U.S. patent number RE38,950 [Application Number 10/330,799] was granted by the patent office on 2006-01-31 for waterproof decking method and apparatus.
Invention is credited to Charles P. Maiers, Gerald J. Maiers.
United States Patent |
RE38,950 |
Maiers , et al. |
January 31, 2006 |
Waterproof decking method and apparatus
Abstract
A waterproof deck includes a deck subflooring supported on
joists adjacent a building, a flashing adjacent a building, and a
drip edge attached along the edge of a subflooring where the water
runs off the deck. An elastomeric waterproofing material covers the
subflooring and a strip of T-bar edging is attached along the edge
of the subfloor and has a portion extending over the elastomeric
waterproofing material and over the drip edge and another portion
extending above the subfloor to form a raised edge therealong.
Concrete covers the elastomeric waterproofing material and subfloor
to the top edge of the T-bar raised edge so that water on the
concrete flooring runs off the deck over the T-bar drip edge and
drains from beneath the concrete floor over the drip edge to
prevent collection of water over the concrete flooring.
Inventors: |
Maiers; Charles P. (Orlando,
FL), Maiers; Gerald J. (Orlando, FL) |
Family
ID: |
23262125 |
Appl.
No.: |
10/330,799 |
Filed: |
December 27, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
08324111 |
Oct 14, 1994 |
05546719 |
Aug 20, 1996 |
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Current U.S.
Class: |
52/408; 52/302.3;
52/302.6; 52/310; 52/96; 52/97 |
Current CPC
Class: |
E04B
5/32 (20130101); E04D 7/00 (20130101); E04D
11/00 (20130101); E04D 13/1415 (20130101); E04D
13/15 (20130101) |
Current International
Class: |
E04B
7/20 (20060101) |
Field of
Search: |
;52/408,319,94,96,97,302.1,302.3,302.6,310 |
References Cited
[Referenced By]
U.S. Patent Documents
Other References
Summerfield Suites Hotel, Two drawings for Project Number 90160.
cited by other .
Order in Farris Gypsum Floors of Florida, Inc., d/b/a Farris Floor
Systems v. Charles P. Maiers, et al., filed Jul. 3, 2001. cited by
other .
Exhibits cited in Farris Gypsum Floors of Florida, d/b/a Farris
Floor Systems v. Charles p. Maiers, et al., filed Jul. 3, 2001,
case No. 6:99-cv-923-Orl-28KRS: cited by examiner .
1. Affidavit of Glenn Bowles, cited by examiner .
2. 2. Cited pages from the Deposition of George T. Barnes, plus
deposition exhibits 11 and 13, cited by examiner .
3. Cited pages from the Deposition of E. keith Voltz, plus
deposition exhibit 6, cited by examiner .
4. Cited pages from the Deposition of Timothy Iseman, cited by
examiner .
Additional exhibits from the litigation Case No.
6:99-cv-923-Orl-28KRS for review by Examiner: cited by examiner
.
5. Fax from Joey Jungman, cited by examiner .
6. Selected pages from Depositoin of Joey Jungman, cited by
examiner .
7. Affidavit of James A. Holt. cited by examiner.
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Primary Examiner: Glessner; Brian E.
Attorney, Agent or Firm: Beusse; James H. Beusse Brownlee
Wolter Mora & Maire, P.A.
