Device and method for reinforcing attachment of lightweight insulating concrete top coat to an underlying roof deck in a roof system

{
  "publication_number": "US7765757B2",
  "country": "US",
  "kind": "B2",
  "title": "Device and method for reinforcing attachment of lightweight insulating concrete top coat to an underlying roof deck in a roof system",
  "abstract": "In a roof system, a top coat of lightweight insulating concrete is anchored to an underlying base slurry coat of lightweight concrete and a metal, gypsum, tectum or concrete roof deck by installing anchoring devices at spaced intervals. The anchoring devices may be made of plastic, steel or aluminum and include a threaded shank extending upwardly from a base plate. The anchoring devices are installed by fastening the base plates to the underlying roof deck structure or by setting the base plates in the lightweight base concrete slurry coat so that the threaded shanks of the anchoring devices extend upwardly through holes in EPS board insulation and into the subsequently applied top coat of lightweight insulating concrete. The base plate and threaded shank effectively anchor the attachment of the lightweight insulating concrete top coat to the underlying base slurry coat and roof deck to enhance resistance to wind uplift forces.",
  "claims": [
    "1. A roof system comprising: a roof deck; a base layer of lightweight insulating concrete; a layer of expanded poly styrene board insulation including a top side, a bottom side and a spaced arrangement of holes formed through said board insulation from said top side to said bottom side, and said bottom side applied to said base layer of lightweight insulating concrete; a top layer of lightweight insulating concrete applied over said top side of said layer of board insulation and within said holes; and a plurality of anchoring devices structured and disposed for holding said top layer of lightweight insulating concrete anchored to said base layer of lightweight insulating concrete with said layer of expanded poly styrene board insulation sandwiched between said base layer and said top layer, said plurality of anchoring devices each including a base set into and anchored within said base layer of lightweight insulating concrete and a shank extending from the base and through a respectively aligned one of the holes in the board insulation and anchored into said top layer of lightweight insulating concrete.",
    "2. The roof system as recited in claim 1 wherein each of said plurality of anchoring devices further comprises: a distal end of said shank; and a spiraling screw thread along said shank between said base and said distal end.",
    "3. The roof system as recited in claim 2 wherein said base of each of said plurality of anchoring devices is flat.",
    "4. The roof system as recited in claim 3 wherein said plurality of anchoring devices are formed of plastic.",
    "5. The roof system as recited in claim 3 wherein said plurality of anchoring devices are formed of steel.",
    "6. The roof system as recited in claim 3 wherein said plurality of anchoring devices are formed of aluminum.",
    "7. A method of installing a roof system on a roof deck of a building structure comprising the steps of: applying a base slurry layer of a lightweight insulating concrete composition on the top of said roof deck to define a base layer; providing expanded poly styrene board insulation including a top side, a bottom side and a spaced arrangement of holes formed through said board insulation from said top side to said bottom side; applying said board insulation on to said base layer of lightweight insulating concrete composition prior to complete curing of said base layer of lightweight insulating concrete composition; providing a plurality of anchoring devices each including a base and a shank extending upwardly from the base; placing the base of each of said plurality of anchoring devices set within said applied base layer prior to curing of the lightweight insulating concrete composition of said base layer so that the shank of each of said plurality of anchoring devices extends upwardly through a respectively aligned one of the holes in the board insulation; and applying a top layer of lightweight insulating concrete composition over the top side of said board insulation and filling said top layer of lightweight insulating concrete composition within said holes so that the shanks of said plurality of anchoring devices are set within and become anchored to said top layer, and allowing said base layer and said top layer to cure so that said plurality of anchoring devices hold said top layer anchored to said base layer with said board insulation sandwiched between said base layer and said top layer."
  ],
  "description_excerpt": "This non-provisional patent application is based on provisional patent application Ser. No. 60/858,321 filed on Nov. 10, 2006.\n\n1. Field of the Invention This invention relates to roofing systems, and, more particularly, to reinforcing the attachment of the top coat of lightweight insulating concrete to an underlying lightweight concrete slurry coat and roof deck structure to provide greater resistance to wind uplift forces. 2. Discussion of the Related Art Currently, lightweight insulating concrete is installed over metal, gypsum, tectum or concrete roof decks by applying a ½ inch to ¾ inch slurry coat of lightweight concrete into which a layer of EPS (expanded poly styrene) board insulation is placed. The EPS ridged board insulation has three inch diameter holes formed through its thickness in a spaced arrangement. The holes in the EPS board insulation allow the slurry coat of lightweight concrete to mate with a subsequently applied two inch top coat layer of lightweight insulating concrete. This attaches the top coat of lightweight concrete to the underlying slurry coat, with the EPS board insulation encapsulated therebetween. The slurry coat is poured directly on top of the metal, gypsum, tectum or concrete roof deck which, in some instances, results in a weak connection. Once the lightweight insulating concrete has cured over a 12 to 36 hour period, the roof membrane system is applied.\n\nDespite the widespread use of lightweight insulating concrete, there is a significant drawback associated with the attachment of the lightweight concrete to the underlying roof deck structure.",
  "cpc": [
    "E04D 11/00",
    "E04D 11/02",
    "F16B 25/00",
    "F16B 33/006",
    "F16B 35/06"
  ],
  "ipc": [
    "E04B 1/74",
    "E04B 5/00",
    "E04G 23/00"
  ],
  "assignees": [
    "GEMBALA HENRY"
  ],
  "inventors": [
    "GEMBALA HENRY"
  ],
  "filing_date": "2007-11-13",
  "publication_date": "2010-08-03",
  "grant_date": "2010-08-03",
  "priority_date": "2006-11-10",
  "application_number": "US-98516307-A",
  "family_id": "40639382",
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}