges is filled with a
butyl caulking compound 155 or the equivalent.
The advantages to such a fabricated wall structure are many. Less
foundation is required because the weight of the planks is
substantially less than the equivalent structure of concrete or
block. The prefinished exterior and interior permits fast
installation and eliminates need for additional work. The
components of the plank, all being non-flammable or fire resistant,
result in a structure with a good U-factor and resultant reduction
in building and insurance costs.
Thus the present invention provides a construction section which
can be used as a basic element of a roof, or other construction
unit. The basic plank is a particularly good structural member
because it incorporates features which give it both good
longitudinal and lateral strength. Used as a roof deck, the
transversely extending tension strap members serve to resist upward
loading on roof due to reduced pressures at the outer roof surface
because of wind. As a wall component, the plank can be prefinished
at the interior and exterior surfaces. Factory assembly of the
plank allows minimum labor cost and provides maximum quality
control resulting in more economical product with fewer field
maintenance problems. The plank is highly versatile and allows
substantial variance of construction to meet various end needs such
as strength, weight, thickness, fire characteristics and thermal
conductivity.
It will be obvious to those skilled in the art to make
modifications and changes to the panels of the present invention.
For example, it will be obvious to substitute other structural
elements for the interior panel member such as aluminum or
fiberglass sheeting. Similarly, various forms of insulation and
interior and exterior panels can be used. The membrane may
similarly be of a wide variety of natural or synthetic materials to
provide the desired weather and waterproof exterior. To the extent
that these changes and modifications do not depart from the spirit
and scope of the present invention they are intended to be
encompassed therein.
* * * * *