Claims
I claim:
1. A waterproof deck comprising: a deck subfloor supported on
joists adjacent a building; a drip edge .Iadd.having an inverted,
generally L-shaped cross-section with a first portion
.Iaddend.attached along .[.the.]. .Iadd.an upper surface of an
.Iaddend.edge of said deck subfloor .Iadd.and a second portion
depending from said first portion and overlaying an end of said
deck subfloor .Iaddend.where.Iadd.by .Iaddend.water .[.runs off of
the deck.]. .Iadd.is adapted to run over the drip edge and off the
deck.Iaddend.; an elastomeric waterproofing material covering said
subfloor .Iadd.and overlaying said first portion of said drip edge
and extending downward onto said second portion of said drip
edge.Iaddend.; a strip of T-bar edging attached along the edge of
said subfloor and having one portion extending over said
elastomeric waterproofing material and over said drip edge and
another portion extending above said subfloor to form a raised edge
therealong; .[.and.]. a concrete floor covering said elastomeric
waterproofing material and subfloor to a level approximately along
the top edge of said T-bar raised edge, whereby water drains off
said concrete floor over said T-bar edging and drains from beneath
said concrete floor over said drip edge to prevent collection of
water below said concrete floor.Iadd.; and a plurality of spacers
positioned between said T-bar edging portion and said elastomeric
material to thereby form a space under said T-bar edging whereby
water accumulated under the concrete floor is adapted to run over
the elastomeric material and the drip edge.Iaddend..
.[.2. A waterproof deck in accordance with claim 1 in which a
plurality of spacers are positioned under said T-bar edging portion
extending over said elastomeric material and drip edge to thereby
form a space under said T-bar edging..].
3. A waterproof deck in accordance with claim .[.2.]. .Iadd.1
.Iaddend.including flashing covering the corners between a building
and said subfloor.
4. A waterproof deck in accordance with claim 3 in which said T-bar
edging has a drip edge lip therealong spaced from and parallel to
said drip edge.
5. A method of making a waterproof deck comprising the steps of:
attaching a deck subfloor to .Iadd.a .Iaddend.building; attaching
.Iadd.a first portion of .Iaddend.a metal drip edge .[.to.].
.Iadd.along an upper surface of .Iaddend.one edge of said deck
subfloor .Iadd.whereby a second portion of said drip edge extends
downward over an end of said deck subfloor.Iaddend.; applying an
elastomeric waterproofing material over said subfloor; selecting a
T-bar strip of material; attaching said T-bar strip of material to
the edge of said deck subfloor with one portion extending over said
drip edge and a second portion forming a raised edge; .[.and.].
.Iadd.placing a plurality of spacers between said T-bar strip and
said elastomer material to create a drainage space whereby water
accumulation below said concrete floor is minimized; and.Iaddend.
pouring concrete over said elastomer waterproofing material covered
subfloor to a level approximately with the top edge of said
attached T-bar strip raised edge, whereby a deck is provided with a
water runoff over a T-bar strip and a water runoff under said
concrete floor and over said drip edge beneath said T-bar
strip.
.[.6. A method of making a waterproof deck in accordance with claim
5 including the step of placing a plurality of spacers between said
T-bar strip and said elastomer covered subfloor to thereby allow
drainage from said subfloor below said concrete floor below said
attached T-bar strip..].
7. A method of making a waterproof deck in accordance with claim
.[.6.]. .Iadd.5 .Iaddend.including the step of cutting said
selected T-bar strip to a predetermined length.
8. A method of making a waterproof deck in accordance with claim 7
including the step of applying corner flashing between said deck
subfloor and an adjacent building.
9. A method of making a waterproof deck in accordance with claim 8
including the step of attaching a subfloor to building joists.
10. A method of making a waterproof deck in accordance with claim 9
including the step of selecting said T-bar strip having a drip edge
formed thereon.
11. A method of making a waterproof deck in accordance with claim
10 in which the step of attaching said T-bar strip to the edge of
said deck subfloor includes nailing said T-bar strip and said metal
drip edge to said deck subfloor.
12. A method of making a waterproof deck in accordance with claim
10 in which the step of attaching a metal drip edge includes
nailing said drip edge to said deck subfloor.
.Iadd.13. The waterproof deck of claim 1, wherein said plurality of
spacers comprises a separate piece of material positioned between
said T-bar edging portion and said elastomeric
material..Iaddend.
.Iadd.14. The waterproof deck of claim 13, wherein said plurality
of spacers comprises 4 inch by 4 inch spacers of elastomer
material..Iaddend.
