Claims
- 1. A fireproof insulated roof structure comprising: roof support members, roof decking adjacent to and supported by said roof support members, incombustible rigid gypsum formboard above and adjacent to said roof decking, synthetic polymer foam above and adjacent to said formboard, and a waterproof wearing surface to the exterior of said foam, wherein the lower surface of said gypsum formboard is bonded to the upper surface of a precast wood fiber cement-bonded board roof decking.
- 2. The fireproof insulated roof structure of claim 1 wherein the rigid formboard is 1/2 inch thick.
- 3. The fireproof insulated roof structure of claim 1 wherein said synthetic polymer foam is selected from the group consisting of polystyrene and polyurethane.
- 4. The fireproof insulated roof structure of claim 3 wherein said foam is polystyrene and having a second rigid gypsum formboard between the upper surface of the polymer foam and the waterproof wearing surface.
- 5. The fireproof insulated roof structure of claim 3 wherein the foam is polyurethane and the waterproof wearing surface is applied directly to the upper surface of the polymer foam.
- 6. An insulated roof deck structure comprising:
- a series of parallel sheet metal structural shapes which are symmetrical about a vertical bisecting plane having a central vertical web, two legs projecting downwardly from the bottom of said web at an angle of about 45.degree. to about 75.degree. to the horizontal, each leg having a substantially horizontal flange projecting outwardly at its lower extremity, and a stiffening member at the upper edge of said web;
- roofing slab assembly having the lower surface of a precast wood fiber cement-bonded board resting on said horizontal flanges and extending between adjacent structural shapes and incombustible rigid gypsum formboard bonded to the upper surface of the precast board and having a layer of synthetic polymer foam above the gypsum formboard; and
- grouting between said roofing slab assemblies and around said stiffener providing uplift resistance.
CROSS REFERENCE TO RELATED APPLICATION
This application is a Continuation-in-Part of my pending application, Ser. No. 457,996, filed Apr. 4, 1974.
This invention relates to improved roof deck structures having high insulation properties. The roof structure of this invention provides superior fire protection than prior use of the components has provided. Particularly favorable fire protection and insulation properties are obtained utilizing the sheet metal structural shape of my prior application, Ser. No. 457,996.
Previously, most efficient integral insulation properties were obtained when conventional metal roof decks were installed followed by foam insulation covered with a weatherproof barrier or traffic layer, such as bitumen and roofing felt. However, such structures do contribute to the spread of a fire in a building under such a metal roof deck. U.S. Pat. No. 3,466,222 is illustrative of recent attempts to overcome such disadvantages. However, the structure shown in the 3,466,222 patent only slows down fire damage and does not eliminate it, the roof being susceptible to total destruction by the foam disintegrating and permitting the weatherproofing materials to burn even when utilizing an expensive metal deck roof system.
Polyurethane foam has also been utilized directly over a steel roof deck and due to its high melting point hot asphalt roofing can be applied directly over the polyurethane foam. This system has the disadvantages of difficult field installation with curling of the foam and only results in a Class 2 fire rating.
Another attempt has been to provide insulation beneath the metal roof deck structure, however, such insulation either adds to combustion in the interior of the building or is expensive if incombustible mineral fiber is used. Other attempts to provide both satisfactory insulation and fireproof properties have been to utilize insulation board which is both incombustible and has insulating properties. Such boards are those manufactured from mineral fiber materials and fiber glass materials, but these are both expensive and do not provide the desired insulation properties while being more difficult to use in field erection.
Other attempts to provide desired fire ratings and insulation properties have been to use precast roof slab boards of wood fibers bonded with inorganic hydraulic cement binder. While these materials are generally non-combustible, they do not by themselves have any hourly fire rating. It is also recognized that polyurethane foam has been laminated to such slab boards to provide desired insulation properties, but the material does not have any hourly fire rating by itself.
It is an object of this invention to overcome the above disadvantages.
It is another object of this invention to provide an economical insulating and Class 1 fire rated steel deck system.
It is yet another object of this invention to provide a sandwich panel roofing assembly of gypsum board -- polymer foam -- gypsum board for use in a wide variety of roof deck assemblies.
It is still another object of this invention to provide an insulating and hourly fire rated deck system utilizing cement-fiber roof deck boards which may advantageously use sheet metal structural shapes as purlins or sub-purlins.
US Referenced Citations (6)
Foreign Referenced Citations (1)
| Number |
Date |
Country |
| 910,156 |
Nov 1962 |
UK |
Continuation in Parts (1)
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Number |
Date |
Country |
| Parent |
457996 |
Apr 1974 |
|
Patent Grant
3965633
