US3677878A - Integrated insulated and weatherproof roof system - Google Patents

Integrated insulated and weatherproof roof system Download PDF

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Publication number
US3677878A
US3677878A US111950A US3677878DA US3677878A US 3677878 A US3677878 A US 3677878A US 111950 A US111950 A US 111950A US 3677878D A US3677878D A US 3677878DA US 3677878 A US3677878 A US 3677878A
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United States
Prior art keywords
mass
concrete
bituminous
slurry
layer
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Expired - Lifetime
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US111950A
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English (en)
Inventor
John David Carlson
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Beazer East Inc
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Koppers Co Inc
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D7/00—Roof covering exclusively consisting of sealing masses applied in situ; Gravelling of flat roofs
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249967—Inorganic matrix in void-containing component
    • Y10T428/249968—Of hydraulic-setting material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249971—Preformed hollow element-containing
    • Y10T428/249972—Resin or rubber element
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2933—Coated or with bond, impregnation or core
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/31504—Composite [nonstructural laminate]
    • Y10T428/31815—Of bituminous or tarry residue
    • Y10T428/31819—Next to cellulosic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2041—Two or more non-extruded coatings or impregnations
    • Y10T442/2098—At least two coatings or impregnations of different chemical composition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
    • Y10T442/2213—Coating or impregnation is specified as weather proof, water vapor resistant, or moisture resistant