.Iadd.15. The method of claim 5 wherein said plurality of spacers
comprises a separate piece of material positioned between said
T-bar edging portion and said elastomeric material..Iaddend.
.Iadd.16. The method of claim 15, wherein said plurality of spacers
comprises 4 inch by 4 inch spacers of elastomer material..Iaddend.
Description
BACKGROUND OF THE INVENTION
The present invention relates to a waterproof deck and to a method
of making a waterproof deck and especially to an apparatus and
method which prevents the accumulation of water between a concrete
floor and the waterproof membrane on the subfloor.
In the past, it has been common to make concrete decks for
apartment buildings and the like in which the deck is placed
between walls on three sides and open on the fourth side. Decks are
typically made with joists mounted between the walls and a plywood
subfloor attached to the joists. Typically, a waterproof membrane,
such as building paper, coated felt roofing material, roofing
asphalt or the like, is used to coat a subfloor and then a concrete
flooring is poured on top of the waterproof coating to form the
floor. A drip edge is commonly used along the open edge of the
deck. The deck may have a slight slope so that rain or water
falling onto the deck drains off the concrete and over the drip
edge. Prior art decks of this type have tended to have the
subflooring and joist rot out in a fairly short period of time as a
result of the accumulation of moisture from the concrete below the
concrete flooring. In a typical deck of this type, flashing has
been placed around the deck along the walls adjacent the attached
deck and a waterproof sheathing has been placed on the subfloor so
that water accumulating from the concrete floor tends to accumulate
under the concrete floor and tends to get through or around the
waterproof sheathing placed on the subfloor. This happens because
the sheathing is sometimes not fully watertight and at other times
tends to get damaged, such as with minute holes that allow the
seepage of water therethrough. The water that accumulates under the
concrete floor has no where to run off and thereby tends to
accumulate and build up until any leak or spacing around the
flashing allows the seepage to make its way to the wooden subfloor
and joists which then very quickly rot out and causes extensive
damage.
For efficient water shedding at the deck and roof edges of a
building, a metal drip edge is usually installed. These have
various shapes and may be formed from 26 gauge galvanized steel.
They extend back about three inches from the deck edge and are bent
downward over the edge and may have an outwardly bend or lip at the
edge of the metal to cause the water to drip free of the underlying
deck or joist construction. It has also been common in the past to
use T-bar edge materials extending over a roof edge especially in
flat or built-up roofs where the metal portion of the T-bar extends
over the roof sheathing and also has raised edges to act as a metal
gravel stop for containing gravel covering the built-up roof.
Built-up roofs commonly use sheathing paper or felt as well as
corner flashing to protect the surfaces.
The present invention is directed towards a system for preventing
the damage by the rotting of concete floor decks wooden components
commonly used in multi-story buildings and the like and provide an
apparatus and method for preventing accumulation of the water and
moisture over and beneath the concrete surface.
Prior U.S. patents that have been found of interest to the present
invention include the O'Riordain, U.S. Pat. No. 4,274,238, for a
roof structure providing for efficient drainage of flat roofs and
includes a drainage board above a water barrier layer and below a
thermal insulation layer so that water falling on a flat roof
passes through the protective layer of gravel through the abutting
joints of a thermal insulation layer and through the drainage board
and to conventional water gulleys and downpipes. In the VanWagoner,
U.S. Pat. No. 4,719,713, a thermally efficient protected membrane
roofing system is provided which also includes a drainage and
insulation board and a vapor barrier. The seams between adjacent
roofing panels is covered with a waterproof but vapor permeable
tape and the panels are covered with a protective layer. The
Paquette, U.S. Pat. No. 4,937,990, shows a ventilation system for
roofs which makes the drying of roof insulation easier. The
Paquette et al. U.S. Pat. No. 5,144,782, similarly has a double
level drainage system for flat roofs so that water which may
collect between the upper and lower membranes of flat, horizontal,
or slightly sloped roofs upon perforation of the upper membrane.
