Roof system

Abstract

A roofing system provides a stronger bond than conventional roof systems to withstand greater uplift pressures in hurricane force winds, while also providing a sound fire rating. The system includes a non-corrosive metal blocking structure, including a perimeter edge closure that has an anchoring flange for attachment to the roof deck, a parallel upper flange and an intermediate flange extending perpendicularly between the upper and lower flanges. The system further includes lightweight insulating concrete applied to the roof deck and filled between the upper and lower flanges of the edge closure, an inter-ply sheet applied by torch or self-adhesive directly to the insulating lightweight concrete, and a torch applied cap membrane over the inter-ply sheet. Direct attachment of the inter-ply sheet to the lightweight insulating concrete without the use of hardware fasteners preserves the integrity of the underlying lightweight insulating concrete for future re-roofing.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view showing one embodiment of a non-corrosive metal blocking structure used in the roof system of the present invention; and

FIG. 2 is an isolated perspective view, shown in cross-section, illustrating the installed arrangement of the component elements of the roof system of the present invention.

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The roof system of the present invention is shown in FIG. 2 and is generally indicated as 10.

Referring to FIG. 1, a non-corrosive metal blocking structure is used in the roof system of the present invention and replaces wood blocking of conventional roof systems. In this particular embodiment, the non-corrosive metal blocking structure is a perimeter edge closure 20 that includes an anchoring flange 22 that attaches to the roof deck 100 using industry standards fasteners. The perimeter edge closure 20 also includes and upper flange 24 extending in spaced, parallel relation above the anchoring flange 22, forming a gap or area of depth therebetween. An intermediate flange 26 extends perpendicularly between the upper flange and the anchoring flange along the outer perimeter of the roof.

Referring now to FIG. 2, the entire assembled components of the roof system 10 are shown in a cross-sectional perspective view. In this particular example, the underlying roof deck 100 is a metal deck having flutes 110. The flutes are filled with lightweight insulating concrete. A slurry coat of lightweight insulating concrete 30 continues above the roof deck 100. The lightweight insulating concrete deck may further include an EPS Holly board insulation layer 32, and a top coat 36 of lightweight insulating concrete. Combined, the slurry coat 30, EPS Holly board insulation layer 32 and top coat 36 form the lightweight insulating concrete deck which is filled within the gap defined between the anchoring flange 22 and upper flange 24 of the perimeter edge closure 20.

Next, an inter-ply sheet 40 is applied to the top coat 36 of lightweight insulating concrete by torch weld or self-adhesive effectively to attach the inter-ply sheet 40 to the insulating lightweight concrete deck. Thereafter, a granulated cap membrane 50 is torch applied to the inter-ply sheet 40.

While the present invention has been shown and described in accordance with a preferred and practical embodiment thereof, it is recognized that departures from the instant disclosure are contemplated within the spirit and scope of the present invention.

Claims

1. A roof system for installation on a roof deck of a building structure comprising: a slurry coat of lightweight insulating concrete applied on a top surface of the roof deck;a layer of insulation applied on top of said slurry coat;a top coat of lightweight insulating concrete applied over said layer of insulation;an inter-ply sheet applied and bonded to said top coat; anda cap membrane applied on top of said inter-ply sheet and bonded to said inter-ply sheet.

2. The roof system as recited in claim 1 wherein said layer of insulation is EPS Holly board.

3. The roof system as recited in claim 1 wherein said inter-ply sheet is bonded to said top coat by torch weld.

4. The roof system as recited in claim 1 wherein said inter-ply sheet is bonded to said top coat with an adhesive.

5. The roof system as recited in claim 1 wherein said cap membrane is bonded to said inter-ply sheet by torch weld.

6. The roof system as recited in claim 1 further comprising a metal edge closure attached to the roof deck and extending about a perimeter of the roof deck.

7. The roof system as recited in claim 6 wherein said metal edge closure comprises: an anchoring flange structured and disposed for attachment to the roof deck;an upper flange extending parallel to said anchoring flange and spaced above said anchoring flange;an intermediate flange extending perpendicularly between said anchoring flange and said upper flange; andsaid anchoring flange and said upper flange being spaced apart to form a gap for receipt of the slurry coat, the layer of insulation and the top coat between said anchoring flange and said upper flange.

8. A roof system for installation on a roof deck of a building structure comprising: a metal edge closure including an anchoring flange structured and disposed for attachment to the roof deck along a perimeter of the roof deck, an upper flange extending in spaced relation above the anchoring flange to form a gap between the anchoring flange and the upper flange, and an intermediate flange extending perpendicularly between said anchoring flange and said upper flange;a lightweight insulating concrete deck applied on a top surface of the roof deck and within the gap between the anchoring flange and the upper flange of the metal edge closure;an inter-ply sheet applied to the lightweight insulating concrete deck and bonded to a top surface of the lightweight insulating concrete deck; anda cap membrane applied on top of the inter-ply sheet and bonded to the inter-ply sheet.

9. The roof system as recited in claim 8 wherein the lightweight insulating concrete deck comprises: a slurry coat of lightweight insulating concrete applied on a top surface of the roof deck;a layer of insulation applied on top of said slurry coat; anda top coat of lightweight insulating concrete applied over said layer of insulation.

10. The roof system as recited in claim 9 wherein said layer of insulation is EPS Holly board.

11. The roof system as recited in claim 9 wherein said inter-ply sheet is bonded to the top coat by torch weld.

12. The roof system as recited in claim 9 wherein said inter-ply sheet is bonded to said top coat with an adhesive.

13. The roof system as recited in claim 9 wherein said cap membrane is bonded to the inter-ply sheet by torch weld.

14. The roof system as recited in claim 8 wherein the roof deck is a metal deck having flutes.