Definitions

  • An integrated, insulated and weatherproof roof system has a base, a first monolithic mass, supported by the base composed of a low-density concrete composition and a second monolithic mass on a surface of the first mass composed of a bituminous material that is mechanically bonded to the surface of the first mass.
  • the roof system is formed from initially flowable materials by forming on a base a slurry cement, expanded beads of a thermoplastic material and water, curing the slurry to a solid monolithic mass and forming a layer of a hot bituminous material on a surface of the solid mass.
  • This invention relates to an integrated, insulated and weatherproof roof system made from initially flowable materials and to a method for making the same.
  • a built-up roof is formed of alternate layers of bituminous material and felt which are assembled or built-up in the field and applied over a subdeck.
  • Such roofs consist of three to five plies of saturated felt that have been cemented or hot mopped together with bituminous materials on the sub-deck at a temperature of about 400 F. at which temperature the bituminous material has the high fluidity that is necessary for good penetration of the felt.
  • the bituminous material is usually of a coal tar or asphalt origin.
  • Conventionally gravel, slag or the like is embedded in the top layer of the bituminous material to protect the under layers of the roof from foot trafiic, sun and wind.
  • a slurry made of, Portland cement, water and lightweight aggregate such as vermiculite or perlite is placed over a base and screeded to form an even surface. After the slurry has cured to a solid monolithic mass the alternate layers of hot bituminous material and felt are conventionally applied over the monolithic mass.
  • This type of concrete sub-deck has several disadvantages. In preparing the slurry, about four gallons of water are needed for each cubic foot of solids in the slurry, and conse quently the slurry has a relatively high moisture content.
  • the curing of the concrete requires six to seven weeks and, generally, the bituminous materials cannot be applied to the surface of the concrete mass for at least seven to eight days after it has been initially formed. Vents must be provided within the roof after the concrete mass has been covered with the bituminous materials so that the excess water contained in the concrete mass may be vented therefrom; and, the concrete mass requires a built-up roofing because the concrete mass itself is not weatherproof.
  • vapor barriers such as a coating of a polyvinyl (alcohol) composition must be applied over the surface of the freshly formed concrete mass before the bituminous materials are applied thereto to protect the freshly formed mass from weathering such as rain which 3,677,878 Patented July 18, 1972 would wash out the cement in the freshly formed mass and to prevent a rapid evaporation of moisture from the surface of the concrete mass so that hydration of the cement may properly occur.
  • An integrated insulated and weatherproof roof system comprises a first layer of a low-density concrete composition comprised of a homogeneous matrix of cement and of expanded beads of a thermoplastic material that are bonded to the cement and a second layer of a bituminous material that coextensively covers a surface of the concrete composition and that is mechanically bonded to the surface.
  • the roof system is made by forming a slurry made of cement, expanded beads of a thermoplastic material and water as a first layer, curing the slurry to a solid monolithic mass and forming a bituminous material as a second layer on a surface of the solid concrete mass by heating the bituminous material to a temperature that disintegrates and displaces the ex panded thermoplastic heads at the surface of the solid concrete mass whereby the second layer of bituminous material becomes mechanically bonded to the surface of the solid concrete mass.
  • FIG. 1 is a perspective view illustrating an embodiment of an integrated roof system made in accordance with the invention
  • FIG. 2 is a cross sectional and greatly exaggerated view of the roof system of FIG. 1, taken at lines 11-11;
  • FIG. 3 is a flow diagram embodying the method for making the integrated roof system of FIG. 1 in accordance with the invention.
  • FIG. 4 is a perspective view illustrating another embodiment of an integrated roof system made in accordance with the invention.
  • the roof system of FIG. 1 includes purlins 11, a base 13, a concrete monolithic mass 15, a bituminous monolithic mass 17 and a gravel layer 19.
  • the monolithic concrete mass 15, as illustrated herein, includes reinforcing members 21 for increasing the strength of the monolithic concrete mass 15; however, reinforcing members are not a necessary part of this invention.
  • the purlins 11 are conventional structural members on top of a building that support the base 13.
  • the base 13 may be composed of any suitable material such as wood, metal or the like.
  • the moonlithic concrete mass 15 in FIG. 1 is a layer of a homogeneous matrix of cement and of expanded beads of a thermoplastic material, preferably expanded polystyrene beads, that are uniformly dispersed throughout the matrix and bonded to the cement.
  • a typical concrete mass made in accordance with the invention comprises /21 parts by Weight of an homogenizing agent, 3 parts by weight of expanded thermoplastic beads, and 50-90 parts by weight of hydrated portland cement.
  • Such a typical mass has physical properties which are ideally suited for roof systems. Typical properties are given in the table below:
  • cements are useable in the practice of the invention such as, for example, conventional portland cements, gypsum products (such as plaster of paris), calcium-aluminate cements, high-alumina-cements, and magnesia cements or combinations thereof.
  • portland cement is used.
  • the expanded thermoplastic beads for use in the practice of this invention are commercially available.
  • expanded beads of polystyrene are used and such beads are sold under the trademark, Dylite, and are made by Sinclair-Koppers Company.
  • Such polystyrene beads are made from expandable styrene polymers and are expanded by heating the beads whereupon the blowing agent contained in the beads causes the beads to expand to the extent of to 30 times their original size.
  • the density of the unexpanded polystyrene beads originally are about that of water, the density of the expanded polystyrene heads is about one pound per cubic foot.
  • a homogenizing agent such as the ones described in US. Pat. 3,272,765 or 3,214,393, have been developed to overcome the agglomeration and segregation of the expanded polystyrene beads in the slurry.
  • the homogenizing agents help to dispose the expanded polystyrene beads uniformly throughout the slurry, maintain a uniform dispersion and provide for the bonding of the expanded polystyrene beads with the cement.
  • the concrete mass may contain nylon fibers, sisal and the like.
  • the concrete mass 15 may also contain a variety of fillers and combinations thereof such as, for example, asbestos, wood fibers, chips shavings and dust, excelsior, cork, slag, fiber glass, hemp, jute, bagasse or the like. The use and the choice of fillers will depend upon the various needs.
  • the bituminous monolithic mass 17 is a layer of a bituminous material that coextensively covers the upper surface of the concrete mass 15.
  • the bituminous material may be comprised of a rubber dissolved in a tar composition, asphaltic compositions, bituminous emulsions, mixtures of aromatic and coal tar pitch and the like.
  • the bituminous layer 17 seals the concrete mass and permtis the concrete to develop its ultimate strength through complete hydration of the cement in the concrete mass 15.
  • the bituminous layer is capable of stretching and flowing as needed to seal minor cracks that may develop in the concrete mass from shifting in the building structure that may occur during the service life of the integrated assembly.
  • Bituminous materials are used in the practice of this invention because they have physical properties which are ideally suited for roof systems. Typical physical properties are given in the table below:
  • bituminous materials for use in the practice of this invention are sold by Koppers Company, Inc. under the trade name Bitumen N0. 1 and Bitumen No. 2.
  • the monolithic bituminous mass or layer 17 is superficially embedded in the upper surface of the monolithic concrete mass 15 and is mechanically bonded to the concrete mass 15 to form an integrated roof system.
  • the bituminous material is yieldable and extensible.
  • the layer 17 can be stretched to about 10% of its original volume without failure of the layer by cracking.
  • the layer 17 is locked with the concrete mass 15 and minor shifting or cracking of the concrete mass, while the roof system is in service, does not adversely affect the sealing quality of the bituminous material as it is capable of shifting along with the concrete mass without itself cracking or separating apart.
  • a conventional gravel layer 19 is used in the practice of this invention.
  • the gravel layer 19 should be equal to the values established in Standard Test ASTM D-1863 for ultraviolet sun light resistance to protect the bituminous layer 17 from any degradation resulting from the sun light exposure.
  • a slurry of concrete composition is prepared, preferably of portland cement, expanded beads of polystyrene, a homogenizing agent and water. These constituents are added to a suitable blender preferably in accordance with the following formulation wherein parts are expressed as parts by weight:
  • the ingredients are thoroughly blended together in the blender, preferably by premixing the expanded beads of polystyrene and the homogenizing agent in the blender, then slowly adding water to this mixture and thoroughly agitating these ingredients until a homogeneous blend is achieved, and then slowly adding the portland cement to the blender and thoroughly mixing these ingredients to obtain a homogeneous slurry.
  • the homogeneous slurry has a consistency such that it is readily flowable.
  • the slurry is then pumped to the roof by conventional pump and hose arrangement and is placed over the base 13 to a thickness of any desired dimension.
  • the slurry should be two inches in thickness.
  • a temporary form has been previously secured on the base at its lateral edges to prevent the slurry from running off of the base.
  • the slurry is then screeded to prepare an even top surface to receive the bituminous materials.
  • bituminous material is poured over the solid concrete '15 to a preferred thickness of about /2 inch.
  • bituminous material is heated to a temperature of about 400 F. so that it has the proper viscosity for pouring onto the roof.
  • the heat of the bituminous material melts and disintegrates those expanded polystyrene beads at the top surface of the solid mass but does not affect those expanded polystyrene beads below the top surface.
  • the bituminous material fills the voids created by the disintegration.
  • bituminous material upon cooling is mechanically bonded to the concrete mass 15.
  • This novel bonding mechanism insures the union of the bituminous material and the upper surface of the solid mass of lightweight concrete. Subsequently, gravel 19 or the like is placed over the layer of hot bituminous material.
  • a desirable feature of this invention is that the cement may be stoichiometrically balanced with the water in the slurry to contain the proper amount of water for hydration. Thus excess quantities of water need not be added to the slurry to achieve proper hydration of the cement. As is well known the less excess water added to the slurry in respect to the cement the greater the strength of the concrete. It is the water to cement ratio, not the cement content nor the granulometric composition, that determines to a large extent the strength of the concrete. Also, it is well known that the shrinkage or the reduction of volume of the concrete during curing is in proportion to the amount of cement paste in the concrete and the wateriness of this paste.
  • the materials of which the roof system are composed are initially iiowable materials.
  • the materials may be prepared and conveniently pumped to the roof for their application in accordance with the invention. While the materials are initially flowable they harden to a solid, particularly the concrete composition, within a very short period of time such that they can sustain foot traffic and the like. Because the concrete composition cures to a hard solid in the short period of time the hot bituminous material can be applied to the surface of the concrete mass within about twenty-four hours or less.
  • the early application of the bituminous material seals the concrete and prevents the formation of fine capillaries as previously described above.
  • Another desirable feature of this invention is that the concrete composition is self-insulated because of the homogeneous distribution of the expanded thermoplastic beads in the concrete. Consequently, the need for other insulation material are eliminated by my invention.
  • FIG. 1 Another embodiment of the invention is shown in FIG. 1
  • a porous membrane or a layer of a reinforcing fabric 23 that is saturated with either an asphalt or tar-base material is disposed between the concrete mass 15 and the bituminous mass 17.
  • the reinforcing fabric 23 reinforces the bituminous mass 17 (in a manner similar to the reinforcement of concrete with a steel mesh or reinforcing rods) so that the bituminous mass may withstand the stresses and strains from wind, vibration, and from the expansion and contraction of the bituminous mass itself.
  • Typical reinforcing fabrics comprise cotton, or glass or jute-woven fabrics that are saturated with either an asphalt or tar-base material. The preferred fabric is cotton.
  • Typical properties of reinforcing fabrics are:
  • the reinforcing fabric 23 is placed over the concrete mass 15 within less than twenty-four hours after the concrete mass has been poured onto base 13. Subsequently, a layer of the hot, bituminous material is placed over the reinforcing fabric. The hot bituminous material will penetrate through the reinforcing fabric and, also, disintegrate the thermoplastic beads at the surface of the concrete mass 15 in the manner aforedescribed. After the bituminous material cools, the reinforcing fabric and the bituminous mass itself will be mechanically bonded to the concrete mass as aforedescribed. A layer of gravel may subsequently be disposed over the bituminous material.
  • the reinforcing fabric will support the bituminous mass and prevent the cracking of the bituminous mass even though the concrete mass may develop a crack of up to A2 inch in size.
  • the reinforcing fabric particularly those made from cotton fibers, are extensible and will stretch with any movement in the concrete mass.
  • a desirable feature of this embodiment is that the reinforcing fabric helps to dissipate the forces exerted on the bituminous mass over a larger area of the upper surface of the concrete mass.
  • An integrated, insulated and weatherproof roof system comprising:
  • the integrated, insulated and weatherproof roof system of claim 1 further comprising a third layer of an aggregate material that coextensively covers said second layer of bituminous material.
  • the integrated insulated and weatherproof roof system of claim 1 including a reinforcing fabric disposed between said first and second layers.
  • composition being formed by mixing said mixture with about 35-45 parts by weight of water to provide a slurry for application to said base.
  • An integrated, insulated and weatherproof roof system comprising:
  • a first monolthic mass comprised of a low-density concrete composition that is supported by said base and that coextensively covers said base; said first monolithic mass being characterized by the following physical properties:
  • a second monolithic mass comprised of a bituminous material that coextensively covers a surface of said first mass and that is mechanically bonded to said surface of said first mass; said second monolithic mass being characterized by the following physical properties:
  • the integrated, insulated and weatherproof roof system of claim 5 including a reinforcing fabric disposed between said first and second masses; said reinforcing fabric being characterized by the following physical prop- 10.
  • a method for making an integrated insulated and erties: weatherproof roof system comprising:

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)
  • Laminated Bodies (AREA)
US111950A 1971-02-02 1971-02-02 Integrated insulated and weatherproof roof system Expired - Lifetime US3677878A (en)

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US11195071A 1971-02-02 1971-02-02

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US (1) US3677878A (it)
CA (1) CA933377A (it)
DE (1) DE2161114A1 (it)
FR (1) FR2124019A5 (it)
GB (1) GB1321548A (it)
IT (1) IT952008B (it)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3962841A (en) * 1974-04-04 1976-06-15 Decks, Incorporated Insulated decking structure and method
US4441944A (en) * 1981-12-31 1984-04-10 Pmp Corporation Building board composition and method of making same
US20050058832A1 (en) * 2001-03-16 2005-03-17 Semmens Blaine K. Lightweight cementitious composite material
US20070066216A1 (en) * 2005-09-17 2007-03-22 Mcintire Wilbur D Exterior roofing surface comprised of foam

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2190736C2 (ru) * 2000-11-24 2002-10-10 Ярошевич Глеб Борисович Покрытие преимущественно кровельное и мастика для него

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3962841A (en) * 1974-04-04 1976-06-15 Decks, Incorporated Insulated decking structure and method
US4441944A (en) * 1981-12-31 1984-04-10 Pmp Corporation Building board composition and method of making same
US20050058832A1 (en) * 2001-03-16 2005-03-17 Semmens Blaine K. Lightweight cementitious composite material
US7255738B2 (en) * 2001-03-16 2007-08-14 Conservation Roofing Systems, Inc. Lightweight cementitious composite material
US20070066216A1 (en) * 2005-09-17 2007-03-22 Mcintire Wilbur D Exterior roofing surface comprised of foam
WO2007040660A1 (en) * 2005-09-17 2007-04-12 Wilbur Dale Mclntire Exterior roofing surface comprised of foam

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FR2124019A5 (it) 1972-09-15
CA933377A (en) 1973-09-11
DE2161114A1 (de) 1972-08-17
IT952008B (it) 1973-07-20
GB1321548A (en) 1973-06-27

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