The insulated panels located between the two membranes are provided
at both their upper and lower faces with a network of intersecting
grooves and a lower drain is sealed to and opens through the lower
membrane to drain any water that has seeped thereinto. The Carter,
U.S. Pat. No. 3,434,260, has a series of separately formed gutters
underlying the joints between adjacent tiles so that water
penetrating the joints is drained by the underlying gutter to the
next floor tile and onto the aligned next lower channel. The
LaRoche et al., U.S. Pat. No. 4,663,894, is a flexible gutter
attached beneath expansion joints for draining off water seeping
between the expansion joints at the abutment of interconnecting
concrete surfaces. The Riley et al., U.S. Pat. No. 4,658,554, is a
protected membrane roof system for high traffic roof areas having a
waterproof membrane attached to the roof deck and extruded panels
of closed cell polystyrene foam mounted on top of the membrane to
protect the membrane from thermal cycling, ultraviolet rays, and
physical damage and is resistant to water. Concrete panels are laid
directly on top of the polystyrene foam. In the Ager, U.S. Pat. No.
2,646,011, a roof gutter is provided for flat roofs which forms a
trough section and spillway with specially formed sheet metal.
The present invention provides a simplified disposal of accumulated
moisture through a concrete floor to prevent the accumulation of
moisture between the floor and the waterproof membrane covering the
subfloor so that the cost of building the decks does not increase
substantially while preventing subfloors, joists, and the like from
rotting out. The problem results because concrete does not provide
a total barrier to the passage of moisture and water tends to
accumulate beneath the concrete surface where the concrete surface
is frequently covered with water. Generally, building codes require
that concrete floors always have a moisture barrier placed over any
wooden surfaces to which the concrete is to be placed upon. This,
however, has not been effective in preventing the wood structure
which supports a concrete deck from being damaged by the
accumulation of moisture which finds its way through or around the
waterproof membrane.
SUMMARY OF THE INVENTION
A method of making a waterproof deck includes the steps of applying
a metal drip edge strip to one edge of a deck subfloor and then
applying an elastomeric waterproofing material over the subfloor. A
strip of T-bar material is selected and attached to the edge of a
deck subfloor over some spacing strips of the elastomeric material
with one portion of the T-bar strip extending over the drip edge
and a second portion forming an upright raised edge and then
pouring concrete over the elastomeric waterproofing material
covering the subfloor to a level approximately to the top edge of
the T-bar strip so that a concrete deck is provided with water
runoff over a T-bar and water under the concrete floor drains over
the drip edge under the T-bar. The selected T-bar has a second drip
edge formed thereon and is spaced with additional elastomeric
waterproofing material. A waterproof deck includes a deck
subflooring supported on joists adjacent a building, a flashing
adjacent a building, and a drip edge attached along the edge of a
subflooring where the water runs off the deck. An elastomeric
waterproofing material covers the subflooring and a strip of T-bar
edging is attached along the edge of the subfloor and has a portion
extending over the elastomeric waterproofing material and over the
drip edge and another portion extending above the subfloor to form
a raised edge therealong. Concrete covers the elastomeric
waterproofing material and subfloor to the top edge of the T-bar
raised edge so that water on the concrete flooring runs off the
deck over the T-bar drip edge and drain from beneath the concrete
floor over the drip edge to prevent collection of water over the
concrete flooring.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features, and advantages of the present invention
will be apparent from the written description and the drawings in
which:
FIG. 1 is a partial perspective view of a deck under
construction;
FIG. 2 is a partial perspective view of a deck under construction
with metal drip installed;
FIG. 3 is a partial perspective view of a partially finished deck
having the elastomeric waterproofing membrane over the
subfloor;
FIG. 4 is a partial perspective view of a partially fin deck having
a T-bar strip added thereto;
FIG. 5 is a partial perspective view of a concrete deck; and
FIG. 6 is a sectional view of a finished deck section.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIGS. 1-6 of the drawings, a portion of a concrete
deck 10 in FIG. 5 is formed by first attaching a subfloor 11 in
FIG. 1, which subfloor may be 3/4 plywood or tongue and groove
subfloor. The subfloor 11 is mounted to adjacent concrete or wood
sidewalls 12 and rear walls 13. The deck has an open front. A pair
of 2.times.10 wooden joists 14 are shown supporting the front edge
of the subflooring but other joists could also be incorporated into
the deck. The subflooring 11 has metal flashing 15 attached at the
corners over the edge of the subflooring and along the walls 12 and
13 and has outside corner flashing 16 applied to the wall corner.
In the case of a post support, the flashing 15 and 16 is wrapped
around the post.
In FIG. 2, a drip edge 17 has been attached along the front edge 20
of the subfloor 11 which edge is the open side of the deck and
adjacent the front supporting joint 14. The drip edge 17 has a
metal portion 18 extending a short distance over the subflooring 11
along the subflooring edge 20 and then a vertically extending
portion 21 extending in front of the subflooring 11 with an angled
lip 22 to form the edge of the drip edge for draining water
therefrom. A waterproof membrane which may be an elastomeric
waterproof material 23, such as BITUTHENE by W. R. Grace Co., which
is a rubberized asphalt with four mils of high density
polyethylene, and provides a flexible waterproof material which is
self-sealing at the edges 24. However, other waterproofing
elastomers can also be utilized without departing from the spirit
and scope of the invention.
The deck under construction in FIG. 3 has a plurality of spacers
25, such as 4.times.4 inch spacers of the elastomer material 23
placed along the front edge 20 of the subflooring 11. As seen in
FIG. 4, a measured strip of metal T-bar material has the one leg 27
placed on top of the spacers 25 and on top of the elastomeric
material 23 over the front edge thereof and directly over the drip
edge 17. The drip edge 17 can be anchored to the subfloor and to
the joist with nails or other fasteners as desired and the T-bar
stud is similarly anchored with nails 28 or the like through the
drip edge 17, top portion 18 and through the T-bar strip portion
27, as shown in FIG. 6. The T-bar strip has a raised edge 30 having
a reinforcing lip 31 along the top thereof and also has a
downwardly extending portion 32 having an angled lip 33 thereon
which acts as a drip edge. The elastomer 23 has also been extended
and turned down over the drip edge to form a front edge 34.
The T-bar strip is attached in FIG. 4 along the front edge 20 of
the subfloor such that a parallel space 35 is formed between the
T-bar strip and the drip edge 17 so that the lip 22 of the drip
edge 17 and the lip 33 of the T-bar strip 30 are spaced from each
other. This allows moisture to drip off without running down the
sides of the wall of a building or the front edge of the deck.
Once the deck has been completed, as shown in FIG. 4, the concrete
floor 36 is then poured to the approximate top edge 37 of the
raised edge 37 and within the confines of the flashing 15 along the
sides and over the waterproof barrier of elastomer material 23
covering the subfloor 11 (FIG. 5). Water from rain covers the top
of the concrete deck and drains off the front open end of the
slightly angled deck and drains over the T-bar strip 30 and off the
lip 33. However, since the concrete is not a complete barrier to
the passage of moisture, it tends to accumulate under the concrete.
The water accumulates on the waterproof elastomer barrier 23 which
is also angled with the deck and the water flows along the
elastomer material until it passes under the T-bar anchoring
portion 27, past the spacers 25 and over the drip edge 17, and off
the drip edge lip 22 to be separately drained and thereby prevent
accumulation on the surface of the elastomer coating 23. The
subflooring 11 and the joist 14 are protected from moisture seepage
through water getting around the flashing 15 from above and through
the concrete and seepage through pinholes or other areas of the
membrane to cause the joist and subfloor to rot.
It should be clear at this time that both a concrete deck and a
method of making a concrete deck have been provided. However, it
should be clear that the present invention is not intended to be
limited to the forms shown which are to be considered illustrative
rather than restrictive.
* * * * *